Airtrek Workshop Maual

00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . .
00-2
SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) . . . . . . . . . . . . . . . . . .
00-27
SRS SERVICE PRECAUTIONS . . . . .
00-28
HOW TO USE
TROUBLESHOOTING/INSPECTION
SERVICE POINTS . . . . . . . . . . . . . . .
00-6
VEHICLE IDENTIFICATION . . . . . . .
00-16
SUPPORT LOCATIONS FOR LIFTING

AND JACKING . . . . . . . . . . . . . . . . . . 00-31
GENERAL DATA AND

SPECIFICATIONS . . . . . . . . . . . . . . .
00-20
STANDARD PART/TIGHTENINGTORQUE TABLE . . . . . . . . . . . . . . . .
PRECAUTIONS BEFORE SERVICE.
00-22
00-33
GENERAL
00-2
HOW TO USE THIS MANUAL

M1001000100660
SCOPE OF MAINTENANCE, REPAIR AND

SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components. For
detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
"On-vehicle Service" is procedures for performing
inspections and adjustments of particularly important
locations with regard to the construction and for
maintenance and servicing, but other inspection (for
looseness, play, cracking, damage, etc.) must also
be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be kept functionally or in strength. It is a value
established outside the range of standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
must be avoided. The differences among DANGER,
WARNING, and CAUTION are as follows:
If a DANGER is not followed, the result is severe
bodily harm or even death.
If a WARNING is not followed, the result could be
bodily injury.
If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
service equipment.
INDICATION OF TIGHTENING TORQUE

Tightening torques (units: Nm) are set to take into
account the central value and the allowable
tolerance. The central value is the target value, and
the allowable tolerance provides the checking range
for tightening torques. If bolts and nuts are not
provided with tightening torques, refer to P.00-33.
MODEL INDICATIONS
The following abbreviations are used in this manual
for identification of model types.
MPI::Indicates the multipoint injection.
SOHC::Indicates an engine with the single overhead
camshaft.
DOHC::Indicates an engine with the double
overhead camshaft.
2000:: Indicates models equipped with the 2,000 mL
<4G63> petrol engine.
2400::Indicates models equipped with the 2,400 mL
<4G69> petrol engine.
M/T:: Indicates the manual transmission.
A/T:: Indicates the automatic transmission.
A/C:: Indicates the air conditioner.
GENERAL
NOTES
00-3
00-4
GENERAL
(s
.
<<A>>
>>A<<
Symbols are used to show the locations for lubrication

.
These symbols are included in the diagram of component parts or on the page following the component
parts page. The symbols do not always have accompanying text to support that symbol.
disassembly.
or reassembly.
Multi-purpose grease unless there is a
AC301960
GENERAL
00-5
For bolts and nuts which do

not have a tightening torque
listed, refer to the "Standard
Parts tightening-torque Table"
parts sets are
On removal,
reassembly are described
AC300860
00-6
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS
M1001000200582
CONTENTS OF TROUBLESHOOTING
Troubleshooting of electronic control systems for which the MUT-II/III can be used follows the basic outline
described below. Even in systems for which the MUT-II/III cannot be used, some of these systems still follow
this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from
that given below, or if additional explanation is required, the details of such differences or additions will also
be listed.
Diagnosis method
Gathering information
from the customer.
Check trouble symptom.
Reoccurs
Read the diagnosis code.
No diagnosis code
or communication
with MUT-II/III not
possible
Does not reoccur
Diagnosis code
displayed.
Diagnosis code
displayed.
After taking note of the

malfunction code, erase the
diagnosis code memory.
No diagnosis
code.
Recheck trouble symptom.

Read the diagnosis codes.
Diagnosis code
displayed.
Refer to the INSPECTION CHART

FOR TROUBLE SYMPTOMS
(Refer to applicable group.)
Read the diagnosis code.
Refer to the INSPECTION CHART

FOR DIAGNOSIS CODES
(Refer to applicable group.)
No diagnosis
code.
INTERMITTENT MALFUNCTIONS
AC300864AC
2. SYSTEM OPERATION AND SYMPTOM

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

Diagnostic trouble codes and diagnostic items are
shown.
5. DIAGNOSIS CODE PROCEDURES
Indicates the inspection procedures corresponding to
each diagnosis code (Refer to How to read
inspection procedure ).
GENERAL
00-7
6. TROUBLE SYMPTOM CHART

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

<Using the MUT-III>
16-PIN
8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgment values have
been provided in this chart as reference information.
MB991911
MB991824
9. CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors,
inspection items, and judgment values have been
provided in this chart as reference information.
10. INSPECTION PROCEDURE BY USING AN
OSCILLOSCOPE
When there are inspection procedures using an
oscilloscope, these are described here.
DIAGNOSIS FUNCTION
HOW TO READ DIAGNOSIS CODE
CAUTION
Before connecting or disconnecting the
MUT-II/III, turn the ignition switch to the "LOCK"
(OFF) position.
<Using the MUT-II>
<Using the MUT-II>
Steering shaft
MUT-II
AC300830 AC
Connect the MUT-II to the diagnosis connector, and

read the diagnosis code.
MB991827
AC308915 AC
Connect the MUT-III to the 16-pin diagnosis

connector, and read the diagnosis code.
NOTE: For details on how to use the MUT-III, refer to
the "MUT-III operation manual."
1. Ensure that the ignition switch is at the
"LOCK" (OFF).
2. Start up the personal computer.
3. Connect MUT-III USB cable MB991827 to
special tool Vehicle Communication Interface
(V.C.I.) MB991824 and the personal
computer.
4. Connect MUT-III main harness B MB991911
to the V.C.I.
5. Connect MUT-III main harness B to the
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON"
position.
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green
colour.
7. Start the MUT-III system on the PC and turn
the ignition switch to the "ON" position.
8. Read the diagnosis code.
9. Disconnecting the MUT-III is the reverse of
the connecting sequence, making sure that
the ignition switch is at the "LOCK" (OFF).
GENERAL
00-8
NOTE: The ABS warning lamp may flash when the

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

MUT-II/III)
CAUTION
Some diagnosis codes can not be erased
according to the procedure below. If you attempt
to erase a diagnosis code, refer to an applicable
GROUP.
1. Turn the ignition switch to the "LOCK" (OFF)
position.
2. Disconnect the negative battery cable, wait for at
least 10 minutes, and then reconnect it.
3. Start the engine and let it run at idle for 10
minutes.
INPUT SIGNAL CHECK (WHEN USING THE
MUT-II/III) <SWS>
Steering shaft
MUT-II
CAUTION
(OFF) position.
<Using the MUT-II>
AC300830 AC
Steering shaft
<Using the MUT-III>
MUT-II
16-PIN
AC300830 AC
<Using the MUT-III>
MB991911
16-PIN
MB991824
MB991911
MB991827
AC308915 AC
MB991824
Connect the MUT-II/III to the diagnosis connector,

and erase the diagnosis code. The procedure is the
same as "HOW TO READ DIAGNOSIS CODE ".
MB991827
AC308915 AC
GENERAL
1. Connect the MUT-II/III to the diagnosis connector,

and erase the diagnosis code.
2. If the MUT-II/III buzzer sounds once when each
switch is operated (ON/OFF), the input signal for
that switch circuit system is normal.
INPUT SIGNAL CHECK (WHEN USING A
VOLTMETER) <SWS>
00-9
1. Use the special tool diagnosis code check

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

PROCEDURES
Steering shaft
MB991529
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC300831AB
The causes of many of the problems occurring in

electric circuitry are generally the connectors,
components, the ECU, the wiring harnesses
between connectors, in that order. These inspection
procedures follow this order. They first try to discover
a problem with a connector or a defective
component.
00-10
GENERAL
Relevant circuit(s) of the component which

the Code No. indicates are described.
AC301964AB
GENERAL
00-11
Explains about the basic

operation of the components.
Start of diagnosis
procedure
Describes
inspection
procedure.
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
Describes possible
causes(s) for that
diagnosis code.
AC301965AB
HARNESS CHECK
Check for an open or short circuit in the harness
between the terminals which were faulty according to
the connector measurements. Carry out this
inspection while referring to the Electrical Wiring
Manual. Here, "Check the wiring harness between
the power supply and terminal xx" also includes
checking for blown fuse. For inspection service
points when there is a blown fuse, refer to
"Inspection Service Points for a Blown Fuse ."
MEASURES TO TAKE AFTER REPLACING THE
ECU
If the trouble symptoms have not disappeared even
after replacing the ECU, repeat the inspection
procedure from the beginning.
CONNECTOR MEASUREMENT SERVICE

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

CONNECTED
<Waterproof Connectors>
MD998459
AC300881AB
Be sure to use special tool harness connector

(MD998459). Never insert a test probe from the
harness side, as this will reduce the waterproof
performance and result in corrosion.
GENERAL
00-12
<Ordinary (non-waterproof) Connectors>
Use the special tool inspection harness (MB991219)

(inspection harness for connector pin contact
pressure in the harness set for inspection). The
inspection harness for connector pin contact
pressure should be used. the test bar should never
be forcibly inserted, as it may cause a defective
contact.
<When Inspecting a Male Pin>
Connector
CAUTION
AC300882AB
Check by inserting the multi-meter test probe from

the harness side. Note that if the connector (control
unit, etc.) is too small to permit insertion of the test
probe, it should not be forced; use the backprobing
tool for this purpose.
IF INSPECTING WITH THE CONNECTOR
DISCONNECTED
<When Inspecting a Female Pin>
AC300890
At this time, be careful not to short the connector

pins with the test bars. To do so may damage the
circuits inside the ECU.Touch the pin directly
with the test bar.
MB991219
ACX00865AB
GENERAL
00-13
CONNECTOR INSPECTION SERVICE

POINTS
VISUAL INSPECTION
Low connection pressure due to rusted terminals

or foreign matter lodged in terminals
CONNECTOR PIN INSPECTION
Connector disconnected or
improperly connected
AC300898
Stretched or broken wires
If the connector pin stopper is damaged, the terminal

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

at terminal section
MB991219
Low contact
pressure
Good
Bad
AC300899AB
AC300896AB
Connector is disconnected or improperly connected

Connector pins are pulled out
Due to harness tension at terminal section
Low contact pressure between male and female
terminals
Use the special tool inspection harness (MB991219)

(connector pin connection pressure inspection
harness of the inspection harness set) to inspect the
engagement of the male pins and females pins. (Pin
drawing force: 1 N or more)
GENERAL
00-14
INSPECTION SERVICE POINTS FOR A

BLOWN FUSE
Battery
Fuse
Load
switch
Short-circuit
occurrence
section
Load
AC300900AB
Remove the blown fuse and measure the resistance

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

MALFUNCTIONS
NOTE: If determining the cause is difficult, the flight
recorder function of the MUT-II/III can also be used.
AC300901
00-15
Intermittent malfunctions often occur under certain

conditions, and if these conditions can be
ascertained, determining the cause becomes simple.
In order to ascertain the conditions under which an
intermittent malfunction occurs, first ask the
customer for details about the driving conditions,
weather conditions, frequency of occurrence and
trouble symptoms, and then try to recreate the
trouble symptoms. Next, ascertain whether the
reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or
some other factor. If vibration is thought to be the
cause, carry out the following checks with the
connectors and components to confirm whether the
trouble symptom occurs. The objects to be checked
are connectors and components which are indicated
by inspection procedures or given as probable
causes (which generates diagnosis codes or trouble
symptoms).
Gently shake the connector up, down and to the
left and right.
Gently shake the wiring harness up, down and to
the left and right.
Gently rock each sensor and relay, etc. by hand.
Gently shake the wiring harness at suspensions
and other moving parts.
GENERAL
00-16
VEHICLE IDENTIFICATION
M1001000400713
VEHICLE IDENTIFICATION CODE PLATE

1
The plate shows model code, engine model,

transmission model and body colour code.
No.
Item
Content
MODEL
CU2WXNMM CU2W:
L6
Vehicle model
XNMML6:
Model series
AC301477AB
The vehicle information code plate is riveted to the

back of the hood.
ENGINE
4G63
Engine model
EXT
W83A
Exterior code
TRANS AXLE F5M42
F5M42:Trans
mission
model
COLOUR
W83
W83: Body
colour code
INT
62A
62A: Interior
code
OPT
ZP3
ZP3:
Equipment
code
For monotone colour vehicles, the body colour code

shall be indicated.
MODELS
Model code
Engine model
Price class
Transmission
model
Fuel supply
system
CU2W
4G63-DOHC (1,997
mL)
Comfort
F5M42
<2WD, 5M/T>
MPI
XNMML6
XNMMZL6
XNHMZL6
CU5W
XNMYZL6
Sport
4G69-SOHC MIVEC
(2,378 mL)
Comfort
XRMYZL6
XRHYZL6
XRHYZR6
W5M42
<4WD, 5M/T>
W4A42
<4WD, 4A/T with
sport mode>
XRMYZR6
XNHYZL6
W5M42
<4WD, 5M/T>
Sport
W5M42
<4WD,5M/T>
W4A42
<4WD, 4A/T with
sport mode>
GENERAL
00-17
MODEL CODE
CU 2 W X N M M Z L 6
2 3 4 5 6 7 8 9 10
No.
Item
Content
Development
CU: MITSUBISHI
OUTLANDER
Engine type
2: 1,997 mL petrol engine

5: 2,378 mL petrol engine
Sort
W: Wagon
Body style
X: 5-door hatchback
Transmission
type
N: 5-speed manual
transmission
R: 4-speed automatic
transmission
Trim level
M: COMFORT
H: SPORT
Specification
engine feature
M: MPI-DOHC
Y: MPI-SOHC MIVEC
Special feature
None: 2WD
Z: 4WD
Steering wheel
location
L: Left hand
R: Right hand
10
Destination
6: For Europe
AC301363 AB
GENERAL
00-18
CHASSIS NUMBER
The chassis number is stamped on the toeboard

inside the engine compartment.
AC300903AB
M B
CU
000001
10
11
AC309285AB
No.
Item
Content
Fixed figure
Asia
Distribution channel
Japan channel
Destination
For Europe, right hand drive
For Europe, left hand drive
Body style
5-door hatchback
Transmission type
5-speed manual transmission
4-speed automatic transmission
Development order
CU
OUTLANDER
Engine
1,997 mL petrol engine
2,378 mL petrol engine
Soft
Station wagon
Model year
2004
10
Plant
Mizushima
11
Serial number
GENERAL
00-19
ENGINE MODEL STAMPING
The engine model is stamped on the cylinder block.

This engine model numbers are shown as follows.
<4G63>
Engine model
Engine displacement
4G63
1,997 mL
4G69
2,378 mL
The engine serial number is stamped near the

engine model number.
Front of the
vehicle
AC300905AD
<4G69>
Front of the vehicle
AC309481AB
GENERAL
00-20
GENERAL DATA AND SPECIFICATIONS

M1001000900558
8
7
9
4
6
5
AC300072AB
Items
CU2W
XNMML6
Vehicle
dimensions mm
Front track
1,495
Overall width
1,750
Front overhang
945
Wheel base
2,625
Rear overhang
975
Overall length
4,545
Ground clearance (unladen)
195
Overall height (unladen)
1,620/1,670*
Rear track
1,505
Vehicle weight kg Kerb weight
1,435
1,540
Max. gross vehicle weight
1,970
2,070
Max. axle weight rating-front
1,050
Max. axle weight rating-rear
1,065
Max. trailer weight
With brake
1,500
Without brake
570
Max. trailer-nose weight

Seating capacity
Engine
Transmission
Fuel system
XNMMZL6
75
5
Model code
4G63
Total displacement mL
1,997
Model code
F5M42
Type
5-speed manual
Fuel supply system
MPI
NOTE: *: Vehicles with roof rails
W5M42
XNHMZL6
GENERAL
00-21
Items
CU5W
XNMYZL6
Vehicle
dimensions
mm
Vehicle
weight kg
XRMYZL6/R XNHYZL6
6
XRHYZL6/R
6
LHD: 1,560,
RHD: 1,565
1,540
LHD: 1,560,
RHD: 1,565
W5M42
W4A42
W5M42
W4A42
Type
5-speed
manual
4-speed
automatic
5-speed
manual
4-speed
automatic
Fuel supply system
MPI
Front track
1 1,495
Overall width
2 1,750
Front overhang
3 945
Wheel base
4 2,625
Rear overhang
5 975
Overall length
6 4,545
Ground clearance (unladen)
7 195
Overall height (unladen)
8 1,620/1,670*
Rear track
9 1,505
Kerb weight
1,540
Max. gross vehicle weight
2,070
Max. axle weight rating-front
1,050
Max. axle weight rating-rear
1,065
Max. trailer weight With brake
1,500
Without
brake
Max. trailer-nose weight
570
75
Seating capacity
Engine
Model code
4G69
2,378
Transmission Model code
Fuel system
NOTE: *: Vehicles with roof rails
00-22
GENERAL
PRECAUTIONS BEFORE SERVICE

M1001000500538
SUPPLEMENTAL RESTRAINT SYSTEM

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

disposing of the air bag module or disposing
of a vehicle equipped with an air bag (Refer to
GROUP 52B Air Bag Module Disposal
Procedures).
Observe the following when carrying out
operations on places where SRS components are
installed, including operations not directly
related to the SRS air bag.
1. When removing or installing parts, do not
allow any impact or shock to the SRS
components.
2. If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt
pre-tensioner.
SRS-ECU, air bag module, clock spring,
front impact sensor, the side impact
sensor: 93 C or more
Seat belt pre-tensioner: 90 C or more
GENERAL
00-23
INITIALIZATION PROCEDURE FOR

LEARNING VALUE IN MPI ENGINE
LEARNING PROCEDURE FOR IDLING IN

MPI ENGINE
Initialization Procedure
1. After the ignition switch is in "LOCK" (OFF)
position, connect MUT-II/III with the diagnosis
connector.
2. Select the item on the screen of the initialization
for learning, and perform the initialization.
Purpose
When the engine-ECU <M/T> or the
engine-A/T-ECU <A/T> is replaced, or when the
learning value is initialized, the idling is not stabilized
because the learning value in MPI engine is not
completed. In this case, carry out the learning
method for the idling through the following
procedures.
Service
Item
At replacing engine
assembly *1,*2
All ranges
*3
Misfire-related
At replacing injector and Learning value for

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

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

NOTE: *2: After initializing the learning value, the
idling learning in MPI engine is required (Refer to
LEARNING PROCEDURE FOR IDLING IN MPI
ENGINE).
NOTE: *3: The datum items on MUT-II/III display are
shown, but do not use them.
Learning Procedure
1. Start the engine and carry out the warm-up for the
engine coolant temperature to reach 80C or
more.
2. When the engine coolant temperature is 80C or
more, the warm-up is not needed if the ignition
switch is in "ON" position once.
3. Place the ignition switch in "LOCK" (OFF) position
and stop the engine.
4. After 10 seconds or more, start the engine again.
5. For 10 minutes, carry out the idling under the
condition shown below and then confirm the
engine has the normal idling.
Transmission: Neutral (A/T: "P" range)
Operation in ignition-related, fan and
attachments: Not to be operated
Engine coolant temperature: 80C or more
NOTE: When the engine stalls during the idling,
check the dirtiness (on the throttle valve) of the
throttle body and then perform the service from
Procedure 1 again.
00-24
GENERAL
SERVICING ELECTRICAL SYSTEM
PRE-INSPECTION CONDITION
CAUTION
Before connecting or disconnecting the negative
() cable, be sure to turn off the ignition switch
and the lighting switch (If this is not done, there
is the possibility of semiconductor parts being
damaged).
"Pre-inspection condition" refers to the condition that

the vehicle must be in before proper engine
inspection can be carried out. If you see the words
"Set the vehicle to the pre-inspection condition". In
this manual, it means to set the vehicle to the
following condition.
Engine coolant temperature 80 to 90C
Lamps, electric cooling fan and all accessories:
OFF
M/T: Neutral
A/T: P range
VEHICLE WASHING
AC300693
Before replacing a component related to the

electrical system and before undertaking any repair
procedures involving the electrical system, be sure to
first disconnect the negative () cable from the
battery in order to avoid damage caused by
short-circuiting.
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will
cause a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover
when applying anti-corrosion agents and undercoats.
Approximately 40 cm
AC300832AB
If high-pressure car-washing equipment or steam

car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to
avoid damage to plastic components, etc.
Spray nozzle distance: Approx. 40 cm or more
Spray pressure: 3,900 kPa or less
Spray temperature: 82C or less
Time of concentrated spray to one point: within
30 sec.
GENERAL
00-25
MUT-II/III
MUT-III sub assembly
MUT-II Sub-assembly
Vehicle communication interface (V.C.I.)
Rom pack
MB991824
MUT-III USB cable

AC300834AB
MB991827
MUT-III main harness A
Do not used
MB991910
MUT-III main harness B
MB991911
MUT-III measurement adapter
MB991825
MUT-III trigger harness
MB991826
AC305090AB
Refer to the "MUT-II REFERENCE MANUAL",

"MUT-II OPERATING INSTRUCTIONS" or "MUT-III
OPERATION MANUAL" for instructions on handling
the MUT-II/III.
GENERAL
00-26
ENGINE OILS
CAUTION
<Using the MUT-II>
Steering shaft
MUT-II
AC300830 AC
<Using the MUT-III>
16-PIN
MB991911
MB991824
MB991827
AC308915 AC
Turn the ignition switch to the "LOCK" (OFF)

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

FROM FIRE
"Improper installation of electrical or fuel related parts
could cause a fire. In order to retain the high quality
and safety of the vehicle, it is important that any
accessories that may be fitted or
modifications/repairs that may be carried out which
involve the electrical or fuel systems, MUST be
carried out in accordance with MMC's
information/Instructions".
Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them.
Other precautions:
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
Avoid contaminating clothes, particularly
underpants, with oil.
Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from
personal clothing.
Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
Obtain First Aid treatment immediately for open
cuts and wounds.
Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
If skin disorders develop, obtain medical advice
without delay.
GENERAL
00-27
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

M1001009800020
The Supplemental Restraint System (SRS) and seat

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

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

module
Passenger's (front)
air bag module
Side air bag module
Side impact sensor
Clock spring
SRS-ECU
Side impact sensor

Side air bag module
Front impact sensor
AC301343 AB
00-28
GENERAL
SRS SERVICE PRECAUTIONS

M1001006000047
CAUTION
DANGER
In order to avoid injury to yourself or others

from accidental deployment of the air bag
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
SRS-ECU connector
CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-9.
CAUTION
Never Attempt to Repair the Following
Components:
1. SRS air bag control unit (SRS-ECU)
2. Front impact sensor
3. Clock spring
4. Driver's and front passenger's air bag
modules
5. Side air bag module
6. Side impact sensor
7. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE
procedures in this manual, starting at page
P.52B-174.
SRS-ECU terminal No. Destination of harness
AC300634 AB
Do not attempt to repair the wiring harness

connectors of the SRS. If a defective wiring
harness is found, repair or replace it by referring
to the table below.
Remedy
1, 2
Instrument panel wiring harness

Front wiring harness (RH) Front
impact sensor (RH)
Correct or replace each wiring

harness.
3, 4

Front wiring harness (LH) Front
impact sensor (LH)
Correct or replace each wiring

harness.

Earth
Correct or replace the instrument

panel wiring harness.

SRS warning lamp

9, 10

Air bag module (Front passenger's
side)

11, 12

Clock spring Air bag module
(Driver's side)
Correct or replace instrument panel

wiring harness. Replace the clock
spring.
13

Junction block (fuse No.3)

GENERAL
00-29
SRS-ECU terminal No.
Destination of harness
Remedy
16

Junction block (fuse No.2)

20

Diagnosis connector

21, 22
Floor wiring harness (RH) Side air Correct or replace the floor wiring
bag module (LH)
harness.
23, 24
Floor wiring harness (RH) Side air Correct or replace the floor wiring
bag module (RH)
harness.
27, 28
Floor wiring harness (RH) Seat

belt pre-tensioner (Front
passenger's side)
Connect or replace the floor wiring

harness.
29, 30
Floor wiring harness (LH) Seat

belt pre-tensioner (driver's side)

harness.
34, 36
Floor wiring harness (LH) Side

impact sensor (LH)

harness.
40, 42
Floor wiring harness (RH) Side

impact sensor (RH)

harness.
DANGER
Insulating tape
Battery
Battery cable
AC300580AB
After disconnecting the battery cable, wait 60

seconds or more before proceeding with the
following work. In addition, insulate the
negative battery terminal with a tape. The
condenser inside the SRS-ECU is designed
to retain enough voltage to deploy the air
bag for a short time even after the battery
has been disconnected, so serious injury
may result from unintended air bag
deployment if work is done on the SRS
system immediately after the battery cables
are disconnected.
GENERAL
00-30
CAUTION
The SRS components and seat belt with
pre-tensioner should not be subjected to heat, so
remove the SRS-ECU, drivers and front
passengers air bag modules, clock spring, side
air bag modules, and seat belt pre-tensioner
before drying or baking the vehicle after painting.
SRS-ECU, air bag modules, clock spring,
impact sensors: 93C or more
Seat belt with pre-tensioner 90C or more
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.
CAUTION
SRS-Harness connector
SRS-ECU harness connector

(rear side)
AC300673AB
If checks are carried out by using the SRS-ECU

harness connector, observe the following
procedures: Insert the special tool (probe in the
harness set) MB991222 into connector from
harness side (rear side), and connect the tester
to this probe. If any tool than special tool is used,
damage to the harness and other components
will result. Never insert the probe directly to the
terminals from the front of the connector. The
terminals are plated to increase their
conductivity, so that if they are touched directly
by the probe, the plating may break, which will
cause drops in reliability.
GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING
00-31

M1001000700093
SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR

DOUBLE-POST LIFT AND PLATE TYPE LIFT
CAUTION
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.
GARAGE JACK
CAUTION
Never support any point other than the specified one, or that point will be deformed.
<2WD>
Rear suspension crossmember
<4WD>
Rear differential
AC300835
GENERAL
00-32
AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT

CAUTION
If rubber attachments with grooves that are too thick are used at the front support positions, the
front fender may become bent, so be sure to use rubber attachments with groove thicknesses of
18 mm or less.
If attachments which are not high enough are used, they may damage areas such as the side step.
Be sure to use attachments which are high enough, or remove the side step if not using
attachments.
AXLE STANDS
Bolts
Bolts
Rubber
Rubber
SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Bolts
Bolts
AC300836AB
GENERAL
00-33
STANDARD PART/TIGHTENING-TORQUE TABLE
PLATE TYPE LIFT
CAUTION
To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift.
Support the side sill flange with a lift.
STANDARD PART/TIGHTENING-TORQUE TABLE

M1001001100362
Each torque value in the table is a standard value for

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

3. If bolts are tightened to plastic or die-cast
inserted nuts.
4. If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
Bolt nominal
diameter (mm)
Pitch
(mm)
Head mark "4"
Head mark "7"
Head mark "8"
M5
0.8
2.5 0.5
5.0 1.0
6.0 1.0
M6
1.0
5.0 1.0
9.0 2.0
10 2
M8
1.25
12 2
22 4
25 4
M10
1.25
24 4
44 10
53 7
M12
1.25
41 8
83 12
98 12
M14
1.5
73 12
140 20
155 25
M16
1.5
110 20
210 30
235 35
M18
1.5
165 25
300 40
340 50
M20
1.5
225 35
410 60
480 70
M22
1.5
300 40
555 85
645 95
M24
1.5
395 55
735 105
855 125
Flange bolt and nut tightening torque

Thread size
Torque Nm
Bolt nominal
diameter (mm)
Pitch
(mm)
Head mark "4"
Head mark "7"
Head mark "8"
M6
1.0
5.0 1.0
10 2
12 2
M8
1.25
13 2
24 4
27 5
M10
1.25
26 4
49 9
58 7
M10
1.5
24 4
45 8
55 10
M12
1.25
46 8
95 15
105 15
M12
1.75
43 8
83 12
98 12
NOTE: .
Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the
bolt strength.
NOTES

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11A-1
GROUP 11A
00
11
ENGINE
MECHANICAL
12
13
14
15
16
CONTENTS
17
GENERAL INFORMATION . . . . . . . .
11A
SERVICE SPECIFICATIONS. . . . . . .
11A
SEALANTS . . . . . . . . . . . . . . . . . . . .
11A
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11A
ON-VEHICLE SERVICE. . . . . . . . . . .
CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
REMOVAL AND INSTALLATION . . . . . . . .
11A
22
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A
25
REMOVAL AND INSTALLATION <2WD>. .
11A
REMOVAL AND INSTALLATION <4WD>. .
11A
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11A
27
CRANKSHAFT OIL SEAL . . . . . . . . . 11A
31
11A
DRIVE BELT TENSION CHECK. . . . . . . . .
11A
AUTO-TENSIONER CHECK . . . . . . . . . . .
11A
IGNITION TIMING CHECK . . . . . . . . . . . . .
11A
IDLE SPEED CHECK . . . . . . . . . . . . . . . . .
11A
IDLE MIXTURE CHECK . . . . . . . . . . . . . . .
11A
COMPRESSION PRESSURE CHECK. . . .
11A
MANIFOLD VACUUM CHECK . . . . . . . . . .
11A
LASH ADJUSTER CHECK . . . . . . . . . . . . .
11A
11A
CYLINDER HEAD GASKET . . . . . . . . 11A

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

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

adjusted)
Deflection mm
5-7

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

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

equivalent
Semi-drying
sealant
Camshaft position sensor support

Rocker cover
Camshaft end seal
3M ATD Part No.8660 or equivalent
Rocker cover gasket

equivalent
Engine oil pan <2WD>

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

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

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

installation
MD998776

installer
MD998285
Crankshaft front oil seal

guide
MD998375

installer
MB991654
Cylinder head bolt wrench

(12)
D998713
D998727
D998781
B990938
D998776

installation
D998285
B991654
Removal and installation of

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

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

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

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

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

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

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

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

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

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

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

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

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

M1111002100255
AC102022
Y0195AU
MUT-II
IDLE SPEED CHECK

M1111003500472
AC102022
Y0195AU
AK000871 AC
MUT-II
AK000871 AC

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

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

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

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

M1111002600465
Crank angle
sensor
connector
AK201364AC

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

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

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

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

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

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

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

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

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

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

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

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

warm up.
3. With no load on the engine, repeat the drive
pattern shown in the illustration above and check
if the abnormal noise disappears (The noise
should normally disappear after 10 - 30
repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is
probably not due to air inside the lash adjusters).
4. After the noise has disappeared, repeat the drive
pattern shown in the illustration above a further 5
times.
5. Run the engine at idle for 1 - 3 minutes and check
that the noise has disappeared.
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-13
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600409
Pre-removal Operation
Under Cover Removal (Refer to GROUP 51, Under Cover
351).
Post-installation Operation
Drive Belt Tension Check (Refer to 311A).
Under Cover Installation (Refer to GROUP 51, Under
Cover 351).
2
1
25 4 Nm
AC300537AB
<<A>>
1.
2.
Removal steps
Drive belt
Crank shaft damper pulley
ENGINE MECHANICAL
11A-14
CRANKSHAFT PULLEY
REMOVAL SERVICE POINT
CAUTION
<<A>> DRIVE BELT REMOVAL

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

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

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

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

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

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

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

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

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

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

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

or equivalent
A
A
3 mm
Sealant: MITSUBISHI GENUINE

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

REMOVAL
<<A>> RADIATOR UPPER HOSE

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

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

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

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

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

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

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

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

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

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

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

CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT
BEARING CAPS, NO. 5/CAMSHAFT BEARING
CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/
CAMSHAFT BEARING CAPS, FRONT
INSTALLATION
Approximately 3
MD998772
Dowel pin
AC201799 AB

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

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

bearing caps, front so that inlet side and exhaust
side cannot be mistaken in the same way as that
of bearing caps No.2 - 5.
CAUTION
Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
adhesion surface during that time.
6. Tighten the bearing cap mounting bolts increasing
the pressure in 2 to 3 times and finally tighten to
the specified torque.
Tightening torque: 20 1 Nm
7. Ensure that the rocker arms are installed properly.
NOTE: Remove an excess of sealant completely.
>>G<< CAMSHAFT OIL SEALS INSTALLATION
Engine front
MD998713
AC201461AB
3. Apply sealant to the positions (6 areas) of the

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

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

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

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

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

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

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

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

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

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

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

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

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

seal as shown in the illustration and install to the
cylinder head.
Specified sealant: 3M ATD Part No.8660 or
equivalent
NOTE: Install the camshaft end seal within 15
CAUTION
3. Tighten the rocker cover mounting bolts to the
specified torque.
Tightening torque: 3.5 0.5 Nm
ENGINE MECHANICAL
11A-23
OIL PAN
OIL PAN
REMOVAL AND INSTALLATION <2WD>
M1112002800592
351).
Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service - Engine Oil Replacement 312).
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler 315).
Front Exhaust Pipe Installation (Refer to GROUP 15,
Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Cover 351).
5
N
35 6 Nm
39 5 Nm
9.0 3.0 Nm
2
26 5 Nm
9.0 1.0 Nm
9.0 3.0 Nm
1.
2.
3.
Removal steps
Exhaust manifold bracket
Flywheel housing front lower cover
Engine oil pan drain plug
AC300542 AB
>>B<< 4.
<<A>> >>A<< 5.

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

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

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

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

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

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

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

new gasket in the direction shown in the illustration.
ENGINE MECHANICAL
11A-25
OIL PAN
REMOVAL AND INSTALLATION <4WD>

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

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

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

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

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

strike it with a hammer to remove the engine lower
oil pan.
<> ENGINE UPPER OIL PAN REMOVAL
1. Remove the engine upper oil pan mounting bolts.
CAUTION
AC102242AB
2. Apply a bead of the sealant to the mating surface

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

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

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

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

>>C<< ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION
Engine lower
oil pan side
4 mm
AC102325 AF
Bolt hole
portion
Groove
portion
AC102243AB

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

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

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

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

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

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

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

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

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

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

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

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

secure the flywheel.
2. Remove the flywheel bolts.

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

inner diameter of the oil seal lip.
MD998285
(Oil applied to the
circumference)
Oil seal
AC102329 AC

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt
Balancershaft
Timing belt tensioner

pulley hole
Plug
AC102336AB
Temporarily tighten the timing belt tensioner pulley as

shown.
Cylinder
block
AC102337 AE
2. Adjust the timing mark of the engine oil pump

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

Inlet side
camshaft sprocket
11A-41
Timing mark
Timing mark
Exhaust side
camshaft sprocket
AC201802 AB
Timing belt
tensioner
pulley
Crankshaft
camshaft
drive
sprocket
Timing belt
idler pulley
(3) Use two wrenches to align the timing mark on

the rocker cover with that on the camshaft
sprocket. Pass the valve timing belt around the
inlet-side camshaft sprocket.
Engine
oil pump
sprocket
AC102488 AC
(1) Pass the valve timing belt around the

crankshaft camshaft drive sprocket, the engine
oil pump sprocket and the timing belt idler
pulley in that order.
Paper clip
AC201803AB
(4) Hold the valve timing belt with paper clips.

(5) Pass the valve timing belt around the timing
belt tensioner pulley.
CAUTION
Paper clip
Incorporate the valve timing belt. Then apply

reverse rotation (anti-clockwise rotation)
pressure to the cam shaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is tight.
(6) Remove the two paper clips.
AC201801AB
(2) Pass the valve timing belt around the exhaustside camshaft sprocket, and hold the valve
timing belt with paper clip.
MD998767
AC102694 AB
4. Turn the timing belt tensioner in the direction

shown using special tool tensioner wrench
(MD998767) to apply tension to the valve timing
belt. Then pre-tighten the timing belt tensioner
pulley.
5. Check that the timing marks are aligned.
ENGINE MECHANICAL
11A-42
TIMING BELT
Bolt
Balancershaft
CAUTION
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
Plug
Cylinder
block
AC102337 AE
6. Remove the bolt inserted in Step 2 above, then

assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque.
8. Adjust the valve timing belt tension.
>>G<< VALVE TIMING BELT TENSION
ADJUSTMENT
MD998767
AC102695AB
6. With special tool tensioner wrench (MD998767)

and torque wrench, apply tension torque 3.5 Nm,
and tighten the timing belt tensioner pulley
mounting bolt to the specified torque.
MD998738
Wire
Timing belt
under cover
AC102492 AB
1. Set special tool adjusting bolt (MD998738) when

removing the valve timing belt.
CAUTION
Always screw in special tool by hand, since use
of a spanner or other tools may damage the wire
or pin inserted in the timing belt tensioner
adjuster.
2. Gradually screw in special tool until the wire or pin
inserted in the timing belt tensioner adjuster lightly
moves.
3. Turn the crankshaft 1/4 turn anti-clockwise.
4. Turn the crankshaft in the clockwise direction until
you align each timing mark to set No.1 cylinder to
TDC of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.
AC102776 AB
7. Remove wire or pin inserted to timing belt

tensioner.
MD998738
Timing belt
under cover
AC102492 AB
8. Remove the special tool adjusting bolt

(MD998738), and install the rubber plug to the
timing belt under cover.
9. Rotate the crankshaft clockwise two turns, and
leave it for about 15 minutes.
ENGINE MECHANICAL
11A-43
TIMING BELT
CAUTION
Always check the tightening torque of the crank
shaft pulley centre bolt when turning the crack
shaft pulley centre bolt anti-clockwise. Retighten if it is loose.
Wire
Timing mark
AC102776 AB
10.Insert wire or pin removed in Step 7 again, and

ensure that it can be pulled out easily. When wire
or pin can be easily removed, appropriate tension
is applied on timing belt. In this case, remove wire
or pin.
Camshaft
sprocket
Crankshaft
camshaft
drive sprocket
Timing belt
tensioner
adjuster
Timing mark
Timing mark
AC102338AB
If the projection of timing belt tensioner adjuster

rod is within the standard value, appropriate
tension is applied.
Standard value (A): 3.8 - 4.5 mm
11.If wire or pin cannot be easily pulled out, repeat
Step 1 through Step 9 to reach proper valve timing
belt tension.
Engine
oil pump
sprocket
AC201411AB
12.Check again that the timing marks on sprockets

are aligned.
>>H<< END CAP INSTALLATION
CAUTION
Always replace the end cap with new parts since
there may be fall-off or sealing defect if the end
cap is re-used.
INSPECTION
M1112004400352
TIMING BELT TENSIONER ADJUSTER

CHECK
1. Check for oil leak from seal, and replace it if leak
is detected.
2. Check for wear or damage at the top of the rod.
Replace it, if required.
ENGINE MECHANICAL
11A-44
TIMING BELT
98 196 N
Movement
BALANCER TIMING BELT TENSION

CHECK
Check the balancer timing belt tension as follows:
B
Approximately 100 N
Rod
Timing belt
tensioner
adjuster
AC102339 AB
3. Hold the timing belt tensioner adjuster by hand,

and press the top end of the rod onto the metal
(e.g. cylinder block) under a pressure of 98 - 196
N to measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
4. If the measured value is out of the standard value,
replace the timing belt tensioner adjuster.
Deflection
AC102693 AB
1. Apply a pressure of approximately 100 N at the

shown then inspect whether the deflection is
within the standard value.
Standard value: 5 - 10 mm
tension. (Refer to 311A).
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-45
ENGINE ASSEMBLY
M1112001000720
CAUTION
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service - Fuel Pump Connector Disconnection
(How to Reduce Pressurized Fuel Lines) 313A.]
Hood Removal (Refer to GROUP 42, Hood 342).
351).
Rocker Cover Centre Cover Removal (Refer to 311A
).
Radiator Assembly Removal (Refer to GROUP 14,
Radiator 314).
Starter Assembly Removal (Refer to GROUP 16, Starter
Motor Assembly 316).
Starter Assembly Installation (Refer to GROUP 16,
Starter Motor Assembly 316).
Radiator Assembly Installation (Refer to GROUP 14,
Radiator 314).
Rocker Cover Centre Cover Installation (Refer to 311A
).
Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Check and
Adjustment 317).
Cover 351).
Hood Installation (Refer to GROUP 42, Hood 342).
Fuel Leak Check
ENGINE MECHANICAL
11A-46
ENGINE ASSEMBLY
9
5.0 1.0 Nm
10
17
12
7
5
6
14
5.0 1.0 Nm
15
11
9.0 2.0 Nm
13
2
1
9.0 2.0 Nm
18
5.0 1.0 Nm
16
9.0 2.0 Nm
5.0 1.0 Nm
1.
2.
3.
4.
5.
6.
7.
8.
9.
Removal steps
A/C compressor connector
Power steering fluid pressure
switch connector
Crank angle sensor connector
Ignition coil connectors
Detonation sensor connector
Purge control solenoid valve
connector
EGR control solenoid valve
connector
Injector connectors
Throttle position sensor connector
10.
11.
12.
13.
14.
<<A>>
15.
16.
17.
18.
AC300549 AB

Idle speed control servo connector
Camshaft position sensor
connector
Oxygen sensor connector
Engine coolant temperature sensor
connector
Engine coolant temperature gauge
unit connector
Capacitor connector
Drive belt
ENGINE MECHANICAL
11A-47
ENGINE ASSEMBLY
23
24
19
25
5.0 1.0 Nm
26 N
(Engine oil)
12 2 Nm
20
44 10 Nm*
22 4 Nm
27
22
22 4 Nm
45 5 Nm*
29
28
21
AC300550 AB
<>
<>
Removal steps
19. Brake booster vacuum hose
connection
20. Canister vacuum hose connection
21. A/C compressor and clutch
assembly
22. Power steering oil pump assembly
23. Heater water hoses connection
24. Fuel return line hose connection
>>E<<
<<C>>
<<D>>
<<E>>
>>E<<
>>D<<
>>C<<
>>B<<
>>A<<

25. Fuel high-pressure hose
connection
26. O-ring
27. Self-locking nuts
28. Engine front mounting bracket
29. Engine assembly
ENGINE MECHANICAL
11A-48
ENGINE ASSEMBLY
<<C>> TRANSMISSION ASSEMBLY REMOVAL

serpentine drive system with the drive belt autotensioner.
Auto-tensioner
AC300950AB
Hole B
Hole A
AC107640AC

hole of the auto-tensioner, and turn the autotensioner anti-clockwise until it hits the stopper.
CAUTION
the belt using chalk.
1. Pre-tighten the 2 bolts on the car to assemble the

radiator support upper insulator to set the special
tools engine hanger MB991895 or engine hanger
MB991928.
2. Remove the transmission assembly (Refer to
GROUP 22A, Transmission Assembly 322A).
<<D>> ENGINE FRONT MOUNTING BRACKET
REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.
MB991895
MB991527
Auto-tensioner
L-shaped
hexagon
wrench
MB991454
AC107631AB
AC107641AB
2. Align hole A with hole B, insert an L-shaped

hexagon wrench, etc. to fix and then remove the
drive belt.
<> A/C COMPRESSOR AND CLUTCH
ASSEMBLY/POWER STEERING OIL PUMP
ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly, and power steering oil pump
assembly from the bracket.
NOTE: Secure the removed A/C compressor and
clutch assembly, and power steering oil pump
assembly with cord or rope at a position where they
will not interfere with the removal of the engine
assembly.
(1) <Special tool engine hanger (MB991895) is

used>
Remove special tool MB991895.
MB991928
MB991527
MB991454
AC211405 AB

used>
ENGINE MECHANICAL
11A-49
ENGINE ASSEMBLY
2. Support the engine assembly with a garage jack.

3. Remove the chain block.
support the engine.
MB991454
MB991527
MB991895
MB991527
AC107632 AB
3. Hold the engine assembly with a chain block, etc.

4. Place a garage jack against the engine oil pan
with a piece of wood in between so that the weight
of the engine assembly is no longer being applied
to the engine front mounting bracket.
5. Loosen the engine front mounting bracket
mounting nuts and bolt, and remove the engine
front mounting bracket.
MB991454
AC107631AB

used>
Set special tool MB991895. (Refer to
GROUP 22A, Transmission Assembly
322A).
<<E>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring
harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
the engine assembly upward from the engine
compartment.
MB991928
MB991527

>>A<< ENGINE ASSEMBLY INSTALLATION
MB991454
AC211405 AB

used>
Set special tool MB991928 (Refer to
322A).
MB991454
MB991527
>>C<< SELF-LOCKING NUTS INSTALLATION
CAUTION
Install the engine assembly, being careful not to
pinch the cables, hoses or wiring harness
connectors.
Do not tighten the self-locking nuts while the

engine is hot.
Tighten the self-locking nuts to the specified torque
while the engine is cold.
>>B<< ENGINE FRONT MOUNTING BRACKET

INSTALLATION
with a piece of wood in between, and install the
engine front mounting bracket while adjusting the
position of the engine.
>>D<< TRANSMISSION ASSEMBLY

INSTALLATION
1. Install the transmission assembly (Refer to
GROUP 22A, Transmission Assembly 322A).
AC107632 AB
ENGINE MECHANICAL
11A-50
ENGINE ASSEMBLY
>>E<< O-RING/FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
AC300950AB
2. Remove from the car the 2 bolts, to assemble the

radiator support upper insulator.
Do not let any engine oil get into the delivery

pipe.
1. Apply a small amount of new engine oil to the Oring.
2. Turning the fuel high-pressure hose to the right
and left, install it to the delivery pipe, while being
careful not to damage the O-ring. After installing,
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel highpressure hose and check the O-ring for damage.
After this, re-insert it to the delivery pipe and
4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
11B-1
GROUP 11B
00
11
ENGINE OVERHAUL
12
13
14
CONTENTS
HOW TO USE THIS MANUAL. . . . . .
11B
11B
GENERAL SPECIFICATIONS . . . . . .
11B
11B
EXHAUST MANIFOLD REMOVAL AND

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

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

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

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

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

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

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

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

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

35
OIL PAN AND OIL PUMP REMOVAL AND

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

11B

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

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

11B
11B

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11B
54
55
ENGINE OVERHAUL
11B-2

M1113025100155

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Oil pump gear side clearance mm
PISTONS AND CONNECTING RODS

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

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

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

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

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

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

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

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

Connecting rod cap nuts
20 2 90 to 94

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

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

or equivalent
3M Nut Locking Part No.4171 or

equivalent
Engine coolant temperature e gauge unit
Water outlet fitting*

Thermostat housing*

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

or equivalent
Oil pressure switch
Oil pan*

or equivalent
Rear oil seal case*

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

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

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

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

auto-tensioner during timing belt
installation
MD998713
Camshaft oil seal

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

wrench

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

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

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

case plug cap
MD998371
Silent shaft bearing

puller
Removal of counterbalancer shaft

front bearing
MD998372

puller
Removal of counterbalancer shaft

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

installer stopper
Guide and stopper for removal

and press-fitting of
counterbalancer shaft rear
bearing
MD998705

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

seal installer
Installation of crankshaft front oil

seal
MD998285
Crankshaft front oil

seal guide
Guide for installation of

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

piston pin
MD998776
Crankshaft rear oil

seal installer
Installation of crankshaft rear oil

seal
MB990938
Handle
Installation of crankshaft rear oil

seal
D998285
D998776
B990938
ENGINE OVERHAUL
11B-13

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

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

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

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

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

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

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

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

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

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

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

REMOVAL
MD998785
AK202739AB
Remove the camshaft sprocket bolt while preventing

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

outlet fitting and thermostat housing.
2. Apply a 2.7 0.3 mm diameter bead of FIPG to
the indicated surface of the water outlet fitting.
Specified sealant:
equivalent
AK202799AB
CAUTION
When using a tool, avoid letting it touch the connector portion which is made of plastic.
1. Remove all old sealant remaining on the threads
of the coolant temperature sensor and in the
threaded hole in the thermostat housing.
2. Apply sealant to the coolant temperature sensors
threads indicated in the drawing.
Specified sealant:
ENGINE OVERHAUL
11B-31

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

<> >>C<<
>>B<<
2.
3.
4.
5.
6.

Retainer lock
Valve spring retainer
Valve spring
<> >>C<<
>>B<<
>>A<<

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

>>A<< 14. Valve stem seal

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

>>A<< VALVE STEM SEAL INSTALLATION
MD998737

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

RECONDITIONING section.
0.5 1 mm
VALVE GUIDE REPLACEMENT

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

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

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

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

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

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

M1113008100301
19 3 Nm
10
Apply engine oil

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

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

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

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

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

MD998162
AK202574 AB
1. Remove the oil pan bolts.

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

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

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

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

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

BEARING INSTALLATION
MB991603
<<F>> COUNTERBALANCER SHAFT FRONT

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

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

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

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

BEARING INSTALLATION
Rear bearing (Right)

Ratchet ball
Oil
hole
Tool element for

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Specified sealant:
equivalent
Timing belt side

M6 8
Timing belt side

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

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

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

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

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

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

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

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

M1113008400528
6
7
8
Apply engine oil to

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

would result from the heat generated by boring,
bore the cylinders in the following sequence: No.
2 No. 4 No. 1 No. 3.
4. Bore all the cylinders to the calculated boring
finish dimension.
5. Hone the bored cylinders to the final finish
dimension (piston diameter + clearance between
piston and cylinder).
6. Check the clearance between the piston and
cylinder.
11C-1
GROUP 11C
ENGINE
MECHANICAL
<4G69>
CONTENTS
11C-2
11C-2
SEALANTS . . . . . . . . . . . . . . . . . . . .
11C-3
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11C-4
ON-VEHICLE SERVICE. . . . . . . . . . .
11C-8
11C-17
CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11C-18
11C-18
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11C-23

11C-23
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11C-26
DRIVE BELT TENSION CHECK. . . . . . . . .
11C-8
AUTO-TENSIONER CHECK . . . . . . . . . . .
11C-8
VALVE CLEARANCE CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
11C-11
ROCKER ARM PISTON OPERATION

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11C-11
IGNITION TIMING CHECK . . . . . . . . . . . . .
11C-13
IDLE SPEED CHECK . . . . . . . . . . . . . . . . .
11C-14
IDLE MIXTURE CHECK . . . . . . . . . . . . . . .
11C-14
11C-36
COMPRESSION PRESSURE CHECK. . . .
11C-15
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11C-45
MANIFOLD VACUUM CHECK . . . . . . . . . .
11C-16
CRANKSHAFT OIL SEAL . . . . . . . . . 11C-26

11C-26
CYLINDER HEAD GASKET . . . . . . . . 11C-30

11C-30
TIMING BELT . . . . . . . . . . . . . . . . . . . 11C-36
ENGINE ASSEMBLY . . . . . . . . . . . . . 11C-47

CRANKSHAFT PULLEY . . . . . . . . . . 11C-17
11C-47
ENGINE MECHANICAL <4G69>
11C-2
GENERAL INFORMATION
GENERAL INFORMATION
M1111000100505
Item
4G69
2,378
Bore Stroke mm
87 100
Compression ratio
9.5
Compression chamber
Pentroof
Camshaft arrangement
SOHC
Number of valve
Intake
Exhaust
Valve timing
Intake valve
Open (BTDC)
10 <low speed cam A>

12 <low speed cam B>
24 <High speed cam>
Closes (ABDC)
42 <low speed cam A>

44 <low speed cam B>
68 <High speed cam>
Exhaust valve
Open (BTDC)
58
Closes (ABDC)
18
Fuel system
Electronically controlled multipoint fuel injection
Rocker arm
Roller type
M1112000300278
Item
Standard value
Limit
A/C compressor type:

MSC90CA
113 145
A/C compressor type:

MSC105CA
120 154
340 555
Intake valve
0.20
Exhaust valve
0.30
Basic ignition timing
5 BTDC 3
Ignition timing
Approximately
10 BTDC
M/T
680 100
A/T
750 100
CO contents %
0.5 or less
HC contents ppm
100 or less
Compression pressure kPa-r/min
1,560 200
1,130 200
Compression pressure difference of all cylinders kPa
Maximum 98
Drive belt tension
Vibration frequency Hz
(Reference)
Tension N (Reference)
Valve clearance (at hot) mm
Idle speed r/min
11C-3
SEALANTS
Item
Standard value
Limit
Intake manifold vacuum kPa
Minimum 60
99.4
Balancer timing belt tension (When adjusted) Deflection mm
57
Balancer timing belt tension (When replaced) Deflection mm
57
Balancer timing belt tension (When checked)
5 10
Timing belt tensioner adjuster rod protrusion amount mm
3.8 4.5
Timing belt tensioner adjuster rod movement mm
Within 1
Deflection mm
SEALANTS
M1112000500294
Item
Specified sealant
Remark

equivalent
Semi-drying
sealant
LOCTITE203MP
Anaerobic
sealant

Taper plug
11C-4
SPECIAL TOOLS
SPECIAL TOOLS
M1112000600332
Tool
Number
Name
Use
MB991502
MUT-II sub assembly

MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826
MUT-III sub assembly

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

MB991668
Belt tension meter set
Drive belt tension check (used

together with MUT-II or MUT-III)
B991502
MB991824
MB991827
DO NOT USED
MB991910
MB991911
MB991825
MB991826
MB991955
B991668
11C-5
SPECIAL TOOLS
Tool
Number
Name
Use
MB990767
Front hub and flange yoke

holder
Holding the camshaft sprocket
MD998719
Pin
MD998772
Valve spring compressor
Compressing valve spring
MD998774
Valve stem seal installer
Valve stem seal installation
MD998713
Camshaft oil seal installer
Camshaft oil seal installation
MD998781
Flywheel stopper
Supporting the flywheel

assembly <M/T>
Supporting the A/T drive plate
<A/T>
MB990938
Installer bar

installation
MD998776

installer
B990767
D998719
MD998772
D998713
D998781
B990938
D998776
11C-6
SPECIAL TOOLS
Tool
Number
Name
Use
MD998285

guide

installation
MD998375

installer
MD998738
Adjusting bolt
Supporting the timing belt

tensioner arm and timing belt
tensioner adjuster
MB991654
Cylinder head bolt wrench

(12)

cylinder head bolt
MB991367
Special spanner
Holding the crankshaft camshaft

drive sprocket
MB991385
Pin
MD998767
Tensioner wrench
D998285
D998738
B991654
B991367
B991385
D998767

adjustment
11C-7
SPECIAL TOOLS
Tool
Number
Name
Use
MB991454
Engine hanger balancer
MB991527
Hanger
When the engine hanger is

used: Supporting the engine
assembly during removal and
installation of the transmission
assembly
NOTE: Special tool MB991454
is a part of engine hanger
attachment set MB991453.
MB991895
Engine hanger
B991454
B991527
Z203830
MB991928
A: MB991929
B: MB991930
E C: MB991931
D: MB991932
E: MB991933
F: MB991934
Slide bracket (HI)
F
A
D
B
C
B991928
Engine hanger
A: Joint (50) 2
B: Joint (90) 2
C: Joint (140) 2
D: Foot (standard) 4
E: Foot (short) 2
F: Chain and hook assembly
11C-8
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003100548
CAUTION
Check the drive belt tension after turning the
crankshaft clockwise one turn or more.
4. If there are any problems in the procedure 1 or 3,

replace the auto-tensioner.(Refer to P.11C-36).
5. Install the drive belt.(Refer to P.11C-17).
FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
When using MUT-II
1. Check the drive belt tension. (Refer to P.11C-8).
Indicator mark
CAUTION
AC301702AB
1. Make sure that the indicator mark is within the

area marked with A in the illustration.
2. If the mark is out of the area, replace the drive
belt. (Refer to P.11C-17).
NOTE: The drive belt tension check is not
necessary as auto-tensioner is adopted.
16-pin
AUTO-TENSIONER CHECK
M1111003000251
MUT-II
OPERATION CHECK
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner.
2. Remove the drive belt.(Refer to P.11C-17).
MB991668
AC211862 AB
AC301703

hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
To prevent damage to MUT-II, always turn the

before connecting or disconnecting MUT-II.
(MB991668) to the MUT-II.
(2) Connect the MUT-II to the diagnosis
connector.
(3) Turn the ignition switch to "ON" position, and
select "BELT TENSION" on the menu screen.
11C-9
ON-VEHICLE SERVICE
CAUTION
possible.
values.
vehicle's engine is running.
Standard value:
<A/C compressor type: MSC90CA> 113 145
Hz
Hz
3. If not within the standard value, replace the
auto-tensioner. (Refer to P.11C-36).
When using V.C.I.
CAUTION
16-pin
Water
pump
pulley
MB991668
15
15
10 20 mm
MB991824
Gentry tap
with your
finger
MB991668
MB991911
Alternator
pulley
AC301266AB

arrow), approximately 10 20 mm away from
15 degree).
AC211863AB
To prevent damage to special tool V.C.I.

(MB991824), always turn the ignition switch to
the "LOCK" (OFF) position before connecting or
disconnecting special tool V.C.I. (MB991824).
(MB991668) to special tool V.C.I. (MB991824).
(2) Connect special tool MUT-III main harness B
(MB991911) to special tool V.C.I. (MB991824).
(3) Connect special tool MUT-III main harness B
(MB991911) to the diagnosis connector.
(4) Turn the ignition switch to "ON" position, and
select "Belt Tension" on the menu screen.
11C-10
ON-VEHICLE SERVICE
CAUTION
possible.
values.
vehicle's engine is running.
Water
pump
pulley
15

alternator drive belt auto tensioner. (Refer to
P.11C-36).
When using a tension gauge
Water pump
pulley
MB991668
15

Standard value:
Hz
Hz
Belt tension
gauge
10 20 mm
Gentry tap
with your
finger
Alternator
pulley
Alternator
pulley
AC301267AB
AC301266AB

arrow), approximately 10 20 mm away from
15 degree).
2. Use a belt tension gauge in the middle of the belt

between the pulleys (at the place indicated by the
arrow) to measure that the belt tension is within
the standard value.
Standard value: 340 555 N
auto-tensioner. (Refer to P.11C-36).
11C-11
ON-VEHICLE SERVICE
Standard value (hot engine):

Intake valve: 0.20 mm
Exhaust valve: 0.30 mm
VALVE CLEARANCE CHECK AND

ADJUSTMENT
M1111001500131
1. Start the engine and allow it to warm up until the

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

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

CHECK
M1111051000023
Intake valve side
Taper plug
Oil control valve
Ignition coils
No. 2 No. 3
No. 1
Exhaust valve side
No. 4
Rocker cover
AK303689 AB
8. Valve clearance inspection and adjustment can be

performed on rocker arms indicated by white
arrow mark when the No.1 cylinder piston is at the
top dead centre on the compression stroke, and
on rocker arms indicated by black arrow mark
when the No.4 cylinder piston is at the top dead
centre on the compression stroke.
9. Measure the valve clearance.
If the valve clearance is not as specified, loosen
the rocker arm lock nut and adjust the clearance
using a thickness gauge while turning the
adjusting screw.
1.
2.
3.
4.
5.
AK304505AB
Remove all of the ignition coils.

Remove the rocker cover.
Remove the oil control valve.
Remove the taper plug.
Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
the lower cover of timing belt.
6. Move the rocker arms on the No.1 and No.4
cylinders up and down by hand to determine
which cylinder has its piston at the top dead
centre on the compression stroke.
11C-12
ON-VEHICLE SERVICE
NOTE:
Intake valve side
No. 2 No. 3
No. 1
Exhaust valve side
No. 4
AK303689 AC
The rocker arm piston operation check can be

performed on rocker arms indicated by white arrow
mark when the No.1 cylinder piston is at the top dead
centre on the compression stroke, and on rocker
arms indicated by black arrow mark when the No.4
cylinder piston is at the top dead centre on the
compression stroke.
Rocker arm
Rocker arm
piston
Oil passage
Blow
compression
air
AK302684AC
7. While shutting up the oil passage hole at the

depth of the oil control valve's installation hole by
finger not to leak air, blow compression air into the
taper plug's installation hole by air blowgun. At
this time, confirm that the rocker arm piston can
operate.
NOTE: To fully confirm the check, prevent the
compression air from leaking as much as possible by
installing the O-ring to the end of air blowgun.
8. Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
the lower cover of timing belt.
9. Confirm the rest of the rocker arm pistons under
the procedure 7.
10.When the rocker arm piston does not operate,
replace the rocker arm assy.
11.Apply sealant to threaded portion.
Specified sealant: LOCTITE203MP
CAUTION
Do not start the engine within one hour after the
engine taper plug has been installed.
12.Install the taper plug and tighten to the specified
torque.
13.Install the oil control valve. (Refer to Camshaft
and Valve Stem Seal Removal and Installation
P.11C-18.)
14.Install all of the ignition coils.
15.Install the rocker cover.

ON-VEHICLE SERVICE
IGNITION TIMING CHECK

M1111001700607
16 PIN
MB991502
AK303691AF
11C-13

position and then connect the MUT-II/III to the
5. Use the MUT-II/III to measure engine idle speed
and check that it is within the standard value.
Standard value
: 680 100 r/min <M/T>
: 750 100 r/min <A/T>
6. Select No. 17 of the MUT-II/III Actuator test.
7. Check that basic ignition timing is within the
standard value.
Standard value: 5 BTDC 3
8. If the basic ignition timing is outside the standard
value, inspect the MPI system (Refer to P.13B-20,
GROUP 13B Troubleshooting Inspection chart
16-PIN
MB991911
MB991824
MB991827
AK303690AB
1. Before inspection, set the vehicle to the

pre-inspection condition.
CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this
condition may damage the engine.
9. Press the MUT-II/III clear key (Select a forced
driving cancel mode) to release the Actuator test.
10.Check that ignition timing is at the standard value.
NOTE: .
The ignition timing may fluctuate within 7
BTDC. This is normal.
In higher altitude, the ignition timing is more
advanced than the standard value by
approximately 5.
11.Remove the timing light.
12.Turn the ignition switch to the "LOCK" (OFF)
position and then remove the MUT-II/III.
11C-14
ON-VEHICLE SERVICE
IDLE SPEED CHECK

M1111003500654
7. If the idle speed is outside the standard value,

inspect the MPI system (Refer to P.13B-20,
GROUP 13B Troubleshooting Inspection chart
IDLE MIXTURE CHECK

M1111002100426
16 PIN
MB991502
AK303691AF
16-PIN
16 PIN
MB991502
AK303691AF
MB991911
16-PIN
MB991824
MB991911
MB991827
AK303690AB

Standard value
: 680 100 r/min <M/T>
: 750 100 r/min <A/T>
NOTE: .
The idle speed is controlled automatically by
the idle speed control system.
When using the MUT-II/III, select item No. 22
and take a reading of the idle speed.
MB991824
MB991827
AK303690AB

6. Run the engine at 2,500 r/min for 2 minutes.
7. Set the CO, HC tester.

ON-VEHICLE SERVICE
8. Check the CO contents and the HC contents at

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

M1111002600636
Crank angle
sensor
connector
AK303421AB

2. Remove all of the ignition coils and spark plugs.
3. Disconnect the crank angle sensor connector.
NOTE: Doing this will prevent the
engine-ECU<M/T> or engine-A/T-ECU<A/T> from
carrying out ignition and fuel injection.
11C-15
CAUTION
Keep away from the spark plug hole when
cranking.
If compression is measured with water, oil,
fuel, etc., that has come from cracks inside
the cylinder, these materials will become
heated and will gush out from the spark plug
hole, which is dangerous.
4. Cover the spark plug hole with a shop towel etc.,
and after the engine has been cranked, check that
no foreign material is adhering to the shop towel.
5. Set compression gauge to one of the spark plug
holes.
6. Crank the engine with the throttle valve fully open
and measure the compression pressure.
Standard value (at engine speed of 200
r/min):
1,560 kPa
Limit (at engine speed of 200 r/min):
Minimum 1130 kPa
7. Measure the compression pressure for all the
cylinders, and check that the pressure differences
of the cylinders are below the limit.
Limit: Maximum 98 kPa
8. If there is a cylinder with compression or a
compression difference that is outside the limit,
pour a small amount of engine oil through the
spark plug hole, and repeat the operations in
steps from (5) to (7).
(1) If the compression increases after oil is added,
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner
surface.
(2) If the compression dose not rise after oil is
added, the cause is a burnt or defective valve
seat, or pressure is leaking from the gasket.
9. Connect the crank angle sensor connector.
10.Install the spark plugs and tighten to the specified
torque.
11.Install the ignition coils.
12.Use the MUT-II/III to erase the diagnosis codes.
NOTE: This will erase the diagnosis code
resulting from the crank angle sensor connector
being disconnected.
11C-16
ON-VEHICLE SERVICE
MANIFOLD VACUUM CHECK

M1111002700569

Ventilation hose
16 PIN
MB991502
AK303691AF
PCV valve
Plug
Vacuum gauge
AK303422 AB
16-PIN
MB991911
MB991824
3. Disconnect the ventilation hose from the PCV

valve, and connect a vacuum gauge to the
ventilation hose.
4. Plug the PCV valve.
5. Start the engine and check that idle speed is
within the standard valve.
Standard value
: 680 100 r/min <M/T>
: 750 100 r/min <A/T>
6. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
MB991827
AK303690AB
7. Turn off the ignition switch.

8. Remove the vacuum gauge and then connect the
ventilation hose.

CRANKSHAFT PULLEY
11C-17
CRANKSHAFT PULLEY
M1112001600539
P.51-19).
Drive Belt Tension Check (Refer to P.11C-8).
Cover P.51-19).
25 4 Nm
AC308973AB
<<A>>
1.
2.
Removal steps
Drive belt
Crank shaft damper pulley

introduction of the serpentine drive system with the
drive belt auto-tensioner.
Auto-tensioner
AC301703

hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
CAUTION
the belt using chalk, etc.
Auto-tensioner
Hole B
Hole A
AC301704AB
L-shaped
hexagon
wrench
AC301705AB
3. Insert an L-shaped hexagon wrench, etc. into the

hole to fix and then remove the drive belt.
11C-18

M1112006600330
CAUTION
* Remove and assemble the marked parts in each cylinder unit.
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-4).
Ignition Coils Removal (Refer to GROUP 16, Ignition
System Ignition Coil P.16-41).
Timing Belt Upper Cover Removal (Refer to P.11C-36).
Timing Belt Upper Cover Installation (Refer to P.11C-36).
Ignition Coils Installation (Refer to GROUP 16, Ignition
System Ignition Coil P.16-41).
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-4).
Valve Clearance Check and Adjustment (Refer to
P.11C-11).
3.5 0.5 Nm
1
7
N8
4
9.0 2.0 Nm
11 1 Nm
24 3 Nm
3
5
6N
(Engine oil)
44 5 Nm
10
AC308974 AB
1.
2.
>>J<<
>>J<<
3.
4.
5.
6.
Camshaft removal steps

Rocker cover PCV hose connection
Rocker cover breather hose
connection
Engine hanger
Oil control valve
O-ring
7.
8.
9.
10.

Rocker cover assembly
Rocker cover gasket
Spark plug guide oil seals
Accumulator assembly
Valve timing belt (Refer to
P.11C-36).
11C-19
Apply engine oil to all

moving parts before
installation.
31 3 Nm
11
13 1 Nm
11 1 Nm
18
12
19
47 7 Nm
21
22
16
14 1 Nm
25 4 Nm
22 4 Nm
23
13
24*
25*
26*
N 28*
29*
17
20
24*
25*
27*
28* N
29*
89 9 Nm
15 N
14
>>I<<
<<A>>
<>
<>
>>H<<
>>G<<
>>F<<
>>F<<
>>E<<
>>E<<
>>D<<
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Connector bracket
Camshaft position sensing cylinder
Camshaft sprocket
Camshaft oil seal
Exhaust rocker arm shaft caps
Exhaust rocker arm and shaft
assembly
Inlet rocker arm shaft caps
Inlet rocker arm and shaft assembly <>
Camshaft
Water inlet fitting and thermostat
<>
<<C>>
P.14-27).
Cylinder head plug
Oil control valve filter
AC308975AB
1.
2.
>>F<<
>>F<<
>>E<<
>>E<<
>>C<<
>>B<<
>>B<<
>>A<<
3.
4.
7.
8.
9.
16.
17.
18.
19.
23.
24.
25.
26.
27.
28.
29.
Valve stem seal removal steps

Rocker cover PCV hose connection
Rocker cover breather hose
connection
Engine hanger
Rocker cover assembly
Rocker cover gasket
Spark plug guide oil seals
Exhaust rocker arm shaft caps
Exhaust rocker arm and shaft
assembly
Inlet rocker arm shaft caps
Inlet rocker arm and shaft assembly
Spark plugs
Valve spring retainer locks
Valve spring retainers
Inlet valve springs
Exhaust valve springs
Valve stem seals
Valve spring seats
11C-20


<<A>> CAMSHAFT SPROCKET REMOVAL

(MD998772) to compress the valve spring and then
remove the valve spring retainer lock.
MB990767
>>A<< VALVE STEM SEALS INSTALLATION

1. Apply a small amount of engine oil to the valve
stem seals.
MD998719
AC102532AB
1. Use the following special tools to hold the

camshaft sprocket.
Front hub and flange yoke holder (MB990767)
Pin (MD998719)
2. Loosen the camshaft sprocket mounting bolt and
remove the camshaft sprocket.
<> EXHAUST ROCKER ARM AND SHAFT
ASSEMBLY/INLET ROCKER ARM AND SHAFT
ASSEMBLY REMOVAL
CAUTION
Never disassemble the exhaust rocker arm and
shaft assembly, and inlet rocker arm and shaft
assembly.
<<C>> VALVE SPRING RETAINER LOCKS
REMOVAL
CAUTION
When removing valve spring retainer locks, leave
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the
cylinder if the piston is not properly in the TDC
position.
MD998772
CAUTION
Do not re-use the valve stem seal.
Special tool valve stem seal installer
(MD998774) must be used to install the valve
stem seal. Improper installation could result
in oil leaking past the valve guide.
MD998774
Valve
Valve stem
seal
Valve guide
AC308654AB
2. Use the special tool to fill a new valve stem seal in

the valve guide using the valve stem area as a
guide.
>>B<< EXHAUST VALVE SPRINGS/INLET VALVE
SPRINGS INSTALLATION
Rocker arm side
Identification
colour
Inlet side:
Light blue
Exhaust side:
Orange
AC107415AC
Install the valve springs with its identification colour

painted end facing the locker arm.
AC301867AB

>>C<< VALVE SPRING RETAINER LOCKS

INSTALLATION
MD998772
11C-21
1. Place the inlet rocker shaft so that its 5.5 mm hole

faces toward the cylinder head.
2. Install the inlet rocker arm shaft caps.
3. Tighten the inlet rocker shaft mounting bolts to the
specified torque.
>>F<< EXHAUST ROCKER ARM AND SHAFT
ASSEMBLY/EXHAUST ROCKER ARM SHAFT
CAPS INSTALLATION
AC301867AB
Engine front

(MD998772) to compress the valve spring and then
install the valve spring retainer lock in the same
manner as removal.
>>D<< CAMSHAFT INSTALLATION
Notch
Dowel pin
AC301870AB
AC301868AB
Set the dowel pin of the camshaft in the position

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

positioned as shown.
2. Install the exhaust rocker arm shaft caps.
3. Tighten the exhaust rocker shaft mounting bolts to
>>G<< CAMSHAFT OIL SEAL INSTALLATION
Camshaft oil seal
>>E<< INLET ROCKER ARM AND SHAFT

ASSEMBLY/INLET ROCKER ARM SHAFT CAPS
INSTALLATION
Engine front
(Engine oil)
5.5 mm
MD998713
AC301869AB
AC102323AC
1. Apply engine oil to the entire inner diameter of the

oil seal lip.
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seal as shown.
11C-22

>>H<< CAMSHAFT SPROCKET INSTALLATION
MB990767
NOTE: Install the camshaft position sensor

support within 15 minutes after applying the
sealant.
3. Install the camshaft position sensor support to the
cylinder head.
CAUTION
Wait at least one hour. Never start the engine or
let engine oil or coolant touch the adhesion
surface during that time.
MD998719
AC102532AB

hold the camshaft sprocket.
Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
>>I<< CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.
4. Tighten the camshaft position sensor support

>>J<< O-RING/OIL CONTROL VALVE
INSTALLATION
CAUTION
Never re-use the O-ring.
Tape
3 mm
AK303651AD
AC301268AB
2. Apply the sealant to the camshaft position sensor

support flange in a continuous bead as shown in
the illustration.
Before installing O-ring, wind the tape with the

soft adhesion (sealing tape) around the oil
passages cut-out area of engine oil control
valve to prevent the damage. If the O-ring is
damaged, it can be the cause of oil leak.
1. Apply a small amount of engine oil to the O-ring
and then install it to the oil control valve.
2. Assemble the oil control valve to the cylinder
head.
3. Tighten the oil control valve mounting bolt to the
specified torque.
11C-23
OIL PAN
OIL PAN
M1112002800763
P.51-19).
Service Engine Oil Replacement P.12-3).
Exhaust Pipe and Main Muffler P.15-13).
Centre Member Removal (Refer to GROUP 32, Engine
Roll Stopper and Centre Member P.32-12).
Centre Member Installation (Refer to GROUP 32, Engine
Roll Stopper and Centre Member P.32-12).
Cover P.51-19).
48 7 Nm
2
8
N
1
12 2 Nm
48 7 Nm
9.0 3.0 Nm
4
N
6
9.0 3.0 Nm
44 10 Nm
39 5 Nm
9.0 3.0 Nm
2.
>>D<<
3.
9.0 1.0 Nm
5
7
1.
Removal steps
Engine oil cooler tube gaskets
<M/T>
Engine oil cooler hose and bracket
assembly <M/T>
Transmission housing front lower
cover stay
22 4 Nm
9.0 3.0 Nm
AC308976 AB
4.
<<A>>
<>
>>C<<
>>B<<
>>A<<
5.
6.
7.
8.
Removal steps (Continued)

<M/T> or torque converter housing
front lower cover <A/T>
11C-24
OIL PAN

<<A>> ENGINE LOWER OIL PAN REMOVAL
1. Remove the engine lower oil pan mounting bolts.
CAUTION
2. Screw in the bolt into bolt hole A in the location

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

>>A<< ENGINE UPPER OIL PAN INSTALLATION
1. Remove sealant from the engine upper oil pan
and cylinder block surfaces.
4 mm

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

strike it with a hammer to remove the engine
lower oil pan.
<> ENGINE UPPER OIL PAN REMOVAL
1. Remove the engine upper oil pan mounting bolts.
CAUTION
A
A
AC102946AB
Groove
portion
Bolt hole
portion
AC102242AB

of the engine upper oil pan as shown.
NOTE: Install the engine upper oil pan within 15
3. Assemble the engine upper oil pan to the cylinder
block.
11C-25
OIL PAN
CAUTION
B
CAUTION
B
B

of the engine lower oil pan as shown.
NOTE: Install the engine lower oil pan within 15
3. Assemble the engine lower oil pan to the engine
upper oil pan.
B-1
B
B-11
B-10
B-4
B-7
B-5
B-8
B
B
A
B-9
A
AC102929AB
4. Insert the bolts to the engine upper oil pan as

shown, and tighten them to the specified torque.
Name
B-6
A-3
Symbol
Flange bolt A
B
Quantity
Size mm
(D L)
M6 16
16
M6 18

>>B<< ENGINE LOWER OIL PAN INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan.
B-2
B-12
AC102930AB
4. Insert the bolts to the engine lower oil pan as

shown, and tighten them to the specified torque in
the order shown.
Name
Symbol
Flange bolt A
B
Quantity
Size mm
(D L)
M6 75
11
M6 10

>>C<< ENGINE OIL PAN DRAIN PLUG GASKET
INSTALLATION
Engine lower
oil pan side
AC102325 AF
4 mm
Groove
portion
Bolt hole
portion
AC102243AB
Replace the gasket with a new one. Install the new

gasket in the direction shown in the illustration.
11C-26
CRANKSHAFT OIL SEAL
>>D<< TRANSMISSION HOUSING FRONT

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

INSPECTION
M1112002900254
Check the oil pan for cracks.

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

M1112003100411
<M/T>
6
132 5 Nm
8
5
7
9N
3
(Lip section)
(Lip section)
Engine oil
3N
1
AC308977 AB
>>D<<
1.
>>C<<
2.
3.

steps
belt (Refer to P.11C-36).
sprocket
Crankshaft key
<<A>>
<>
>>B<<
>>A<<
4.
5.
6.
7.
8.
9.

steps
Flywheel bolts
Flywheel assembly
Crankshaft bush
11C-27
CRANKSHAFT OIL SEAL
<A/T>
6
N
132 5 Nm
5
7
(Lip section)
(Lip section)
Engine oil
3N
1
AC308978AB
>>D<<
>>C<<
1.
2.
3.

steps
belt (Refer to P.11C-36).
sprocket
Crankshaft key
<>
>>B<<
>>A<<
4.
5.
6.
7.
8.

steps
Transmission assembly (Refer to
GROUP 23A, Transmission
Assembly P.23A-172).
A/T drive plate bolts
A/T drive plate adapter plate
A/T drive plate
Crankshaft bush
11C-28
CRANKSHAFT OIL SEAL

<<A>> TRANSMISSION ASSEMBLY REMOVAL
CAUTION
AC300897
Engine front
Flywheel
assembly

2. Use the following special tools to press-fit the oil
seal.
Installer bar (MB990938)
>>B<< FLYWHEEL BOLTS/A/T DRIVE PLATE
BOLTS INSTALLATION
Flywheel
bolt
MD998781
AC308604 AB
Do not remove the flywheel bolt shown by the

arrow. If this bolt is removed, the flywheel
assembly will become out of balance and
damaged.
Refer to GROUP 22A, Transmission Assembly
P.22A-15.
<> FLYWHEEL BOLTS/A/T DRIVE PLATE
BOLTS REMOVAL
MD998781
AC301855AB

secure the flywheel assembly or A/T drive plate in
the same manner as removal.
2. Tighten the flywheel bolts or A/T drive plate bolts
>>C<< CRANKSHAFT FRONT OIL SEAL
INSTALLATION
Crankshaft
MD998375
AC301854AB
(Engine oil)

secure the flywheel assembly or A/T drive plate.
2. Remove the flywheel bolts or A/T drive plate bolts.

>>A<< CRANKSHAFT REAR OIL SEAL
INSTALLATION
Oil seal
MB990938
(Engine oil)
MD998776
Crankshaft
AC102328 AB
MD998285
(Oil applied to the
circumference)
Oil seal
AC102329AC
1. Apply a small amount of engine oil to the outer

diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal.

CRANKSHAFT OIL SEAL
>>D<< CRANKSHAFT BALANCER SHAFT DRIVE

SPROCKET INSTALLATION
: Clean
Crankshaft
balancershaft
drive sprocket
Crankshaft
Front case
Engine front
AC301346AB
11C-29
1. Clean or degrease the front case, the crankshaft

and the crankshaft balancer shaft drive sprocket
as shown.
2. Install the crankshaft balancer shaft drive sprocket
in the direction shown in the illustration.
11C-30

M1112004000848
Fuel Line Pressure Reduction [Refer to GROUP 13B,
On-vehicle Service Fuel Pump Connector
Disconnection (How to Reduce Pressurized Fuel Lines)
P.13B-428].
Service Engine Coolant Replacement P.14-17).
P.15-4).
Accelerator Cable Removal (Refer to GROUP 17,
Accelerator Cable and Pedal P.17-7).
Accelerator Cable Installation (Refer to GROUP 17,
P.15-4).
Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service Accelerator Cable Check and
Adjustment P.17-5).
Fuel Leak Check
5.0 1.0 Nm
3
2
9.0 2.0 Nm
13 1 Nm
14 3 Nm
(Engine oil)
AC308979AB
1.
2.
3.
4.
Removal steps
Radiator lower hose clamp
Canister vacuum hose connection
5.
6.
7.

Brake booster vacuum hose
connection
Engine oil level gauge and guide
assembly
O-ring
11C-31
13
14
(Engine oil)
<Cold engine>
78 2 Nm 0 Nm 20 2 Nm +90 +90
15
12
(Engine oil)
16
8
11 1 Nm
17 N
11
31 3 Nm
10
31 3 Nm
89 9 Nm
Removal steps
Detonation sensor connection
Inlet manifold stay
Exhaust manifold (Refer to GROUP
15, Exhaust Manifold P.15-11).
Timing belt upper cover (Refer to
P.11C-36).
11. Camshaft sprocket
12. Radiator upper hose connection
13. Water hose connection
8.
9.
10.
<<A>>
<>
>>E<<
>>D<<
AC308980AB
<<C>>
>>C<<
14.
<<D>>
>>B<<
>>A<<
15.
16.
17.

Water inlet fitting and thermostat
P.14-27).
connection
Rocker cover assembly (Refer to
P.11C-18).
Cylinder head bolts
11C-32

<<A>> CAMSHAFT SPROCKET REMOVAL
3. Screw in the special tool until it comes in contact

with the timing belt tensioner arm.
AC107621
CAUTION
Wiring band
Timing mark
AC301451AC
AC301450AB
1. Turn the crankshaft clockwise, align the timing

marks on the camshaft sprocket to set No.1
cylinder to TDC of its compression stroke.
4. Secure the camshaft sprocket and valve timing

belt with wiring bands and so on to prevent
slippage between the camshaft sprocket and
valve timing belt.
MB990767
MD998738
MD998719
Timing belt
under cover
AC301452AB

and then set special tool adjusting bolt
(MD998738).
AC100302 AB

camshaft sprocket.
Pin (MD998719)
CAUTION
Do not rotate the crankshaft after camshaft
sprocket removal.
Timing belt
tensioner arm
MD998738
AC301373AB
6. Remove the camshaft sprocket with the valve

timing belt and place it on the timing belt lower
cover.
11C-33
<> RADIATOR UPPER HOSE

DISCONNECTION
2. Remove the fuel high-pressure hose in the

direction shown in the figure while the retainer is
pulled up.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.
<<D>> CYLINDER HEAD BOLTS REMOVAL
Mating marks
AC200641AB
MB991654
Make mating marks on the radiator upper hose and

the hose clamp. Disconnect the radiator upper hose.
<<C>> FUEL HIGH-PRESSURE HOSE REMOVAL
Engine front
10
Stopper
AC304581AB
1. Remove the fuel high-pressure hose stopper.
AC301454AB
Use special tool cylinder head bolt wrench

(MB991654) to loosen the cylinder head bolts in two
or three steps in the order of the numbers shown in
the illustration. If the cylinder head bolts cannot be
pulled out due to the washer being trapped in the
valve spring, raise the bolt slightly, then remove it
while holding it by using a magnet.
Retainer
AC304582AB
11C-34

>>A<< CYLINDER HEAD GASKET
INSTALLATION
CAUTION
Do not allow any foreign materials get into the
coolant passages, oil passages and cylinder.
MB991654
1. Degrease the cylinder head gasket mounting

surface.
Engine front
Identification
mark "381"
10
Exhaust side
AC302180AB
2. Assemble to the cylinder block so the cylinder

head gasket identification mark of "381" is at the
top surface and on the exhaust side.
>>B<< CYLINDER HEAD BOLTS INSTALLATION
(Engine oil)
AC301456AB
3. Use special tool cylinder head bolt wrench

(MB991654) to tighten the cylinder head bolts in
the following procedures.
(1) Tighten the bolts to 78 2 Nm in the order
shown.
(2) Loosen the bolts fully in the reverse sequence
to that shown.
(3) Tighten the bolts to 20 2 Nm in the order
shown.
Step (4)
90
Step (5)
90
AC102537AC
1. Check that the nominal length of each cylinder

head bolt meets the limit. If it exceeds the limit,
replace the bolts with a new one.
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.
Paint marking
Paint marking
AC102331AB
(4) Apply a paint mark to the heads of the cylinder

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

CAUTION
The bolt is not tightening sufficiently if the
tightening angle is less than a 90 degree
angle.
If the tightening angle exceeds the standard
specification, remove the bolt and start over
from step 1.
(5) Tighten in a 90 degree angle as shown in the
instructions of the figure, then check to see
that the paint mark on the head of the cylinder
head bolts and the paint mark on the cylinder
head is on a linear line.
>>C<< FUEL HIGH-PRESSURE HOSE
INSTALLATION
CAUTION
Fuel
high-pressure
hose
11C-35
>>D<< RADIATOR UPPER HOSE CONNECTION

Projection
Water outlet fitting
Mating marks
AC200642 AB
1. Insert radiator upper hose until it contacts the

projection on the water outlet fitting.
2. Align the mating marks on the radiator upper hose
and hose clamp, and then secure the radiator
upper hose.
3 mm
>>E<< CAMSHAFT SPROCKET INSTALLATION
MB990767
Fuel line pipe
(Engine oil applied)
AC301864AB
MD998719
AC100302 AB
Stopper
AC304583AB
After connecting the fuel high-pressure hose,

slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.

hold the camshaft sprocket.
Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
11C-36
TIMING BELT
TIMING BELT
M1112004300827
P.51-19).
Crankshaft Shaft Damper Pulley Removal (Refer to
P.11C-17).
Crankshaft Shaft Damper Pulley Installation (Refer to
P.11C-17).
Cover P.51-19).
2
14 3 Nm
11 1 Nm
3
5
4
12
14 1 Nm
11
48 5 Nm
14 1 Nm
6
9
8.8 1.0 Nm
11 1 Nm
21 4 Nm
8
13
44 10 Nm
23 3 Nm
10
22 4 Nm
79 5 Nm
11 1 Nm
9.0 1.0 Nm
AC308981AB
1.
2.
3.
4.
5.
6.
Removal steps
Connector bracket
(Refer to GROUP 32, Engine
Mount P.32-5).
Harness bracket
Timing belt upper cover
Water pump pulley
>>G<<
<<A>>
>>F<<
>>E<<
>>D<<
7.
8.
9.
10.
11.
12.
13.

Idler pulley
Auto-tensioner
Timing belt lower cover
adjustment (Installation only)
Valve timing belt
Timing belt tensioner pulley
Timing belt tensioner arm
Timing belt tensioner adjuster

TIMING BELT
11C-37
14
35 6 Nm
22
21
19 3 Nm
18
(Engine oil)
20
19
167 Nm
17
16
15
8.5 0.5 Nm
AC308982 AB
<>
<>
<>
>>C<<
>>C<<
>>C<<
14.
15.
16.
17.
18.
19.
Removal steps
Timing belt Idler pulley
Timing belt lower cover bracket
Crank angle sensor
Crankshaft pulley centre bolt
<<C>>
Crankshaft pulley washer
Crankshaft camshaft drive sprocket
>>C<<
>>B<<
>>A<<
>>A<<

20. Crankshaft angle sensing blade
Balancer timing belt tension
adjustment (Installation only)

21. Balancer timing belt tensioner
22. Balancer timing belt
11C-38
TIMING BELT

<<A>> VALVE TIMING BELT REMOVAL
CAUTION

and then set special tool adjusting bolt
(MD998738).
Timing belt
tensioner arm
Timing mark
MD998738
AC301373AB
Camshaft
sprocket
3. Screw in the special tool with hands until it

contacts the timing belt tensioner arm.
Timing mark
Timing mark
Crankshaft
camshaft
drive sprocket
Engine oil pump

sprocket
CAUTION
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner
adjuster rod will not easily retract and the special
tool may bend.
A
AC301866AB
1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke.
MD998738
AC301856 AB
Timing belt
under cover
AC301452AB
4. Gradually screw in the special tool and then align

the timing belt tensioner adjuster rod set hole A
with the timing belt tensioner adjuster cylinder set
hole B.
11C-39
TIMING BELT

pulley mounting bolt
>>A<< BALANCER TIMING BELT/BALANCER

TIMING BELT TENSIONER INSTALLATION
Wire or pin
Balancershaft
sprocket
Belt tension
side
AC302414AB
5. Insert a wire or pin in the set hole aligned.
CAUTION
To reuse the valve timing belt, draw an arrow
the back of the belt using chalk, etc.
Timing
mark
Timing
mark
6. After removal of the special tool, loosen the timing

belt tensioner pulley mounting bolts and remove
the valve timing belt.
Crankshaft
balancershaft
drive sprocket
<> CRANKSHAFT PULLEY CENTRE

BOLT/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT CAMSHAFT DRIVE
SPROCKET REMOVAL
Crankshaft
camshaft
drive
sprocket
MB991385
MB991367
AC301402AB
1. Ensure that the crankshaft balancer shaft drive

sprocket timing marks and balancer shaft
sprocket timing marks are aligned.
2. Install the balancer timing belt on the crankshaft
balancer shaft drive sprocket and balancer shaft
sprocket. There should be no slack on the tension
side.
Centre of the
mounting bolt
AC102332AB

Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft pulley washer and
<<C>> BALANCER TIMING BELT REMOVAL
CAUTION
To reuse the balancer timing belt, draw an arrow
indicating the rotating direction on the back of
Centre of
the pulley
AC301403AB
3. Assemble and temporarily fix the centre of the

pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the
assembling bolt, and the pulley flange is at the
front-side of the engine.
4. Adjust the balancer timing belt tension.
11C-40

TIMING BELT
>>B<< BALANCER TIMING BELT TENSION

ADJUSTMENT
CAUTION
When tightening the mounting bolts, ensure that
the tensioner does not rotate with the bolts.
Allowing it to rotate with the bolts can cause
excessive tension of the belt.
Balancershaft
sprocket
Timing
mark
Timing
mark
AC301404
1. Lift with your fingers the balancer timing belt

tensioner in the direction of the arrow. Apply a
tensile torque of 3.0 0.4 Nm to the balancer
timing belt so the belt is tense without any
looseness. Tighten the assembling bolt to the
specified torque in this state. Then, fix the
balancer timing belt tensioner.
Crankshaft
balancershaft
drive sprocket
AC301402AC
2. Turn the crankshaft clockwise two turns to set

No.1 cylinder to TDC of its compression stroke
and check that sprocket timing marks are aligned.
Approximately 100 N
Deflection
AC301405AB

shown in the figure, then inspect whether the belt
deflection is within the standard value.
Standard value:
<When adjusting> 5 7 mm
<When replacing> 5 7 mm
tension again.
11C-41
TIMING BELT
>>C<< CRANKSHAFT ANGLE SENSING

BLADE/CRANKSHAFT CAMSHAFT DRIVE
SPROCKET/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT PULLEY CENTRE BOLT
INSTALLATION
: Clean
: Apply engine oil
Crankshaft pulley
centre bolt
Crankshaft angle
sensing blade
Crankshaft
pulley washer

hold the crankshaft camshaft drive sprocket.
Pin (MB991385)
6. Tighten the crankshaft pulley centre bolt to the
specified torque.
Tightening torque: 167 Nm
>>D<< TIMING BELT TENSIONER ADJUSTER
INSTALLATION
1. Set according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.
CAUTION
If the compression is too fast the procedure may
damage the rod. Make a point to slowly and
thoroughly compress.
A
Crankshaft camshaft
drive sprocket
Engine front
Crankshaft
AC301347AB
1. Clean or degrease the crankshaft, the crankshaft

angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as
shown.
2. Install the crankshaft angle sensing blade and
crankshaft camshaft drive sprocket in the
direction shown.
3. Place the larger chamfer side of the crankshaft
pulley washer in the direction shown in the Figure
and then assemble on the crankshaft pulley
centre bolt.
4. Apply a small of engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
Crankshaft
camshaft
drive
sprocket
AC302024 AB
(1) Slowly compress the timing belt tensioner

adjuster rod using a press or vice, then align
the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.
Wire or pin
AC302025AB
MB991385
MB991367
AC102332AB
(2) Insert a wire or pin in the set hole aligned.

NOTE: When replacing the timing belt
tensioner adjuster with new parts, the timing
belt tensioner adjuster is set with a pin.
2. Install the timing belt tensioner adjuster to the
engine and then tighten the mounting bolt to the
specified torque. Do not remove the wire or pin
until the tension of the valve timing belt is
adjusted.
11C-42
TIMING BELT
>>E<< TIMING BELT TENSIONER PULLEY
INSTALLATION
2. Adjust the timing mark of the engine oil pump

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

pulley hole
AC102336AB
Temporarily tighten the timing belt tensioner pulley

as shown.
>>F<< VALVE TIMING BELT INSTALLATION
Timing belt
tensioner
pulley
Belt tension
side
Timing mark
Timing belt
Idler pulley
Camshaft
sprocket
Crankshaft
camshaft
drive sprocket
Engine oil pump

sprocket
AC301372AC
Timing mark
Timing mark
Engine oil pump
sprocket
Crankshaft
camshaft
drive sprocket
AC301374AB
1. Align the timing marks on the camshaft sprocket,

crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt
CAUTION
Incorporate the valve timing belt. Then apply
reverse rotation (anti-clockwise rotation)
pressure to the camshaft sprocket. Re-check to
see that each timing mark is aligned while the
tension side of the belt is right.
(4) Place the valve timing belt on the camshaft
sprocket.
Balancershaft
Plug
Cylinder block
3. Incorporate the valve timing belt in the following

manner so that the tensile force of the belt is not
lax.
(1) Place the valve timing belt on the timing belt
tensioner pulley and crankshaft camshaft
driver sprocket and then support it with your
left hand so it does not slide.
(2) Place the valve timing belt on the engine oil
pump sprocket while pulling it with the right
hand.
(3) Place the valve timing belt on the timing belt
idler pulley.
AC301871AB
11C-43
TIMING BELT
Bolt
MD998767
Balancershaft
Plug
AC301858 AB
4. Turn the timing belt tensioner pulley in the

direction shown in the figure using special tool
tensioner wrench (MD998767) to apply tension to
the valve timing belt. Then temporarily tighten and
fix the timing belt tensioner pulley mounting bolt.
Cylinder block
AC301871AB
6. Remove the bolt inserted in Step 2 above, then

assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque.
8. Adjust the valve timing belt tension.
Timing mark
>>G<< VALVE TIMING BELT TENSION

ADJUSTMENT
MD998738
Camshaft
sprocket
Timing mark
Timing belt
under cover
AC301452AB
Timing mark
Crankshaft
camshaft
drive sprocket
Engine oil pump

sprocket
AC301372AB
5. Check that the timing marks are aligned.
1. Set special tool adjusting bolt (MD998738) used

when removing the valve timing belt.
CAUTION
Always screw in the special tool in with your
hands, since use of a spanner or other tools may
damage the wire or pin inserted in the timing belt
tensioner adjuster.
2. Gradually screw in the special tool to a position in
which the wire or pin inserted in the timing belt
tensioner adjuster lightly moves.
3. Turn the crankshaft 1/4 of a revolution in the
anti-clockwise direction.
11C-44
TIMING BELT
Timing mark
Wire or pin
Camshaft
sprocket
AC301857AB
Timing mark
Timing mark
Crankshaft
camshaft
drive sprocket
7. Remove wire or pin inserted to timing belt

tensioner adjuster.
MD998738
Engine oil pump
sprocket
AC301372AB
4. Turn the crankshaft in the clockwise direction,

align each timing mark to set No.1 cylinder to TDC
of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.
CAUTION
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
Timing belt
under cover
AC301452AB
8. Remove special tool adjusting bolt (MD998738),

and install the rubber plug to the timing belt under
cover.
9. Rotate crankshaft clockwise two turns, and leave
it for about 15 minutes.
Wire or pin
MD998767
AC301857AB
AC301859 AB
6. With special tool tensioner wrench (MD998767)

and torque wrench, apply tension torque 3.5 Nm
to the valve timing belt, and tighten the timing belt
tensioner pulley mounting bolt to the specified
torque.
10.Insert wire or pin removed in Step 7 again, and

ensure that it can be pulled out with a light load.
When wire or pin can be lightly removed,
appropriate tension is applied on timing belt. In
this case, remove wire or pin.
11C-45
TIMING BELT
12.Check again that the timing marks on sprockets

are aligned.
INSPECTION
M1112004400460
Rod
AC301375AB
Also the projection of timing belt tensioner

adjuster rod (A) is within the standard value,
appropriate tension is applied.
Standard value (A): 3.8 4.5 mm
11.If wire or pin cannot be easily pulled out, repeat
Step 1 through Step 9 to reach proper valve timing
belt tension.
CAUTION
Always check the tightening torque of the
crankshaft pulley centre bolt when turning the
crankshaft pulley centre bolt anti-clockwise.
Re-tighten if it is loose.
Timing mark
1. Check for oil leak from seal, and replace it if leak

is detected.
2. Check for wear or damage at the top of the rod.
Replace it, if required.
98 196 N
A
Movement
Rod
AC301376AB
3. Hold the timing belt tensioner adjuster by hand,

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

CHECK
Engine oil pump

sprocket
AC301866AB
11C-46
TIMING BELT
BALANCER TIMING BELT TENSION

CHECK
Check the balancer timing belt tension in the
following procedures.
Approximately 100 N
Deflection
AC301405AB

shown in the figure, then inspect whether the
flexure is within the standard value.
Standard value: 5 10 mm
tension. (Refer to P.11C-36).

ENGINE ASSEMBLY
11C-47
ENGINE ASSEMBLY
M1112001000946
<M/T>
CAUTION
P.51-19).
P.13B-428].
Transmission Oil Draining (Refer to GROUP 22A,
On-vehicle Service Transmission Oil Replacement
P.22A-8).
Transfer Oil Draining (Refer to GROUP 22A, On-vehicle
Service Transfer Oil Replacement P.22A-8).
Hood Removal (Refer to GROUP 42, Hood P.42-4).
P.15-4).
Radiator P.14-29).
Radiator P.14-29).
P.15-4).
Hood Installation (Refer to GROUP 42, Hood P.42-4).
Transfer Oil Refilling (Refer to GROUP 22A, On-vehicle
Transmission Oil Refilling (Refer to GROUP 22A,
On-vehicle Service Transmission Oil Replacement
P.22A-8).
Adjustment P.17-5).
Fuel Leak Check
Cover P.51-19).
Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service Front Wheel Alignment
Check and Adjustment P.33-6).
11C-48
ENGINE ASSEMBLY
9.0 2.0 Nm
9.0 2.0 Nm
5.0 1.0 Nm
6N
48 7 Nm
9.0 2.0 Nm
5.0 1.0 Nm
12 2 Nm
48 7 Nm
AC308983 AB
1.
2.
3.
4.
Removal steps
connection
<<A>>
5.
6.
7.

Drive belt
Engine oil cooler tube gaskets
Engine oil cooler hose and bracket
assembly
11C-49
ENGINE ASSEMBLY
11
10
(Engine oil)
15
24 4 Nm
13
44 10 Nm
70 4 Nm*
44 10 Nm*
22 4 Nm
44 10 Nm*
12
14
AC308984 AB
<>
<<C>>
<<D>>
Removal steps
Power steering oil pump and
bracket assembly
9. A/C compressor and clutch
assembly
10. Heater water hoses connection
11. Fuel high-pressure hose
connection
8.
>>E<<
<<E>>
>>D<<
<<F>>
<<G>>
>>B<<
>>A<<
12.
13.
14.
15.

Earth cable connection
Self-locking nuts
Engine assembly
11C-50

ENGINE ASSEMBLY
<A/T>
CAUTION
P.51-19).
P.13B-428].
Transmission Fluid Draining (Refer to GROUP 23A,
On-vehicle Service Automatic Transmission Fluid
Change P.23A-144).
Transfer Oil Draining (Refer to GROUP 23A, On-vehicle
Hood Removal (Refer to GROUP 42, Hood P.42-4).
P.15-4).
Radiator P.14-29).
Radiator P.14-29).
P.15-4).
Hood Installation (Refer to GROUP 42, Hood P.42-4).
Transfer Oil Refilling (Refer to GROUP 23A, On-vehicle
Transmission Fluid Refilling (Refer to GROUP 23A,
On-vehicle Service Automatic Transmission Fluid
Change P.23A-144).
Adjustment P.17-5).
Fuel Leak Check
Cover P.51-19).
Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service Front Wheel Alignment
Check and Adjustment P.33-6).
11C-51
ENGINE ASSEMBLY
9.0 2.0 Nm
1
3
9.0 2.0 Nm
5.0 1.0 Nm
9.0 2.0 Nm
5.0 1.0 Nm
AC308985AB
1.
2.
3.
Removal steps
4.
<<A>>
5.

connection
Drive belt
11C-52
ENGINE ASSEMBLY
9
(Engine oil)
13
24 4 Nm
44 10 Nm
44 10 Nm*
11
45 5 Nm*
22 4 Nm
44 10 Nm*
10
12
<>
6.
<<C>>
7.
<<D>>
>>E<<
8.
9.
Removal steps
Power steering oil pump and
bracket assembly
A/C compressor and clutch
assembly
Heater water hoses connection
connection
7
<<E>>
>>D<<
<<F>>
<<G>>
>>C<<
>>B<<
>>A<<
10.
11.
12.
13.
AC308986AB

Earth cable connection
Self-locking nuts
Engine assembly
11C-53
ENGINE ASSEMBLY

introduction of the serpentine drive system with the
drive belt auto-tensioner.
Auto-tensioner
AC301703
Hole B
NOTE: After removing the power steering oil pump

and bracket assembly, secure it with a cord in the
location where the removal and installation of the
engine assembly cannot be hindered.
<<C>> A/C COMPRESSOR AND CLUTCH
ASSEMBLY REMOVAL
With the hose installed, remove the A/C compressor
and clutch assembly from the bracket.
NOTE: After removing the A/C compressor and
clutch assembly, secure it with a cord in the location
where the removal and installation of the engine
assembly cannot be hindered.
Hole A
AC301704AB
<<D>> FUEL HIGH-PRESSURE HOSE REMOVAL

hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
CAUTION
Auto-tensioner
L-shaped
hexagon
wrench
Stopper
AC304581AB
1. Remove the fuel high-pressure hose stopper.
AC301705AB
3. Insert an L-shaped hexagon wrench, etc. into the

hole to fix and then remove the drive belt.
<> POWER STEERING OIL PUMP AND
BRACKET ASSEMBLY REMOVAL
With the hose installed, remove the power steering
oil pump and bracket assembly from the engine
assembly.
Retainer
AC304582AB
2. Remove the fuel high-pressure hose in the

direction shown in the figure while the retainer is
pulled up.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.
11C-54
ENGINE ASSEMBLY
<<E>> TRANSMISSION ASSEMBLY REMOVAL

used>
MB991454
MB991527
AC300950AB
1. Pre-tighten the 2 bolts on the car to assemble the

radiator support upper insulator to set special tool
engine hanger MB991895 or engine hanger
MB991928.
2. Remove the transmission assembly (M/T: Refer to
GROUP 22A, Transmission Assembly P.22A-15,
A/T: Refer to GROUP 23A, Transmission
<<F>> ENGINE FRONT MOUNTING BRACKET
REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.
MB991895
MB991527
AC107632 AB
3. Hold the engine assembly with a chain block, etc.

with a piece of wood in between so that the weight
of the engine assembly is no longer being applied
to the engine front mounting bracket.
5. Loosen the engine front mounting bracket
mounting nuts and bolts, and remove the engine
front mounting bracket.
<<G>> ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and wiring
harness connectors and so on are disconnected
from the engine, lift the chain block slowly to remove
the engine assembly upward from the engine
compartment.

>>A<< ENGINE ASSEMBLY INSTALLATION
MB991454
AC107631AB
MB991454
MB991527

used>
MB991928
AC107632 AB
Install the engine assembly, being careful not to

pinch the cables, hoses or wiring harness
connectors.
MB991527
MB991454
AC211405AB
11C-55
ENGINE ASSEMBLY
>>B<< ENGINE FRONT MOUNTING BRACKET

INSTALLATION
with a piece of wood in between, and install the
engine front mounting bracket while adjusting the
position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
support the engine.
>>D<< TRANSMISSION ASSEMBLY

INSTALLATION
1. Install the transmission assembly. (M/T: Refer to
GROUP 22A, Transmission Assembly P.22A-15,
A/T: Refer to GROUP 23A, Transmission
MB991895
MB991527
AC300950AB
MB991454
2. Remove from the car the two bolts, to assemble

the radiator support upper insulator.
AC107631AB

used>
Set special tool MB991895. (M/T: Refer to
P.22A-15, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-172).
>>E<< FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
Fuel
high-pressure
hose
3 mm
MB991928
Fuel line pipe

(Engine oil applied)
MB991527
AC301864AB
MB991454
AC211405AB

used>
Set special tool MB991928. (M/T: Refer to
P.22A-15, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-172).
>>C<< SELF-LOCKING NUTS INSTALLATION
CAUTION
Do not tighten the self-locking nuts while the
engine is hot.
Tighten the self-locking nuts to the specified torque
while the engine is cold.
Stopper
AC304583AB
After connecting the fuel high-pressure hose,

slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.
NOTES
12-1
GROUP 12
ENGINE
LUBRICATION
CONTENTS
12-2
SERVICE SPECIFICATION . . . . . . . .
12-2
LUBRICANT. . . . . . . . . . . . . . . . . . . .
12-2
SEALANT. . . . . . . . . . . . . . . . . . . . . .
12-3
SPECIAL TOOLS. . . . . . . . . . . . . . . .
12-3
ON-VEHICLE SERVICE . . . . . . . . . . .
12-3
ENGINE OIL CHECK . . . . . . . . . . . . . . . . .
12-3
ENGINE OIL REPLACEMENT . . . . . . . . . .
12-3
ENGINE OIL FILTER REPLACEMENT. . . .
12-4
OIL PRESSURE CHECK . . . . . . . . . . . . . .
12-5
ENGINE OIL COOLER . . . . . . . . . . . .
12-6
12-6
ENGINE LUBRICATION
12-2
GENERAL INFORMATION
GENERAL INFORMATION
M1121000100346
The lubrication method is a fully force-fed, full-flow

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

underpants, with oil.
Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separate from
personal clothing.
Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
Obtain First Aid treatment immediately for open
cuts and wounds.
Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
If skin disorders develop, obtain medical advice
without delay.
SERVICE SPECIFICATION
M1121000300254
Item
Standard value
Oil pressure kPa
at idle
29 or more
at 3,500 r/min
294 686
LUBRICANT
M1121000400529
Item
Specification
Engine oil ACEA classification
A1, A2 or A3
Engine oil API classification
SG or higher
Engine oil quantity L
4G63, 4G69 (A/T)

4G69 (M/T)
Oil filter
0.3
Total
4.3
Oil filter
0.3
Oil cooler
0.3
Total
4.6
ENGINE LUBRICATION
12-3
SEALANT
SEALANT
M1121000500258
Item
Specified sealant
Remark
Oil pressure switch
3M ATD Part No. 8660 or equivalent
Semi-drying sealant
SPECIAL TOOLS
M1121000600363
Tool
Number
Name
Use
MB991610
Oil filter wrench
Removal and installation

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

wrench
Removal and installation

of oil pressure switch
MB991610
ON-VEHICLE SERVICE
ENGINE OIL CHECK
M1121000900320
1. Pull out the level gauge slowly and check that the
oil level is in the illustrated range.
2. Check that the oil is not excessively dirty, that
there is no coolant or petrol mixed in, and that it
has sufficient viscosity.
Drain plug
Drain plug
gasket
Oil pan side
ENGINE OIL REPLACEMENT
Oil pan
M1121001000494

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

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

Specified Engine Oil (ACEA and API
classification): ACEA A1, A2 or A3/API SG or
higher
Total quantity (Includes volume inside engine
oil filter):
4.3 L <4G63, 4G69 (A/T)>
4.6 L <4G69 (M/T)>
5. Use the respective tool in the following table to

remove the engine oil filter.
6. Clean the filter bracket side mounting surface.
6. Install the engine oil filler cap.

7. Check oil level.
ENGINE OIL FILTER REPLACEMENT
O-ring
M1121001100350

temperature of the coolant reaches 80 C to 90
C.
2. Remove the engine oil filler cap.
CAUTION
Use care as oil could be hot.
3. Remove the drain plug to drain oil.
4. Remove the under cover.
AC103250AD
7. Apply a small amount of engine oil to the O-ring of

the new oil filter.
8. Once the O-ring of the oil filter is touching the
flange, use the respective tool in the following
table to tighten to the specified torque.
9. Install the drain plug and refill the engine oil (Refer
to P.12-3).
10.Race the engine 23 times, and check to be sure
that no engine oil leaks from installation section of
the oil filter.
Number
Special tool
Tightening torque
MD356000
Oil filter wrench (MB991610)

or equivalent
Approximately 3/4 turn (14 2 Nm)
MD136466,
MD322508
Commercially- available tool
Approximately 3/4 turn (17 3 Nm)
ENGINE LUBRICATION
12-5
ON-VEHICLE SERVICE
OIL PRESSURE CHECK

M1121002300432
Standard value:
At idle: 29 kPa or more
At 3,500 r/min: 294 686 kPa
7. Remove the oil pressure gauge.
Cylinder block
Oil pressure switch
AK000197AF
1. Check engine oil quantity.

2. Remove the oil pressure switch terminal.
CAUTION
AKX00295AD
8. Apply the specified sealant to the thread of oil

pressure switch.
Specified sealant: 3M ATD Part No. 8660 or
equivalent
MD998054
CAUTION
MD998054
AKX00294 AD
Since sealant is applied to the thread of oil

pressure switch, take care not to damage the oil
pressure switch when removing it.
3. Use the special tool Oil pressure switch wrench
(MD998054) to remove the oil pressure switch.
4. Install the oil pressure gauge.
NOTE: Use an adapter of PT 1/8 thread.
5. Run the engine to warm it.
6. After the engine has been warmed up, check that
oil pressure is within the standard value.
AKX00294 AD
Do not start the engine within one hour after the

oil pressure switch has been installed.
9. Use the special tool Oil pressure switch wrench
(MD998054) to tighten the oil pressure switch to
10.Install the oil pressure switch terminal.
ENGINE LUBRICATION
12-6
ENGINE OIL COOLER
ENGINE OIL COOLER

M1121001300116
Front Under Cover (LH) Removal (Refer to GROUP 51,
Under Cover P.51-19).
Front Under Cover (LH) Installation (Refer to GROUP 51,
Under Cover P.51-19).
Engine Oil Refilling and Level Check (Refer to P.12-3).
5.0 1.0 Nm
12 2 Nm
12 2 Nm
27
26
45 5 Nm
21
12 2 Nm
13
24
17
14
2
45 5 Nm
48 7 Nm
20
22
33 2 Nm
12 2 Nm
23
12 2 Nm
11
15
4N
4N
10
25
19 N
12
12 2 Nm
16
9
10
12 2 Nm
48 7 Nm
18
12 2 Nm
6
AC309226AB
1.
2.
3.
4.
5.
6.
7.
8.
Engine oil cooler removal steps

Splash Shield Mounting Clips (LH)
(Refer to GROUP 51, Front Bumper
P.51-3).
Eye bolt
Gasket
Eye bolt
Gasket
Engine oil cooler assembly
Bracket
Bracket
Engine oil cooler
Engine oil cooler removal steps

9. Collar
10. Bush
Engine oil cooler hose removal
steps (Engine oil cooler side)
11. Engine oil cooler return hose
connection
1. Eye bolt
2. Gasket
12. Engine oil cooler return hose
13. Bolt
ENGINE LUBRICATION
ENGINE OIL COOLER
14.
3.
4.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
11.
14.
17.
21.
26.
27.

steps (Engine oil cooler side)
Reserve tank assembly (Refer to
GROUP 14, Radiator P.14-29).
Engine oil cooler feed hose
connection
Eye bolt
Gasket
steps (Engine side)
Side under cover (RH) (Refer to
GROUP 51, Under cover P.51-3).
Clamp
Engine oil cooler return hose
connection
Eye bolt
Gasket
connection
Eye bolt
Gasket
Bracket
Engine oil cooler feed and return
tube removal steps
Front bumper beam (Refer to
GROUP 51, Front bumper assembly
P.51-3).
connection
connection
connection
connection
Engine oil cooler feed and return tube
Clamp
12-7
NOTES
13A-1
GROUP 13A
MULTIPORT FUEL
INJECTION (MFI)
00
11
12
13
14
15
CONTENTS
16
17
13A
ENGINE CONTROL RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A
13A
FUEL PUMP RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A
22
SEALANT. . . . . . . . . . . . . . . . . . . . . .
13A
INTAKE AIR TEMPERATURE SENSOR

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A
25
SPECIAL TOOLS. . . . . . . . . . . . . . . .
13A
ENGINE COOLANT TEMPERATURE

SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A
26
TROUBLESHOOTING . . . . . . . . . . . .
13A
THROTTLE POSITION SENSOR CHECK . 13A
27
ON-VEHICLE SERVICE. . . . . . . . . . . 13A

THROTTLE BODY (THROTTLE VALVE
AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A
THROTTLE POSITION SENSOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13A
BASIC IDLE SPEED ADJUSTMENT . . . . . 13A
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A
FUEL PUMP CONNECTOR
DISCONNECTION (HOW TO REDUCE
PRESSURIZED FUEL LINES) . . . . . . . . . . 13A
FUEL PUMP OPERATION CHECK . . . . . . 13A
COMPONENT LOCATION . . . . . . . . . . . . . 13A
OXYGEN SENSOR CHECK . . . . . . . . . . . . 13A
21
INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A
31
IDLE SPEED CONTROL (ISC) SERVO

(STEPPER MOTOR) CHECK . . . . . . . . . . . 13A
32
INJECTOR . . . . . . . . . . . . . . . . . . . . . 13A
33
REMOVAL AND INSTALLATION . . . . . . . . 13A
34
THROTTLE BODY ASSEMBLY . . . . . 13A
35
36
THROTTLE BODY ASSEMBLY

DISASSEMBLY AND REASSEMBLY . . . . . 13A
ENGINE ECU . . . . . . . . . . . . . . . . . . . 13A

37
42
51
52
54
55
MULTIPORT FUEL INJECTION (MFI)
13A-2
GENERAL INFORMATION
GENERAL INFORMATION
M1131000100701
The Multipoint Fuel Injection System consists of sensors which detect the engine conditions, the engineECU which controls the system based on signals
from these sensors, and actuators which operate
under the control of the engine-ECU. The engineFUEL INJECTION CONTROL
The injector drive times and injection timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continuallychanging engine operation conditions.
A single injector is mounted at the intake port of each
cylinder. Fuel is sent under pressure from the fuel
tank by the fuel pump, with the pressure being regulated by the fuel pressure regulator. The fuel thus
regulated is distributed to each of the injectors.
Fuel injection is normally carried out once for each
cylinder for every two rotations of the crankshaft. The
firing order is 1-3-4-2. This is called sequential fuel
injection. The engine-ECU provides a richer air/fuel
mixture by carrying out "open-loop" control when the
IDLE AIR CONTROL
The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle
valve in accordance with changes in idling conditions
and engine load during idling. The engine-ECU
drives the idle speed control motor to keep the
engine running at the pre-set idle target speed in
accordance with the engine coolant temperature and
ECU carries out activities such as fuel injection control, idle speed control and ignition timing control. In
addition, the engine-ECU is equipped with several
diagnosis modes which simplify troubleshooting
when a problem develops.
engine is cold or operating under high load conditions in order to maintain engine performance. In
addition, when the engine is warm or operating under
normal conditions, the engine-ECU controls the
air/fuel mixture by using the oxygen sensor signal to
carry out "closed-loop" control in order to obtain the
theoretical air/fuel mixture ratio that provides the
maximum cleaning performance from the three way
catalyst.
air conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is
idling, the idle speed control motor operates to adjust
the throttle valve bypass air amount in accordance
with the engine load conditions in order to avoid fluctuations in the engine speed.
IGNITION TIMING CONTROL

The power transistor located in the ignition primary
circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition
timing in order to provide the optimum ignition timing
with respect to the engine operating conditions. The
ignition timing is determined by the engine-ECU from
the engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.
SELF-DIAGNOSIS FUNCTION
When an abnormality is detected in one of the
sensors or actuators related to emission control,
the engine warning lamp (check engine lamp)
illuminates as a warning to the driver.
sensors or actuators, a diagnosis code corresponding to the abnormality is output.
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control
The RAM data inside the engine-ECU that is

related to the sensors and actuators can be read
by means of the MUT-II. In addition, the actuators
can be force-driven under certain circumstances.
Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running.

GENERAL INFORMATION
2. A/C Relay Control

Turns the compressor clutch of the A/C ON and OFF.
3. Fan Motor Control
The revolutions of the radiator fan and condenser fan
are controlled in response to the engine coolant
temperature and vehicle speed.
4. Purge Control Solenoid Valve Control
(Refer to 317, GROUP 17 - Engine And Emission

Control - Evaporative Emission Control System).
5. EGR Control Solenoid Valve Control
[Refer to 317, GROUP 17 - Engine And Emission Control - Exhaust Gas Recirculation (EGR)
System].
Items
Throttle body
Specifications
Throttle bore mm
60
Throttle position sensor
Variable resistor type
Idle speed control servo
Stepper motor type
Engine-ECU
Identification No.
E6T38971
Sensors
Air flow sensor
Karman vortex type
Barometric pressure Sensor
Semiconductor type
Intake air temperature sensor
Thermistor type
Engine coolant temperature
Thermistor type
Oxygen sensor
Zirconia type
Inhibitor switch
Contact switch type
Hall element type
Crank angle sensor
Hall element type
Detonation sensor
Piezoelectric type
Power steering fluid pressure switch
Contact switch type
Engine control relay type
Contact switch type
Fuel pump relay type
Contact switch type
Injector type and number
Electromagnetic type, 4
Injector identification mark
HDA 250E
Duty cycle type solenoid valve
Actuators
Fuel pressure Regulator pressure kPa

regulator
13A-3
329
13A-4
GENERAL INFORMATION
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM

1
2
3
4
Oxygen sensor (front)

Oxygen sensor (rear)
Air flow sensor
Intake air temperature
sensor
5 Throttle position sensor
6 Camshaft position
sensor
7 Crank angle sensor
8 Barometric pressure
sensor
9 Engine coolant
temperature sensor
10 Detonation sensor
Power supply
Ignition switch-IG
Ignition switch-ST
A/C switch
A/C load signal
A/C pressure
sensor
Power steering
fluid pressure switch
Alternator FR
terminal
Vehicle speed
sensor
Engine control relay

Fuel pump relay
A/C compressor relay
Ignition coil
Fan controller
Engine warning lamp
Diagnosis output
Alternator G terminal
Oxygen sensor heater
Tachometer
4 Intake air temperature sensor

2 Idle speed control servo
3 Air flow sensor
(Stepper motor)
8 Barometric
5 Throttle position
pressure sensor
sensor
6 Camshaft position sensor
Air
Fuel pressure
regulator
To
fuel tank
1 Injector
2 Idle speed control
servo (Stepper motor)
3 EGR control solenoid
valve
4 Purge control solenoid
valve
Engine-ECU
From
fuel pump
EGR valve
Canister
1 Oxygen sensor
(front)
1 Injector
Catalytic
converter
9 Engine coolant
temperature sensor
3 EGR control
solenoid valve
10 Detonation sensor
2 Oxygen sensor (rear)
Catalytic
converter
4 Purge control
solenoid valve
AK204338 AB
13A-5
M1131000300459
Items
Specifications
Basic idle speed r/min
700 50
Throttle position sensor adjusting voltage mV
535 - 735
Throttle position sensor resistance kW
3.5 - 6.5
Idle speed control servo coil resistance (at 20C) W
28 - 33
Intake air temperature sensor -20C

resistance kW
0C
13 - 17

sensor resistance kW
5.3 - 6.7
20C
2.3 - 3.0
40C
1.0 - 1.5
60C
0.56 - 0.76
80C
0.30 - 0.42
-20C
14 - 17
0C
5.1 - 6.5
20C
2.1 - 2.7
40C
0.9 - 1.3
60C
0.48 - 0.68
80C
0.26 - 0.36
Oxygen sensor output voltage (at racing) V
0.6 - 1.0

resistance (at 20C) W
front
4.5 - 8.0
rear
11 - 18
Fuel pressure kPa
Vacuum hose disconnection
330 - 350 at curb idle
Vacuum hose connection
Approximately. 270 at curb idle
Injector coil resistance (at 20C) W
10.5 - 13.5
SEALANT
M1131000500237
Item
Specified sealant
Remark

Threaded portion
3M Nut Locking Part No. 4171 or equivalent
Drying sealant
13A-6
SPECIAL TOOLS
SPECIAL TOOLS
M1131000600342
Tool
Number
Name
Use
MB991502
MUT-II sub
assembly
Reading diagnosis code

MPI system inspection
MB991348
Test harness set
Measurement of voltage during

troubleshooting
Inspection using an oscilloscope
MB991709
Test harness

troubleshooting
Adjusting of idle speed control servo
MD998478
Test harness (3pin, triangle)

Troubleshooting
MB991536
Check harness
for throttle
position sensor
adjustment

Troubleshooting
Adjusting of throttle position sensor
MD998464
Test harness (4pin, square)

Troubleshooting
Inspection of oxygen sensor (front)
MB991658
Test harness

Troubleshooting
Inspection of oxygen sensor (rear)
B991502
MB991348
MB991536
MB991658

SPECIAL TOOLS
Tool
13A-7
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Check at the ECU terminals

A: Connector pin contact inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester connection
MD998709
Adaptor hose
Measurement of fuel pressure
MD998742
Hose adaptor
MB991637
Fuel pressure
gauge set
MB991223
MB991637
13A-8
TROUBLESHOOTING
Tool
Number
Name
Use
MD998706
Injector test set
Checking the spray condition of

injectors
MB991607
Injector test
harness
MD998741
Injector test
adaptor
MB991608
Clip
MD998706
MB991607
MD998741
MB991608
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1131150000342
Refer to 300, GROUP 00 - How to Use Troubleshooting/Inspection Service Points.

NOTE: If the engine-ECU is replaced, the steering
lock cylinder and ignition key should be replaced
together with it.
DIAGNOSIS FUNCTION
M1131155500074
ENGINE WARNING LAMP (CHECK

ENGINE LAMP)
Engine warning lamp

(check engine lamp)
AK300251AB
If an abnormality occurs in any of the following items

related to the Multipoint Fuel Injection (MPI) system,
the engine warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.

TROUBLESHOOTING
ENGINE WARNING LAMP INSPECTION ITEMS

Code No.
Diagnosis item
Engine-ECU
P0100
Air flow sensor system
P0105
Barometric pressure sensor system
P0110
Intake air temperature sensor system
P0115
Engine coolant temperature sensor system
P0120
Throttle position sensor system
P0125*
Feedback system monitor
P0130
Oxygen sensor (front) system <Sensor 1>
P0135
Oxygen sensor heater (front) system <Sensor 1>
P0136
Oxygen sensor (rear) system <Sensor 2>
P0141
Oxygen sensor heater (rear) system <Sensor 2>
P0170
Abnormal fuel system
P0201
No. 1 injector system
P0202
P0203
P0204
P0300
Random cylinder mis-fire detection system
P0301*
No. 1 cylinder mis-fire detection system
P0302*
P0303*
P0304*
P0325
Detonation sensor system
P0335
Crank angle sensor system
P0340
Camshaft position sensor system
P0403
EGR control solenoid valve system
P0420
Catalyst deterioration system
P0443
Purge control solenoid valve system
P0500
Vehicle speed sensor system
P0505
Idle speed control system
P0551*
Power steering fluid pressure switch system
P1603*
Battery back-up line system
P1610
Immobilizer system
13A-9
13A-10
TROUBLESHOOTING
NOTE: .
If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is
next turned on and the same malfunction is re-detected.However, for items marked with a "*" in the diagnosis code number column, the engine warning lamp illuminates only on the first detection of the malfunction.
After the engine warning lamp illuminates, it will be switched off under the following conditions.
When the engine-ECU monitored the power train malfunction three times* met set condition requirements, it detected no malfunction.
*: In this case, "one time" indicates from engine start to stop.
For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
Sensor 1 indicates, the sensor mounted at a position closest to the engine, and sensor 2 indicates the
sensor mounted at the position second closest to the engine.
METHOD OF READING AND ERASING

DIAGNOSIS CODES
INSPECTION USING MUT-II DATA LIST

AND ACTUATOR TESTING
Refer to 300, GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
1. Carry out inspection by means of the data list and

the actuator test function, if there is an
abnormality, check and repair the chassis harness
and components.
2. After repairing, re-check using the MUT-II and
check that the abnormal input and output have
returned to normal as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II, and then start the engine
again and carry out a road test to confirm that the
problem has disappeared.
DIAGNOSIS USING DIAGNOSIS 2 CODES

1. Switch the diagnosis mode of the engine control
unit to DIAGNOSIS 2 mode using the MUT-II.
2. Carry out a road test.
3. Take a reading of the diagnosis code and repair
the problem location.
4. Turn the ignition switch to OFF and then back to
ON again.
NOTE: By turning the ignition switch to OFF, the
ENGINE-ECU will switch the diagnosis mode
from DIAGNOSIS 2 mode to DIAGNOSIS 1
mode.
5. Erase the diagnosis codes.
FREEZE FRAME DATA

When the engine-ECU detects a malfunction and
stores a diagnosis code, it also stores a current status of the engine. This function is called "Freeze
frame data". By analysing this "Freeze frame" data
with the MUT-II, an effective troubleshooting can be
performed.
The display items of freeze frame data are shown
below.
DISPLAY ITEM LIST

Item No.
Data
Unit
21
22
Engine speed
r/min
24
Vehicle speed
km/h
80
Long-term fuel compensation (long-term fuel trim)
82
Short-term fuel compensation (short-term fuel trim)
13A-11
TROUBLESHOOTING
Item No.
Data
88
Fuel control condition
87
Unit
Open loop
OL
Closed loop
CL
Open loop owing to drive condition
OL-DRV.
Open loop owing to system malfunction
OL-SYS.
Closed loop based on one oxygen sensor
CL- H02S
Calculation load value
Diagnosis code during data recording
NOTE: If malfunctions have been detected in multiple systems, store one malfunction only, which has
been detected first.
READINESS TEST STATUS

The engine-ECU monitors the following main diagnosis items, judges if these items are in good condition
or not, and the stores its history. this history can be
read out by using MUT-II. (If the ECU has judged a
item before, the MUT-II displays "Complete").
In addition, if diagnosis codes are erased or the battery cable is disconnected, this history will also be
erased (the memory will be reset).
Catalyst: P0420
Oxygen sensor: P0130
Oxygen sensor heater: P0135, P0141
FAIL-SAFE FUNCTION REFERENCE TABLE

When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by
means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item
Control contents during malfunction
Air flow sensor
1. Uses the throttle position sensor signal and engine speed signal (crank angle
sensor signal) to take reading of the basic injector drive time and basic ignition
timing from the pre-set mapping.
2. Fixes the idle speed control servo in the appointed position so idle control is not
performed.

sensor
Controls as if the intake air temperature is 25C.
Barometric pressure
sensor
Controls as if the barometric pressure is 101 kPa.
Throttle position sensor No increase in fuel injection amount during acceleration due to the throttle position
sensor signal.
Engine coolant
temperature sensor
Controls as if the engine coolant temperature is 80C.
Camshaft position
sensor
Injectors fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
ignition switch is turned to the "ON" position, the No. 1 cylinder top dead centre is
not detected at all)
Air/fuel ratio feedback control (closed loop control) is not performed.
Performs the feedback control (closed loop control) of the air/fuel ratio by using
only the signal of the oxygen (front) installed on the front of the catalytic converter.
Detonation sensor
Fixes the ignition timing as that for regular gasoline.
13A-12
TROUBLESHOOTING
Malfunctioning item
Ignition coil
(incorporating power
transistor)
Cuts off the fuel supply to cylinders with an abnormal ignition.
Alternator FR terminal
Does not control the output of the alternator according to an electrical load. (works
as a normal alternator)
Misfiring
If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be
shut down.
INSPECTION CHART FOR DIAGNOSIS CODE

M1131151000624
Code No.
Diagnosis item
Reference page
P0100
313A
P0105
Barometric pressure sensor system
313A
P0110
313A
P0115
313A
P0120
Throttle position sensor system
313A
P0125*
313A
P0130
Oxygen sensor (front) system <Sensor 1>
313A
P0135
Oxygen sensor heater (front) system <Sensor 1>
313A
P0136
Oxygen sensor (rear) system <Sensor 2>
313A
P0141
Oxygen sensor heater (rear) system <Sensor 2>
313A
P0170
Abnormal fuel system
313A
P0201
No.1 Injector system
313A
P0202
313A
P0203
313A
P0204
313A
P0300
Random cylinder mis-fire detection system
313A
P0301*
No.1 cylinder mis-fire detection system
313A
P0302*
313A
P0303*
313A
P0304*
313A
P0325
313A
P0335
313A
P0340
313A
P0403
EGR control solenoid valve system
313A
P0420
Catalyst deterioration system
313A
P0443
313A
P0500
Vehicle speed sensor system
313A
P0505
Idle speed control system
313A
P0551*
313A

TROUBLESHOOTING
13A-13
Code No.
Diagnosis item
Reference page
P0622
Alternator FR terminal system
313A
P1603*
Battery back-up line system
313A
P1610
Immobilizer system
313A
NOTE: .
Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the engine
is started and the same malfunction is re-detected. However, for items marked with "*", the diagnosis
code is recorded on the first detection of the malfunction.
Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates the sensor mounted at the position second closest to the engine.
13A-14
TROUBLESHOOTING
INSPECTION PROCEDURE FOR

DIAGNOSIS CODES
Code No. P0100 Air Flow Sensor System
Air flow sensor circuit
Battery
W-B
W-B
3
4
B-17X
4
B-08
Air flow sensor
1 2 3 4 5 6 7
G-W
20
J/C (1)
C-16
G-B
W-R
C-135
17
G-W
19
40
90
C-137
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
C-134
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V:Violet
AK300252 AB

TROUBLESHOOTING
OPERATION
Power is supplied to the air flow sensor (terminal
No. 4) from the engine control relay (terminal No.
1) and earthed to the engine-ECU (terminal No.
40) from the air flow sensor (terminal No. 5).
A power voltage of 5 V is applied to the air flow
sensor output terminal (terminal No. 3) from the
engine-ECU (terminal No. 90).
An air flow sensor filter reset signal is inputted to
the air flow sensor (terminal No. 7) from the
FUNCTION
Air flow sensor outputs a pulse signal proportional to the intake air flow rate.
The engine-ECU determines the basic injection
timing of the injector using the pulse signal output
from the air flow sensor and the engine speed
signal.
When the throttle position sensor output is low,
the engine-ECU causes the power transistor in
the unit to be ON to send an air flow sensor filter
reset signal to the air flow sensor. In response to
the reset signal, the air flow sensor resets the filter circuit to improve the ability of the air flow sensor to measure the air flow rate in the area where
the intake air flow rate is low.
TROUBLE JUDGMENT
Check Condition
Engine speed is 500 r/min or more.
Judgment Criterion
Sensor output frequency of 3.3 Hz or less for 2
seconds.
PROBABLE CAUSE
Failed air flow sensor
Open/short circuit in air flow sensor circuit or
loose connector contact
Failed engine-ECU
13A-15
DIAGNOSIS PROCEDURE
STEP 1. MUT-II data list
Refer to Data list reference table 313A.
a. Item 12: Air flow sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 - How to Use
Troubleshooting/Inspection Service Points
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-08 air flow sensor
connector
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
Harness side connector
AK300253 AB

YES : Go to Step 3 .
NO : Repair.
STEP 3. Measure voltage at B-08 air flow sensor

connector.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Disconnect connector, and measure at harness

side.
Ignition switch: ON
Voltage between terminal No. 3 and earth.
OK: 4.9 - 5.1 V
NO : Go to Step 4 .
13A-16
TROUBLESHOOTING
STEP 4. Measure voltage at C-137 engine-ECU

connector.
CONNECTOR: C-137
STEP 5. Connector check: C-137 engine-ECU

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Measure engine-ECU terminal voltage.

Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 6 .
AK300254 AB
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

YES : Check and repair harness between B-08
(terminal No. 3) air flow sensor connector

and C-137 (terminal No. 90) engine-ECU
connector.
Check output line for open circuit.
NO : Repair.
13A-17
TROUBLESHOOTING

connector.
CONNECTOR: C-137
STEP 7. Check harness between B-08 (terminal

No. 3) air flow sensor connector and C-137
(terminal No. 90) engine-ECU connector.
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300253 AB
CONNECTOR: C-137

AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Check output line for short circuit.

NO : Repair.

00 - How to Use
300).
NO : Replace engine-ECU.
13A-18
TROUBLESHOOTING

connector.
STEP 10. Connector check: B-17X engine control

relay connector
CONNECTOR: B-17X
Connector: B-08
Relay boxs
triangle marks
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 10 .
B-17X
Harness side
connector
AK300255 AB
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB


and B-17X (terminal No.1) engine control
relay connector.
Check power supply line for
open/short circuit.
NO : Repair.
STEP 11. Check at B-08 air flow sensor
connector.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Disconnect and measure at harness side.

Resistance between terminal No. 5 and earth.
OK: 2 W or less
13A-19
TROUBLESHOOTING

connector
CONNECTOR: C-135

Connector: B-08
C-135
B-08 (B)
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300253 AB
CONNECTOR: C-135

AK300256 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
NOTE: Before checking harness, check intermediate

connector C-16, and repair if necessary.
Check earthing line for open circuit and damage.
NO : Repair.
13A-20
TROUBLESHOOTING

connector.
Connector: B-08

Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Use special tool test harness (MB991709) to connect connector, and measure at pick-up harness.
Ignition switch: ON
OK: 7 - 8 V
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-134

C-134

connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
CONNECTOR: C-134

AK300257 AB
Check reset signal line for short circuit.

C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

YES : Replace air flow sensor.
NO : Repair.
13A-21
TROUBLESHOOTING

connector.
Connector: B-08

Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Transmission: Neutral
OK:
0 - 1 V (Engine: Idling)
6 - 9 V (Engine: 3,000 r/min)
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-134

C-134

connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

CONNECTOR: C-134
AK300257 AB
Check reset signal line for open circuit and damage.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

NO : Repair.
13A-22
TROUBLESHOOTING
STEP 20. Measure output waveform at B-08 air

flow sensor connector (Use oscilloscope).
Connector: B-08

No. 4) air flow sensor connector and B-17X
(terminal No. 1) engine control relay connector.
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Engine: Idling
OK: Waveforms should be displayed on
inspection procedure using an oscilloscope
(Refer to 313A) and noise should not be
displayed in the waveform.
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

AK300255 AB
Check power supply line for damage.
STEP 21. Replace air flow sensor.

After replacing the air flow sensor, re-check the
trouble symptoms.
NO : Check end.

NO : Repair.

connector
CONNECTOR: C-134

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300255 AB
AK300257 AB

NO : Repair.

NO : Repair.
13A-23
TROUBLESHOOTING

STEP 26.Connector check: C-135 engine-ECU

connector
CONNECTOR: C-135
Connector: B-08
B-08 (B)
C-135
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-137
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
Connector: B-08
C-137
B-08 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
7 6 5 4 3 2 1
AK300253 AB
AK300254 AB
Check output line for damage.

NO : Repair.

YES : Check intermediate connector C-16, and
repair if necessary. If intermediate

connector is normal, check and repair
harness between B-08 (terminal No. 5) air
flow sensor connector and C-135 (terminal
No. 40) engine-ECU connector.
Check earthing line for damage.
No : Repair.
13A-24
TROUBLESHOOTING
Code No. P0105: Barometric Pressure Sensor System
Barometric pressure sensor circuit
B-08
Barometric pressure sensor
(Incorporated in air flow sensor)
1 2 3 4 5 6 7
2
B-W
20
Y-B
J/C (1)
C-16
G-W
17
B-W
81
85
40
C-135
C-137
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code

AK300258 AB
OPERATION
A power voltage of 5 V is applied to the barometric pressure sensor power terminal (terminal No.
1) of the air flow sensor connector from the
engine-ECU (terminal No. 81) and earthed to the
engine-ECU (terminal No. 40) from the air flow
sensor (terminal No. 5).
The sensor signal is inputted to the engine-ECU
(terminal No. 85) from the barometric pressure
sensor output terminal (terminal No. 2) of the air
flow sensor connector.
FUNCTION
The barometric pressure sensor converts the barometric pressure into a voltage signal and inputs
the signal to the engine-ECU.
In response to the signal, the engine-ECU corrects the fuel injection amount, etc.
TROUBLE JUDGMENT
Check Condition
2 seconds later after the ignition switch has been
in "ON" position or the engine has started up.
The battery voltage is 8 V or more.
Judgment Criterion
The sensor output voltage is 4.5 V or more (Barometric pressure of above 114 kPa or equivalent)
for 2 seconds.
Or
The sensor output voltage is 0.2 V or less (Barometric pressure of below 53kpa or equivalent) for
2 seconds.
13A-25
TROUBLESHOOTING
PROBABLE CAUSE
Failed barometric pressure sensor
Open/short circuit in barometric pressure sensor
circuit or loose connector contact
Failed engine-ECU

connector.
Connector: B-08
DIAGNOSIS PROCEDURE
a. Item 25: Barometric pressure sensor
00 - How to Use
300).
NO : Go to Step 2 .
connector
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 4 .
Connector: B-08

connector.
CONNECTOR: C-137
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 6 .
13A-26
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300254 AB
AK300253 AB


connector.
Check power supply line for open
circuit.
NO : Repair.
13A-27
TROUBLESHOOTING


connector.
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-137
AK300253 AB

side.
OK: 2 W or less
C-137

connector
CONNECTOR: C-135
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Check power supply line for short circuit.

NO : Repair.

a. Item No. 25: Barometric pressure sensor
00 - How to Use
300).
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-28
TROUBLESHOOTING


connector.
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Check earthing line for open circuit or damage.
NO : Repair.
AK300253 AB
Use special tool test harness (MB991709) to connect only terminal No. 1, No. 2 and No. 5, and
then measure at pick-up harness.
Ignition switch: ON
OK: 4.9 - 5.1 V

TROUBLESHOOTING

connector
CONNECTOR: C-137
13A-29

connector.
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-08
Ignition switch: ON
OK: 0.5 V or less
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB


connector.
NO : Repair.
AK300253 AB
13A-30
TROUBLESHOOTING

connector
CONNECTOR: C-135

connector.
Connector: B-08
B-08 (B)
C-135
7 6 5 4 3 2 1

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
Connector: B-08
AK300253 AB
Ignition switch: ON
OK:
Altitude 0m: 3.8 - 4.2 V
Altitude 600m: 3.5 - 3.9 V
Altitude 1,200m: 3.3 - 3.7 V
Altitude 1,800m: 3.0 - 3.4 V
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB


NO : Repair.

connector
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-31
TROUBLESHOOTING


connector.
CONNECTOR: C-137
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK:
Altitude 0m: 3.8 - 4.2 V
Altitude 600m: 3.5 - 3.9 V
Altitude 1,200m: 3.3 - 3.7 V
Altitude 1,800m: 3.0 - 3.4 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Check output line for short circuit and damage.

YES : Replace air flow sensor.
NO : Repair.

13A-32
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300254 AB
AK300253 AB


connector.
Check output line for open circuit and
damage.
NO : Repair.
13A-33
TROUBLESHOOTING
Code No. P0110: Intake Air Temperature Sensor System
Intake air temperature sensor circuit
B-08
(Incorporated in air flow sensor)
1 2 3 4 5 6 7
B-W
20
J/C (1)
C-16
Y-L
17
B-W
72
40
C-137
C-135
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
5V
Engine-ECU
Wire colour code

AK300259 AB
OPERATION
A power voltage of 5 V is applied to the intake air
temperature sensor output terminal (terminal No.
engine-ECU (terminal No. 72)
The power voltage is earthed to the engine-ECU
(terminal No. 40) from the air flow sensor (terminal No. 5).
FUNCTION
The intake air temperature sensor converts the
intake air temperature into a voltage and inputs
the voltage signal to the engine-ECU.
In response to the signal, the engine-ECU corrects the fuel injection amount, etc.
The intake air temperature sensor is a kind of
resistor, which has characteristics to reduce its
resistance as the intake air temperature rises.
Therefore, the sensor output voltage varies with
the intake air temperature, and becomes lower as
the intake air temperature rises.
TROUBLE JUDGMENT
Check Condition
Judgment Criterion
The sensor output voltage is 4.6 V or more
(intake air temperature of below -45C or equivalent) for 2 seconds.
Or
The sensor output voltage is 0.2 V or loss (intake
air temperature above 125C or equivalent) for 2
seconds.
PROBABLE CAUSE
Failed intake air temperature sensor
Open/short circuit in intake air temperature sensor circuit or loose connector contact
Failed engine-ECU
13A-34
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector.

a. Item 13: Intake air temperature sensor
OK: At ambient temperature (atmospheric
temperature) or equivalent.
00 - How to Use
300).
NO : Go to Step 2 .
connector
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

side.
OK: 2 W or less
NO : Go to Step 5 .
Connector: B-08

connector
B-08 (B)
CONNECTOR: C-135
7 6 5 4 3 2 1
AK300253 AB

NO : Repair.
C-135
STEP 3. Check intake air temperature sensor

itself.
Check intake air temperature sensor itself (Refer
to 313A).
NO : Replace air flow sensor.
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-08
13A-35

00 - How to Use
300).
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-135

connector.
Connector: B-08
C-135
B-08 (B)
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
AK300253 AB

side.
Ignition switch: ON
OK: 4.5 - 4.9 V
NO : Go to Step 9 .
13A-36
TROUBLESHOOTING

connector.
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1
AK300253 AB

Disconnect B-08 air flow sensor connector.
Ignition switch: ON
OK: 4.5 - 4.9 V

AK300254 AB
AK300253 AB


connector.
NO : Repair.
13A-37
TROUBLESHOOTING

connector
CONNECTOR: C-137

Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300253 AB
CONNECTOR: C-137

AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-38
TROUBLESHOOTING

connector.
Connector: B-08

Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB
Use special tool test harness (MB991709) to connect only terminal No. 5 and No. 6, and then
measure at pick-up harness.
Ignition switch: ON
OK:
Ambient temperature at -20C: 3.8 - 4.4 V
Ambient temperature at 0C: 3.2 - 3.8 V
7 6 5 4 3 2 1
AK300253 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

connector
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

NO : Repair.

TROUBLESHOOTING

connector
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1
AK300253 AB

YES : Check intermediate connector C-16 and

NO : Repair.
13A-39
13A-40
TROUBLESHOOTING
Code No. P0115: Engine Coolant Temperature Sensor System
Engine coolant temperature sensor circuit
B-108
(MU802406)
1 2
BR
Y-G
92
83
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
5V
Wire colour code

AK300260 AB
OPERATION
A power voltage of 5 V is applied to the engine
coolant temperature sensor output terminal (terminal No. 1) from the engine-ECU (terminal No.
83).
(terminal No. 92) from the engine coolant temperature sensor (terminal No. 2).
FUNCTION
The engine coolant temperature sensor converts
the engine coolant temperature into a voltage signal, and inputs the voltage to the engine-ECU.
In response to the signal, the engine-ECU controls the fuel infection amount and the fast idle
speed when the engine is cold state.
The engine coolant temperature sensor is a kind

of resistor, which has characteristics to reduce its
resistance as the engine coolant temperature
rises. Therefore, the sensor output voltage varies
with the engine coolant temperature, and
becomes lower as the engine coolant temperature rises.
TROUBLE JUDGMENT
Check Condition
in "ON" position or just after the engine has
started up.
Judgment Criterion
The sensor output voltage is 4.6 V or more (water
temperature of below -45C or equivalent) for 2
seconds.
Or
The sensor output voltage of 0.1 V or less (water
temperature of above 140C or equivalent) for 2
seconds.
13A-41
TROUBLESHOOTING
Check Condition
After the engine has started up.
STEP 3. Measure resistance at B-108 engine

coolant temperature sensor connector.
Judging Conditions
The sensor output voltage rises 1.6 V or more
(engine coolant temperature below 40C or
equivalent) from 1.6 V or less (engine coolant
temperature above 40C or equivalent).
Connector: B-108
2 1
Harness side
connector
PROBABLE CAUSE
Failed engine coolant temperature sensor
Open/short circuit in engine coolant temperature
sensor circuit or loose connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
a. Item 21: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
Engine hot state: At 80 - 120C
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-108 engine coolant
temperature sensor connector
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

NO : Repair.
B-108 (B)
AK300261 AB
Disconnect connector, and measure at sensor

side.
Resistance between terminal No. 1 and No. 2.
OK:
Engine coolant temperature at -20C: 14 - 17
kW
Engine coolant temperature at 0C: 5.1 - 6.5
kW
kW
kW
Engine coolant temperature at 60C: 0.48 0.68 kW
Engine coolant temperature at 80C: 0.26 0.36 kW
NO : Replace engine coolant temperature
sensor.
13A-42
TROUBLESHOOTING
STEP 4. Measure voltage at B-108 engine coolant

temperature sensor connector.
Connector: B-108

connector.
CONNECTOR: C-137
2 1
Harness side
connector
B-108 (B)
C-137
AK300261 AB

side.
Ignition switch: ON
OK: 4.5 - 4.9 V
NO : Go to Step 5 .
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

Disconnect B-108 engine coolant temperature
sensor.
Ignition switch: ON
OK: 4.5 - 4.9 V
NO : Go to Step 7 .
13A-43
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

(terminal No. 1) engine coolant temperature

sensor connector and C-137 (terminal No.
83) engine-ECU connector.
NO : Repair.
AK300254 AB

NO : Repair.
13A-44
TROUBLESHOOTING

No. 1) engine coolant temperature sensor
connector and C-137 (terminal No. 83) engineECU connector.
STEP 10. Measure voltage at B-108 engine

Connector: B-108
2 1
Connector: B-108
Harness side
connector
2 1
Harness side
connector
B-108 (B)
AK300261 AB
B-108 (B)
AK300261 AB
CONNECTOR: C-137
Disconnect connector and measure at harness

side.
OK: 2 W or less

connector
C-137

CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

OK:
Engine hot state: At 80 - 120 C
00 - How to Use
300).
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
NO : Repair.
13A-45
TROUBLESHOOTING

STEP 13. Measure voltage at B-108 engine

Connector: B-108
2 1
Connector: B-108
Harness side
connector
2 1
Harness side
connector
B-108 (B)
AK300261 AB
B-108 (B)
AK300261 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Ignition switch: ON
OK:
Engine coolant temperature at -20C: 3.9 - 4.5
V
Engine coolant temperature at 0C: 3.2 - 3.8 V
V
V
V
V
13A-46
TROUBLESHOOTING

connector
CONNECTOR: C-137

Connector: B-108
2 1
Harness side
connector
C-137
B-108 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300261 AB
CONNECTOR: C-137
AK300254 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

TROUBLESHOOTING

connector
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

YES : Check harness between B-108 (terminal

connector and C-137 (terminal No. 92)
engine-ECU connector.
NO : Repair.
13A-47
13A-48
TROUBLESHOOTING
Code No. P0120: Throttle Position Sensor System

Throttle position sensor circuit
B-06
(MU802724)
1 2 3 4
Y-B
81
BR
84
92
C-137
Engine-ECU
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
Wire colour code

AK300262 AB
OPERATION
A power voltage of 5 V is applied to the throttle
position sensor (terminal No. 1) from the engineECU (terminal No. 81).
(terminal No. 92) from the throttle position sensor
(terminal No. 4).
(terminal No. 84) from the throttle position sensor
output terminal (terminal No. 2).
FUNCTION
The throttle position sensor converts the opening
of the throttle valve into a voltage and inputs the
voltage signal to the engine-ECU.
In response to the signal, the engine-ECU checks
the opening of the throttle valve.
TROUBLE JUDGMENT
Check Condition
Ignition switch: ON
Or
Excluding 2 seconds after the ignition switch has
been in "ON" position or just after the engine has
started up.
Judgment Criteria
The sensor output voltage is 0.2 V or less for 2
seconds.
Or
When the engine speed is 1,000 r/min or less and
the charging efficiency is 40% or less, the throttle
position sensor output voltage is 4.4 V or more for
2 seconds.
13A-49
TROUBLESHOOTING
PROBABLE CAUSE
Failed throttle position sensor
Open/short circuit in throttle position sensor circuit or loose connector contact
Failed engine-ECU
STEP 4. Measure voltage at B-06 throttle position

sensor connector.
Connector: B-06
B-06 (B)
DIAGNOSIS PROCEDURE
a. Item 14: Throttle position sensor
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-06 throttle position
sensor connector
4 3 2 1
AK300263 AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 5 .
Connector: B-06
B-06 (B)

connector.
CONNECTOR: C-137
4 3 2 1
AK300263 AB

NO : Repair.
STEP 3. Check throttle position sensor itself.

Check throttle position sensor itself (Refer to
313A).
NO : Replace throttle position sensor.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 7 .
13A-50
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-06
B-06 (B)
4 3 2 1
AK300254 AB
AK300263 AB

(terminal No. 1) throttle position sensor

circuit.
NO : Repair.
13A-51
TROUBLESHOOTING

No. 1) throttle position sensor connector and C137 (terminal No. 81) engine-ECU connector.
STEP 10. Measure resistance at B-06 throttle

position sensor connector.
Connector: B-06
Connector: B-06
B-06 (B)
B-06 (B)
4 3 2 1
4 3 2 1
AK300263 AB
CONNECTOR: C-137
AK300263 AB

side.
OK: 2 W or less
C-137

connector
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

00 - How to Use
300).
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-52
TROUBLESHOOTING

No. 4) throttle position sensor connector and C137 (terminal No. 92) engine-ECU connector.
STEP 13. Measure voltage at B-06 throttle

Connector: B-06
Connector: B-06
B-06 (B)
B-06 (B)
4 3 2 1
4 3 2 1
AK300263 AB
CONNECTOR: C-137
Ignition switch: ON
OK: 4.9 - 5.1 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
AK300263 AB
13A-53
TROUBLESHOOTING

connector
CONNECTOR: C-137

Connector: B-06
B-06 (B)
C-137
4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-06
4 3 2 1
Ignition switch: ON
OK: 0.5 V or less
B-06 (B)
AK300263 AB


NO : Repair.
AK300263 AB
13A-54
TROUBLESHOOTING

connector
CONNECTOR: C-137

Connector: B-06
B-06 (B)
C-137
4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-06
B-06 (B)
AK300263 AB
Ignition switch: ON
OK:
Accelerator pedal fully released: 0.535 - 0.735
V
Accelerator pedal fully depressed: 4.5 - 5.0 V
4 3 2 1
AK300263 AB


NO : Repair.
STEP 18. Adjust throttle position sensor

Adjust throttle position sensor (Refer to 313A
).
Q: Is the adjusted value normal?
NO : Adjust throttle position sensor.
13A-55
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK:
Accelerator pedal fully released: 0.535 - 0.735
V
Accelerator pedal fully depressed: 4.5 - 5.0 V
Connector: B-06
B-06 (B)
4 3 2 1
AK300254 AB
AK300263 AB


Check output line for short circuit and
damage.
NO : Repair.

13A-56
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-06
B-06 (B)
4 3 2 1
AK300254 AB
AK300263 AB


damage.
NO : Repair.
Code No. P0125: Feedback system monitor

OPERATION
Refer to P0201 injector circuit 313A.
Refer to P0130 Oxygen sensor (front) circuit
313A.
FUNCTION
The engine-ECU effects air-fuel ratio feedback
control in accordance with the signals from the
heater oxygen sensor (front).
If the heated oxygen sensor (front) has deteriorated, corrections will be made by the heated oxygen sensor (rear).
diagnosis code P0125 becomes stored in memory if a failure is detected in the above air/fuel
ratio feedback control system.
TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature approximately.
82C or more.
13A-57
TROUBLESHOOTING
Within the range of air-fuel ratio feedback operation.

Not in low speed operation.
Judgment Criteria
The oxygen sensor output voltage is not deviated
from 0.5 V for 30 seconds.
PROBABLE CAUSE
Failed oxygen sensor (front)
Harness damage in oxygen sensor (front) circuit
or loose connector contact
Failed oxygen sensor (rear)
NOTE: When the oxygen sensor (front) begins to
deteriorate, the oxygen sensor output voltage will
deviate from the voltage when the sensor was new
(normally 0.5 volt at stoichiometric ratio). This deviation will be corrected by the oxygen sensor (rear).If
the oxygen sensor (rear) responds poorly because it
has deteriorated, it will improperly correct the oxygen
sensor (front). Thus, even when closed loop control
is being effected, the fluctuation of the oxygen sensor (front) output voltage decreases, without intersecting with 0.5 volt. As a result, there is a possibility
of diagnosis code P0125 becoming registered.
Failed fuel system
Failed exhaust system
Failed engine-ECU
STEP 3.Check for intake of air from intake hose

and inlet manifold.
NO : Repair.
STEP 4.Check for leakage of exhaust emission

from exhaust manifold.
NO : Repair.
STEP 5.Check throttle body (throttle valve

portion) for contamination.
NO : Clean throttle body (throttle valve portion)
(Refer to 313A).
STEP 6. Connector check: B-112 oxygen sensor
(front) connector, C-137 engine-ECU connector
Connector: B-112
B-112 (B)
DIAGNOSIS PROCEDURE
STEP 1. MUT-II self-diag code
Q: Is any other diagnosis code than P0170 output?
YES : Inspection chart for diagnosis code (Refer
to 313A).
NO : Go to Step 2 .
2 1
4 3
CONNECTOR: C-137
STEP 2.MUT-II data list

b. Item 21: Engine coolant temperature sensor
c. Item 25: Barometric pressure sensor
d. Item 69: Oxygen sensor (rear)
Q: Are the check results normal?
NO : Perform the diagnosis code classified check
procedure for the sensor that has shown an

abnormal data valve (Refer to Inspection
Chart for Diagnosis Codes 313A).
AK300264 AB
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-58
TROUBLESHOOTING
STEP 7. Check oxygen sensor (front) itself.

Check oxygen sensor (front) itself (Refer to
313A).
STEP 9. Connector check: Injector connector

Connector: B-01, B-02, B-04, B-05

NO : Replace oxygen sensor (front).
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
STEP 8. Check harness between B-112 oxygen

sensor (front) connector and C-137 engine-ECU
connector.
Connector: B-112
B-112 (B)
2 1
a.
b.
c.
d.
AK300265 AB
B-01 (No.1 injector connector)


NO : Repair.
2 1
4 3
AK300264 AB
CONNECTOR: C-137
STEP 10. Check injector itself.

Check Injector itself (Refer to 313A).
NO : Replace injector.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-59
TROUBLESHOOTING

relay connector and B-134 engine-ECU
connector.
CONNECTOR: B-17X
Relay boxs
triangle marks
STEP 12. Check harness between B-17X engine

control relay connector and injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
B-17X
Harness side
connector
Harness side
connector
AK300255 AB
AK300255 AB
Connector: B-01, B-02, B-04, B-05

CONNECTOR: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
2 1
AK300265 AB
a. Check harness between B-17X (terminal No. 1)

engine control relay connector and B-01 (terminal
No. 1) No. 1 injector connector.
b. Check harness between B-17X (terminal No. 1)
c. Check harness between B-17X (terminal No. 1)
d. Check harness between B-17X (terminal No. 1)
NO : Repair
13A-60
TROUBLESHOOTING
STEP 13. Check harness between injector

connector and C-134 engine-ECU connector.

YES : Repair.
NO : Replace engine-ECU
Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
2 1
AK300265 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
a. Check harness between B-01 (terminal No. 2)

No. 1injector connector and C-134 (terminal No.
b. Check harness between B-02 (terminal No. 2)
No. 2 injector connector and C-134 (terminal No.
c. Check harness between B-04 (terminal No. 2)
d. Check harness between B-05 (terminal No. 2)
NO : Repair
STEP 14. Measure fuel pressure.

Measure fuel pressure (Refer to 313A).
13A-61
TROUBLESHOOTING
Code No. P0130: Oxygen Sensor (Front) System <sensor 1>
Oxygen sensor (front) circuit
B-112
(MU802605)
1 2
3 4
From Engine control relay
To engine-ECU
B
2
B
W
92
J/C (2)
C-17
76
B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code

AK300266 AB
OPERATION
(terminal No. 76) from the oxygen sensor output
terminal (terminal No. 4).
The oxygen sensor (terminal No. 2) is earthed
with engine-ECU (terminal No. 92).
FUNCTION
The oxygen sensor converts the concentration of
oxygen in the exhaust emission into a voltage
and inputs the signal to the engine-ECU.
When the air-fuel ratio is richer than the theoretical air-fuel ratio, the oxygen sensor outputs a voltage of about 1 V. When it is leaner than the
theoretical air-fuel ratio, it outputs a voltage of
about 0 V.
In response to the signal, the engine-ECU controls the fuel infection amount so that the air-fuel
ratio can be equivalent to the theoretical air-fuel
ratio.
TROUBLE JUDGMENT
Check Condition
Above 3 minutes later after the engine has
started up.
The engine coolant temperature approximately
82C or more.
The engine speed is 1,200 r/min or more.
The volumetric efficiency 25% or more.
The monitoring time is 5 seconds.
Judgment Criteria
When the oxygen sensor (front) output voltage is
0.2 V or less and a power voltage of 5 V is
applied to the oxygen sensor (front) in the
engine-ECU, the sensor output voltage is 4.5 V or
more.
Check Condition
The engine speed is 3,000 r/min or less.
During the air-fuel ratio feedback control
13A-62
TROUBLESHOOTING
Judgment Criteria
When the oxygen sensor (front) output frequency
is 6 or less for 10 seconds on the average.
STEP 3. Measure voltage at B-112 oxygen sensor

(front) connector.
Connector: B-112
PROBABLE CAUSE
Failed oxygen sensor
Open/short circuit in oxygen sensor (front) circuit
Failed engine-ECU

B-112 (B)
2 1
4 3
DIAGNOSIS PROCEDURE
a. Item 11: Oxygen sensor (front)
00 - How to Use
300).
NO : Go to Step 2 .
(front) connector
AK300264 AB

side.
OK: 2 W or less
NO : Go to Step 4 .

connector
CONNECTOR: C-137
Connector: B-112
B-112 (B)
C-137
2 1
4 3

NO : Repair.
AK300264 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-63
TROUBLESHOOTING

No. 2) oxygen sensor (front) connector and C-137
Connector: B-112
B-112 (B)
2 1
4 3

00 - How to Use
300).
STEP 7. Measure at B-112 oxygen sensor (front)
connector.
AK300264 AB
Connector: B-112
CONNECTOR: C-137

B-112 (B)
2 1
4 3
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
AK300264 AB
Use special tool test harness (MD998464) to connect connector, and measure at pick-up harness.
Engine: After warm-up
Ignition switch: ON
OK: 0.5 V or less
NO : Go to Step 8 .
13A-64
TROUBLESHOOTING

connector
CONNECTOR: C-137

(front) connector.
Connector: B-112
B-112 (B)
2 1
4 3
C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB

(terminal No. 2) oxygen sensor (front)

NO : Repair.
AK300264 AB
Use special tool test harness (MD998464) to connect connector, and measure at pick-up harness.
OK:
600 - 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
deceleration from 4,000 r/min.
STEP 10. Check oxygen sensor itself

Check oxygen sensor (front) itself (Refer to
313A).
NO : Replace oxygen (front) sensor.
13A-65
TROUBLESHOOTING

connector

connector.
CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB


NO : Repair.
AK300254 AB

OK:

13A-66
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB


NO : Repair.
AK300254 AB

NO : Repair.
13A-67
TROUBLESHOOTING
Code No. P0135: Oxygen Sensor Heater (Front) System <Sensor 1>
Oxygen sensor (front) heater circuit
Battery
W-B
W-B
B-17X

B-112
(MU8026053)
Engine
control
relay
1
1 2
3 4
2
1
To engine-ECU
Y-R
60
C-136
51 52 53 54 55 56
57 58 59 60 61 62
Engine-ECU
Wire colour code

AK300267 AB
OPERATION
Power is supplied to the heater power terminal
(terminal No. 1) of the oxygen sensor (front) connector from the engine control relay (terminal No.
1).
The heater (terminal No. 3) of the oxygen sensor
(front) connector is controlled by the power transistor in the engine-ECU (terminal No. 60).
FUNCTION
The power supply to the oxygen sensor heater
(front) is controlled by the ON/OFF control of the
power transistor in the engine-ECU.
Heating the oxygen sensor heater (front) enables
the oxygen sensor to provide good response
even when the exhaust emission temperature is
low.
13A-68
TROUBLESHOOTING
TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature is approximately.
20C or higher.
The oxygen sensor heater (front) is in "ON" position.
The engine speed is 50 r/min or more.
The battery voltage is 11 - 16 V.
Judgment Criteria
The heater current of oxygen sensor heater
(front) is below 0.2 A or above 3.5 A for 1 second.
PROBABLE CAUSE
Failed oxygen sensor heater
Open/short circuit in oxygen sensor (front) circuit
Failed engine-ECU
STEP 2. Measure resistance at B-112 oxygen

sensor (front) connector.
Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB

side.
OK: 4.5 - 8.0 W
NO : Replace oxygen sensor (front).
DIAGNOSIS PROCEDURE
(front) connector

(front) connector.
Connector: B-112
Connector: B-112
B-112 (B)
B-112 (B)
2 1
4 3

NO : Repair.
AK300264 AB
2 1
4 3
AK300264 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13A-69
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
CONNECTOR: C-136
B-17X
Relay boxs
triangle marks

connector.
C-136
Harness side
connector
AK300255 AB
56 55 54 53 52 51
62 61 60 59 58 57
Connector: B-112
B-112 (B)

Ignition switch: ON
OK: System voltage
2 1
4 3
AK300268 AB
AK300264 AB

(terminal No. 1) oxygen sensor connector

and B-17X (terminal No. 1) engine control
relay connector.
open/short circuit.
NO : Repair.

NO : Go to Step 6 .

connector
CONNECTOR: C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.
13A-70
TROUBLESHOOTING


connector
CONNECTOR: C-136
Connector: B-112
B-112 (B)
C-136
2 1
4 3
AK300264 AB
56 55 54 53 52 51
62 61 60 59 58 57
CONNECTOR: C-136

AK300268 AB

NO : Repair.
C-136

No. 1) oxygen sensor (front) connector and B17X (terminal No. 1) engine control relay
connector.
56 55 54 53 52 51
62 61 60 59 58 57
Connector: B-112
AK300268 AB
Check earthing line for open/short circuit.
B-112 (B)

YES : Replace engine-ECU.
NO : Repair.
2 1
4 3
AK300264 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-112
B-112 (B)
2 1
4 3
AK300264 AB
CONNECTOR: C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.
13A-71
STEP 11. Check the trouble symptoms.

Q: Does trouble symptom persist?
NO : Intermittent malfunction (Refer to GROUP
00 - How to Use
300).
13A-72
TROUBLESHOOTING
Code No. P0136: Oxygen Sensor (Rear) System <Sensor 2>
Oxygen sensor (rear) circuit
C-18
(MU801688)
1 2
3 4
From engine control relay
To engine-ECU
J/C (2)
C-17
92
75
B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code

AK300269 AB
OPERATION
(terminal No. 75) from the oxygen sensor (rear)
The oxygen sensor (rear) (terminal No. 3) is
earthed with engine-ECU (terminal No. 92).
FUNCTION
The oxygen sensor (rear) converts the concentration of oxygen in the exhaust emission into a voltage signal and inputs the voltage signal to the
engine-ECU.
When the air-fuel ratio is richer than the theoretical air-fuel ratio, the oxygen sensor (rear) outputs
a voltage of about 1 V. When it is leaner than the
theoretical air-fuel ratio, it outputs a voltage of
about 0 V.
In response to the signal, the engine-ECU controls the fuel infection amount so that the air-fuel
ratio can be equivalent to the theoretical air-fuel
ratio.
TROUBLE JUDGMENT
Check Conditions
started up.
82C or higher.
The engine speed is 1,200 r/min or more.
The volumetric efficiency is 25% or more.
Judgment Criteria
When the oxygen sensor (rear) output voltage is
0.2 V or less and a power voltage of 5 V is
applied to the oxygen sensor (rear) in the engineECU, the sensor output voltage is 4.5 V or more.
PROBABLE CAUSE
Failed oxygen sensor
Open/short circuit in oxygen sensor (rear) circuit
Failed engine-ECU
13A-73
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 3. Measure voltage at C-18 oxygen sensor

(rear) connector.

a. Item 59: Oxygen sensor (rear)
Connector: C-18
1 2
3 4

00 - How to Use
300).
NO : Go to Step 2 .
Harness side
connector
C-18
STEP 2. Connector check: C-18 oxygen sensor

(rear) connector
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB

side.
OK: 2 W or less
NO : Go to Step 4 .

connector
AK300270 AB
CONNECTOR: C-137

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-74
TROUBLESHOOTING
STEP 5. Check harness between C-18 (terminal

No. 3) oxygen sensor (rear) connector and C-137

a. Item 59: Oxygen sensor (rear)
Connector: C-18
1 2
3 4
Harness side
connector
00 - How to Use
300).
C-18

(rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector
AK300270 AB
C-18
CONNECTOR: C-137
C-137
AK300270 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Ignition switch: ON
OK: 0.5 V or less
NO : Go to Step 8 .
13A-75
TROUBLESHOOTING

connector
CONNECTOR: C-137

(rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector
C-18
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB

YES : Check and repair harness between C-18

connector.
NO : Repair.
AK300270 AB
OK:
STEP 10. Check oxygen sensor (rear) itself.

Check oxygen sensor (rear) itself (Refer to
313A).
NO : Replace oxygen (rear) sensor.
13A-76
TROUBLESHOOTING

connector

connector.
CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB


connector.
NO : Repair.
AK300254 AB

OK:

13A-77
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB

(terminal No. 4) oxygen sensor (rear)

NO : Repair.
AK300254 AB

NO : Repair.
13A-78
TROUBLESHOOTING
Code No. P0141: Oxygen Sensor Heater (Rear) System <Sensor 2>
Oxygen sensor (rear) heater circuit
Battery
W-B
W-B
B-17X

C-18
(MU801688)
Engine
control
relay
1
1 2
3 4
2
2
R
To engine-ECU
2
J/C (2)
C-17
Y-R
54
C-136
51 52 53 54 55 56
57 58 59 60 61 62
Engine-ECU
Wire colour code
AK300271 AB
OPERATION
(terminal No. 2) of the oxygen sensor (rear) connector from the engine control relay (terminal No.
1).
The heater (terminal No. 1) of the oxygen sensor
(rear) connector is controlled by the power transistor in the engine-ECU (terminal No. 54).
FUNCTION
The power supply to the oxygen sensor heater
(rear) is controlled by the ON/OFF control of the
power transistor in the engine-ECU.
Heating the oxygen sensor heater (rear) enables
the oxygen sensor to provide good response
even when the exhaust emission temperature is
low.
13A-79
TROUBLESHOOTING
TROUBLE JUDGMENT
Judgment Criteria
20 C or higher.
The oxygen sensor heater (rear) is in "ON" position.
Judgment Criteria
The heater current of front oxygen sensor heater
(rear) is below 0.2 A or above 3.5 A for 1 second.
STEP 2. Measure resistance at C-18 oxygen

sensor (rear) connector.
Connector: C-18
1 2
3 4
Harness side
connector
C-18
PROBABLE CAUSE
Failed oxygen sensor heater (rear)
Open/short circuit in oxygen sensor (rear) circuit
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-18 oxygen sensor
(rear) connector
Connector: C-18
1 2
3 4
Harness side
connector
AK300270 AB

side.
OK: 11 - 18 W
NO : Replace oxygen (rear) sensor.

(rear) connector.
Connector: C-18
C-18
1 2
3 4
Harness side
connector
C-18
AK300270 AB

NO : Repair.
AK300270 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13A-80
TROUBLESHOOTING

relay connector
CONNECTOR: C-137

connector.
CONNECTOR: C-136
C-136
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
56 55 54 53 52 51
62 61 60 59 58 57

AK300254 AB
Connector: C-18
1 2
3 4
Harness side
connector
C-18
AK300268 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .

connector
CONNECTOR: C-136
AK300270 AB


harness between C-18 (terminal No. 2)
oxygen sensor (rear) connector and B-17X
(terminal No. 1) engine control relay
connector.
open/short circuit.
NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.
13A-81
TROUBLESHOOTING

No. 1) oxygen sensor connector and C-136

connector
CONNECTOR: C-136
Connector: C-18
1 2
3 4
Harness side
connector
C-136
C-18

56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB
AK300270 AB
CONNECTOR: C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.

NO : Repair.
13A-82
TROUBLESHOOTING

No. 2) oxygen sensor connector and B-17X
Connector: C-18

No. 1) oxygen sensor connector and C-136
Connector: C-18
1 2
3 4
1 2
3 4
Harness side
connector
C-18
Harness side
connector
C-18
AK300270 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
AK300270 AB
CONNECTOR: C-136
B-17X
Harness side
connector
C-136
AK300255 AB

NO : Repair.
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB

NO : Repair.

00 - How to Use
300).

TROUBLESHOOTING
13A-83
Code No. P0170: Abnormal Fuel System

OPERATION
FUNCTION
If the fuel system goes out of order, the fuel correction value will become larger.
The engine-ECU checks whether the fuel correction value is within the standard limits.
TROUBLE JUDGMENT
Check Conditions
In learning air-fuel ratio
Judgment Criteria
The compensation value of fuel injection amount
is too low for 2 seconds or more.
Or
The compensation value of fuel injection amount
is too high for 2 seconds or more.
PROBABLE CAUSE
Failed fuel supply system
Failed purge control solenoid valve
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .

b. Item 13: Intake air temperature sensor
c. Item 21: Engine coolant temperature sensor
d. Item 22: Barometric pressure sensor

abnormal data value (Refer to Inspection
STEP 3. Check for intake of air from intake hose
and inlet manifold.
NO : Repair.
STEP 4. Check for leakage of exhaust emission

NO : Repair.
STEP 5. Check throttle body (throttle valve

(Refer to 313A).
a. Item 11: Oxygen sensor (front).
NO : Check oxygen sensor (front) system (Refer
to313A, Code No. P0130).
13A-84
TROUBLESHOOTING
STEP 7. Connector Check: Injector connector

Connector: B-01, B-02, B-04, B-05

connector
CONNECTOR: B-17X
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
2 1
a.
b.
c.
d.
AK300265 AB
B-01 (No.1 injector connector).

Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
CONNECTOR: C-134

NO : Replace.

C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Replace.
13A-85
TROUBLESHOOTING

Connector: B-01, B-02, B-04, B-05
Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
AK300265 AB
CONNECTOR: B-17X
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
2 1
Relay boxs
triangle marks

2 1
AK300265 AB
CONNECTOR: C-134
B-17X
Harness side
connector
C-134
AK300255 AB

NO : Replace.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Replace.
STEP 12. Check purge control solenoid valve

itself.
Check purge control solenoid valve itself (Refer to
GROUP 17 - Emission Control System - Evaporative Emission Control System 317).
NO : Replace purge control solenoid valve.
13A-86

TROUBLESHOOTING

NO : Repair.
13A-87
TROUBLESHOOTING
Code No. P0201: No. 1 Injector System
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
R
R
Injector
No. 1
B-01
R
1
1 2
Injector
No. 2
Injector
No. 4
B-04
B-05
1 2
1 2
1 2
Y-R
Injector
No. 3
B-02
Y-G
14
15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300272 AB
13A-88

TROUBLESHOOTING
OPERATION
Power is supplied to the injector (terminal No. 1)
from the engine control relay (terminal No. 1).
The engine-ECU (terminal No. 1) makes the
power transistor in the unit be in "ON" position,
and that makes currents go on the injector (terminal No. 2).
FUNCTION
The engine-ECU controls the power supply interval of the injector.
The fuel injection amount of the injector depends
on the power supply interval.
TROUBLE JUDGMENT
Check Conditions
The engine speed is 50 - 1,000 r/min.
The throttle position sensor output voltage is 1.15
V or less.
Injector not in forced drive (actuator test) mode
Judgment Criterion
No surge voltage of the injector coil is detected
for 2 seconds.
PROBABLE CAUSE
Failed No. 1 injector
Open/short circuit in injector circuit or loose connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. MUT-II actuator test
Refer to Actuator test reference table list 313A
.
a. Item 01: No. 1 injector
OK: Idling state varies.
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-01 No. 1 injector

connector
Connector: B-01
B-01 (GR)
2 1
AK300265 AC

NO : Repair.
STEP 3. Measure resistance at B-01 No. 1 injector

connector.
Connector: B-01
B-01 (GR)
2 1
AK300265 AC
Disconnect connector, and measure at injector

side.
OK: 10.5 - 13.5 W
NO : Replace No. 1 injector.
13A-89
TROUBLESHOOTING
STEP 4. Measure voltage at B-01 No. 1 injector

connector.

relay connector
CONNECTOR: B-17X
Connector: B-01
Relay boxs
triangle marks
B-17X
B-01 (GR)
2
2 1
AK300265 AC

side.
Ignition switch: ON
OK: System voltage
Harness side
connector
AK300255 AB
Connector: B-01
B-01 (GR)

NO : Go to Step 5 .
2 1
AK300265 AC

YES : Check and repair harness between B-17X

connector and B-01 (terminal No. 1) No. 1
injector connector.
open/short circuit.
NO : Repair.
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

NO : Repair.
AK300255 AB
13A-90
TROUBLESHOOTING
STEP 7. Check harness between B-17X (terminal

No. 1) engine control relay connector and B-01
(terminal No. 1) No. 1 injector connector.
CONNECTOR: B-17X
Relay boxs
triangle marks

No. 2) No.1 injector connector and C-134
Connector: B-01
B-17X
B-01 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AC
CONNECTOR: C-134
Connector: B-01
B-01 (GR)
C-134
2 1
AK300265 AC

NO : Repair.

AK300257 AB

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
Check output line for open/short circuit and damage.

NO : Repair.

TROUBLESHOOTING
STEP 10. Measure signal waveform at C-134

engine-ECU connector (Use oscilloscope).
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Engine: Idling
OK: Waveforms should be display on
Inspection procedure using an oscilloscope
(Refer to 313A).
00 - How to Use
300).
13A-91
13A-92
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
R
R
Injector
No. 1
B-01
R
1
1 2
Injector
No. 2
Injector
No. 4
B-04
B-05
1 2
1 2
1 2
Y-R
Injector
No. 3
B-02
Y-G
14
15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300272 AB
13A-93
TROUBLESHOOTING
OPERATION
FUNCTION
TROUBLE JUDGMENT
Check Conditions
The engine speed is 50 - 1,000 r/mim.
The throttle position sensor output voltage 1.15 V
or less.
Judgment Criteria
for 2 seconds.
PROBABLE CAUSE
Open/short circuit in No. 2 injector circuit or loose
connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
.
00 - How to Use
300).
NO : Go to Step 2 .

connector
Connector: B-02
B-02 (GR)
2 1
AK300265 AD

NO : Repair.
STEP 3. Measure at resistance B-02 No. 2 injector

connector.
Connector: B-02
B-02 (GR)
2 1
AK300265 AD

side.
OK: 10.5 - 13.5 W
13A-94
TROUBLESHOOTING

connector.

relay connector
CONNECTOR: B-17X
Connector: B-02
Relay boxs
triangle marks
B-17X
B-02 (GR)
2
2 1
AK300265 AD

side.
Ignition switch: ON
OK: System voltage
Harness side
connector
AK300255 AB
Connector: B-02
B-02 (GR)

NO : Go to Step 5 .
2 1
AK300265 AD


injector connector.
open/short circuit and damage.
NO : Repair.
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

NO : Repair.
AK300255 AB
13A-95
TROUBLESHOOTING

CONNECTOR: B-17X
Relay boxs
triangle marks

No. 2) No. 2 injector connector and C-134
Connector: B-02
B-17X
B-02 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AD
CONNECTOR: C-134
Connector: B-02
B-02 (GR)
C-134
2 1
AK300265 AD

NO : Repair.

AK300257 AB

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.
13A-96
TROUBLESHOOTING

CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Engine: Idling
OK: Waveform should be display on Inspection procedure using an oscilloscope (Refer
to 313A).
00 - How to Use
300).
13A-97
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
R
R
Injector
No. 1
B-01
R
1
1 2
Injector
No. 2
Injector
No. 4
B-04
B-05
1 2
1 2
1 2
Y-R
Injector
No. 3
B-02
Y-G
14
15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300272 AB
13A-98

TROUBLESHOOTING
OPERATION
FUNCTION
TROUBLE JUDGMENT
Check Conditions
The throttle position sensor output voltage is 1.15
V or less.
Judgment Criteria
for 2 seconds.
PROBABLE CAUSE
connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
.
00 - How to Use
300).
NO : Go to Step 2 .

connector
Connector: B-04
B-04 (GR)
2 1
AK300265 AE

NO : Repair.

connector.
Connector: B-04
B-04 (GR)
2 1
AK300265 AE

side.
OK: 10.5 - 13.5 W
13A-99
TROUBLESHOOTING

connector.

relay connector
CONNECTOR: B-17X
Connector: B-04
Relay boxs
triangle marks
B-17X
B-04 (GR)
2
2 1
AK300265 AE

side.
Ignition switch: ON
OK: System voltage
Harness side
connector
AK300255 AB
Connector: B-04
B-04 (GR)

NO : Go to Step 5 .
2 1
AK300265 AE


injector connector.
open/short circuit.
NO : Repair.
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

NO : Repair.
AK300255 AB
13A-100
TROUBLESHOOTING

CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-04
B-17X
B-04 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AE
CONNECTOR: C-134
Connector: B-04
B-04 (GR)
C-134
2 1
AK300265 AE

NO : Repair.

AK300257 AB

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

TROUBLESHOOTING

CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Engine: Idling
to 313A).
00 - How to Use
300).
13A-101
13A-102
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
R
R
Injector
No. 1
B-01
R
1
1 2
Injector
No. 2
Injector
No. 4
B-04
B-05
1 2
1 2
1 2
Y-R
Injector
No. 3
B-02
Y-G
14
15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300272 AB
13A-103
TROUBLESHOOTING
OPERATION
FUNCTION
TROUBLE JUDGMENT
Check Conditions
The throttle position sensor output 1.15 V or less.
Judgment Criterion
for 2 seconds
PROBABLE CAUSE
connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
.
00 - How to Use
300).
NO : Go to Step 2 .

connector
Connector: B-05
B-05 (GR)
2 1
AK300265 AF

NO : Repair.

connector.
Connector: B-05
B-05 (GR)
2 1
AK300265 AF

side.
OK: 10.5 - 13.5 W
13A-104
TROUBLESHOOTING

connector.

relay connector
CONNECTOR: B-17X
Connector: B-05
Relay boxs
triangle marks
B-17X
B-05 (GR)
2
2 1
AK300265 AF

side.
Ignition switch: ON
OK: System voltage
Harness side
connector
AK300255 AB
Connector: B-05
B-05 (GR)

NO : Go to Step 5 .
2 1
AK300265 AF


injector connector.
NO : Repair.
relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector

YES : Go to Step 7.
NO : Repair.
AK300255 AB
13A-105
TROUBLESHOOTING

CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-05
B-17X
B-05 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AF
CONNECTOR: C-134
Connector: B-05
B-05 (GR)
C-134
2 1
AK300265 AF

NO : Repair.

AK300257 AB

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.
13A-106
TROUBLESHOOTING

CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Engine: Idling
to 313A).
00 - How to Use
300).
Code No. P0300: Random cylinder mis-fire detected

OPERATION
FUNCTION
If a misfire occurs while the engine is running, the
engine speed changes for an instant.
The engine-ECU checks for such changes in
engine speed.
TROUBLE JUDGMENT
Check Conditions
5 seconds later after the engine has started up.
The engine coolant temperature is -10C or
higher.
The intake air temperature is -10C or higher.
The barometric pressure is 72 kPa or more.

The volumetric efficiency is 30 - 60%.
The adaptive learning has been completed with
the vane that generates the crankshaft position
signals.
During the engine operation except the shift
change or low speed driving and rapid acceleration and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after
changing to ON from OFF or to OFF from ON).
The throttle deviation is within the range of 0.059 V/10ms to 0.059 V/10ms.
Judgment Criteria
The number of misfiring (in the catalyst temperature of above 950C) is beyond the specified
number (of 7.3 % on more than the two cylinders)
with the engine speed of 200 r/min.
Or
13A-107
TROUBLESHOOTING
The number of misfiring (that is 1.5 times the

emission standard limit) is beyond the specified
number (of 2 % on more than the two cylinders)
PROBABLE CAUSE
Ignition system related part(s) failed
Failed crank angle sensor
Incorrect air-fuel ratio
Low compression pressure
Failed coolant temperature sensor
Skipping of timing belt teeth.
EGR system and EGR valve failed
Failed engine-ECU
STEP 3.Check ignition coil spark.

Q: Is the check resuit normal?
NO : Check ignition circuit system (Refer to
Inspection procedure 29 313A).

STEP 4.Connector check: Injector connector
Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
DIAGNOSIS PROCEDURE
M

Item 22: Crank angle sensor
OK: Keep the engine speed constant to
make the pulse width of output waveform
constant.
NO : Check crank angle sensor system (Refer to
Code No. P0335 313A).

b. Item 81: Long-term fuel compensation
c. Item 82: Short-term fuel compensation

abnormal data valve (Refer to, Inspection
2 1
a.
b.
c.
d.
AK300265 AB


NO : Repair.
STEP 5.Check injector itself.

13A-108
TROUBLESHOOTING
STEP 6.Connector check: B-17X engine control

connector
CONNECTOR: B-17X
Relay boxs
triangle marks

CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
B-17X
Harness side
connector
Harness side
connector
AK300255 AB
AK300255 AB
Connector: B-01, B-02, B-04, B-05

CONNECTOR: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
2 1
AK300265 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
13A-109

Measure fuel pressure (Refer to fuel pressure
test 313A)
NO : Repair.

and inlet manifold.
M
2 1
AK300265 AB

NO : Repair.
CONNECTOR: C-134
STEP 11. Check for skipped timing belt teeth.

NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
STEP 12. Exhaust gas recirculation system

check.
Exhaust gas recirculation system check [Refer to
GROUP 17 - Exhaust gas recirculation (EGR)
system 317].
YES : Replace engine-ECU
NO : Repair.
13A-110

TROUBLESHOOTING
Code No. P0301: No. 1 cylinder mis-fire detection system

OPERATION
FUNCTION
engine speed.
TROUBLE JUDGMENT
Check Conditions
higher.
The volumetric efficiency is 30 - 60 %.
signals.
Judgment Criterion
Or
with the engine speed of 1,000 r/min.
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE
NO : Check ignition Circuit System (Refer to
Inspection procedure 29 313A)

STEP 2.Connector check: B-01 No.1 injector
connector
Connector: B-01
B-01 (GR)
2 1
AK300265 AC

NO : Repair.
STEP 3.Check No.1 injector itself.

NO : Replace No.1 injector.
13A-111
TROUBLESHOOTING

connector
CONNECTOR: B-17X
Relay boxs
triangle marks
STEP 5.Check harness between B-17X (terminal

(terminal No. 1) No.1 injector connector.
CONNECTOR: B-17X
B-17X
Relay boxs
triangle marks
Harness side
connector
AK300255 AB
CONNECTOR: C-134
B-17X
Harness side
connector
AK300255 AB
Connector: B-01
B-01 (GR)
C-134
2 1
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
AK300265 AC

NO : Repair.
13A-112
TROUBLESHOOTING
STEP 6. Check harness between B-01(terminal

(terminal No. 1) engine-ECU connector

test 313A).
NO : Repair.
Connector: B-01
B-01 (GR)
2 1
AK300265 AC
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

OPERATION
FUNCTION
engine speed.
TROUBLE JUDGMENT
Check Conditions
higher.

The volumetric efficiency is 30 - 60 %.
signals.
13A-113
TROUBLESHOOTING
Judgment Criterion
Or
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE


connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
CONNECTOR: C-134

STEP 2.Check connector: B-02 No.2 injector
connector
Connector: B-02
C-134
B-02 (GR)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

M
2 1

NO : Repair.
AK300257 AB
AK300265 AD

NO : Repair.
13A-114
TROUBLESHOOTING

No. 1) engine control relay connector and B02(terminal No. 1) No.2 injector connector.

CONNECTOR: B-17X
Relay boxs
triangle marks
Connector: B-02
B-17X
B-02 (GR)
3
M
Harness side
connector
2 1
AK300255 AB
AK300265 AD
CONNECTOR: C-134
Connector: B-02
B-02 (GR)
C-134
2 1
AK300265 AD
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

AK300257 AB

NO : Repair.

test 313A)
NO : Repair.

OPERATION
FUNCTION
engine speed.
TROUBLE JUDGMENT
Check Conditions
higher.
13A-115
TROUBLESHOOTING

signals.
Judgment Criterion
Or


relay connector, B-134 engine-ECU connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
CONNECTOR: C-134
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

connector
Connector: B-04
B-04 (GR)
2 1

NO : Repair.
AK300265 AE
AK300257 AB

NO : Repair.
13A-116
TROUBLESHOOTING


CONNECTOR: B-17X
Relay boxs
triangle marks
Connector: B-04
B-17X
B-04 (GR)
3
M
Harness side
connector
2 1
AK300255 AB
AK300265 AE
CONNECTOR: C-134
Connector: B-04
B-04 (GR)
C-134
2 1
AK300265 AE
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

AK300257 AB

NO : Repair.

test 313A)
NO : Repair.

OPERATION
FUNCTION
engine speed.
TROUBLE JUDGMENT
Check Conditions
higher.
13A-117
TROUBLESHOOTING

signals.
Judgment Criterion
Or


connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
CONNECTOR: C-134
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE
C-134
STEP 1.Check the ignition coil spark.

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

connector
Connector: B-05
B-05 (GR)
2 1

NO : Repair.
AK300265 AF

NO : Repair.
13A-118
TROUBLESHOOTING

CONNECTOR: B-17X
Relay boxs
triangle marks

Connector: B-05
B-17X
B-05 (GR)
3
M
Harness side
connector
AK300255 AB
2 1
AK300265 AF
CONNECTOR: C-134
Connector: B-05
B-05 (GR)
C-134
2 1
AK300265 AF

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

test 313A)
NO : Repair.
13A-119
TROUBLESHOOTING
Code No. P0325: Detonation Sensor System
Detonation sensor circuit
C-137
Engine-ECU
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
78
W
B-103
(MU802661)
B
2
1 2
Detonation sensor
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown
R: Red P: Pink V: Violet
O: Orange GR: Gray
AK300273 AB
OPERATION
(terminal No. 78) from the detonation sensor (terminal No. 1).
FUNCTION
The detonation sensor detects the vibration of the
cylinder block caused by detonation waves, and
inputs a signal to the engine-ECU.
In response to the signal, the engine-ECU provides controls to retard the ignition timing when
the detonation occurs.
TROUBLE JUDGMENT
Check Condition
Judgment Criteria
The change amount of the detonation sensor output voltage (the detonation sensor peak voltage
in every one third a turn of the crankshaft) is
below 0.08 V in 200 consecutive times.
13A-120
TROUBLESHOOTING
PROBABLE CAUSE
Failed detonation sensor
Open/short circuit in detonation sensor circuit or
Failed engine-ECU
STEP 2. Measure resistance at B-103 detonation

sensor connector.
Connector: B-103
2 1
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-103 detonation
sensor connector
Harness side
connector
B-103 (GR)
Connector: B-103
2 1
Harness side
connector
B-103 (GR)
Detonation sensor
Alternator
AK300274 AB

side.
OK: 2 W or less
Detonation sensor
Alternator
AK300274 AB

NO : Repair.

NO : Check and repair harness between B-103
(terminal No. 2) detonation sensor

connector and body earth.
Check earthing line for open circuit
and damage.
13A-121
TROUBLESHOOTING

connector
CONNECTOR: C-137

No. 1) detonation sensor connector and C-137
(terminal No.78) engine-ECU connector.
Connector: B-103
2 1
Harness side
connector
B-103 (GR)
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Detonation sensor
Alternator
AK300274 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

00 - How to Use
300).
13A-122

TROUBLESHOOTING
STEP 6. Replace detonation sensor.

After replacing the detonation sensor, re-check
the trouble symptoms.
NO : Check end.
13A-123
TROUBLESHOOTING
Code No. P0335: Crank Angle Sensor System

Crank angle sensor circuit
Battery
W-B
W-B
3
4
B-17X
1
R
B-29
(MU802603)
1 2
3
Crank angle sensor
1
B-W
18
J/C(1)
C-16
G-R
17
B-W
40
89
C-137
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
5V
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code
O: Orange GR: Gray
AK300275 AB
13A-124

TROUBLESHOOTING
OPERATION
Power is supplied to the crank angle sensor (terminal No. 3) from the engine control relay (terminal No. 1) and is earthed to the engine-ECU
(terminal No. 40) from the crank angle sensor
(terminal No. 1).
A power voltage of 5 V is applied to the crank
angle sensor output terminal (terminal No. 2)
from the engine-ECU (terminal No. 89).
FUNCTION
The crank angle sensor detects the crank angle
(position) and inputs a pulse signal to the engineECU.
In response to the signal, the engine-ECU controls the injector, etc.
DIAGNOSIS PROCEDURE
a. Item 22: Crank angle sensor
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-29 crank angle
sensor connector
Connector: B-29
TROUBLE JUDGMENT
Check Condition
Engine in cranking state.
Judgment Criterion
The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.
2 1
3
Harness side
connector
B-29 (B)
PROBABLE CAUSE
Open/short circuit in crank angle sensor circuit or
Failed engine-ECU
Crank angle sensor

AK300276 AB

NO : Repair.
13A-125
TROUBLESHOOTING
STEP 3. Measure voltage at B-29 crank angle

sensor connector.

connector.
Connector: B-29
CONNECTOR: C-137
2 1
3
Harness side
connector
B-29 (B)
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-29
2 1
3
Harness side
connector
Crank angle sensor

AK300276 AB
B-29 (B)

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 4 .
Crank angle sensor

AK300276 AB

Disconnect B-29 crank angle sensor connector.
Ignition switch: ON
OK: 4.9 - 5.1 V

NO : Go to Step 6 .
13A-126
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
Connector: B-29
2 1
3
Harness side
connector
AK300254 AB
B-29 (B)
Crank angle sensor

AK300276 AB

(terminal No. 2) crank angle sensor

NO : Repair.
13A-127
TROUBLESHOOTING

No. 2) crank angle sensor connector and C-137

Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
00 - How to Use
300).
STEP 9. Measure voltage at B-29 crank angle
sensor connector.
Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
Crank angle sensor

AK300276 AB
CONNECTOR: C-137
Crank angle sensor

C-137
AK300276 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

side.
Ignition switch: ON
OK: System voltage
13A-128
TROUBLESHOOTING

relay connector
Connector: B-29
CONNECTOR: B-17X
Relay boxs
triangle marks
Harness side
connector
STEP 11. Measure resistance at B-29 crank angle

sensor connector.
B-17X
2 1
3
Harness side
connector
B-29 (B)
AK300255 AB
Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
Crank angle sensor

AK300276 AB

side.
OK: 2 W or less
Crank angle sensor
AK300276 AB


connector
CONNECTOR: C-135

connector and B-17X (terminal No. 1)
engine control relay connector.
open/short circuit.
NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-129
TROUBLESHOOTING

STEP 14. Measure output waveform at B-29 crank

angle sensor connector (Use oscilloscope).
Connector: B-29
Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
2 1
3
Harness side
connector
B-29 (B)
Crank angle sensor

Crank angle sensor
AK300276 AB
AK300276 AB
CONNECTOR: C-135
C-135

38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
Engine: Idling
(Refer to 313A), its maximum value
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in
waveform.
13A-130
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
Connector: B-29
B-17X
Harness side
connector

No. 3) crank angle sensor connector and B-17X
2 1
3
Harness side
connector
B-29 (B)
AK300255 AB

NO : Repair.
Crank angle sensor

AK300276 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB

NO : Repair.
13A-131
TROUBLESHOOTING
STEP 17. Connector check: C-135 and C-137

engine-ECU connectors
CONNECTOR: C-135, C-137

Connector: B-29
2 1
3
Harness side
connector
B-29 (B)
C-135
C-137
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
C-135 Harness side connector
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300277 AB

NO : Repair.
Crank angle sensor

AK300276 AB
CONNECTOR: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-132
TROUBLESHOOTING

STEP 20. Check the crankshaft sensing blade.
Connector: B-29

NO : Replace the crankshaft sensing blade.
2 1
3
Harness side
connector
STEP 21: MUT-II data list

B-29 (B)

00 - How to Use
300).
NO : Replace crank angle sensor.
Crank angle sensor

AK300276 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-133
TROUBLESHOOTING
Code No. P0340: Camshaft Position Sensor System
Camshaft position sensor circuit
Battery
W-B
W-B
3
4
B-17X
R
3
B-106
(MU802337)
1 2 3
1
B-W
19
J/C (1)
C-16
L-Y
17
B-W
40
88
C-135
C-137
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code

AK300278 AB
OPERATION
Power is supplied to the camshaft position sensor
(terminal No. 3) from the engine control relay (terminal No. 1) and is earthed to the engine-ECU
(terminal No. 40) from the camshaft position sensor (terminal No. 1).
A power voltage of 5 V is applied to the camshaft

position sensor output terminal (terminal No. 2)
from the engine-ECU (terminal No. 88).
FUNCTION
The camshaft position sensor detects the top
dead center on the compression stroke of the No.
1 cylinder and inputs a pulse signal to the engineECU.
13A-134
TROUBLESHOOTING
TROUBLE JUDGMENT
STEP 2. Measure voltage at B-106 camshaft

Check Condition
Connector: B-106
Judgment Criterion
PROBABLE CAUSE
Failed camshaft position sensor
Open/short circuit in camshaft position sensor circuit or loose connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-106 camshaft
position sensor connector
Connector: B-106
3 2 1
Harness side
connector
B-106 (B)
AK300279 AB

NO : Repair.
3 2 1
Harness side
connector
B-106 (B)
AK300279 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 3 .

TROUBLESHOOTING

relay connector
STEP 4. Measure voltage at B-106 camshaft

Connector: B-106
CONNECTOR: B-17X
Relay boxs
triangle marks
13A-135
B-17X
3 2 1
Harness side
connector
B-106 (B)
Harness side
connector
AK300255 AB
Connector: B-106
3 2 1
Harness side
connector
AK300279 AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 5 .
B-106 (B)
AK300279 AB

(terminal No. 3) camshaft position sensor

open/short circuit.
NO : Repair.
13A-136
TROUBLESHOOTING

connector.
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: B-106
Connector: B-106
3 2 1
3 2 1
Harness side
connector
Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB

Disconnect B-106 camshaft position sensor connector.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 7 .
AK300254 AB
AK300279 AB


NO : Repair.
13A-137
TROUBLESHOOTING

connector
CONNECTOR: C-137

No. 2) camshaft position sensor connector and
C-135 (terminal No. 56) engine-ECU connector.
Connector: B-106
3 2 1
Harness side
connector
C-137
B-106 (B)
AK300279 AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
CONNECTOR: C-135

AK300254 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.

00 - How to Use
300).
13A-138
TROUBLESHOOTING
STEP 10. Measure resistance at B-106 camshaft

Connector: B-106

Connector: B-106
3 2 1
3 2 1
Harness side
connector
Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB

side.
OK: 2 W or less
AK300279 AB
CONNECTOR: C-135

C-135

connector
CONNECTOR: C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
C-135

NO : Repair.
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.

13A-139
TROUBLESHOOTING
STEP 13. Measure output waveform at B-106

camshaft position sensor connector (Use
oscilloscope).
Connector: B-106

B-17X (terminal No. 1) engine control relay
connector.
Connector: B-106
3 2 1
3 2 1
Harness side
connector
Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB
Engine: Idling
(Refer to 313A), its maximum value
waveform.
B-17X
Harness side
connector

NO : Repair.
Relay boxs
triangle marks
B-17X
Harness side
connector

NO : Repair.
CONNECTOR: B-17X
CONNECTOR: B-17X
AK300255 AB

relay connector.
Relay boxs
triangle marks
AK300279 AB
AK300255 AB
13A-140
TROUBLESHOOTING

engine-ECU connectors

Connector: B-106
3 2 1
Harness side
connector
C-135
C-137
B-106 (B)
AK300279 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

C-137
AK300277 AB

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-106
13A-141
STEP 19. Check camshaft position sensing

cylinder.
NO : Replace camshaft position sensing cylinder.
3 2 1
Harness side
connector

YES : Replace camshaft position sensor.
B-106 (B)
AK300279 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
00 - How to Use
300).
13A-142
TROUBLESHOOTING
Code No. P0403: EGR Control Solenoid Valve System
EGR control solenoid valve circuit
Battery
W-B
W-B
4
B-17X
1
1
B-102
1 2

2
76
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

O: Orange GR: Gray
AK300280 AB
OPERATION
Power is supplied to the EGR control solenoid
valve (terminal No. 1) from the engine control
relay (terminal No. 1).

power transistor in the unit be in "ON", and that
makes currents go on the EGR control solenoid
valve (terminal No. 2).
13A-143
TROUBLESHOOTING
FUNCTION
In response to the signal from the engine-ECU,
the EGR control solenoid valve controls the operation of the EGR valve.
STEP 3. Measure resistance at B-102 EGR

control solenoid valve connector.
Connector: B-102
2 1
Harness side
connector
TROUBLE JUDGMENT
Check Conditions
Except the engine stalling
B-102 (BR)
Judgment Criteria
If the off surge voltage from the motor coil is not
generated when the EGR valve control motor is
driven.
PROBABLE CAUSE
Failed EGR control solenoid valve
Open/short circuit in EGR control solenoid valve
Failed engine-ECU
DIAGNOSIS PROCEDURE
Refer to Actuator test reference table 313A.
a. Item 10: EGR control solenoid valve
OK: Operating sound can be heard and the
valve vibrates.
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-102 EGR control
solenoid valve connector
Connector: B-102
2 1
Harness side
connector
B-102 (BR)
AK300281 AB

NO : Repair.
AK300281 AB
Disconnect connector, and measure at solenoid

valve side.
OK: 29 - 35 W (at 20C)
NO : Replace EGR control solenoid valve.
STEP 4. Measure voltage at B-102 EGR control

solenoid valve connector.
Connector: B-102
2 1
Harness side
connector
B-102 (BR)
AK300281 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13A-144
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

connector.
CONNECTOR: C-134
B-17X
C-134
Harness side
connector
AK300255 AB
Connector: B-102
2 1
Harness side
connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
B-102 (BR)
AK300281 AB

(terminal No. 1) EGR control solenoid valve

open/short circuit.
NO : Repair.

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 7 .
13A-145
TROUBLESHOOTING

connector

connector
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Connector: B-102
2 1
Harness side
connector
B-102 (BR)
AK300281 AB

(terminal No. 2) EGR control solenoid valve

Check output line for open/short
circuit.
NO : Repair.
AK300257 AB

NO : Repair.
13A-146
TROUBLESHOOTING

No. 2) EGR control solenoid valve connector and
Connector: B-102
2 1

No. 1) EGR control solenoid valve connector and
connector.
Connector: B-102
2 1
Harness side
connector
Harness side
connector
B-102 (BR)
B-102 (BR)
AK300281 AB
AK300281 AB
CONNECTOR: C-134
CONNECTOR: B-17X
Relay boxs
triangle marks
C-134
B-17X
Harness side
connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
AK300255 AB

NO : Repair.

Refer to actuator test reference table list 313A
.
Item 10: EGR control solenoid valve
valve vibrates.
00 - How to Use
300).

TROUBLESHOOTING
13A-147
Code No. P0420: Catalyst malfunction

FUNCTION
The signal from the heated oxygen sensor (rear)
differs from the heated oxygen sensor (front).
That is because the catalytic converter purifies
exhaust gas. When the catalytic converter has
deteriorated, the signal from the heated oxygen
sensor (front) becomes similar to the heated oxygen sensor (rear).
The engine-ECU compares the output of the front
and rear heated oxygen sensor signals.

b. Item 59: Oxygen sensor (rear)

TROUBLE JUDGMENT
Check Conditions
Engine speed: 3,000 r/min or less.
During the driving.
During the air-fuel ratio feedback control.
Judgment Criterion
When the output frequency ratio of the oxygen
sensor (rear) vs. The oxygen sensor (front) is 0.8
or more on the average for 12 seconds.
PROBABLE CAUSE
Catalytic converter deteriorated
Failed engine-ECU
DIAGNOSIS PROCEDURE
NO : Repair.

OK: 0 - 0.4 and 0.6 - 1.0 volt should alternate
15 times or more within 10 seconds (engine
speed at 2,000 r/min).
NO : Replace the oxygen sensor (front).
STEP 4.Replace the oxygen sensor (rear).

After replacing the oxygen sensor (rear), recheck the trouble symptoms.
NO : Check end.
STEP 5.Replace the catalytic converter.

After replacing the catalytic converter, re-check
YES : Replacing engine-ECU.
NO : Check end.
13A-148
TROUBLESHOOTING
Code No. P0443: Purge Control Solenoid Valve System

Purge control solenoid valve circuit
Battery
W-B
W-B
4
B-17X
1
B-101
(MU802779)
1 2
1
BR
9
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

O: Orange GR: Gray
AK300282 AB
OPERATION
Power is supplied to the purge control solenoid

and that makes currents go on the purge control
solenoid valve (terminal No. 1).
13A-149
TROUBLESHOOTING
FUNCTION
In response to a signal from the engine-ECU, the
purge control solenoid valve controls the flow rate
of the purge air to be introduced into the surge
tank.
STEP 3: Measure resistance at B-101 purge

control solenoid valve connector.
Connector: B-101
2 1
Harness side
connector
TROUBLE JUDGMENT
Check Conditions
Ignition switch: ON
Judgment Criteria
The surge voltage (system voltage + 2 V) of solenoid coil is not detected when the purge control
solenoid valve is turned in OFF position from ON.
B-101 (B)
AK300283AB

valve side.
OK: 30 - 34 W (at 20C)
PROBABLE CAUSE
Open/short circuit in purge control solenoid value
Failed engine-ECU

DIAGNOSIS PROCEDURE
STEP 4. Measure voltage at B-101 purge control

solenoid valve connector.

Item 08: Purge control solenoid valve
valve vibrates
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-101 purge control
Connector: B-101
2 1
Harness side
connector
B-101 (B)
AK300283AB

NO : Repair.
Connector: B-101
2 1
Harness side
connector
B-101 (B)
AK300283AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13A-150
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks

connector.
CONNECTOR: C-134
B-17X
C-134
Harness side
connector
AK300255 AB
Connector: B-101
2 1
Harness side
connector
B-101 (B)
AK300283AB

(terminal No. 2) purge control solenoid valve

Check power line for open/short
circuit.
NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 7 .
13A-151
TROUBLESHOOTING

connector

connector
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Connector: B-101
2 1
Harness side
connector
B-101 (B)
AK300283AB


Check output line for open and short
circuit.
NO : Repair.
AK300257 AB

NO : Repair.
13A-152
TROUBLESHOOTING

No. 1) purge control solenoid valve connector
connector.
Connector: B-101

and B-17X (terminal No. 1) engine control relay
connector.
Connector: B-101
2 1
2 1
Harness side
connector
Harness side
connector
B-101 (B)
B-101 (B)
AK300283AB
AK300283AB
CONNECTOR: B-17X
CONNECTOR: C-134
Relay boxs
triangle marks
C-134
B-17X
Harness side
connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
AK300255 AB
Check power line for damage.

NO : Repair.

NO : Repair.

Item 08: purge control solenoid valve
valve vibrates
00 - How to Use
300).
13A-153
TROUBLESHOOTING
Code No. P0500: Vehicle speed sensor system
Vehicle speed sensor circuit
Ignition switch
Engine-ECU
C-137
C-303
1 2 3
4 5 6
LOCK
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
ST
ACC
IG1 IG2
2
L-B
86
C-203
6
W-L
2 J/B
7.5A
C-202
11
3
J/C (1)
C-16
Meter and gauge
B-W
2
C-106
3
W-L
B-W
3
1
B-115
1 2 3
Vehicle speed sensor
2
B
8
J/C (2)
C-17
B
Wire colour code

O: Orange GR: Gray
AK300284 AB
OPERATION
A power voltage of 5 V is applied to the vehicle
speed sensor (terminal No. 3) from the engineECU (terminal No. 86).
FUNCTION
The vehicle speed sensor converts the vehicle
speed to the voltage, and then input it into the
engine-ECU
13A-154

TROUBLESHOOTING
TROUBLE JUDGMENT
Check Conditions
Engine speed: 2,000 r/min or more.
Under the high load operation (The volumetric
efficiency is 40 - 75 %).
Judgment Criterion
PROBABLE CAUSE
Failed Vehicle speed sensor
Open/short circuit in vehicle speed sensor circuit
Failed engine-ECU

a. Item 24: Vehicle speed sensor
00 - How to Use Troubleshooting/Inspection

Service Points 300).
STEP 3.Check connector: C-137 engine-ECU
connector
CONNECTOR: C-137
DIAGNOSIS PROCEDURE
STEP 1.Check the speedometer
NO : Check the speedometer (Refer to GROUP
54A -Combination Meter Assembly and

Vehicle speed sensor - On-vehicle Service
354A).
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.

TROUBLESHOOTING
STEP 4.Check harness between C-137 (terminal

No. 86) engine-ECU connector and B-115
(terminal No. 3) Vehicle speed sensor connector.
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
CONNECTOR: B-115
3 2 1
Harness side
connector
AK300285AB

Check output line for open circuit and damage.
NO : Repair.
STEP 5.Check the trouble symptoms.


C-137
B-115 (B)
13A-155
13A-156
TROUBLESHOOTING
Code No. P0505: Idle Speed Control Servo System
Idle speed control servo circuit

Battery
W-B
W-B
3
B-17X
1
R
2
B-105
1 2 3
4 5 6
L-Y
Y-L
17
G-Y
18
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code
AK300286 AB
13A-157
TROUBLESHOOTING
OPERATION
The power is supplied to the idle speed control
servo (terminal No. 2 and No. 5) from the engine
control relay (terminal No. 1).
The engine-ECU (terminal No. 4, No. 5, No. 17
and No. 18) makes power transistor in the unit be
in "ON" position in order, and that makes currents
go on the idle speed control servo (terminal No.
1, No. 3, No. 4 and No. 6).
Judgment Criteria
The actual idle speed is higher than the target
idle speed by 100 r/min or more for 10 seconds.
FUNCTION
The idle speed control servo opens and closes
the servo valve in response to a signal from the
engine-ECU to control the intake air flow rate during idling.
DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT
Check conditions
The vehicle speed has reached 1.5 km/h or more
at least once.
During the closed-loop idle speed control.
Judgment Criteria
Check conditions
at least once.
The highest ambient temperature at the last drive
is 45 C or less.
82C or higher.
Judgment Criteria
Check conditions
82C or higher.
The power steering switch is in OFF position.
The charging efficiency is 40 % or less.
PROBABLE CAUSE
Failed idle speed control servo
Open/short circuit in idle speed control servo circuit or loose connector contact
Failed engine-ECU
STEP 1. MUT-II Data List

a. Item 45: Idle speed control position
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: B-105 idle speed
control servo connector
Connector: B-105
3
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB

NO : Repair.
STEP 3. Check idle speed control servo itself.

Check idle speed control servo itself (Refer to
313A).
NO : Replace idle speed control servo.
13A-158
TROUBLESHOOTING
STEP 4. Measure voltage at B-105 idle speed

control servo connector.
Connector: B-105
STEP 5. Check connector: B-17X engine control

relay connector
CONNECTOR: B-17X
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB

side.
Ignition switch: ON
Voltage between terminal No. 2 and earth, also
between terminal No. 5 and earth.
OK: System voltage
NO : Go to Step 5 .
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB
Connector: B-105
3
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB

(terminal No. 2 or No. 5) idle speed control

servo connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
13A-159
TROUBLESHOOTING

connector.
CONNECTOR: C-134

open/short circuit.
connector
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
Connector: B-105
AK300257 AB
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB

side.
Ignition switch: ON
Voltage between terminal No. 4 and earth,
between terminal No. 5 and earth, between terminal No. 17 and earth, also voltage between terminal No. 18 and earth.
OK: System voltage
idle speed control servo and C-134 engineECU.

1. Harness between idle speed control
servo terminal No. 1 and engineECU connector terminal No. 4

NO : Repair.
13A-160
TROUBLESHOOTING
STEP 8. Check harness between B-105 idle

speed control servo and C-134 engine-ECU.
Connector: B-105
3
2 1

No. 2 or No. 5) idle speed control servo
connector and B-17X (terminal No. 1) engine
control relay connector.
Connector: B-105
6 5 4
Harness side
connector
2 1
6 5 4
Harness side
connector
B-105 (B)
AK300287 AB
B-105 (B)
CONNECTOR: C-134
AK300287 AB
CONNECTOR: B-17X
Relay boxs
triangle marks
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side
connector
AK300255 AB

AK300257 AB
1. Harness between idle speed control servo terminal No. 1 and engine-ECU connector terminal
No. 4
No. 17
No. 5
No. 18
NO : Repair.
B-17X

NO : Repair.

a. Item 45: Idle speed control position
00 - How to Use
300).

TROUBLESHOOTING
13A-161
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering pressure switch
C-135
Engine-ECU
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
37
B-28
(MU801211)
1
Power steering pressure switch
Wire colour code

AK300288 AB
CONDITION
The battery voltage is applied to the power steering fluid pressure switch (terminal No. 1) from the
FUNCTION
It is detected whether a load is applied on the
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU. When
the power steering fluid pressure switch "ON" signal (a large load on the power steering fluid
pump) is inputted, the engine-ECU provides the
idle-up control.
TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature is approximately

30C or higher.
Repeat, 10 times or more, the *1 running and
stop also *2 running.
*1 running: engine speed of 2,500 r/min or more
(Vehicle speed of 50 km/h or more).
*2 running: Vehicle speed of 1.5 km/h or less.
Judgment Criteria
The power steering pressure switch remains in
ON position.
PROBABLE CAUSE
Failed power steering fluid pressure switch
Open/short circuit in power steering fluid pressure switch circuit or loose connector contact
Failed engine-ECU
13A-162
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector.
STEP 1. Connector check: B-28 power steering

fluid pressure switch connector
CONNECTOR: C-135
CONNECTOR: B-28
C-135
B-28 (B)
1
Harness side
connector
AK300289 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

NO : Repair.
AK300256 AB
STEP 2. Measure voltage at B-28 power steering

fluid pressure switch connector.

NO : Go to Step 5 .
CONNECTOR: B-28
B-28 (B)
1
Harness side
connector
AK300289 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 3 .

Ignition switch: ON
OK: System voltage
13A-163
TROUBLESHOOTING

connector
CONNECTOR: C-135

connector
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
CONNECTOR: B-28
B-28 (B)
1
Harness side
connector
AK300256 AB
AK300289 AB

(terminal No. 1) power steering fluid

pressure switch connector and C-135
NO : Repair.
13A-164
TROUBLESHOOTING

No. 1) power steering fluid pressure switch

connector.
CONNECTOR: C-135
CONNECTOR: B-28
B-28 (B)
C-135
1
Harness side
connector
AK300289 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

CONNECTOR: C-135
AK300256 AB
C-135

Engine: Idling
OK:
System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
NO : Go to Step 9 .
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.

connector
CONNECTOR: C-135

a. Item 27: Power steering fluid pressure switch
C-135

00 - How to Use
300).
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-165
TROUBLESHOOTING


connector
CONNECTOR: C-135
CONNECTOR: B-28
B-28 (B)
C-135
1
Harness side
connector
AK300289 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

CONNECTOR: C-135
AK300256 AB

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

YES : Replace power steering fluid pressure
switch.
NO : Repair.
13A-166
TROUBLESHOOTING
Code No. P0622: Alternator FR Terminal System
Alternator circuit
C-135
Engine-ECU
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
41
Y-B
B-19
1
Y-B
B-30
(MU802046)
1 2 3 4
IC Voltage
regulator
Alternator
Wire colour code

O: Orange GR: Gray
AK300290 AB
OPERATION
The energized state of the alternator field coil is
inputted from the alternator (terminal No. 4) to the
FUNCTION
A signal of the power supply duty ratio for the
alternator field coil is inputted to the engine-ECU.
In response to the signal, the engine-ECU
detects the alternator output current and controls
the idling speed according to the output current
(electric load).
TROUBLE JUDGMENT
Check Condition
Engine speed is 50 r/min or more.
Judgment Criterion
Input voltage from alternator FR terminal is the
system voltage or more for 20 seconds.
PROBABLE CAUSE
Alternator FR terminal circuit open circuited
Failed engine-ECU
13A-167
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector
STEP 1. Connector check: B-19 intermediate

connector
CONNECTOR: B-19
CONNECTOR: B-19
B-19 (B)
B-19 (B)
Female side
connector
3 2 1
6 5 4
Female side
connector
3 2 1
6 5 4
AK300294 AB

NO : Repair.
STEP 2. Measure voltage at B-19 intermediate

connector.
AK300294 AB

NO : Repair.

No. 1) intermediate connector and C-135
CONNECTOR: B-19
CONNECTOR: B-19
B-19 (B)
B-19 (B)
1 2 3
4 5 6
1 2 3
4 5 6
Male side
connector
Male side
connector
AK300295 AB
Disconnect connector, and measure at male connector side.

Ignition switch: ON
OK: System voltage
AK300295 AB
CONNECTOR: C-135

NO : Go to Step 3 .
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-168

TROUBLESHOOTING

00 - How to Use
300).
connector.
B-19 (B)
3 2 1
6 5 4
B-30 (GR)
4 3 2 1
AK300296 AB

NO : Repair.

No. 4) alternator connector and B-19 (terminal
No. 1) intermediate connector.
AK300294 AB
Ignition switch: ON
OK: System voltage
NO : Go to Step 7 .
CONNECTOR: B-30
Harness side
connector
CONNECTOR: B-19
Female side
connector
STEP 7. Connector check: B-30 alternator

connector
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side
connector
AK300296 AB
CONNECTOR: B-19
B-19 (B)
3 2 1
6 5 4
Female side
connector
AK300294 AB

YES : Replace alternator.
NO : Repair.

TROUBLESHOOTING

connector.
CONNECTOR: B-19
13A-169

No. 4) alternator connector and B-19 (terminal
No. 1) intermediate connector pin No. 1.
CONNECTOR: B-30
B-19 (B)
B-30 (GR)
3 2 1
6 5 4
Female side
connector
4 3 2 1
AK300294 AB
Engine: Idle after warm-up
Radiator fan: Inactive
OK: Switching the headlamps to ON from
OFF causes the voltage to fall.
Harness side
connector
CONNECTOR: B-19
B-19 (B)
3 2 1
6 5 4
Female side
connector

connector
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side
connector

NO : Repair.
AK300296 AB
AK300296 AB

NO : Repair.
AK300294 AB
13A-170
TROUBLESHOOTING

No. 1) intermediate connector and C-135
CONNECTOR: B-19
Q: Same symptoms regenerated?

NO : Intermittent malfunction (Refer to Group 00
- How to Use troubleshooting/Inspection

B-19 (B)
1 2 3
4 5 6
Male side
connector
AK300295 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
STEP 13. Check trouble symptom.

TROUBLESHOOTING
13A-171
Code No. P1603: Battery Backup Line System
Battery backup circuit

Battey
9
20A
Relay box
W-B
A-14
5
W-B
80
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Battery
backup
Engine-ECU
Wire colour code

O: Orange GR: Gray
AK300297 AB
OPERATION
Power is directly supplied to the engine-ECU (terminal No. 80) from the battery.
TROUBLE JUDGMENT
FUNCTION
The engine-ECU is check the open circuit of battery backup line.
Judgment Criterion
The battery backup line voltage 6 V or less.
Check Condition
Ignition switch: ON
PROBABLE CAUSE
Open/short circuit in battery backup line circuit or
Failed engine-ECU
13A-172
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector
STEP 1 MUT-II self-diag code

Temporarily place the ignition switch in "LOCK"
(OFF) position, and 10 seconds after that, place it
in "ON" position again.
CONNECTOR: C-137
Q: Is the diagnosis code P1603 set?

00 - How to use Troubleshooting/Inspection

connector.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
CONNECTOR: C-137
AK300254 AB

NO : Repair.
C-137

8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
00 - How to Use
Troubleshooting/Inspection Service
Points300).

AK300254 AB

side.
Ignition switch: ON
OK: System voltage
NO : Check intermediate connector A-14, and

harness between battery and C-137
open/short circuit.

TROUBLESHOOTING
13A-173
Code No. P1610: Immobilizer System
Immobilizer-ECU circuit
Signal
transmission
circuit
C-304-1
Immobilizer-ECU
1
2
3 4 5 6 7
C-304
(MU801547)
V
11
C-104
V
51
C-136
51 52 53 54 55 56
57 58 59 60 61 62
Engine-ECU
Wire colour code

AK300298 AB
OPERATION
The signals are sent and received between
engine-ECU (terminal No. 51) and immobilizerECU (terminal No. 7).
FUNCTION
Engine-ECU sends or receives the control signals to or from immobilizer-ECU to certify the
ignition key.
NOTE: .
If the registered ignition keys are close each
other when starting the engine, radio interference may cause this code to be displayed.
This code may be displayed when registering
the key encrypted code.
TROUBLE JUDGMENT
Check Condition
Ignition switch: ON
Judgment Criterion
Improper communication problems between the
engine-ECU and the immobilizer-ECU are
detected.
PROBABLE CAUSE
Open/short circuit in immobilizer system circuit or
Failed immobilizer-ECU
Failed engine-ECU
13A-174
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-304 immobilizerECU connector and C-136 engine-ECU connector

No. 3) immobilizer-ECU connector and C-136
Connector: C-304
Harness side
connector
Connector: C-304
Harness side
connector
1
2
76543
1
2
76543
C-304
C-304
AK203418 AC
AK203418 AC
CONNECTOR: C-136
CONNECTOR: C-136
C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AB
AK300268 AB

NO : Repair.

NO : Repair.

00 - How to Use
300).
STEP 4. After replacing the immobilizer-ECU, recheck the trouble symptoms.
NO : Check end.

TROUBLESHOOTING
13A-175
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1131151500522
Items
Trouble symptom
Inspection
procedure
No.
Communication
with MUT-II is
impossible
Communication with all system is not possible
Communication with engine-ECU only is not possible
Engine warning
lamp
The engine warning lamp does not illuminate right after the ignition switch 3
is turned the "ON" position
The engine warning lamp remains illuminating and never goes out
Starting
Starting impossible
(No initial combustion)
The starter is impossible to operate. 5
Starting impossible
(Starter operative but no initial
combustion)
The starter is operative and cranks

the engine, but none of initial
combustion is in the cylinders and
the engine is not started.
Starting impossible
The initial combustion occurs, but
(Initial combustion but no complete the engine stalls soon due to the
combustion)
incomplete combustion.
Improper idling
Engine stalls
Improper starting
(Long time to start)
It is long cranking to start the engine.
Unstable idling
(Rough idling, hunting)
The engine speed is not constant

8
and changeable during the idling.
Usually, the judgment can be based
on the movement of the tachometer
pointer, also on the vibration
transmitted to the steering wheel, sift
lever, vehicle body and so on.
Improper idling speed
The proper idling speed is not

satisfied.
Engine stalled during idling

(Die out)
The engine stalls during the idling in

no relation to the vehicle movement.
The engine stalls when starting the The engine stalls during the
car
operation, or when the accelerator
(Pass out)
pedal is depressed from the idling.
The engine stalls when
decelerating
The engine stalls at the deceleration. 10
13A-176
TROUBLESHOOTING
Items
Trouble symptom
Inspection
procedure
No.
Driving
Engine does not revolve up
The engine speed is not higher when 11

the accelerator pedal is depressed.
Hesitation, sag
The response of vehicle speed

12
(engine speed) is delayed when the
accelerator pedal is depressed, or
the vehicle speed (engine speed) is
temporarily dropped during the
acceleration. These phenomena are
called "hesitation" and the serious
hesitation is called "sag".
Poor acceleration
The engine cannot obtain the

acceleration corresponding to the
degree of throttle opening although
the engine is smooth at the constant
speed.
Stumble
The engine speed increase is

delayed when the accelerator pedal
is initially depressed at the starting.
Surge
The vehicle body is repeated to

vibrate jollity in the forward and
backward directions at the constant
speed or acceleration.
The feeling of impact or vibration

when accelerating
The large impact feeling occurs at

the acceleration.
13

when decelerating

the deceleration.
14
Knocking
Sharp sound like a hammer striking

on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
15
Ignition timing offset
The basic ignition timing is deviated

from the datum value.
16
Stopping
Run on (Dieseling)
The engine continues to run after the 17

ignition switch is in "LOCK (OFF)"
position.
Exhaust gas
Odor, white smoke, black smoke,

high-concentration CO/HC during
idling
The exhaust gas is extremely rank

odor, white smoke or black smoke.
The concentration of CO & HC is
high during the idling.
18
Charging
performance
Battery rundown
The battery is soon rundown or the

charging ability of battery is small.
19

TROUBLESHOOTING
13A-177
Items
Trouble symptom
Cooling
performance
Overheating
The temperature of engine cooling

water is extremely high.
20
Abnormal rotation of fan Motor
The fan motor is abnormally rotated

when the ignition switch is in "ON"
position in no relation to the engine
cooling water temperature.
21
Poor A/C Performance
The temperature of air cooling from

A/C is not efficient or very far from
the target temperature.
22
A/C performance
Inspection
procedure
No.
PROBLEM SYMPTOMS TABLE

Inspection Trouble symptom
procedure
No.
Reference
page
313A
Communication with engine-ECU only is not possible
313A
The engine warning lamp does not illuminate right after the ignition switch is
turned the "ON" position
313A
313A
Starting impossible (No initial combustion)
313A
Starting impossible (Starter operative but no initial combustion)
313A
Starting impossible (Initial combustion but no complete combustion)
313A
Starting impossible (Long time to start)

8
Unstable idling (Rough idling, hunting)
313A
Improper idling speed (Too high or too low)

Engine stalls during idling (Die out)
9
The engine stalls when starting the car (pass out)
313A
10
The engine stalls when decelerating
313A
11
313A
12
Hesitation, sag
313A
Poor acceleration
Stumble
Surge
13
The feeling of impact or vibration when accelerating
313A
14
The feeling of impact or vibration when decelerating
313A
15
Knocking
313A
16
313A
17
Run on (Dieseling)
313A
18
Odor, white smoke, black smoke, high-concentration CO/HC during idling
313A
19
Battery rundown
313A
20
Overheating
313A
13A-178
TROUBLESHOOTING

procedure
No.
Reference
page
21
Abnormal rotation of fan motor
313A
22
Poor A/C performance
313A
23
Engine-ECU power supply, engine control relay, ignition switch-IG1 system
313A
24
Fuel pump system
313A
25
Fan control relay system
313A
26
A/C switch system
313A
27
A/C compressor relay system
313A
28
A/C load signal system
313A
29
A/C pressure sensor system
313A
30
Ignition circuit system
313A
13A-179
TROUBLESHOOTING
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is not Possible

Data link connector circuit
Fusible link (1)
C-116
15
R
C-204
1
15
15A
J/B
12
C-205
W-B
C-24
16
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Data link connector

5
4
B
Wire colour code

AK300300 AB
OPERATION
Battery voltage is applied to diagnosis connector
(terminal No.16).
Diagnosis connector (terminals No. 4 and 5) are
earthed to the vehicle body.
COMMENT ON TROUBLE SYMPTOM

Failure is possibly caused by failed power supply
circuit or failed earthing circuit of diagnosis connector.
PROBABLE CAUSE
Failed diagnosis connector
Open/short circuit in diagnosis connector circuit
Failed MUT-II
13A-180
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 3: Measure voltage at C-24 diagnosis

connector.
STEP 1: Check connector: C-24 diagnosis

connector
Connector: C-24
Connector: C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)

AK203424 AE

AK203424 AE

NO : Repair.
STEP 2: Measure resistance at C-24 diagnosis

connector.
Connector: C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)
Disconnect connector, and measure at the harness side.

OK: System voltage
NO : Check intermediate connectors C-116, C-204
and C-205, and repair if necessary. If

connectors are normal, check and repair
diagnosis connector and battery.
open/short circuit.
STEP 4: Replace MUT-II
After replacing the MUT-II, re-check the trouble
symptoms.
C-24 (B)

AK203424 AE

side.
Resistance between terminal No. 4 and earth,
also between terminal No. 5 and earth.
OK: 2 W or less
NO : Check and repair harness between C-24
(terminal No. 4) diagnosis connector and

body earth, also between C-24 (terminal No.
5) diagnosis connector and body earth.
and damage.

NO : Check end

TROUBLESHOOTING
STEP 5: Check harness between C-24 (terminal

No. 6) diagnosis connector and battery.
Connector: C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)

AK203424 AE

connectors C116, C-204 and C-205, and repair if
necessary.
(terminal No. 4 and No. 5) diagnosis

NO : Repair.
13A-181
13A-182
TROUBLESHOOTING
Inspection Procedure 2: Communication with Engine-ECU only is not Possible.
Data link connector circuit
C-136
Engine-ECU
51 52 53 54 55 56
57 58 59 60 61 62
62
O-W
C-105
5
O-W
32
J/C (3)
C-02
29
O-L
C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Data link connector
Wire colour code

AK300301 AB
OPERATION
There is data communication between diagnosis
connector output terminal (terminal No. 7) and
DIAGNOSIS PROCEDURE

circuit or failed earthing circuit of engine-ECU.
Q: Is lamp illuminating for few seconds?

NO : Check engine-ECU power supply, engine
PROBABLE CAUSE
Open/short circuit in engine-ECU power circuit
Between engine-ECU and diagnosis connector
for short circuit
Failed engine-ECU
STEP 1: Check engine warning lamp.

Ignition switch: OFF ON
control relay and ignition switch IG1 system

(Refer to Inspection Procedure 23 313A
).
13A-183
TROUBLESHOOTING
STEP 2: Connector check: C-136 engine-ECU

connector
CONNECTOR: C-136

No. 7) diagnosis connector and C-136 (terminal
Connector: C-24
C-136
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)

AK203424 AE
56 55 54 53 52 51
62 61 60 59 58 57
CONNECTOR: C-136

AK300268 AB

NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57

AK300268 AB
NOTE: Before Checking harness, check intermediate connectors C-105 and C-02, and repair if necessary.
Check communication line for open/short circuit
and damage.
NO : Repair.
STEP 4: Check the trouble symptom.

00 - How to Use
300).
13A-184
TROUBLESHOOTING
Inspection Procedure 3: The Engine Warning Lamp Does not Illuminate Right after the Ignition Switch
is Turned The "ON" Position
Malfunction indicator lamp (Engine warning lamp) circuit
Ignition switch
C-303
LOCK
1 2 3
4 5 6
ST
ACC
IG1
IG2
2
L-B
C-203
6
2
7.5A
J/B
25
C-205
C-04
B-W
42
31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G
Malfunction indicator lamp

(Engine warning lamp)
C-05
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122
G
14
R-W
7
C-105
R-W
36
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Engine-ECU
Wire colour code

AK300302 AB
OPERATION
Battery voltage is applied to engine warning lamp
of combination meter connector (terminal No. 42)
from ignition switch.
Engine-ECU (terminal No. 36) makes power transistor in unit be in "ON" position, and that makes
currents go on engine warning lamp of combination meter connector (terminal No. 14).
13A-185
TROUBLESHOOTING
COMMENTS ON TROUBLE SYMPTOM

Engine-ECU turns on engine warning lamp for 5
seconds to check for burnt-out bulb immediately
after ignition switch is turned to ON.
If engine warning lamp is not lit just after turning
ignition switch to "ON" position, failure is possibly
caused by burn-out bulb, open/short circuit or
other faults.
STEP 3: Connector check: C-04 combination

meter connector
CONNECTOR: C-04
C-04
PROBABLE CAUSE
Engine warming lamp bulb burnt out
Failed ignition switch
Open/short circuit in engine warning lamp circuit
for or loose connector contact
Failed engine-ECU
DIAGNOSIS PROCEDURE
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G
STEP 1: Check engine start-up.

Q: Is engine started?

).
STEP 2: Check engine warning lamp for burntout bulb.
AK300303AB

NO : Repair
STEP 4: Measure voltage at C-04 combination

meter connector.
CONNECTOR: C-04
C-04

NO : Replace engine warning lamp.
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

AK300303AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13A-186
TROUBLESHOOTING
STEP 5: Connector check: C-303 ignition switch

connector
CONNECTOR: C-303

connector
CONNECTOR: C-135
C-303
3 2 1
6 5 4
C-135
Harness side
connector
AK300304 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-04
C-04
AK300256 AB

NO : Repair.
STEP 7: Measure voltage at C-135 engine-ECU

connector.
CONNECTOR: C-135
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

AK300303AB

YES : Check intermediate connectors C-203 and
C-205, and repair if necessary. If

intermediate connectors are normal, check
and repair harness between C-04 (terminal
No. 42) combination meter connector and
C-303 (terminal No. 2) ignition switch
connector.
open/short circuit.
NO : Repair
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
13A-187
TROUBLESHOOTING
STEP 8: Check connector: C-05 combination

meter connector

connector
CONNECTOR: C-303
CONNECTOR: C-05
C-05 (L)
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

NO : Repair.
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G

AK300305 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB


combination meter connector and C-135
circuit.
NO : Repair
13A-188
TROUBLESHOOTING

No. 42) combination connector and C-303
(terminal No. 2) ignition switch connector.

connector
CONNECTOR: C-05
CONNECTOR: C-04
C-05 (L)
C-04
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G
AK300305 AB

AK300303AB
CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

connectors C-203 and C-205, and repair if necessary.
NO : Repair.

NO : Repair.

TROUBLESHOOTING

CONNECTOR: C-05
C-05 (L)
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G

AK300305 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-189
STEP 13: Check the trouble symptoms.

00 - How to Use
300).
13A-190
TROUBLESHOOTING
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out
Malfunction indicator lamp (Engine warning lamp) circuit
Ignition switch
C-303
LOCK
1 2 3
4 5 6
ST
ACC
IG1
IG2
2
L-B
C-203
6
2
7.5A
J/B
25
C-205
C-04
B-W
42
31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G
Malfunction indicator lamp

(Engine warning lamp)
C-05
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122
G
14
R-W
7
C-105
R-W
36
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Engine-ECU
Wire colour code

AK300302 AB
OPERATION
(terminal No. 42) from ignition switch.
Engine-ECU (terminal No. 36) makes power transistor in unit be in "ON" position, and that makes
currents go on engine warning lamp (terminal No.
14).
13A-191
TROUBLESHOOTING

Engine-ECU has detected failed sensor or failed
actuator. Or failure is possibly caused by short
circuit or other faults.

connector.
CONNECTOR: C-135
PROBABLE CAUSE
Short circuit in between engine warning lamp and
engine-ECU circuit.
Failed engine-ECU
DIAGNOSIS PROCEDURE
C-135
STEP 1: MUT-II self-diag code

Q: Diagnosis code set?
to 313A.)
NO : Go to Step 2 .
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

connector
CONNECTOR: C-05
C-05 (L)
CONNECTOR: C-135
C-135
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300305 AB

AK300256 AB

NO : Repair

Ignition switch: ON
OK: System voltage
NO : Check intermediate connector C-105, and

13A-192

TROUBLESHOOTING

00 - How to Use
300).
Inspection Procedure 5: Starting impossible (No Initial Combustion)

Failure is possibly caused by failed starter itself
or failed related circuit.

connector
CONNECTOR: C-137
PROBABLE CAUSE
Failed battery
Failed starter motor
Open/short circuit in starter associated circuit or
DIAGNOSIS PROCEDURE
STEP 1: Check battery voltage.
Measure battery voltage at cranking.
OK: 8 V or higher
NO : Check battery (Refer to GROUP 54A -
Battery - On-vehicle Service - Battery Test

354A).
Item 18: Cranking signal
OK:
ON (Ignition switch: ST)
OFF (Ignition switch: ON)
NO : Go to Step 3 .
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

NO : Repair.
13A-193
TROUBLESHOOTING

connector.
STEP 6: Check ignition switch.

CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
AK300254 AB

Ignition switch: ST
OK: System voltage
NO : Go to Step 5 .
CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

connector

CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

NO : Repair.
Check ignition switch (Refer to GROUP 54A Ignition Switch - Ignition Switch 354A).
B-19, and repair if necessary. If intermediate

connector are normal, check and repair
inhibitor switch connector and C-303
open/short circuit.
NO : Replace ignition switch.
13A-194
TROUBLESHOOTING

connector and B-26 starter connector
STEP 8: Check connector: B-26 starter connector

CONNECTOR: B-26
CONNECTOR: C-303
B-26 (B)
C-303
3 2 1
6 5 4
1
Harness side
connector
Harness side
connector
AK300306 AB
AK300304 AB

NO : Repair.
CONNECTOR: B-26
STEP 9: Measure voltage at B-26 starter

connector.
B-26 (B)
CONNECTOR: B-26
1
Harness side
connector
AK300306 AB


ignition switch connector and B-26 (terminal
No. 1) starter connector.
NO : Repair.
B-26 (B)
1
Harness side
connector
AK300306 AB

Ignition switch: ST
OK: System voltage
13A-195
TROUBLESHOOTING

connector
CONNECTOR: C-303
STEP 11: Connector check: B-25 starter

connector
CONNECTOR: B-25
C-303
3 2 1
6 5 4
B-25
1
Harness side
connector
AK300304 AB
AK300307 AB

NO : Repair.
CONNECTOR: B-26
STEP 12: Measure voltage at B-25 starter

connector.
B-26 (B)
CONNECTOR: B-25
1
Harness side
connector
Harness side
connector
AK300306 AB

YES : Check intermediate connectors B-19 and C-
106, and repair if necessary. If intermediate

damage.
NO : Repair.
B-25
1
Harness side
connector
AK300307 AB

OK: System voltage
(terminal No. 1) starter connector and

battery.
open/short circuit.
13A-196
TROUBLESHOOTING

No. 5) ignition switch connector and B-26
(terminal No. 1) starter connector.
STEP 14: Check harness between B-25 (terminal

No. 1) starter connector and battery.
CONNECTOR: B-25
CONNECTOR: C-303
C-303
3 2 1
6 5 4
B-25
1
Harness side
connector
Harness side
connector
AK300304 AB
AK300307 AB

YES : Replace starter.
NO : Repair.
CONNECTOR: B-26
B-26 (B)
1
Harness side
connector
AK300306 AB

connectors B-19 and C-106, and repair if necessary.
NO : Repair.
Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion)

Failure is possibly caused by failed ignition circuit, failed fuel feed or other faults.
PROBABLE CAUSE
Failed battery
Timing belt broken
Failed idle speed control
Throttle valve fouled around
Failed ignition system
Failed fuel system
Failed immobilizer system
Failed engine-ECU
DIAGNOSIS PROCEDURE
OK: 8 V or higher
YES : Go to STEP 2 .
NO : Check battery (Refer to GROUP 54 -
Battery - On-vehicle Service - Battery test

354A).
13A-197
TROUBLESHOOTING
STEP 2: Check engine warning lamp for burnt out

bulb.

).
YES : Inspection chart for diagnosis codes (Refer
to 313A)
NO : Go to Step 4 .
STEP 8: MUT-II DATA LIST

OK:
NO : Go to Step 9 .

connector
CONNECTOR: C-137
STEP 4: MUT-II actuator test

Item 07: Fuel pump
OK: Operating sound of fuel pump can be
heard.
C-137

NO : Check fuel pump system (Refer to
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Inspection Procedure 24 313A)

STEP 5. Check timing belt for breakage.
Engine: Cranking
OK: Camshaft rotates.

AK300254 AB
CONNECTOR: C-303

NO : Replace timing belt.
STEP 6. Check the engine start ability.

With depressing the accelerator pedal slightly,
and start the engine.
Q: Is the start ability good?
NO : Go to Step 8 .
STEP 7: Check idling speed control for operating

sound.
Check idle speed control servo for operating
sound (Refer to 313A).
YES : Clean throttle body (throttle valve portion)
(Refer to 313A).
NO : Check idle speed control servo system
(Refer to code No. P0505 313A).
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB

YES : Check intermediate connectors B-19 and C-

ignition switch connector and C-137
circuit.
NO : Repair.
13A-198

TROUBLESHOOTING
STEP 10: MUT-II DATA LIST

STEP 12: Connector check: B-110 and B-111

ignition coil connectors
Connector: B-110, B-111

Code No. P0335 313A).
B-111 (GR)
3 2 1
Harness side
connector
STEP 11: Check injector for operating sound.

Check injector for operating sound (Refer to
313A).
Q: Can operating sound be heard?
NO : Check the injector system of the defective
cylinder.
(Refer to Code No. P0201: No. 1 injector
system 313A.)
system 313A.)
system 313A.)
system 313A.)
B-110 (GR)
AK300308 AB

NO : Repair.
STEP 13: Measure voltage at each of B-110 and

B-111 ignition coil connectors.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

Ignition switch: ON
OK: System voltage
13A-199
TROUBLESHOOTING

connector
STEP 15: Check ignition coil spark.

CONNECTOR: C-303
CONNECTOR: C-303
C-303
3 2 1
6 5 4
C-303
3 2 1
6 5 4
Harness side
connector
Harness side
connector
AK300304 AB
AK300304 AB

B-111 (GR)
3 2 1
Harness side
connector
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB

YES : Check intermediate connectors A-14, C-
116, C-203 and C-205, and repair if

necessary. Check and repair harness
between C-303 (terminal No. 2) ignition
switch connector and (terminal No. 1)
affected cylinders ignition coil connector.
open/short circuit.
NO : Repair.

NO : Check intermediate connectors A-14, C-116,
C-203 and C-205, and repair if necessary.

Check and repair harness between C-303
(terminal No. 2) ignition switch connector
and (terminal No. 1) affected cylinders
ignition coil connector.
STEP 16: Replace engine-ECU
After replacing the engine-ECU, re-check the
trouble symptoms.
YES : Check for foreign matters (water, kerosene,
etc.) in fuel and replace if necessary.

NO : Check end.
Inspection Procedure 7: Starting Impossible (Initial Combustion But no Complete Combustion),

Improper Starting (Long time to Start)
Failure is possibly caused by poor ignition, incorrect air-fuel ratio at cranking, improper fuel pressure or other faults.
PROBABLE CAUSE
Failed battery
Failed fuel system
Air-fuel ratio control

Failed idle speed control system
Failed intake system
Failed exhaust gas cleaning system
Timing belt not in place
Compression pressure improper
Failed engine-ECU
13A-200

TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1: Check battery condition.
Q: Have the battery terminal been disconnected?
YES : After warm-up engine, idle for about 10
minutes.
NO : Go to Step 2 .

OK: 8 V or higher
Battery - On-vehicle Service - Battery Test

354A).
to 313A)
NO : Go to Step 4 .

c. Item 25: Barometric pressure sensor

STEP 5: Check start ability.
With depressing the accelerator pedal slightly,
and start the engine.
Q: Is the start ability good?
NO : Go to Step 7 .
STEP 6: Check idle speed control servo for

operating sound.
YES : Clean throttle body (throttle valve portion)
(Refer to 313A).
(Refer to Code No. P0505 313A).

STEP 7: MUT-II actuator test
Item 07: Fuel pump
heard.
Inspection Procedure 24 313A).

STEP 8: Check air intake from intake hose and
inlet manifold.
NO : Repair.

Check injector for operating sound at engine
cranking (Refer to 313A).
cylinder.
(Refer to Code No. P0201: No.1 injector system
313A.)
313A.)
313A.)
313A.)
STEP 10. Check timing marks of timing belt.
NO : Align timing marks.
13A-201
TROUBLESHOOTING

connector.
CONNECTOR: C-134
STEP 13: Connector check: B110 and B-111

B-111 (GR)
3 2 1
Harness side
connector
C-134
B-110 (GR)
AK300308 AB
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.
AK300257 AB

Ignition switch: ON
OK: 0.5 V or less

STEP 15: Check spark plug.


NO : Replace spark plug.

connector
CONNECTOR: C-134
STEP 16: Check spark plug cable itself.

Check spark plug cable itself (Refer to GROUP
16 - Ignition System - On-vehicle Service 316
).
NO : Replace spark plug cable.
C-134
STEP 17: Check ignition coil itself.

Check ignition coil itself (Refer to GROUP 16 Ignition System - On-vehicle Service 316).
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

(terminal No. 13 and No. 26) engine-ECU

and damage.
NO : Repair.

NO : Replace ignition coil.
13A-202
TROUBLESHOOTING
STEP 18: Check harness between terminal No. 2

of each cylinders ignition coil connector and
vehicle body earth.
B-111 (GR)
3 2 1
Harness side
connector
STEP 19: Check spray condition of injector.

Check each injector for spray condition (Refer to
313A).
STEP 20: Check compression pressure.

Check compression pressure (Refer to GROUP
11A - On-vehicle Service 311A).
B-110 (GR)
AK300308 AB

NO : Repair.
CONNECTOR: C-134
C-134
STEP 21: Check EGR control solenoid valve

itself.
Check EGR control solenoid valve itself [Refer to
GROUP 17 - Emission Control System Exhaust Gas Recirculation (EGR) System 317
].
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

YES : Check and repair harness between terminal
No. 3 of each cylinders ignition coil

connector and C-134 engine-ECU
connector.
Check signal line for open/short
circuit and damage.
NO : Repair.
STEP 22: Check EGR valve itself.

Check EGR valve itself [Refer to GROUP 17 Emission Control System - Exhaust Gas Recirculation (EGR) System 317].
NO : Replace EGR valve.
STEP 23: Replace engine-ECU.

After replacing the engine-ECU, re-check the
trouble symptoms.

NO : Check end.
Inspection Procedure 8: Unstable idling (Rough idling, hunting), Improper idling speed (Too high or
too low), Engine stalls during idling (Die out)
Probable causes can be widely found in ignition
system, air-fuel ratio control system, idle speed
control system, fuel system, etc. A sudden
engine stall is possibly caused by poor connector
contact.
PROBABLE CAUSE
Failed fuel system
Failed air-fuel ratio control system
Failed intake/exhaust system

TROUBLESHOOTING
Failed emission gas cleaning system

Throttle valve body fouled
Timing belt out of place
Failed engine-ECU
DIAGNOSIS PROCEDURE
13A-203
STEP 5: Check idle speed control servo for

operating sound.

Q: Has the battery terminal been disconnected?
minutes.
NO : Go to Step 2 .

to 313A).
NO : Go to Step 3 .
c. Item 14: Throttle position sensor
d. Item 21: Engine coolant temperature sensor
e. Item 25: Barometric pressure sensor

NO : Check power steering fluid pressure switch
system (Refer to Code No. P0551 313A

).
STEP 6: Check throttle body (throttle valve

(Refer to 313A).
inlet manifold.
NO : Repair.

313A).
cylinder.
system 313A.)
system 313A.)
system 313A.)
system 313A.)
STEP 9: Check timing marks of timing belt.

to Code No. P0130 313A).
13A-204
TROUBLESHOOTING

connector.

connector.
CONNECTOR: C-134
CONNECTOR: C-135
C-134
C-135
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300257 AB

Ignition switch: ON
OK: 0.5 V or less

connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

(terminal No. 13 and No. 26) engine-ECU

and damage.
NO : Repair.
AK300256 AB

Engine: Idling after warm-up
Radiator fan: Not operating
OFF causes the voltage to increase by 0.2 3.5 V.

13A-205
TROUBLESHOOTING

connector and B-30 alternator connector
CONNECTOR: C-135

No. 33) engine-ECU connector and B-30 (terminal
No. 1) alternator connector.
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
AK300256 AB
CONNECTOR: B-30
CONNECTOR: B-30
B-30 (GR)
B-30 (GR)
4 3 2 1
Harness side
connector

NO : Repair.
4 3 2 1
AK300296 AB
Harness side
connector
AK300296 AB

connector B-19, and repair if necessary.
NO : Repair.
13A-206
TROUBLESHOOTING

connector.
CONNECTOR: C-135

CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB


AK300256 AB
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side
connector

NO : Repair.
AK300296 AB
13A-207
TROUBLESHOOTING

No. 54) engine-ECU connector and B-30 (terminal

connector.
CONNECTOR: C-134
CONNECTOR: C-135
C-134
C-135
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300257 AB
AK300256 AB
CONNECTOR: B-30
B-30 (GR)
4 3 2 1
Harness side
connector
AK300296 AB

NO : Repair.

Engine: Idling
A/C switch: ON (A/C compressor ON)
OK:
1 V or less (with outside air temperature sensor ambient temperature at 18C or higher
and A/C set for maximum air flow at minimum temperature)
System voltage (with A/C set for minimum air
flow at room temperature)

NO : Check A/C load signal system (Refer to

STEP 21. Connector check: B-110 and B-111

B-111 (GR)
3 2 1
Harness side
connector
00 - How to Use
300).
B-110 (GR)
AK300308 AB

NO : Repair.
13A-208

TROUBLESHOOTING
STEP 22. Check ignition coil spark.

STEP 26. Check harness between terminal No. 2

of ignition coil connector of each cylinder and
body earth.
STEP 23. Check spark plug.

STEP 24. Check individual spark plug cable

).
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
Q: Q: Is the check result normal?

STEP 25. Check ignition coil itself.

C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Check earthing line for open/short circuit and

damage.
No. 3 of ignition coil connector of each

cylinder and C-134 engine-ECU
Check signal line for open/short and
damage.
NO : Repair.
STEP 27. Check injector for spray condition.
313A).
STEP 28. Check compression pressure.

NO : Repair.

TROUBLESHOOTING

itself.
Check purge control solenoid valve itself (Refer to
GROUP 17 - Emission Control System - Evaporative Emission Control System 317)
STEP 30. Check EGR control solenoid valve

itself.
].
13A-209

itself.
].

Item 07: Fuel pump
OK: Operating sounds of fuel pump can be
heard.
inspection Procedure 24 313A).

STEP 33. Replace engine-ECU.
After engine-ECU is replaced, re-check for trouble symptom.
Q: Does trouble system persist?

NO : Check end.
Inspection Procedure 9: The Engine Stalls when Starting the Car (Pass Out)
Engine stall on starting is possibly caused by misfire due to failed spark plug, improper air-fuel
ratio at accelerator pedal depression or other
faults.
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 2. Check EGR control solenoid valve itself.

].
STEP 3. Check EGR valve itself.

13A-210
TROUBLESHOOTING
STEP 4. Check air intake from intake hose and

inlet manifold.
NO : Repair.


ignition connectors.
B-111 (GR)

3 2 1
Harness side
connector

body earth.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
B-110 (GR)

NO : Repair.
AK300308 AB
CONNECTOR: C-134

NO : Go to Step 7 .
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
STEP 8.Check spark plug cable itself.

).
AK300257 AB


cylinder and C-134 engine-ECU.
circuit and damage.
NO : Repair.
13A-211
TROUBLESHOOTING
Inspection Procedure 10. The Engine Stalls when Decelerating

Engine stall on deceleration is possibly caused
by insufficient air intake, improper air-fuel ratio
due to failed exhaust gas recirculation system or
other faults.
PROBABLE CAUSE
Failed emission control system
Throttle valve fouled
Failed engine-ECU
DIAGNOSIS PROCEDURE


(Refer to 313A).
to 313A).
NO : Go to Step 2 .


B-111 (GR)
3 2 1
Harness side
connector

NO : Check throttle position sensor system
B-110 (GR)

Item 45: Idle speed control servo position
OK: Idle speed control servo drops to 0 - 2
Steps at deceleration (engine at 1,000 r/min
or higher).

].
AK300308 AB

NO : Repair.

NO : Go to Step 9 .

13A-212

TROUBLESHOOTING
STEP 10. Check spark plug cable itself.

).

body earth.

B-111 (GR)
3 2 1
Harness side
connector

B-110 (GR)

AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB


circuit and damage.
NO : Repair.
Inspection Procedure 11: Engine does not Revole Up

Failure is possibly caused by failed fuel system,
ignition system or other faults.
DIAGNOSIS PROCEDURE
PROBABLE CAUSE
Failed fuel system
Failed engine-ECU

to 313A).
NO : Go to Step 2 .
13A-213
TROUBLESHOOTING

NO : Align match marks.
STEP 8. Check harness between terminal No. 2 of

ignition coil connector of each cylinder and body
earth.

B-111 (GR)
3 2 1
Harness side
connector
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
B-110 (GR)
AK300308 AB

NO : Repair
C-134

NO : Go to Step 5 .
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB


).



circuit and damage.
NO : Repair
NO : Repair
13A-214

TROUBLESHOOTING
Inspection Procedure 12: Hesitation, sag,poor acceleration, stumble, surge

Failure is possibly caused by failed ignition system, improper air-fuel ratio, improper compression pressure or other faults.
PROBABLE CAUSE
Failed fuel system
Failed intake and exhaust system
Improper compression pressure
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 2. Check injector for operating sound.
313A).
cylinder.
(Refer to code No. P0201: No. 1 injector system
313A).
313A).
313A).
313A).

a. Idem 13: Intake air temperature sensor
b. Item 14: Throttle position sensor
Procedure for the sensor that has shown an

itself.
Check purge control solenoid valve itself (Refer
to GROUP 17 - Emission Control System Evaporative Emission Control System 317).

].

Check EGR itself [Refer to GROUP 17 - Emission Control System - Exhaust Gas Recirculation
(EGR) System 317].

NO : Check oxygen sensor system (Refer to
Code No. P0130 313A).
13A-215
TROUBLESHOOTING

B-111 (GR)
3 2 1
Harness side
connector

body earth.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB

NO : Repair
CONNECTOR: C-134

C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

).



cylinder and C-134 engine-ECU
circuit and damage.
NO : Repair.
(Refer to 313A).
NO : Repair.
13A-216
TROUBLESHOOTING

NO : Repair.
Inspection Procedure 13. The Feeling of Impact or Vibration when Accelerating

Failure is possibly caused by failed ignition leak
with rise in spark plug-required voltage at acceleration.
PROBABLE CAUSE
Failed engine-ECU

NO : Go to Step 4 .

DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 2. Check connector: B-110 and B-111

B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

NO : Repair.

).


TROUBLESHOOTING
13A-217
STEP 7. Check harness between terminal No. 2 of

ignition coil connector of each cylinder and body
earth.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

3 of ignition coil connector of each cylinder

and C-134 engine-ECU
circuit and damage.
NO : Repair.
Inspection Procedure 14: The feeling of impact or vibration when decelerating

Failure is possibly caused by insufficient air
intake due to failed idle speed control system.
PROBABLE CAUSE
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
13A-218

TROUBLESHOOTING
STEP 2. Check idle speed control servo for

operating sound.

NO : Check throttle position sensor system

STEP 4. Check throttle body (throttle valve)
contamination.
(Refer to 313A).
Inspection Procedure 15: Knocking

Failure is possibly caused by failed detonation
control, improper thermal value of spark plug or
other faults.
PROBABLE CAUSE
Defective detonation sensor
Failed detonation control system
Defective spark plug
Failed engine-ECU

B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
AK300308 AB

NO : Repair.

YES : Check detonation sensor (Refer to Code
No. P0325 313A).

NO : Go to Step 4 .

13A-219
TROUBLESHOOTING

16 -Ignition System - On-vehicle Service 316
).
STEP 7. Check harness between ignition coil

connector terminal No. 2 of each cylinder and
body earth.

B-111 (GR)
3 2 1
Harness side
connector

B-110 (GR)
AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

YES : Check and repair harness between ignition
coil connector terminal No. 3 of each

cylinder and C-134 engine-ECU connector.
Check signal line for open circuit,
short circuit and damage.
NO : Repair.
Inspection Procedure 16: Ignition Timing Offset

Failure is possibly caused by failed crank angle
sensor, failed camshaft position sensor, improper
installed timing belt or other faults.
PROBABLE CAUSE
Improperly installed timing belt
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
13A-220
TROUBLESHOOTING
STEP 2. Measure output waveforms of crank

angle sensor and camshaft position sensor (Use
oscilloscope).
Connector: B-29

NO : Go to Step 4 .
2 1
3
Harness side
connector
B-29 (B)

00 - How to Use
300).
STEP 4. Check crank angle sensor and camshaft
position sensor mounted conditions.
NO : Repair.

Crank angle sensor

AK300276 AB
STEP 6. Check crank angle sensor vane.
Connector: B-106
3 2 1
Harness side
connector

NO : Replace crank angle sensor vane.

cylinder.
B-106 (B)
AK300279 AB
Crank Angle Sensor

Use special tool test harness (MB998478) to connect B-29 crank angle sensor connector, and
Engine: Idling
Camshaft Position Sensor
Use special tool test harness (MD991709) to connect B-106 camshaft position sensor connector,
and measure at pick-up harness.
Engine: Idling
OK: Output waveform timings of both sensors are the same as the check procedure
(Refer to 313A) using an oscilloscope.

STEP 8. Replace crank angle sensor.

After replacing the crank angle sensor, re-check
NO : Check end.

TROUBLESHOOTING
13A-221
STEP 9. Replace camshaft position sensor.

After replacing the camshaft position sensor, recheck the trouble symptoms.
00 - How to Use
300).
Inspection Procedure 17: Run on (Dieseling)

Failure is possibly caused by leakage from injector.
PROBABLE CAUSE
Failed injector
Failed engine-ECU
DIAGNOSIS PROCEDURE
313A).
Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC during
Idling
Failure is possibly caused by improper air-fuel
ratio, deteriorated catalyst, failed ignition system,
failed fuel system, failed compression pressure or
other faults.
PROBABLE CAUSE
Incorrect air/fuel ratio
Failed fuel system
Failed compression pressure
Failed catalytic converter
Failed engine-ECU

313A).
cylinder.
(Refer to 313A, Code P0201: No. 1 injector
System)
System)
System)
(Refer to 313A, Code P0204: No. 4
injector System)
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 3. Check ignition timing.

Check ignition timing. (Refer to GROUP 11A On-vehicle Service 311A).
NO : Check for offset ignition timing (Refer to
13A-222

TROUBLESHOOTING


itself.
].



inlet manifold.
NO : Repair.
STEP 6. Check for emission leakage from

exhaust manifold.
NO : Repair.

(Refer to 313A).


NO : Repair.
STEP 13. Check positive crankcase ventilation

valve itself.
Check positive crankcase ventilation valve itself
(Refer to GROUP 17 - Emission Control System
- crankcase Emission Control System 317).
NO : Replace positive crankcase ventilation
valve.



to Code No. P0130 313A).

STEP 9. Check Purge control solenoid valve
itself.
to GROUP 17 - Emission Control System Evaporative Emission Control System 317).

).

TROUBLESHOOTING
13A-223

STEP 18. Check injector for spraying condition.

313A).



STEP 19. Replace catalytic converter.

After replacing the catalytic converter, re-check

NO : Repair.

NO : Check end
Inspection Procedure 19: Battery Rundown

Failure is possibly caused by failed alternator,
failed generation control circuit or other faults.
STEP 2. Connector check: B-19 intermediate

connector
CONNECTOR: B-19
PROBABLE CAUSE
Failed battery
Alternator G terminal short-circuited
Failed alternator
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Check battery voltage.
Measure battery voltage during cranking.
OK: 8 V or more

354A).
B-19 (B)
3 2 1
6 5 4
Female side
connector

NO : Repair.
AK300294 AB
13A-224

TROUBLESHOOTING

connector.
STEP 4. Connector check: C-303 ignition switch

connector
CONNECTOR: C-303
CONNECTOR: B-19
B-19 (B)
C-303
3 2 1
6 5 4
1 2 3
4 5 6
Male side
connector
Harness side
connector
Disconnect connector, and measure at male connector side.

Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
AK300304 AB
AK300295 AB
CONNECTOR: B-19
B-19 (B)
1 2 3
4 5 6
Male side
connector
AK300295 AB

YES : Check intermediate connectors C-04, C-05,
C-105, C-203 and C-205, and repair if

necessary. If intermediate connectors are
normal, check and repair harness between
B-19 (terminal No. 5) intermediate
ignition switch connector.
open/short circuit.
NO : Repair.
13A-225
TROUBLESHOOTING

connector.
CONNECTOR: B-19

No. 4) intermediate connector and B-30 (terminal
CONNECTOR: B-19
B-19 (B)
B-19 (B)
3 2 1
6 5 4
Female side
connector
3 2 1
6 5 4
AK300294 AB
Disconnect connector, and measure at female

connector side.
Ignition switch: ON
OK: System voltage
Female side
connector
AK300294 AB
CONNECTOR: B-30

NO : Go to Step 6 .
B-30 (GR)

connector
Harness side
connector
4 3 2 1
CONNECTOR: B-30
4 3 2 1
Harness side
connector

NO : Repair.

NO : Repair.
B-30 (GR)
AK300296 AB
AK300296 AB
13A-226

TROUBLESHOOTING

No. 5) intermediate connector and B-30 (terminal
CONNECTOR: B-19

No. 3) alternator connector and C-303 (terminal
No. 2) ignition switch connector.
CONNECTOR: B-30
B-19 (B)
B-30 (GR)
3 2 1
6 5 4
Female side
connector
4 3 2 1
AK300294 AB
Harness side
connector
AK300296 AB
CONNECTOR: C-303
CONNECTOR: B-30
B-30 (GR)
C-303
3 2 1
6 5 4
4 3 2 1
Harness side
connector
Harness side
connector
Check power supply line for open/short circuit.

NO : Repair.
AK300304 AB
AK300296 AB

connectors C-04, C-05, C-105, C-203 and C-205 and
repair if necessary.
NO : Repair.

connector
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-227
TROUBLESHOOTING

connector.

connector.
CONNECTOR: C-135
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
CONNECTOR: B-19
B-19 (B)
1 2 3
4 5 6
Male side
connector
AK300295 AB

side.
Ignition switch: ON
OK: System voltage
(terminal No. 4) intermediate connector and

C-135 (terminal No. 33) engine-ECU
connector.
AK300256 AB

OFF causes the voltage to increase by 0.2 3.5 V.

NO : Check alternator.

00 - How to Use
300).
13A-228

TROUBLESHOOTING
Inspection Procedure 20: Overheating

Failure is possibly caused by failed engine cooling system, failed fan controller, failed engine
coolant temperature sensor or other faults.
PROBABLE CAUSE
Insufficient or deteriorated engine coolant
Failed fan controller
Failed thermostat
Failed water pump
Failed radiator core
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
STEP 2. Check engine coolant
NOTE: If engine coolant level falls too early, check
for leaky spots, and repair if necessary.
Check engine coolant (Refer to GROUP 14 - Onvehicle Service 314).
NO : Replace or add engine coolant.

Item 21: Fan controller
OK: Fan motor rotating
NO : Check fan control relay system (Refer to

Item 21: Engine coolant temperature sensor
OK:
Engine hot state: At 80 - 120C
NO : Check engine coolant temperature sensor
system (Refer to Code No. P0115 313A

).
STEP 5. Check thermostat.
Check thermostat (Refer to GROUP 14 - Thermostat 314).
NO : Replace thermostat.
STEP 6. Check water pump.

Check water pump.
YES : Replace radiator.
NO : Replace water pump.

TROUBLESHOOTING
13A-229
Inspection Procedure 21: Abnormal Rotation of Fan Motor
Fan controller (Radiator fan, A/C condensor fan) Circuit
5V
A-20
(MU802322)
1 2 3
Fan controller
2
L-W
7
A-14
L-W
21
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300309 AB
OPERATION
The control (duty) signal is inputted to the fan
controller (terminal No. 2) from the engine-ECU
(terminal No. 21).
FUNCTION
The engine-ECU inputs a duty signal suitable for
the engine coolant temperature, vehicle speed
and A/C switch position to the fan controller. In
response to the signal, the fan controller controls
the rotating speeds of the radiator fan and A/C
condenser fan (The fan speed becomes higher
as the average voltage of the terminal comes
nearer to 5V).
PROBABLE CAUSE
Open/short circuit in fan controller circuit or loose
connector contact
Failed engine-ECU
13A-230
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector

00 - How to Use
300).
CONNECTOR: C-134

connector.
C-134
CONNECTOR: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

C-134
AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
STEP 2. Check at C-134 engine-ECU connector.

CONNECTOR: C-134
AK300257 AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

YES : Replace fan controller.
NO : Go to Step 5 .
STEP 5. Connector check: A-20 fan controller

connector
Connector: A-20
AK300257 AB

side.
Ignition switch: ON
Short-circuit terminal No. 21 to earth.
OK: Fan motor stops rotating.
NO : Go to Step 4 .
A-20 (GR)
3 2 1
Harness side
connector

NO : Repair.
AK203423 AC

TROUBLESHOOTING
13A-231
STEP 6. Check harness between A-20 (terminal

No. 2) fan controller connector and C-134
Connector: A-20
A-20 (GR)
3 2 1
Harness side
connector
AK203423 AC
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

connector A-14, and repair if necessary.
YES : Replace fan controller.
NO : Repair.
Inspection Procedure 22: Poor A/C Performance

Failure is possibly caused by short /overcharged
A/C refrigerant, failed A/C control system, failed
fan control system or other faults.
PROBABLE CAUSE
Short or overcharged A/C refrigerant
Failed A/C compressor relay
Failed A/C-ECU
Failed engine-ECU
DIAGNOSIS PROCEDURE
to 313A).
NO : Go to Step 2 .
13A-232

TROUBLESHOOTING
STEP 2. A/C compressor magnet clutch

operation check.
Engine: Idling
A/C set temperature:
Maximum Cool when temperature in cabin is
25C or more
Maximum Hot when temperature in cabin is 25C
or less
OK:
Magnet clutch active (when A/C is ON)
Magnet clutch inactive (when A/C is OFF)

Item 49: A/C relay
a. Engine: Running at idle
b. A/C set temperature:
25C or more.
Maximum Hot when temperature in cabin is
25C or less.
OK:
ON (when A/C is ON)
OFF (when A/C is OFF)

NO : Go to Step 3 .

YES : Check A/C system (Refer to GROUP 55A -
Troubleshooting 355A).
NO : Check A/C compressor relay (Refer to

Item 28: A/C switch
a. Engine: Idling
25C or more
25C or less
OK:
ON (when A/C is ON)
NO : Check A/C switch (Refer to Inspection
Procedure 26 313A).
inspection procedure 27 313A).

STEP 5. Check charged amount of A/C
refrigerant.
Check charged amount of A/C refrigerant (Refer
to GROUP 55A - On-vehicle Service 355A).
NO : Adjust charged amount of A/C refrigerant.

OK: Fan motor rotates.
YES : Check A/C load signal system (Refer to

NO : Check fan control relay system (Refer to
Inspection Procedure 25313A).
13A-233
TROUBLESHOOTING
Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1
System
Power supply and ignition switch-IG circuit
Battery
9
20A
Relay box
Ignition switch
123
456
ACC
ST
W-B
C-303
LOCK
R
IG1
A-14
5
IG2
W-B
L-B
6
W-B
W-B
4
B-17X
8
7.5A
J/B
3
1
C-202
Engine
control
relay
L-B
R
C-106
10
J/C (2)
C-17
W-B
Y-G
9
L-B
10
R
12
25
38
80
82
Battery
backup
Power
source
C-134
C-135
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Engine-ECU
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Wire colour code

AK300310
AB
13A-234

TROUBLESHOOTING
OPERATION
The battery voltage is applied to the engine control relay (terminal No. 3 and 4).
power transistor in the unit be in "ON" position
and makes currents go on the engine control
relay coil, and that makes the relay be in "ON"
position.
When the engine control relay is in "ON" position,
the battery voltage is supplied to the engineECU, the sensor and the actuator from the
engine control relay (terminal No. 1).
FUNCTION
When the ignition switch ON signal is input to the
engine-ECU, the engine-ECU places the engine
control relay in the ON position. Accordingly, the
battery voltage is supplied to the engine-ECU,
sensor and actuator.
PROBABLE CAUSE
Failed engine control relay
Open/short circuit in engine control relay circuit or
Failed engine-ECU
DIAGNOSIS PROCEDURE

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
Harness side
connector
AK300255 AB

NO : Repair.
STEP 3. Check engine control relay.

Check engine control relay (Refer to 313A).
NO : Replace engine control relay.
STEP 4. Measure voltage at B-17X engine control

relay connector.
CONNECTOR: B-17X
STEP 1. Check battery voltage.

Measure battery voltage during cranking.
OK: 8 V or more

354A).
Relay boxs
triangle marks
Harness side
connector
B-17X
AK300255 AB
Remove relay, and measure at relay box side.

OK: System voltage

harness between B-17X (terminal No. 4)
engine control relay connector and battery.
open/short circuit.
13A-235
TROUBLESHOOTING

connector.

connector.
CONNECTOR: C-137
CONNECTOR: C-134
C-134
C-137
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300257 AB

Ignition switch: ON
OK: System voltage
YES : Check and repair C-134 engine-ECU
AK300254 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
connector.
NO : Go to Step 6 .

connector

connector
CONNECTOR: C-137
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AB

AK300254 AB

NO : Repair.

NO : Repair.
13A-236
TROUBLESHOOTING
STEP 9. Check ignition switch.

Check ignition switch (Refer to GROUP 54A Ignition Switch - Ignition Switch 354A).

No. 2) ignition switch connector and C-137
CONNECTOR: C-303

connector
CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
C-303
CONNECTOR: C-137
3 2 1
6 5 4
Harness side
connector
AK300304 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

connectors C-106, C-202 and C-203, and repair if
necessary.
Check output line for open/short circuit.
YES : Check and repair ignition switch IG1 power
supply line harness and connector.

Check power supply line for short
circuit.
NO : Repair.
13A-237
TROUBLESHOOTING

connector.
CONNECTOR: C-135

connector.
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Ignition switch: ON
OK: 1 V or less
CONNECTOR: B-17X
Relay boxs
triangle marks
Harness side
connector
AK300256 AB
B-17X

AK300255 AB

Ignition switch: OFF
OK: System voltage
NO : Check and repair harness between B-17X

Check earthing line for open/short
circuit.
13A-238
TROUBLESHOOTING

connector, C-303 ignition switch connector
CONNECTOR: C-135

CONNECTOR: C-303
C-303
C-135
3 2 1
6 5 4
Harness side
connector
AK300304 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-137

AK300256 AB
CONNECTOR: C-303
C-137
C-303
3 2 1
6 5 4
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Harness side
connector
AK300304 AB

AK300254 AB

NO : Repair.

connectors C-106, C-202 and C-203 and repair if
necessary.
NO : Repair.

00 - How to Use
300).
13A-239
TROUBLESHOOTING
STEP 17. Check harness between B-17X

(terminal No. 1) engine control relay connector
and C-134 (terminal No. 12 and No. 25) engineECU connector.
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
STEP 18. Check engine control relay output

power supply harness and connector for short
circuit.
NO : Repair.

(terminal No. 3 and No. 4) engine control relay
connector and battery.
CONNECTOR: B-17X
Harness side
connector
AK300255 AB
Relay boxs
triangle marks
B-17X
CONNECTOR: C-134
2
Harness side
connector
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
AK300255 AB

NO : Repair.
13A-240
TROUBLESHOOTING

connector.
CONNECTOR: B-17X
B-17X
Relay boxs
triangle marks
Harness side
connector
AK300255 AB
CONNECTOR: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-241
TROUBLESHOOTING
Inspection Procedure 24: Fuel Pump System
Fuel pump circuit

Battery
C-303
123
456
24
15A
L-B
C-202
2
4
C-213
1 2
3 4
1 2
3 4
OFF
Fuel
pump
relay (1)
C-215
C-203
6
ON
Ignition switch
ACC
IG2
C-116
41
C-215
ST
IG1
Reray box
LOCK
ON
OFF
Fuel
pump
relay (2)
C-213
C-209 1
C-205 11
8
7.5A
J/B
C-205
14
B-L
D-24 6
G
B-L
5
Fuel pump
D-16
(MU802058)
1 2 3
4 5
B
D-24 4
G
B
22
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

AK300311 AB
13A-242
TROUBLESHOOTING
OPERATION
The battery voltage is applied to the fuel pump
relay (1) (terminal No. 3) form the ignition switch
and is earthed to the vehicle body from the fuel
pump relay (1) (terminal No. 2).
relay (1) (terminal No. 4) and to the fuel pump
relay (2) (terminal No. 1) from the fuel pump relay
(1) (terminal No. 1).
relay (2) (terminal No. 3) from the ignition switch.
power transistor in the unit be in "ON" position
and makes currents go on the fuel pump relay (2)
coil, and that makes the relay be in "ON" position.
When the fuel pump relay (2) is in "ON" position,
the battery voltage is supplied to the fuel pump
(low pressure) from the fuel pump relay (2) (terminal No. 4).
FUNCTION
When the ignition switch ON signal is input to the
engine-ECU, the engine-ECU places the fuel
pump relay in the "ON" position. Accordingly, the
battery voltage is supplied to the fuel pump.
PROBABLE CAUSE
Failed fuel pump relay
Failed fuel pump
Open/short circuit in fuel pump drive circuit or
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-215 fuel pump relay
(1) connector and C-213 fuel pump relay (2)
connector
Junction blocks
triangle marks
C-215
C-213
2 1
4 3
Harness side
connector
AK300312 AB

NO : Repair.
STEP 2. Check fuel pump relay.

Fuel pump relay, continuity check (Refer to
313A).
NO : Replace fuel pump relay.
STEP 3. Measure resistance at C-215 fuel pump

relay (1) connector.
CONNECTOR: C-215
Junction blocks
triangle marks
C-215
2 1
4 3
Harness side
connector
AK300313 AB
Remove relay, and measure at junction block

side.
OK: 2 W or less

fuel pump relay (1) connector and body
earth.
and damage.
13A-243
TROUBLESHOOTING
STEP 4. Measure voltage at C-215 fuel pump

CONNECTOR: C-215
Junction blocks
triangle marks

connector
CONNECTOR: C-303
C-215
2 1
4 3
Harness side
connector
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
AK300313 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
CONNECTOR: C-215
Junction blocks
triangle marks
C-215
2 1
4 3
Harness side
connector
AK300313 AB


fuel pump relay (1) connector and C-303
circuit and damage.
NO : Repair.
13A-244

TROUBLESHOOTING

CONNECTOR: C-215
Junction blocks
triangle marks

connector
CONNECTOR: C-303
C-215
2 1
4 3
Harness side
connector
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
AK300313 AB

side.
OK: System voltage
NO : Check intermediate connectors C-116 and

No. 4) fuel pump relay (1) connector and
battery.
open/short circuit.
CONNECTOR: C-213
C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
AK300321 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
CONNECTOR: C-213
C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
AK300321 AB


ignition switch connector and C-213
(terminal No. 3) fuel pump relay (2)
connector.
open/short circuit.
NO : Repair.
13A-245
TROUBLESHOOTING

connector

connector.
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
AK300257 AB
CONNECTOR: C-213
C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
AK300321 AB

side.
Ignition switch: ON
OK: System voltage
NO : Check intermediate connectors C-106 and

No. 2) fuel pump relay (2) connector and C134 (terminal No. 22) engine-ECU
connector.
circuit.
13A-246

TROUBLESHOOTING
STEP 11. Connector check: D-16 fuel pump

connector
Connector: D-16

No. 4) fuel pump relay (2) connector and D-16
(terminal No. 5) fuel pump connector.
CONNECTOR: C-213
D-16 (GR)
3 2 1
5 4
Harness side
connector
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
C-213
AK203431AC
AK300321 AB

NO : Repair.
Connector: D-16
STEP 12. Measure voltage at D-16 fuel pump

connector.
D-16 (GR)
Connector: D-16
3 2 1
5 4
Harness side
connector
D-16 (GR)
3 2 1
5 4
Harness side
connector
AK203431AC

side.
Ignition switch: ON
Using a jumper wire, connect C-134 (terminal No.
22) engine-ECU connector and earth.
OK: System voltage
AK203431AC

connectors D-209 and D-24, and repair if necessary.
NO : Repair.
13A-247
TROUBLESHOOTING
STEP 14. Measure resistance at D-16 fuel pump

connector.
Connector: D-16

(terminal No. 3) fuel pump relay (1) connector.
CONNECTOR: C-303
D-16 (GR)
3 2 1
5 4
Harness side
connector
C-303
3 2 1
6 5 4
AK203431AC

side.
OK: 2 W or less
NO : Check intermediate connector D-24, and

harness between D-16 (terminal No. 4) fuel
pump connector and body earth.
and damage.
connector
CONNECTOR: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
CONNECTOR: C-215
C-215
2 1
4 3
Harness side
connector
AK300313 AB
NOTE: Before checking harness,check intermediate

YES : Go to Step 17.
NO : Repair.
STEP 17. Check harness between battery and C215 (terminal No. 4) fuel pump relay (1)
connector.
CONNECTOR: C-215
Harness side
connector
AK300304 AB
Junction blocks
triangle marks
Junction blocks
triangle marks
C-215
2 1
4 3
Harness side
connector

NO : Repair.
AK300313 AB

NO : Repair.
13A-248
TROUBLESHOOTING

No. 1) fuel pump relay (1) connector and C-213
Junction blocks
triangle marks

No. 3) fuel pump relay (2) connector and C-134
CONNECTOR: C-213
Junction blocks
triangle marks
C-215
C-213
2 1
4 3
Harness side
connector
2 1
4 3
Harness side
connector
C-213
AK300312 AB
AK300321 AB
CONNECTOR: C-134

NO : Repair.

C-134
CONNECTOR: C-303
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

C-303
AK300257 AB
3 2 1
6 5 4
Harness side
connector
AK300304 AB
CONNECTOR: C-213
C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
AK300321 AB

NO : Repair.

NO : Repair.

TROUBLESHOOTING

No. 3) fuel pump relay (2) connector and D-16
(terminal No.5) fuel pump connector.
CONNECTOR: C-213
Junction blocks
triangle marks
2 1
4 3
Harness side
connector
C-213
AK300321 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

connectors D-24 and C-205, and repair if necessary.
YES : Replace fuel pump.
NO : Repair.
13A-249
13A-250
TROUBLESHOOTING
Inspection Procedure 25: Fan Control Relay System
Fan control relay Circuit

Battery
W
9
20A
W-B
A-14
5
W-B
W-B
3
4
B-17X
1
Engine control system
R
To engine-ECU
Fusible link (2)
J/C (2)
C-17
R
A-14
11
L-W
R
4
A-10X
Fan control relay
4
2
3
B
L
3
A-20
(MU802322)
1 2 3
Smoothing
circuit
Fan controller
Wire colour code

O: Orange GR: Gray

AK300323 AB

TROUBLESHOOTING
OPERATION
The battery voltage is applied to the fan control
relay (terminal No. 1) from the engine control
relay (terminal No. 1) and is earthed to the vehicle body from the fan control relay (terminal No.
3).
The battery voltage is applied to the fan control
When the fan control relay is in "ON" position, the
battery voltage is supplied to the fan controller
(terminal No. 3) from the fan control relay (terminal No. 2).
FUNCTION
When the engine control relay is in "ON" position,
the fan control relay is also simultaneously
placed in "ON" position. Accordingly, the battery
voltage is supplied to the fan controller.
PROBABLE CAUSE
Failed fan control relay
Failed radiator fan motor
Failed condenser fan motor
Open/short circuit in fan control relay circuit or
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: A-10X fan control
relay connector
CONNECTOR: A-10X
STEP 2. Check fan control relay.

Check fan control relay (Refer to GROUP 14 On-vehicle Service 314).
NO : Replace fan control relay.
STEP 3. Measure resistance at A-10X fan control

relay connector.
CONNECTOR: A-10X
A-10X
1
4
Harness side
connector
Remove relay and measure at relay box side.

OK: 2 W or less
NO : Check and repair harness between A-10X
(terminal No. 3) fan control relay connector

and body earth.
and damage.
CONNECTOR: A-10X
A-10X
4
Harness side
connector

NO : Repair.
AK300324 AB
STEP 4. Measure voltage at A-10X fan control

relay connector.
A-10X
13A-251
AK300324 AB
1
4
Harness side
connector
AK300324 AB
Remove relay and measure at relay box side.

Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13A-252
TROUBLESHOOTING

relay connector
CONNECTOR: B-17X
Relay boxs
triangle marks
STEP 6. Measure voltage at A-10X fan control

relay connector.
CONNECTOR: A-10X
B-17X
A-10X
Harness side
connector
AK300255 AB
A-10X
4
Harness side
connector
1
4
Harness side
connector
AK300324 AB

Voltage between terminal No. 4 and earth
OK: System voltage
CONNECTOR: A-10X
AK300324 AB

YES : Check intermediate connectors A-14 and C-

engine control relay connector and A-10X
(terminal No. 1) fan control relay connector.
open/short circuit.
NO : Repair.

NO : Check and repair harness between battery
and A-10X (terminal No. 4) fan control relay

connector.
open/short circuit.
STEP 7. Connector check: A-20 fan controller
connector
Connector: A-20
A-20 (GR)
3 2 1
Harness side
connector

NO : Repair.
AK203423 AC
13A-253
TROUBLESHOOTING
STEP 8. Measure voltage at A-20 fan controller

connector.

relay connector
CONNECTOR: B-17X
Connector: A-20
Relay boxs
triangle marks
B-17X
A-20 (GR)
3 2 1
Harness side
connector
AK203423 AC

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 9 .
STEP 9. Check harness between A-10X (terminal

No. 2) fan control relay connector and A-20
(terminal No. 3) fan controller connector.
Harness side
connector
AK300255 AB

NO : Repair.

and A-10X (terminal No. 1) fan control relay
connector.
CONNECTOR: B-17X
Relay boxs
triangle marks
B-17X
CONNECTOR: A-10X
A-10X
1
4
Harness side
connector
Harness side
connector
AK300255 AB
CONNECTOR: A-10X
AK300324 AB
A-10X
Connector: A-20
3
1
4
Harness side
connector
A-20 (GR)
3 2 1
Harness side
connector
AK300324 AB

connectors A-14 and C-17, and repair if necessary.
AK203423 AC

NO : Repair.

YES : Check and repair harness between A-10X
(terminal No. 3) fan control relay connector

and body earth.
NO : Repair.
13A-254
TROUBLESHOOTING

connector
CONNECTOR: C-134

C-134
00 - How to Use
300).
connector.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
CONNECTOR: C-134

AK300257 AB

NO : Repair.
C-134
STEP 13. Fan motor drive test.

CONNECTOR: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
Disconnect C-134 engine-ECU connector.

Ignition switch: ON

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
13A-255
TROUBLESHOOTING
STEP 16. Check harness between A-10X

(terminal No. 4) fan control relay connector and
battery.
CONNECTOR: A-10X

No. 2) fan controller connector and C-134
Connector: A-20
A-10X
A-20 (GR)
3
1
4
Harness side
connector
AK300324 AB
3 2 1
Harness side
connector
AK203423 AC
CONNECTOR: C-134

NO : Repair.
STEP 17. Check harness between A-10X

(terminal No. 2) fan control relay connector and
A-20 (terminal No. 3) fan controller connector.
C-134
CONNECTOR: A-10X
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
A-10X

AK300257 AB
1
4
Harness side
connector
AK300324 AB

YES : Replace fan motor and fan controller.
NO : Repair.
Connector: A-20
A-20 (GR)
3 2 1
Harness side
connector

AK203423 AC

YES : Replace fan motor and fan controller.
NO : Repair.
13A-256
TROUBLESHOOTING
Inspection Procedure 26: A/C Switch System
A/C Switch circuit
C-06
A/C-ECU
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
4 <Manual A/C>
34 <Auto A/C>
G-B
C-104
7
G-B
45
C-135
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Engine-ECU
Wire colour code

AK300325 AB
OPERATION
The battery voltage is applied to the engine-ECU
(terminal No. 45) from the A/C-ECU (terminal No.
4) <Manual A/C> or A/C-ECU (terminal No. 34)
<Auto A/C>.
FUNCTION
When the A/C switch is in "ON" position, A/C
switch ON signal is inputted to the engine-ECU
from the A/C-ECU. In response to the signal, the
engine-ECU controls the A/C compressor relay.
PROBABLE CAUSE
Failed A/C
Failed A/C system
Open/short circuit in A/C circuit or loose connector contact
Failed engine-ECU
13A-257
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
connector.
CONNECTOR: C-135
STEP 2. Measure voltage at C-06 A/C-ECU

connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C>.
Connector: C-06
<Manual A/C>
C-06 (B)
C-135
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

Engine: Running at idle
25C or more
or less
OK:
System voltage (when A/C is ON)
0.5 V or less (when A/C is OFF)
NO : Go to Step 2 .
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
AK300327AB

Engine: Idling
25C or more
or less
Voltage between terminal No. 4 and earth <Manual A/C>
Voltage between terminal No. 34 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 3 .
13A-258
TROUBLESHOOTING
STEP 3. Connector check: C-06 A/C-ECU

connector <Auto A/C> C-135 engine-ECU
connector
Connector: C-06
<Manual A/C>
STEP 4. Check harness between C-06 A/C-ECU

connector <Auto A/C> and C-135 (terminal No.
Connector: C-06
<Manual A/C>
C-06 (B)
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
AK300327AB
CONNECTOR: C-135
C-26 (B)
Harness side
connector
AK300327AB
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
AK300256 AB

NO : Repair.
13A-259
TROUBLESHOOTING
STEP 5. Connector check: C-06 A/C-ECU

connector <Auto A/C> and C-135 engine-ECU
connector

connector
CONNECTOR: C-135
Connector: C-06
<Manual A/C>
C-06 (B)
C-135
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
AK300326 AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
Connector: C-26
<Auto A/C>
AK300256 AB

NO : Repair.
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
AK300327AB
CONNECTOR: C-135
C-135

Item 28: A/C switch
a. Engine: Idling
25C or more.
25C or less.
OK:
ON (when A/C is ON)
00 - How to Use
300).
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB


harness between C-06 (terminal No. 4) or
C-26 (terminal No. 34) A/C-ECU connector
connector.
NO : Repair.
13A-260
TROUBLESHOOTING
Inspection Procedure 27: A/C Compressor Relay System
A/C compressor relay Circuit

Ignition switch
C-303
1 2 3
4 5 6
LOCK
ST
IG1
ACC
IG2
4
L-R
Battery
C-203
2
5 J/B
7.5A
10
10A
C-205
16
Relay box
L-R
B-R
C-106
11
A-14
9
B-R
L-R
3
4
B-18X
A/C-ECU
B-W
1
8
Engine-ECU
A/C compressor
assembly
B-27
(MU802653)
A/C refrigerant
temperature
switch
Magnetic
clutch
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

O: Orange GR: Gray

AK300328 AB
13A-261
TROUBLESHOOTING
OPERATION
The battery voltage is applied to the A/C compressor relay (terminal No. 4).
The battery voltage is applied to the A/C compressor relay (terminal No. 3) from the ignition
switch. The engine-ECU (terminal No. 8) makes
the power transistor in the unit be in "ON" position and makes currents go on the A/C compressor relay coil, and that makes the relay be in "ON"
position.
When the A/C compressor is in "ON" position, the
battery voltage is supplied to the A/C compressor
(terminal No. 1) from the A/C compressor relay
(terminal No. 1).
FUNCTION
When the A/C switch "ON" signal is input to the
engine-ECU, the engine-ECU places the A/C
compressor relay in the "ON" position. Accordingly, the battery voltage supplied to the A/C compressor operates the magnet clutch.
PROBABLE CAUSE
Failed A/C compressor relay
Failed A/C compressor magnet clutch
Open/short circuit in A/C compressor relay circuit
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-18X A/C
compressor relay connector
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X
Harness side
connector

NO : Repair.
AK300329 AB
STEP 2. A/C compressor relay check.

Check A/C compressor relay (Refer to GROUP
NO : Replace A/C compressor relay.
STEP 3. Measure voltage at B-18X A/C

compressor relay connector.
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X
Harness side
connector
AK300329 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13A-262
TROUBLESHOOTING

connector
STEP 5. Measure voltage at B-18X A/C

compressor relay connector.
CONNECTOR: B-18X
CONNECTOR: C-303
Relay boxs
triangle marks
B-18X
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
Harness side
connector
Harness side
connector
AK300329 AB

OK: System voltage
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X

AK300329 AB

YES : Check intermediate connectors C-106, C-
202 <Auto A/C>, C-203 and C-205 <Manual

A/C>, and repair if necessary. If
and repair harness between B-18X
(terminal No. 3) A/C compressor relay
ignition switch connector.
open/short circuit.
NO : Repair.

A/C compressor relay connector and
battery.
open/short circuit.
STEP 6. Connector check: B-27 A/C compressor
connector
CONNECTOR: B-27
B-27 (B)
1
Harness side
connector

NO : Repair.
AK300330 AB
13A-263
TROUBLESHOOTING
STEP 7. Measure voltage at B-27 A/C compressor

connector.

connector.
CONNECTOR: C-134
CONNECTOR: B-27
B-27 (B)
C-134
1
Harness side
connector
AK300330 AB
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X

AK300257 AB
Harness side
connector

Ignition switch: ON
OK: System voltage
AK300329 AB

side.
Remove B-18X (terminal No. 1 and No. 4) A/C
compressor relay and short-circuit of harness
side connector.
Ignition switch: ON
OK: System voltage

NO : Go to Step 9 .

connector
CONNECTOR: C-134

(terminal No. 1) A/C compressor connector

and B-18X (terminal No. 1) A/C compressor
relay connector.
circuit.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13A-264
TROUBLESHOOTING

(terminal No. 2) A/C compressor relay connector
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X

Item 49: A/C relay
a. Engine: Idling
25C or more
25C or less
OK:
ON (when A/C is ON)
Harness side
connector
AK300329 AB
CONNECTOR: C-134
00 - How to Use
300).
connector
C-134
CONNECTOR: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

C-134
AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13A-265
TROUBLESHOOTING

connector.

No. 4) ignition switch connector and B-18X
(terminal No. 3) A/C compressor relay connector.
CONNECTOR: C-303
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X
C-303
2
3 2 1
6 5 4
Harness side
connector
AK300304 AB
Harness side
connector
AK300329 AB
CONNECTOR: B-18X
CONNECTOR: C-134
Relay boxs
triangle marks
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.

connector
CONNECTOR: C-303
Harness side
connector
3 2 1
6 5 4
AK300329 AB

connectors C-106, C-202 <Auto A/C>, C-203 and C205 <Manual A/C>, and repair if necessary.
NO : Repair.
STEP 16. Check harness between battery and B18X (terminal No. 4) A/C compressor relay
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks
C-303
B-18X
Harness side
connector
Harness side
connector
AK300304 AB

NO : Repair.
B-18X
AK300329 AB

NO : Repair.
13A-266
TROUBLESHOOTING

and B-27 (terminal No. 1) A/C compressor relay
connector.
CONNECTOR: B-18X
Relay boxs
triangle marks
B-18X
Harness side
connector
AK300329 AB
CONNECTOR: B-27
B-27 (B)
1
Harness side
connector
AK300330 AB

YES : Replace A/C compressor magnet clutch.
NO : Repair.

TROUBLESHOOTING
13A-267
Inspection Procedure 28: A/C Load Signal System
A/C load signal circuit
C-06
A/C-ECU
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
5 <Manual A/C>
32 <Auto A/C>
L-W
C-106
6
L-W
24
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Engine-ECU
Wire colour code

AK300338 AB
OPERATION
The A/C load signal is inputted to the engineECU (terminal No. 24) from the A/C-ECU (terminal No. 5). <Manual A/C> or (terminal No. 32)
<Auto A/C>
FUNCTION
The magnitude of the A/C compressor load is
detected and input to the engine-ECU. The
engine-ECU provides A/C idle up control according to the A/C compressor load condition.
PROBABLE CAUSE
Failed A/C-ECU
Open/short circuit in A/C load signal circuit or
Failed engine-ECU
13A-268
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

connector

connector.
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

AK300257 AB

Engine: Idling
A/C switch: ON (A/C compressor in driven state)
Voltage between terminal No. 24 and earth
OK:
1 V or less (when the temperate around the
atmospheric air temperature sensor is 18C
or more, and the A/C is set to the lowest temperature and the maximum air flow rate)
System voltage (when the A/C is set to the
temperature in the cabin and the minimum
air flow rate)

NO : Go to Step 4 .

NO : Repair.

00 - How to Use
300).
connector
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13A-269
TROUBLESHOOTING
STEP 5. Measure voltage at C-06 A/C-ECU

connector <Auto A/C>.
Connector: C-06
<Manual A/C>
STEP 6. Connector Check: C-06 A/C-ECU

connector <Auto A/C>
Connector: C-06
<Manual A/C>
C-06 (B)
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
AK300327AB
Measure A/C-ECU terminal voltage.

Engine: Idling
25C or more
or less
Voltage between terminal No. 5 and earth <Manual A/C>
Voltage between terminal No. 32 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 6 .
C-26 (B)
Harness side
connector

NO : Repair.
AK300327AB
13A-270
TROUBLESHOOTING

No. 5) or C-26 (terminal No. 32) A/C-ECU
Connector: C-06
<Manual A/C>
STEP 8. Check connector: C-06 A/C-ECU

connector <Auto A/C>
Connector: C-06
<Manual A/C>
C-06 (B)
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side
connector
Harness side
connector
AK300326 AB
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
Connector: C-26
<Auto A/C>
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-26 (B)
Harness side
connector
C-26 (B)
Harness side
connector
AK300326 AB
AK300327AB
AK300327AB
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
AK300257 AB

NO : Repair.


harness between C-06 (terminal No. 5) or
C-26 (terminal No. 32) A/C-ECU connector
connector.
NO : Repair.
13A-271
TROUBLESHOOTING
Inspection Procedure 29: A/C Pressure Sensor System
A/C Pressure sensor circuit
A-02
(MU802509)
A/C Pressure sensor
1 2 3
3
1
BR
G-Y
G-R
C-116
5
17
A-14
17
BR
G-R
C-105
21
C-104
4
G-Y
81
A/C-ECU
G-R
BR
92
42
C-135
C-137
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code

AK300339 AB
OPERATION
A power voltage of 5 V is applied to the A/C pressure sensor power terminal (terminal No. 3) from
the engine-ECU (terminal No. 81) and is earthed
to the engine-ECU (terminal No. 92) from the A/C
pressure sensor (terminal No. 1).
(terminal No. 42) from the A/C pressure sensor
FUNCTION
The A/C pressure sensor detects the A/C refrigerant pressure and inputs the pressure signal to
the engine-ECU. The engine-ECU uses the signal for ON/OFF control of the magnet clutch of
the A/C compressor.
PROBABLE CAUSE
Failed A/C pressure sensor
Open/short circuit in A/C pressure sensor circuit
Failed engine-ECU
13A-272
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 3. Measure voltage at A-02 A/C pressure

sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
Harness side
connector
3 2 1
Harness side
connector
AK300340AB

a. Item 3A: A/C pressure sensor
00 - How to Use
300).
NO : Go to Step 2 .
STEP 2. Connector check: A-02 A/C pressure
sensor connector
AK300340AB

side.
Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 4 .

connector.
CONNECTOR: C-137
Connector: A-02
A-02 (B)
C-137
3 2 1
Harness side
connector
AK300340AB

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Ignition switch: ON
OK: 4.9 - 5.1 V
NO : Go to Step 5 .
13A-273
TROUBLESHOOTING

connector
CONNECTOR: C-137

connector
CONNECTOR: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
AK300254 AB

NO : Repair.
Connector: A-02
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

YES : Check intermediate connector A-14, and

harness between A-02 (terminal No. 3) A/C
pressure sensor connector and C-137
Check power line for open circuit.
NO : Repair.
13A-274
TROUBLESHOOTING

No. 3) A/C pressure sensor connector and C-137
STEP 9. Measure resistance at A-02 A/C pressure

sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
Harness side
connector
3 2 1
Harness side
connector
AK300340AB
CONNECTOR: C-137
AK300340AB

side.
Resistance between terminal No. 1 and earth
OK: 2 W or less
C-137

connector
CONNECTOR: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Check power line for short circuit.
NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

a. Item 3A: A/C pressure sensor
00 - How to Use
300).
AK300254 AB

NO : Repair.
13A-275
TROUBLESHOOTING


sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
Harness side
connector
3 2 1
Harness side
connector
AK300340AB
CONNECTOR: C-137
AK300340AB
Ignition switch: ON
OK: 4.9 - 5.1 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB

Check earthing line for open circuit or damage.
NO : Repair.
13A-276
TROUBLESHOOTING

connector

sensor connector.
Connector: A-02
CONNECTOR: C-137
A-02 (B)
3 2 1
Harness side
connector
C-137
AK300340AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: A-02
Ignition switch: ON
OK: 0.5 or less
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

YES : Check intermediate connector A-14, and

harness between A-02 (terminal No. 3) A/C
NO : Repair.
13A-277
TROUBLESHOOTING

connector

sensor connector.
Connector: A-02
CONNECTOR: C-137
A-02 (B)
3 2 1
Harness side
connector
C-137
AK300340AB
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

AK300254 AB
Connector: A-02
A/C switch: ON
OK:
1.8 - 2.0 V (A/C refrigerant pressure: 1 kPa)
A-02 (B)
3 2 1
Harness side
connector
AK300340AB


connector
CONNECTOR: C-135

and repair harness between A-02 (terminal
No. 1) A/C pressure sensor connector and
connector.
NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB

NO : Repair.
13A-278
TROUBLESHOOTING

(terminal No. 42) engine-A/T-ECU connector.

connector.
CONNECTOR: C-135
Connector: A-02
A-02 (B)
C-135
3 2 1
Harness side
connector
AK300340AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
CONNECTOR: C-135

AK300256 AB
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

A/C switch: ON
OK:


AK300256 AB

YES : Replace A/C pressure sensor.
NO : Repair.
13A-279
TROUBLESHOOTING

connector
CONNECTOR: C-135

connector
CONNECTOR: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39

AK300256 AB
AK300256 AB

NO : Repair.
Connector: A-02
A-02 (B)
3 2 1
Harness side
connector
AK300340AB


and repair harness between A-02 (terminal
No. 2) A/C pressure sensor connector and
connector.
Check power line for open circuit and
damage.
NO : Repair.
13A-280
TROUBLESHOOTING
Inspection Procedure 30: Ignition Circuit System
Ignition circuit
Ignition switch
C-303
1 2 3
4 5 6
LOCK
ST
IG1
ACC
IG2
L-B
C-203
6
1
10A
J/B
10
C-205
C-116
26
A-14
16
W
Ignition coil 1
B-110
Ignition coil 2
B-111
1 2 3
1 2 3
3
Spark
plug
B-107
Capacitor
B
W-L
B-L
B
10
23
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300341 AB
13A-281
TROUBLESHOOTING
OPERATION
The battery voltage is applied to the ignition coil
(terminal No. 1) from the ignition switch and is
earthed to the vehicle body from the ignition coil
(terminal No. 2).
A power voltage of 12 V is applied to the ignition
coil output terminal (terminal No. 3) from the
engine-ECU (terminal No. 10 and No. 23).
FUNCTION
When the engine-ECU makes the power transistor in the unit be in "OFF" position, the battery
voltage in the unit is applied to the power transistor unit, and that makes the power transistor unit
be in "ON" position. The engine-ECU makes the
power transistor in the unit be in "ON", and that
makes the power transistor unit be in "OFF" position.
In response to the signal from the engine-ECU,
the power transistor unit is in "ON" position. The
primary current is going to the ignition coil. When
the power transistor unit is in "OFF" position, the
primary current is interrupted and high voltage is
generated in the secondary coil.
PROBABLE CAUSE
Failed ignition coil
Failed spark plug
Failed spark plug cable
Open/short circuit in ignition primary circuit or
Failed engine-ECU
DIAGNOSIS PROCEDURE
).


B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

NO : Repair.

STEP 5. Measure voltage at B-111 and B-110

ignition coil connectors.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .
13A-282
TROUBLESHOOTING

connector
CONNECTOR: C-303
STEP 7. Measure voltage at B-111 and B-110

C-303
B-111 (GR)
3 2 1
Harness side
connector
3 2 1
6 5 4
Harness side
connector
B-110 (GR)
AK300304 AB
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

YES : Check intermediate connectors A-14, C-
203, C-205 and C-116, and repair if

necessary. If intermediate connectors are
normal, check and repair harness between
connector and B-111 (terminal No. 1)
ignition coil connector, also between C-303
(terminal No. 2) ignition switch connector
and B-110 (terminal No. 1) ignition coil
connector.
open/short circuit.
NO : Repair.
AK300308 AB

side.
Engine: Cranking
OK: 0.5 - 4.0 V
NO : Go to Step 8 .
13A-283
TROUBLESHOOTING

connector.

connector
CONNECTOR: C-134
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
B-111 (GR)
AK300257 AB

3 2 1
Harness side
connector
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB

Disconnect B-111 and B-110 ignition coil connectors.
Engine: Cranking
OK: 0.5 - 4.0 V
B-111 (GR)
3 2 1
Harness side
connector

(terminal No. 3) ignition coil connector and

connector, also between B-110 (terminal
No. 3) ignition coil connector and C-134
NO : Repair.
13A-284
TROUBLESHOOTING

connector
CONNECTOR: C-134

No. 3) ignition coil connector and C-134 (terminal
No. 23) engine-ECU connector, also between B110 (terminal No. 3) ignition coil connector and
CONNECTOR: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

NO : Repair.

00 - How to Use
300).
13A-285
TROUBLESHOOTING
STEP 13. Measure resistance at B-111 and B-110

B-111 (GR)
3 2 1
Harness side
connector

(terminal No. 1) ignition coil connector, also
between C-303 (terminal No. 2) ignition switch
connector and B-110 (terminal No. 1) ignition coil
connector.
CONNECTOR: C-303
B-110 (GR)
AK300308 AB

side.
OK: 2 W or less
(terminal No. 2) ignition coil connector and

body earth, also between B-110 (terminal
No. 2) ignition coil connector and body
earth.
and damage.
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AB
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB

connectors A-14, C-116, C-203 and C-205, and
NO : Repair.
13A-286
TROUBLESHOOTING

No. 3) ignition coil connector and C-134 (terminal
No. 23) engine-ECU connector, also between B110 (terminal No. 3) ignition coil connector and C134 (terminal No. 10) engine-ECU connector.
B-111 (GR)
3 2 1
Harness side
connector
B-110 (GR)
AK300308 AB
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14

AK300257 AB

NO : Repair.
13A-287
TROUBLESHOOTING
Data List Reference Table

M1131152000735
Item Inspection
No. item
11
Inspection condition
Oxygen
Engine: After
sensor (front) warm-up (leaner
by deceleration,
richer by
acceleration)
Engine: After
warm-up (using
oxygen sensor,
check air-fuel
ratio as well as
control status by
engine-ECU.
12
13
14
16
Air flow
sensor *1
Intake air
temperature
sensor
Throttle
position
sensor
Normal
condition
Inspection
procedure
No.
Reference
page
Excessive
deceleration from
4,000 r/min
200 mV or less
Code No.
P0130
313A
At excessive
acceleration
600 - 1,000 mV
Idle operation
400 mV or less
600 - 1,000
mV (altered)
Code No.
P0110
313A
Code No.
P0120
313A
Procedure
No. 23
313A
2,500 r/min
Engine coolant Idle operation

temperature:
2,500 r/min
80 - 95C
Lamps, electric Acceleration
cooling fan and
all
accessories:
OFF
Transmission:
Neutral
Ignition switch:
ON or engine
running
Ignition switch:
ON
16 - 24 Hz
72 - 112 Hz
According to
acceleration,
frequency is
amplified.
Intake air
temperature:
-20C
-20C
Intake air
temperature: 0C
0 C
Intake air
temperature: 20C
20C
Intake air
temperature: 40C
40C
Intake air
temperature: 80C
80 C
Set to Idle position
535 - 735 mV
Release accelerator
pedal gradually
Increased
according to
accelerator pedal
stroke
Release accelerator
pedal fully
4,500 - 5,000
mV
Power supply Ignition switch: ON

voltage
System voltage
13A-288
TROUBLESHOOTING
Item Inspection
No. item
Normal
condition
Inspection
procedure
No.
Reference
page
18
Cranking
signal
(ignition
switch-ST)
Ignition switch:
ON
Engine: Stopped
OFF
313A
Engine: Cranking
ON
Procedure
No. 23
Engine
coolant
temperature
sensor
Ignition switch:
ON or engine
running
Coolant temperature: -20C

-20C
Code No.
P0115
313A
Code No.
P0335
313A
Code No.
P0105
313A
Code No.
P0551
313A
Procedure
No. 26
313A
21
Coolant temperature: 0C
0 C
20C
40C
80C
22
Crank angle
sensor
Engine:
Cranking
Tachometer:
Connected
Compare engine
Matched
speed on tachometer
with the value
displayed on MUT-II
Engine: Idle
operation
Coolant temperature: 1,100 - 1,300

-20C
r/min
0 C
r/min
20C
r/min
Coolant temperature: 940 - 1,140 r/min
40C
Coolant temperature: 650 - 850 r/min
80C
25
27
28
Barometric
pressure
sensor
Ignition switch:
ON
Altitude: 0m
101 kPa
Altitude: 600m
95 kPa
Altitude: 1,200m
88 kPa
Altitude: 1,800m
81 kPa
Power
Engine: Idle
steering fluid operation
pressure
switch
Steering wheel: Not

operated
OFF
Steering wheel:
Operated
ON
A/C switch
AC switch: OFF
OFF
AC
A/C
switch: compressor
ON
is not driven
OFF
Engine: Idle
A/C
compressor
is driven
ON
13A-289
TROUBLESHOOTING
Item Inspection
No. item
Normal
condition
Inspection
procedure
No.
Reference
page
37
Engine coolant
temperature:
80 - 95C
Lamps, electric
cooling fan and
all
accessories:
OFF
Idel operation
13 - 33 %
2,500 r/min
12 - 32 %
Excessive
acceleration
According to
acceleration,
volumetric
efficiency is
increased.
A/C in MAX COOL

state (under high
load)
2,200 mV or
more
Procedure
No. 29
313A
Procedure
No. 30
313A
3A
41
Volumetric
efficiency
A/C pressure
sensor
Injectors *2
After engine
warm-up, idle
operation
A/C switch: ON
A/C in MAX HOT

1,800 mV or less
state (under low load)
Engine: Cranking Coolant temperature: 5.6 - 8.4 ms

0C (all cylinders in
simultaneous
injecting operation)
Coolant temperature: 5.6 - 8.4 ms
20C
Coolant temperature: 5.6 - 8.4 ms
80C
Injectors*3
44
Ignition
advance
Engine coolant
temperature:
80 - 95C
Lamps, electric
cooling fan and
all
accessories:
OFF
Transmission:
Neutral
Idle operation
2.0 - 3.2 ms
2,500 r/min
2.2 - 3.4 ms
Excessive
acceleration
Increased
Engine: After
Idle operation
warm-up
2,500 r/m
Install timing
light (for use to
measure
actual ignition
timing)
2 - 18BTDC
18 - 38BTDC
13A-290
TROUBLESHOOTING
Item Inspection
No. item
Normal
condition
Inspection
procedure
No.
Reference
page
45
ISC (stepper
motor) servo
position*4
Engine coolant A/C switch: OFF

temperature:
A/C switch: OFF
80 - 95C
ON
Lighting,
electric cooling
fan and
accessories:
OFF
Transmission:
Neutral
Engine: Idle
operation
(When A/C
switch is ON,
A/C
compressor
must be ON)
2 - 25 steps
A/C relay
Engine: After
warm-up, idle
operation after
warm-up
Procedure
No. 27
313A
0 mV or less
600 - 1,000 mV
(altered)
Code No.
P0136
313A
0.9 - 4.9 gm/s
49
A/C switch: OFF
OFF
A/C
A/C
switch: compressor
ON
is not driven
OFF
A/C
compressor
is driven
59
Oxygen
Engine: After
sensor (rear) warm-up
12
*5
Air flow
sensor
Increased 10 70 steps
At excessive
acceleration
Engine coolant Idle operation

temperature:
2,500 r/min
80 - 95C
Lamps, electric Acceleration
cooling fan and
all
accessories:
OFF
Transmission:
Neutral
ON
7.2 - 13.2 gm/s

According to
acceleration,
frequency is
amplified.
13A-291
TROUBLESHOOTING
Item Inspection
No. item
Normal
condition
Inspection
procedure
No.
Reference
page
13
*5
Ignition switch:
ON or engine
running
Intake air
temperature:
-20C
-20C
Code No.
P0110
313A
Intake air
temperature: 0C
0 C
Intake air
temperature: 20C
20C
Intake air
temperature: 40C
40C
Intake air
temperature: 80C
80 C
Code No.
P0115
313A
21
*5
Intake air
temperature
sensor
Engine
coolant
temperature
sensor
Ignition switch:
ON or engine
running
Coolant temperature: -20C

-20C
0C
20C
40C
80C
22
*5
Crank angle
sensor
Engine:
Cranking
Tachometer:
Connected
Compare engine
Matched
speed on tachometer
with the value
displayed on MUT-II
Engine: Idle
operation

-20C
r/min
r/min
0C
r/min
20C
Coolant temperature: 940 - 1,140 r/min
40C
Coolant temperature: 650 - 850 r/min
80C
24
*5
Vehicle
Drive 40 km/h
speed sensor
Approximately 40 Code No.

km/h
P0500
313A
44
*5
Ignition
advance
2 - 18 deg
Engine: After
Idle operation
warm-up
2,500 r/m
Install timing
light (for use to
measure
actual ignition
timing)
18 - 38 deg
13A-292
Item Inspection
No. item
TROUBLESHOOTING
Normal
condition
Inspection
procedure
No.
Reference
page
81
*5
Long-term
Engine: After warm-up, 2,500 r/min
fuel
without any load (during closed loop)
compensatio
n
-12.5 - 12.5 %
Code No.
P0170
313A
82
*5
Shot-term
Engine: After warm-up, 2,500 r/min
fuel
without any load (during closed loop)
compensatio
n
-25 - 25 %
Code No.
P0170
313A
87
*5
Calculation
losd value
Engine: After
warm-up
Idle operation
13 - 33 %
2,500 r/m
12 - 32 %
88
*5
Fuel control
condition
Engine: After
warm-up
2,500 r/m
Closed loop
Acceleration
Open loop-drive
condition
8A
*5
Throttle
position
sensor
(Throttle
opening
angle)
Ignition switch:
ON
Set to Idle position
0 - 10 %
313A
Release accelerator
pedal gradually
Increased
according to
accelerator pedal
stroke
Code No.
P0120
Release accelerator
pedal fully
80 - 100 %
Excessive
deceleration from
4,000 r/min
0.2 V or less
0.6 - 1 V
(altered)
Code No.
P0130
313A
Idle operation
2,500 r/min
0.4 V or less
0.6 - 1 V
(altered)
At excessive
acceleration
0 V or less 0.6 Code No.

- 1 V (altered)
P0136
313A
A1
*5
Oxygen
Engine: After
sensor (front) warm-up (leaner
by deceleration,
richer by
acceleration)
Engine: After
warm-up (using
oxygen sensor,
check air-fuel
ratio as well as
control status by
engine-A/ECU.
A1
*5
Oxygen
Engine: After
sensor (rear) warm-up
CAUTION
When shifting the select lever to D range, the brakes should be applied so that the vehicle does not
move forward
NOTE: *1: On the new vehicle (mileage: 500 km or less), air flow sensor output frequency may be higher by
approx. 10%.
NOTE: *2: Injector drive time ranges shown are when power voltage is 11 V and the cranking speed is 250
r/min. or less.
NOTE: *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approx. 10%.
NOTE: *4: On the new vehicle (mileage: 500 km or less), the number of steps of stepper motor may be larger
by approx. 30 steps.
NOTE: *5: When service data in check mode is selected, the data is not displayed.
13A-293
TROUBLESHOOTING
Actuator Test Reference Table

M1131152500439
Item Inspection
No. item
Drive content
Inspection conditions
Normal
condition
Code No.
/Inspection
procedure
No.
Reference
page
01
Cut off No. 1

injector
Engine: After warm-up,

idle operation (Cut off
injectors sequentially to
check for a cylinder that
does not change engine in
idle status.
Engine is
changed
(becomes
unstable or
stalled)
Code No.
P0201
313A
Code No.
P0202
313A
Code No.
P0203
313A
Code No.
P0204
313A
Procedure
No. 24
313A
Injector
02
Cut off No. 2

injector
03
Cut off No. 3

injector
04
Cut off No. 4

injector
07
Fuel pump
Drive fuel
pump to
circulate fuel
Ignition
Hold return Pulse is felt
switch: "ON" hose with
fingers to
feel pulse of
fuel flowing
Check for
pump
operating
noise near
fuel tank
Operating
noise audible
08
Purge
control
solenoid
valve
Switch solenoid Ignition switch: "OFF"

valve from OFF
to ON
When the valve Code No.

is actuated,
P0443
operating noise
is audible
313A
10
EGR control
solenoid
valve
Switch solenoid Ignition switch: "ON"

valve from OFF
to ON
When the valve Code No.

is actuated,
P0403
operating noise
is audible.
313A
17
Basic ignition Switch engine- Engine: Idle operation

timing
ECU to ignition Install timing light
timing adjusting
mode
5 BTDC
21
Fan
controller
Fan motor is
rotated
Procedure
No. 21
313A
Actuate fan
motor
Ignition switch: "ON"

A/C switch: ON
13A-294
TROUBLESHOOTING
CHECK AT THE ECU TERMINALS
NOTE: .
1. Make the voltage measurement with the
engine-ECU connector connected.
2. You may find it convenient to pull out the
engine-ECU to make it easier to reach the
connector terminals.
3. The checks can be carried out off the order
given in the chart.
M1131153500175
TERMINAL VOLTAGE CHECK CHART

Needle-nosed wire probe
CAUTION
Short-circuiting the positive (+) probe between a
connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU or all of
them. Be careful to prevent this!
3. If voltmeter shows any division from standard
value, check the corresponding sensor, actuator
and related electrical wiring, then repair or
replace.
4. After repair or replacement, recheck with the
voltmeter to confirm that the repair has corrected
the problem.
AK201749AB
1. Connect a needle-nosed wire probe to a voltmeter

probe.
2. Insert the needle-nosed wire probe into each of
the engine-ECU connector terminals from the wire
side, and measure the voltage while referring to
the check chart.
Engine-ECU Connector Terminal Arrangement

Engine-ECU Connector
C-134
C-135
C-136
C-137
1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 51 52 53 54 55 56 71 72 73 74 75 76 77 78 79 80 81
14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 57 58 59 60 61 62 82 83 84 85 86 87 88 89 90 9192
AK300342 AB
Terminal
No.
Check item
Check condition (Engine condition)
Normal condition
No. 1 injector
14
No. 2 injector
While engine is idling after having warmed

up, suddenly depress the accelerator pedal.
From 11 - 14 V,
momentarily drops slightly
No. 3 injector
15
No. 4 injector
Stepper motor coil

<A1>
17
Stepper motor coil

<A2>
Stepper motor coil

<B1>
18
Stepper motor coil

<B2>
EGR control
solenoid Valve
Engine: Soon after the warmed up engine System voltage 1 V or

is star
less (Changes repeatedly)
A/C switch: OFF ON (A/C compressor
is operating)
System Voltage
While engine is idling, suddenly depress the

accelerator pedal.
From system voltage,

momentarily drops
13A-295
TROUBLESHOOTING
Terminal
No.
Check item
Normal condition
A/C relay
Engine: Idle speed

A/C switch: OFF ON (A/C compressor
is operating)
System voltage or
Momentarily 6V or more
1 V or less
Purge control
solenoid valve
System voltage
Running at 3,500 r/min while engine is

warming up after having been started.
1 V or less
10
Ignition coil - No. 1,

No. 4
Engine r/min: 3,000 r/min
0.3 - 3.0 V
23
Ignition coil - No. 2,

No. 3
12
Power supply
System voltage
25
19
21
22
Air flow sensor reset Engine: Idle speed

Signal
6-9V
Fan controller
Radiator and condenser fan is not operating
0 - 0.3 V
Radiator and condenser fan is operating
0.7 V or more
Ignition switch: ON
System voltage
Engine: Idle speed
1 V or less
Fuel pump relay
24
A/C load signal
33
36
Engine warming
lamp
Ignition switch: "LOCK" (OFF) "ON"
37
Power steering fluid

pressure switch
Engine: Idling after

warming up
0-1V
Refer to GROUP 55 - Troubleshooting (Inspection at the Automatic

compressor - ECU Terminal)
Engine: Warm, idle (radiator fan: OFF)
Headlamp: OFF ON
Stop lamp: OFF ON
Rear defogger switch: OFF ON
Voltage increases by 0.2 3.5 V
1 V or less System
voltage (After several
seconds have elapsed)
When steering wheel System voltage

is Stationary
When steering wheel 1 V or less
is turned
38
Control relay (Power Ignition switch: "LOCK" (OFF)

supply)
Engine: Warm, idle (radiator fan: OFF)
Headlamp: OFF ON
Stop lamp: OFF ON
Rear defogger switch: OFF ON
41
Alternator FR
terminal
42
A/C pressure sensor Engine: Idling

A/C switch: ON
When A/C is "MAX,

COOL" condition
(when the load by
A/C is high)
System voltage
1 V or less
Voltage decreases
2.2 V or more
When A/C is "MAX,

1.8 V or less
HOT" condition (when
the load by A/C is
low)
13A-296

TROUBLESHOOTING
Terminal
No.
Check item
Normal condition
45
A/C switch
Engine: Idle speed
0.5 V or less
Turn the A/C switch

OFF
Turn the A/C switch

System voltage
ON (A/C compressor
is operating)
54
Oxygen sensor
heater (rear)
Engine: Idling after warming up
1 V or less
Engine r/min:Racing
System voltage
58
Tachometer signal
0.3 - 3.0 V
60
Oxygen sensor
heater (front)
Engine: Idling after warming up
1 V or less
Engine r/min:5,000 r/min
System voltage
71
Ignition switch - ST
Engine: Cranking
8 V or more
72
Intake air
temperature sensor
When intake air

3.8 - 4.4 V
temperature is -20C
When intake air
temperature is 0C
3.2 - 3.8 V
When intake air

temperature is 20C
2.3 - 2.9 V
When intake air

temperature is 40C
1.5 - 2.1 V
When intake air

temperature is 60C
0.8 - 1.4 V
When intake air

temperature is 80C
0.4 - 1.0 V
75
Oxygen sensor
(rear)
Engine: Idling after warmed up (Check using 0 0.6 V (Changes

a digital type voltmeter)
repeatedly)
76
Oxygen sensor
(front)
Engine: Running at 2,500 r/min after warmed 0 0.8 V (Changes

up (Check using a digital type voltmeter)
repeatedly)
80
Backup power
supply
Ignition switch: "LOCK" (OFF)
System voltage
81
Sensor impressed
voltage
4.9 - 5.1 V
82
Ignition switch - IG
System voltage
83
Engine coolant
temperature sensor
When engine coolant 3.9 - 4.5 V

temperature is -20C
temperature is 0C
temperature is 20C
temperature is 40C
temperature is 60C
temperature is 80C
13A-297
TROUBLESHOOTING
Terminal
No.
Check item
Normal condition
84
Throttle position
sensor
Set throttle valve to

idle Position
0.535 - 0.735 V
Fully open throttle

valve
4.4 - 5.3 V
Altitude: 0 m
3.8 - 4.2 V
Altitude: 600 m
3.5 - 3.9 V
Altitude: 1,200 m
3.3 - 3.7 V
Altitude: 1,800 m
3.0 - 3.4 V
85
Barometric pressure Ignition switch: "ON"

sensor
86
Vehicle speed
sensor

Move the vehicle forword slowly
0 5 V Changes
repeatedly
88
Camshaft position
sensor
Engine: Cranking
0.4 - 3.0 V
Engine: Idling
1.5 - 3.0 V
Crank angle sensor
Engine: Cranking
0.4 - 4.0 V
Engine: Idling speed
1.5 - 2.5 V
Engine: Idle speed
2.2 - 3.2 V
89
90
Air flow sensor
CHECK CHART FOR RESISTANCE AND

CONTINUITY BETWEEN TERMINALS
2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity
between the terminals of the engine-ECU
harness-side connector while referring to the
check chart.
NOTE: .
1. When measuring resistance and checking
continuity, a harness for checking contact pin
pressure should be used instead of inserting a
test probe.
2. Checking need not be carried out in the order
given in the chart.
CAUTION
If the terminals that should be checked are mistaken, or if connector terminals are not correctly
shorted to earth, damage may be caused to the
vehicle wiring, sensors, engine-ECU and/or ohmmeter. Be careful to prevent this!
4. If the ohmmeter shows any deviation from the
standard value, check the corresponding sensor,
actuator and related electrical wiring, and the
repair or replace.
5. After repair or replacement, recheck with the
ohmmeter to confirm that the repair or
replacement has corrected the problem.
13A-298
TROUBLESHOOTING
Engine-ECU Harness Side Connector Terminal Arrangement

Engine-ECU Harness Side Connector
C-137
C-136
C-135
C-134
8180 79 78 77 76 75 74 73 72 71 56 55 54 53 52 51 38 37 36 35 34 33 32 31 13 12 11 10 9 8 7 6 5 4 3 2 1
92 91 90 89 88 87 86 85 84 83 82 62 61 60 59 58 57 46 45 44 43 42 41 40 39 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300343 AB
Terminal
No.
Inspection item
Normal condition (Check condition)
1 - 12
No. 1 injector
13 - 16 W (At 20C)
12 - 14
No. 2 injector
2 - 12
No. 3 injector
12 - 15
No. 4 injector
4 - 12
Stepper motor coil (A1)
12 - 17
Stepper motor coil (A2)
5 - 12
Stepper motor coil (B1)
12 - 18
Stepper motor coil (B2)
6 - 12
29 - 35 W (At 20C)
9 - 12
29 - 35 W (At 20C)
12 - 54
Oxygen sensor heater(rear)
11 - 18 W (At 20C)
12 - 60
Oxygen sensor heater(front)
4.5 - 8.0 W (At 20C)
26 - 33 W (At 20C)
13 - Body ECU earth

earth
Continuity (0 W)
26 - Body
earth
81 - 83
14 - 17 kW (When coolant temperature is -20C)

5.1 - 6.5 kW (When coolant temperature is 0C)
72 - 81
13 - 17 kW (When intake air temperature is -20C)

5.3 - 6.7 kW (When intake air temperature is 0C)
INSPECTION PROCEDURE USING

OSCILLOSCOPE
M1131154500479
The output signals of the sensors and the conditions

of the actuation signals of the actuators can be
inspected visually by observing the waveforms on
the oscilloscope.
13A-299
TROUBLESHOOTING
AIR FLOW SENSOR
2. Connect the oscilloscope special patterns pickup

to air flow sensor connector terminal No. 3.
Measurement Method
Oscilloscope
1 2 3 4 5 6 7
Special
patterns
pickup
Alternate Method (Test harness not available)

to engine-ECU terminal No. 90.
Standard Wave Pattern
Observation conditions
Function
Special patterns
AK000786 AE
1. Disconnect the air flow sensor connector, and

connect the special tool Test harness (MB991709)
in between (All terminals should be connected).
Pattern height
Low
Pattern selector
Display
Engine speed
Idle
Standard wave pattern

(V)
10
The time (cycle time) T is reduced when

the amount of intake air inereases.
T
T1
T2
Times T1 and T2 are equal.
Time
AK202334 AB
Observation conditions (from conditions above engine is increased by racing.)

(V)
10
Time
AK202335 AB
Wave Pattern Observation Points

Check that cycle time T becomes shorter and the frequency increases when the engine speed is
increased.
13A-300

TROUBLESHOOTING
Examples of Abnormal Wave Patterns
CAMSHAFT POSITION SENSOR AND

CRANK ANGLE SENSOR
Measurement Method
Camshaft position Oscilloscope
sensor connector
1 2 3
Special patterns
pick-up
AKX01597
Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when
Example 2
Cause of problem
Damaged rectifier or vortex generation column
Unstable wave pattern with non-uniform frequency. However, when an ignition leak
occurs during acceleration, the wave pattern
will be distorted temporarily, even if the air
flow sensor is normal.
1 2
3
Crank angle
sensor connector
AK000840AC
1. Disconnect the camshaft position sensor

connector and connect the special tool Test
harness (MB991709) in between (All terminals
should be connected).
2. Connect the oscilloscope special pattern pickup to
camshaft position sensor terminal No. 2.
3. Disconnect the crank angle sensor connector and
connect the special tool Test harness
(MD998478) in between.
to crank angle sensor terminal No. 2.
to engine-ECU terminal No. 88 (When checking
the camshaft position sensor signal wave
pattern).
the crank angle sensor signal wave pattern).
13A-301
TROUBLESHOOTING

Observation condition
Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine speed
Idle
2 engine revolutions
(1 camshaft revolution)

(V)
The time (cycle time)

T is reduced when the
engine speed increases
75 BTDC
5 BTDC
Crank angle
sensor output
wave pattern
0
Camshaft position
sensor output
wave pattern
Time
0
TDC: Top dead centre
No.1 TDC

Check that cycle time T becomes shorter when the
engine speed increases.
No.3 TDC
No.4 TDC
No.2 TDC
AK202336 AB

Rectangular wave pattern is output even when
AKX01602
AKX01597
Example 1
Cause of problem
Sensor interface malfunction
Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern is displaced to the left or right.
13A-302
TROUBLESHOOTING
INJECTOR
Measurement Method
Oscilloscope
1 2
Special
patterns
pickup
AK101807AC
1. Disconnect the injector connector, and then

connect the special tool Test harness set
(MB991348) in between (All terminals should be
connected).
to terminal No. 2 of the injector connector.

to engine- ECU terminal No. 1 (When checking
the No. 1 cylinder).
to engine-ECU terminal No. 2 (When checking the
No. 3 cylinder).
Function
Special patterns
Pattern height
Variable
Variable knob
Adjust while viewing the

wave pattern
Pattern selector
Display
Engine speed
Idle

Point A.
(V)
Solenoid back
electromotive
force
(Approx.710V)
50
Point B
Injector drive
time
Time
Power
voltage
0 Drive signal: ON
Drive signal: OFF

AK202347AB
13A-303
TROUBLESHOOTING

Point A: Height of solenoid back electromotive force
Contrast with standard wave
pattern
Probable
cause
Solenoid coil back electromotive

force is low or doesnt appear at
all.
Short in the
injector solenoid
1. Disconnect the ISC servo connector, and connect

the special tool Test harness (MB991709) in
between.
to the ISC servo-side connector terminal No. 1,
No. 3, No. 4 and No. 6 respectively.
to engine-ECU terminal No. 4, connection
terminal No. 5, connection terminal No. 17, and
connection terminal No. 18 respectively.
Point B: Injector drive time

Function
Special patterns
When idling
When racing
AKX01605AE
The injector drive time will be synchronized with the

MUT-II tester display.
When the engine is suddenly raced, the drive
time will be greatly extended at first, but the drive
time will soon match the engine speed.
Pattern height
High
Pattern selector
Display
Engine condition
When the engine coolant

temperature is 20C or
below, turn the ignition
switch from LOCK (OFF)
position to ON (without
starting the engine).

(STEPPER MOTOR)
While the engine is

idling, turn the A/C
switch to ON.
Measurement Method
Immediately after
starting the warm
engine.
Oscilloscope
1 2 3
4 5 6
Special
patterns
pickup
AK300344AB
13A-304
TROUBLESHOOTING
(V)
30
Stepper
motor
control
signal
wave
pattern
The wave pattern

appears for an
instant, but soon
disappears.
Point B
Coilreverse electromotive
force (Approx.3x10V)
Point A
Induced electromotive force
from the motor turning
20
10
Time
AK201857 AB
Wave pattern Observation Points

Check that the standard wave pattern appears when
the stepper motor is operating.
Point A: Presence or absence of induced electromotive force from the motor turning (Refer to the abnormal wave pattern).
pattern
Probable
cause
Induced electromotive force does

not appear or is extremely small.
Motor is
malfunctioning
Example 1
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Induced electromotive force from the motor turning does not appear.
Open
circuit
side
Point B: Height of coil reverse electromotive force

pattern
Probable
cause
Coil reverse electromotive force

does not appear or is extremely
small.
Short in the
coil
Examples of Abnormal Wave Pattern
AKX01608AE
Normal
side
AKX01609AF
Example 2
Cause of problem
Open circuit in the line between the stepper
motor and the engine-ECU.
Current is not supplied to the motor coil on the
open circuit side (Voltage does not drop to 0
V).
Furthermore, the induced electromotive force
waveform at the normal side is slightly different from the normal waveform.
13A-305
TROUBLESHOOTING
IGNITION COIL AND POWER TRANSISTOR

Measurement Method
Oscilloscope
1 2 3
Special
patterns
pickup
1. Disconnect the ignition coil connector, and

connect the special tool Test harness set
(MB991348) in between (All terminals should be
connected).
Crank angle
sensor output
wave pattern

to engine-ECU terminal No. 10 (No. 1 - No. 4),
connection terminal No. 23 (No. 2 - No.3)
respectively.
AK300345 AB

to terminal No. 3 of each ignition coil connector in
turn.
Observation condition
Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Approximately. 1,200
r/min
(V)
6
4
T
5 BTDC
Compression top dead center
75 BTDC
2
0
4
Power transistor
control signal
wave pattern
T1
Ignition period
2
0
OFF
ON
Dwell section
T : Revolution time corresponding to a crank angle of 180

T1 : Time computed by the engine-ECU
: Spark advance angle

Point: Condition of wave pattern build-up section and
maximum voltage (Refer to abnormal wave pattern
examples 1 and 2).
AK204435 AC
Condition of wave pattern

build-up section and
maximum voltage
Probable cause
Rises from approximately. 2 V

to approximately 4.5 V at the
top-right
Normal
2 V rectangular wave
Open-circuit in
ignition primary
circuit
Rectangular wave at power

voltage
Power transistor
malfunction
13A-306
ON-VEHICLE SERVICE
Normal wave pattern

VB
Normal wave pattern
2V
AKX01613AD
AKX01612AD
Example 1
Wave pattern during engine cranking
Cause of problem
Open-circuit in ignition primary circuit
Top-right part of the build-up section cannot be
seen, and voltage value is approximately 2 V
too low.
Example 2
Wave pattern during engine cranking
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor
is ON.
ON-VEHICLE SERVICE
THROTTLE BODY (THROTTLE VALVE
AREA) CLEANING
M1131001000332
1. Remove the air intake hose from the throttle body.

2. Spray cleaning fluid on a clean cloth.
5. Adjust the basic idle speed (Refer to 313A).
THROTTLE POSITION SENSOR

ADJUSTMENT
M1131001100414
CAUTION
Do not spray the cleaning fluid directly to the
throttle valve.
Make sure the cleaning fluid does not enter
the motor from the bypass line. Also make
sure it does not enter the sensor through the
shaft.
Be careful not to rub off the molybden applied
around the throttle valve shaft.
Throttle position
sensor
2 3 4
Equipment side connector
AK300346 AB
1. Connect the MUT-II to the diagnosis connector.

When not using the MUT-II, proceed as follows.
15 mm
15 mm
Throttle position
sensor
Areas on throttle valve to
apply molybdenum disulfide
AK000833AD
3. Wipe off the dirt around the throttle valve with the
cloth sprayed with cleaning fluid.
4. Attach the air intake hose.
MB991536
AK201752AB

ON-VEHICLE SERVICE
(1) Disconnect the throttle position sensor

connector and connect the special tool Test
harness (MB991536) between the
disconnected connector taking care not to
confuse the terminal to be connected.
(2) Connect digital voltmeter between the terminal
No. 2 (special tools yellow clip on the sensor
output) and the terminal No. 4 (special tools
red clip on the sensor earth) of the throttle
2. Turn the ignition switch to "ON" position (but do
not start the engine).
3. Check the output voltage of the throttle position
sensor.
Standard value: 535 - 735 mV
AK300347AB
4. If not within the standard value, loosen the throttle

position sensor mounting bolts. Then rotate the
sensor body to adjust.
6. Remove the MUT-II. If the MUT-II is not used,
remove the special tool, and then connect the
throttle position sensor connector.
7. If a diagnosis code is displayed, erase the
diagnosis code by using the MUT-II or disconnect
the negative battery cable from the battery
terminal and then leave it for at least 10 seconds.
After that, reconnect the battery cable, and then
let the engine run at idle for approximately 10
minutes.
13A-307
BASIC IDLE SPEED ADJUSTMENT

M1131001800468
CAUTION
The standard idling speed has been adjusted
by the speed adjusting screw (SAS) by the
manufacturer, and there should usually be no
need for readjustment.
If the adjustment has been changed by mistake, the idle speed may become too high or
the idle speed may drop too low when loads
from components such as the A/C are placed
on the engine. If this occurs, adjust by the following procedure.
The adjustment, if made, should be made
after first confirming that the spark plugs, the
injectors, the idle speed control servo, the
compression pressure, etc., are all normal.
1. Before inspection and adjustment, set the vehicle
to the pre-inspection condition.
2. Connect the MUT-II to the diagnosis connector
(16-pin).
NOTE: When the MUT-II is connected, the diagnosis control terminal should be earthed.
3. Start the engine and run at idle.
4. Select the item No. 30 of the MUT-II Actuator test.
NOTE: This holds the ISC servo at the basic step
to adjust the basic idle speed.
NOTE: .
The engine speed may be 20 to 100 r/min
lower than indicated above for a new vehicle
[driven approximately 500 km or less], but no
adjustment is necessary.
If the engine stalls or the engine speed is low
even though the vehicle has been driven
approximately 500 km or more, it is probable
that deposits are adhered to the throttle valve,
so clean it (Refer to 313A).
AK300348
6. If not within the standard value range, turn the

speed adjusting screw (SAS) to make the
necessary adjustment.
13A-308
ON-VEHICLE SERVICE
NOTE: If the idling speed is higher than the standard value range even when the SAS is fully
closed, check whether or not there is any indication that the fixed SAS has been moved. If there is
an indication that it has been moved, adjust the
fixed SAS.
7. Press the MUT-II clear key, and release the ISC
servo from the Actuator test mode.
NOTE: Unless the ISC servo is released, the
Actuator test mode will continue 27 minutes.
9. Disconnect the MUT-II.
10.Start the engine again and let it run at idle speed
for about 10 minutes; check that the idling
condition is normal.
FUEL PRESSURE TEST

M1131001900368
1. Release residual pressure from the fuel pipe line

to prevent fuel gush out (Refer to 313A).
<When using the fuel pressure gauge set (special tool)>

a. Remove the union joint and bolt from the special
tool Adaptor hose (MD998709) and attach the
special tool Hose adaptor (MD998742) to the
adaptor hose.
b. Via a gasket, install the special tool Fuel pressure
gauge set (MB991637) into the special tool that
has already assembled as described in (a)
above.
<When using the fuel pressure gauge>
a. Remove the union joint and bolt from special tool
Adaptor hose (MD998709) and attach the special
tool Hose adaptor (MD998742) to the adaptor
hose.
b. Via a suitable O-ring or gasket, install the fuel
pressure gauge to the special tool that has
already assembled as described in (a) above.
Fuel pressure
gauge set
CAUTION
Cover the hose connection with rags to prevent
splash of fuel that could be caused by some
residual pressure in the fuel pipe line.
O-ring or gasket
MD 998709
Delivery
pipe
MD 998742
High-pressure
fuel hose
AKX01457AF
4. Install the assembled fuel pressure measurement

tools between the fuel rail and fuel high-pressure
hose.
CAUTION
AK300349AB
2. Disconnect the high-pressure fuel hose at the

delivery pipe side.
MB 991637
Gasket
MD 998709
Delivery
pipe
MD 998742
High-pressure
fuel hose
AKX01458AG
3. Assemble the fuel pressure measurement tools as

follows.
To prevent damage to the MUT-ll, always turn the

before connecting or disconnecting the MUT-ll.
6. Turn the ignition switch to "ON" position (But do
7. Select "Item No. 07" from the MUT-II Actuator test
to drive the fuel pump. Check that there are no
fuel leaks from any parts.
8. Finish the actuator test or turn the ignition switch
to "LOCK" (OFF) position.
9. Start the engine and run at idle.
10.Measure fuel pressure while the engine is running
at idle.
Standard value: Approximately. 270 kPa at
cerb idle

ON-VEHICLE SERVICE
AK300349AB
11.Disconnect the vacuum hose from the fuel

pressure regulator and measure fuel pressure
with the hose end closed by a finger.
Symptom
Probable cause
Fuel pressure too low

Fuel pressure drops after racing
No fuel pressure in fuel return
hose
Fuel pressure too high
13A-309
Standard value: 330 - 350 kPa at cerb idle

12.Check to see that fuel pressure at idle does not
drop even after the engine has been raced several
times.
13.Racing the engine repeatedly, hold the fuel return
hose lightly with fingers to feel that fuel pressure
is present in the return hose.
NOTE: If the fuel flow rate is low, there will be no
fuel pressure in the return hose.
14.If any of fuel pressure measured in steps 10 to 13
is out of specification, troubleshoot and repair
according to the table below.
Remedy
Clogged fuel filter
Replace fuel filter
Fuel leaking to return side due to Replace fuel pressure regulator

poor fuel regulator valve seating or
settled spring
Low fuel pump delivery pressure
Replace fuel pump
Binding valve in fuel pressure

regulator
Replace fuel pressure regulator
Clogged fuel return hose or pipe
Clean or replace hose or pipe
Same fuel pressure when vacuum Damaged vacuum hose or

hose is connected and when
Clogged nipple
disconnected
15.Stop the engine and check change of fuel
pressure gauge reading. Normal if the reading
does not drop within 2 minutes. If it does, observe
the rate of drop and troubleshoot and repair
according to the table below.
Symptom
Probable cause
Replace vacuum hose or clean

nipple
Remedy
Fuel pressure drops gradually after Leaky injector

engine is stopped
Leaky fuel regulator valve seat
Replace injector
Fuel pressure drops sharply

immediately after engine is
stopped
Replace fuel pump
Check valve in fuel pump is held

open
16.Release residual pressure from the fuel pipe line

(Refer to 313A).
CAUTION
Cover the hose connection with rags to prevent
splash of fuel that could be caused by some
residual pressure in the fuel pipe line.
17.Remove the fuel pressure gauge and special tool
from the delivery pipe.
Replace fuel pressure regulator
18.Replace the O-ring at the end of the fuel high

pressure hose with a new one. Furthermore,
apply engine oil to the new O-ring before
replacement.
19.Fit the fuel high pressure hose over the delivery
pipe and tighten the bolt to specified toque.
20.Check for any fuel leaks by following the
procedure in step 7.
21.Disconnect the MUT-II.
13A-310
ON-VEHICLE SERVICE
FUEL PUMP CONNECTOR

DISCONNECTION (HOW TO REDUCE
PRESSURIZED FUEL LINES)
M1131000900558
(2) Remove the rear seat assembly (Refer to

GROUP 52A,Rear Seat Assembly Removal
and Installation 352A).
Service hole cover
WARNING
When removing the fuel pipe, etc., release
fuel pressure to prevent fuel spray.
1. Remove the rear seat assembly (Refer to GROUP
52A - Rear Seat Assembly 352A).
Service hole cover
AC102784 AB
(3) Remove the service hole cover.
AC102784 AB
2. Remove the service hole cover.

Fuel pump assembly <2WD>
or fuel tank pump and gauge assembly <4WD>
AC101011AE
connector
(4) Disconnect the fuel pump assembly <2WD> or

the fuel tank pump and gauge assembly
<4WD> connector.
Fuel pump assembly <2WD> or
fuel tank pump and gauge assembly <4WD>
connector
AC101011AD
3. Disconnect the fuel pump assembly connector

<2WD> or fuel tank pump and gauge assembly
connector <4WD>.
4. After starting the engine and letting it run until it
stops naturally, turn the ignition switch to the
"LOCK" (OFF) position.
5. Connect the fuel pump assembly connector
<2WD> or fuel tank pump and gauge assembly
connector <4WD>.
6. Install the service hole cover and rear seat
assembly (Refer to GROUP 52A - Rear Seat
Assembly 352A).
FUEL PUMP OPERATION CHECK

M1131002000584
1. Check the operating of the fuel pump by MUT-II to

force-drive the fuel pump.
2. If the fuel pump will not operate, check by using
the following procedure. If normal, check the fuel
pump drive circuit.
(1) Turn the ignition switch to the "LOCK" (OFF)
position.
2
4
3
5
AC101012 AD
(5) When the fuel pump drive connector is

attached directly to the battery, check if the
sound of the fuel pump operation can be
heard. If no operating sound is heard, replace
the fuel tank pump (Refer to GROUP 13A,
Fuel Pump Module Disassembly and
Assembly 352A).
NOTE: As the fuel pump is an in-tank type, the
fuel pump sound is hard to hear. Remove the
fuel tank filler tube cap and check from the tank
inlet.
(6) Check for fuel pressure by pinching the fuel
hose with fingertips.

ON-VEHICLE SERVICE
(7) Connect the fuel pump assembly <2WD> or

the fuel tank pump and gauge assembly
<4WD> connector.
13A-311
(8) Install the service hole cover and rear seat

assembly (Refer to GROUP 52A, Rear Seat
Assembly Removal and Installation P.52A-25).
COMPONENT LOCATION
M1131002100622
Name
Symbol
Name
Symbol
Air flow sensor

(with intake air temperature sensor and
barometric pressure sensor)
Engine-ECU
Engine warming lamp

(check engine lamp)
A/C relay
Fuel pump relay (1) and (2)
A/C switch
A/C pressure sensor
Ignition coil
Injector
Crank angle sensor
Detonation sensor
Diagnosis connector
H
P
AK300351AB
13A-312
ON-VEHICLE SERVICE

CHECK

CHECK
M1131050000185
Relay boxs
triangle marks
M1131002800364
Intake air
temperature
sensor
Equipment side
connector
1 2 3 4 5 6 7

AK300352 AB
Tester
Battery Voltage
Connectio
n Terminal
Normal
State
2-3
No Voltage
Continuity
1-4
No Voltage
No continuity
Voltage (Connect
Continuity
positive (+) terminal of
battery to terminal No. 3
and negative (-)
terminal of battery to
terminal No. 2.)
AK300354 AB
1. Disconnect the air flow sensor connector.

2. Measure resistance between terminals No. 5 and
No. 6.
Standard value:
13 - 17 kW (at -20C)
5.3 - 6.7 kW (at 0C)
2.3 - 3.0 kW (at 20C)
1.0 - 1.5 kW (at 40C)
0.56 - 0.76 kW (at 60C)
0.30 - 0.42 kW (at 80C)
3. Remove the air flow sensor
FUEL PUMP RELAY CONTINUITY CHECK

sensor
M1131033000193
Junction blocks
triangle marks
Fuel pump
relay (1)
Fuel pump
relay (2)
1
3
2
4
AKX01621AD
Equipment side
connector
AK300353 AB
Tester
Battery Voltage
Connectio
n Terminal
Normal
State
2-3
No Voltage
Continuity
1-4
No Voltage
No continuity
Voltage (Connect
Continuity
positive (+) terminal of
battery to terminal No. 3
and negative (-)
terminal of battery to
terminal No. 2.)
4. Measure resistance while heating the sensor

using a hair drier.
Normal condition:
Temperature (C)
Resistance (kW)
Higher
Smaller
5. If the value deviates from the standard value or

the resistance remains unchanged, replace the air
flow sensor assembly.
6. Install the air flow sensor and tighten it to the
specified torque.
Tightening torque: 8.8 1 Nm
13A-313
ON-VEHICLE SERVICE
ENGINE COOLANT TEMPERATURE

SENSOR CHECK
M1131003100335
CAUTION
Be careful not to touch the connector (resin section) with the tool when removing and installing.
1 2
4. Apply sealant to threaded portion.

Specified sealant:
3M NUT Locking Part No. 4171 or equivalent
5. Install the engine coolant temperature sensor and
tighten it to the specified torque.
THROTTLE POSITION SENSOR CHECK

M1131003200398
Throttle position
sensor
AK300355
1. Remove the engine coolant temperature sensor.
2 3 4
AKX01622
2. With temperature sensing portion of engine

coolant temperature sensor immersed in hot
water, check resistance.
Standard value:
14 - 17 kW (at -20C)
5.1 - 6.5 kW (at 0C)
2.1 - 2.7 kW (at 20C)
0.9 - 1.3 kW (at 40C)
0.48 - 0.68 kW (at 60C)
0.26 - 0.36 kW (at 80C)
3. If the resistance deviates from the standard value
greatly, replace the sensor.
AK300346 AB
1. Disconnect the throttle position sensor connector.

2. Measure the resistance between the throttle
position sensor side connector terminal No. 1 and
terminal No. 4.
Standard value: 3.5 - 6.5 kW
3. Measure the resistance between the throttle
position sensor side connector terminal No. 2 and
terminal No. 4.
Normal condition:
Throttle valve slowly
Changes smoothly in
open until fully open from proportion to the opening
the idle position
angle of the throttle valve
4. If the resistance is outside the standard value, or if
it doesnt change smoothly, replace the throttle
position sensor.
NOTE: For the throttle position sensor adjustment
procedure, refer to 313A.
OXYGEN SENSOR CHECK

M1131005000497
AKX01623AD
1 2
3 4
AK300356 AB
13A-314
ON-VEHICLE SERVICE
1. Disconnect the oxygen sensor connector and

connect the special tool Test harness
(MD998464) to the connector on the oxygen
sensor side.
2. Make sure that there is continuity (4.5 - 8.0 W at
20C) between terminal No. 1 (red clip of special
tool) and No. 3 (blue clip of special tool) on the
oxygen sensor connector.
3. If there is no continuity, replace the oxygen
sensor.
4. Warm up the engine until engine coolant is 80C
or higher.
5. Perform a tracing for 5 minutes or more with the
engine speed of 4,500 r/min.
Oxygen
sensor
equipment
side connector
Black
White
MD998464
AKX01624 AF
6. Connect a digital voltage meter between terminal

No. 2 (black clip of special tool) and No. 4 (white
clip of special tool).
7. While repeatedly racing the engine, measure the
oxygen sensor output voltage.
Standard value:
Engine
Oxygen
Remarks
sensor
output
voltage
When
racing the
engine
0.6 - 1.0 V
If you make the air-fuel

ratio rich by racing the
engine repeatedly, a
normal oxygen sensor
will output a voltage of
0.6 - 1.0 V.
CAUTION
Be very careful when connecting the jumper
wire; incorrect connection can damage the
oxygen sensor.
Be careful the heater is broken when voltage
of beyond 8V is applied to the oxygen sensor
heater.
NOTE: If the sufficiently high temperature (of
approximate 400C or more) is not reached
although the oxygen sensor is normal, the output
voltage would be possibly low although the rich
air-fuel ratio. Therefore, if the output voltage is
low, use a jumper wire to connect the terminal
No.1 (red clip of special tool) and the terminal No.
3 (blue clip of special tool) of the oxygen sensor
with a (+) terminal and (-) terminal of 8 V power
supply respectively, then check again.
8. If the sensor is defective, replace the oxygen
sensor.
NOTE: For removal and installation of the oxygen
sensor, refer to GROUP 15 - Exhaust Manifold.
315.
2 1
4 3
Equipment side
connector
Oxygen sensor
connector (rear)
AK300357 AB
1. Disconnect the oxygen sensor connector and

connect the special tool Test harness (MB991658)
to the connector on the oxygen sensor side.
2. Make sure that there is continuity (11 - 18 W at
20C) between terminal No. 1 and No. 2 on the
oxygen sensor connector.
3. If there is no continuity, replace the oxygen
sensor.
4. Warm up the engine until engine coolant is 80C
or higher.
5. Perform a tracing for 5 minutes or more with the
engine speed of 4,500 r/min.
13A-315
ON-VEHICLE SERVICE
INJECTOR CHECK
M1131005200327
Oxygen sensor
Check the Operation Sound

Injector
1 2
Equipment side
connector
MB991658
AK000121 AC
6. Connect a digital voltage meter between terminal

No. 3 and No. 4.
7. While repeatedly racing the engine, measure the
oxygen sensor output voltage.
Standard value:
Engine
Oxygen
Remarks
sensor
output
voltage
When
racing the
engine
0.6 - 1.0 V
If you make the air-fuel

ratio rich by racing the
engine repeatedly, a
normal oxygen sensor
will output a voltage of
0.6 - 1.0 V.
CAUTION
Be very careful when connecting the jumper
wire; incorrect connection can damage the
oxygen sensor.
Be careful the heater is broken when voltage
of beyond 8V is applied to the oxygen sensor
heater.
NOTE: If the sufficiently high temperature (of
approximate 400C or more) is not reached
although the oxygen sensor is normal, the output
voltage would be possibly low although the rich
air-fuel ratio. Therefore, if the output voltage is
low, use a jumper wire to connect the terminal
No.2 and the terminal No. 1 of the oxygen sensor
with a (+) terminal and (-) terminal of 8 V power
supply respectively, then check again.
8. If the sensor is defective, replace the oxygen
sensor.
NOTE: For removal and installation of the oxygen
sensor, refer to GROUP 15 - Exhaust Pipe and
Main Muffler 315.
AK300358 AB
1. Use a stethoscope to listen to the operation sound

(clicking) of the injectors while the engine is idling
or cranking.
CAUTION
Beware that the operation sounds of other injectors can be heard even if the injector that is being
inspected might not be operating.
2. Verify that the operation sound increases with the
engine speed.
NOTE: If the operating sound cannot be heard,
inspect the injector actuation circuit.
Measurement of Resistance between Terminals

1. Disconnect the injector connector.
2. Measure the resistance between terminals.
Standard value: 10.5 - 13.5 W (at 20C)
3. Connect the injector connector.
Check the Injection Condition

1. Following the steps below, bleed out the residual
pressure within the fuel pipe line to prevent flow of
the fuel (Refer to 313A).
2. Remove the injector.
3. Assemble the following special tools as shown in
Fig.
Injector test set (MD998706)
Injector test harness (MB991607)
Injector test adaptor (MD998741)
Clip (MB991608)
13A-316
ON-VEHICLE SERVICE
High-pressure fuel hose

MD998741
Return hose
MB991607
Pressure regulator
Clip (MB991608) MD998706
Injector
Battery
AK101794 AD

5. Turn the ignition switch to "ON" position (But do
6. Select "Item No. 07" from the MUT-II Actuator test
to drive the fuel pump.

(STEPPER MOTOR) CHECK
M1131005400417
Check the Operation Sound
Mainhose
1 2
4 5
Equipment side
connector
Return hose
Injector
Idle speed
control servo
AK300359 AB
Battery
AK101795 AC
7. Activate the injector and check the atomized

spray condition of the fuel.
The condition can be considered satisfactory
unless it is extremely poor.
8. Stop the actuation of the injector, and check for
leakage from the injectors nozzle.
Standard value: 1 drop or less per minute
9. Activate the injector without activating the fuel
pump; then, when the spray emission of fuel from
the injector stops, disconnect the special tool and
restore it to its original condition.
10.Disconnect the MUT-II.
1. Check that the engine coolant temperature is

20C or below.
NOTE: Disconnecting the engine coolant temperature sensor connector and connecting the harness-side of the connector to another engine
coolant temperature sensor that is at 20C or
below is also okay.
2. Check that the operation sound of the stepper
motor can be heard after the ignition is turned to
the "ON" position (but without starting the engine).
3. If the operation sound cannot be heard, check the
stepper motors activation circuit.
If the circuit is normal, it is probable that there is a
malfunction of the stepper motor or of the engineECU.

ON-VEHICLE SERVICE
Check the Coil Resistance
13A-317
Operation Check
1 2 3
4 5 6
AKX01626
1 2 3
4 5 6
AKX01561AE
1. Disconnect the idle speed control servo

connector.
2. Measure the resistance between terminal No. 2
and either terminal No. 1 or terminal No. 3 of the
connector at the idle speed control servo side.
Standard value: 28 - 33 W (at 20C)
3. Measure the resistance between terminal No. 5
and either terminal No. 6 or terminal No. 4 of the
connector at the idle speed control servo side.
Standard value: 28 - 33 W (at 20C)
1. Remove the throttle body.

2. Remove the stepper motor.
3. Connect the special tool Test harness
(MB991709) to the idle speed control servo
connector.
4. Connect the positive (+) terminal of a power
supply (approximately 6 V) to the terminals No. 2
and No. 5.
5. With the idle speed control servo as shown in the
illustration, connect the negative (-) terminal of
the power supply to each clip as described in the
following steps, and check whether or not a
vibrating feeling (a feeling of very slight vibration
of the stepper motor) is generated as a result of
the activation of the stepper motor.
(1) Connect the negative (-) terminal of the power
supply to the terminal No. 1 and terminal No.
4.
4.
6.
6.
4.
(6) Repeat the tests in sequence from (5) to (1).
6. If vibration is detected during the test, the stepper
motor can be considered to be normal.
13A-318
INJECTOR
INJECTOR
M1131007100649
315).
Fuel Leakage Inspection.
Fuel Discharge Prevention (Refer to 313A).
315).
11 1 Nm
8.9 1.9 Nm
9
5
8
7N
6
5.0 1.0 Nm
19
15 N
16
18
17
10
N
6,10
7,11
11
18
12
13
19
16
N 15
14
Engine Oil
AC300484 AB
1.
2.
3.
4.
5.
>>A<<
>>A<<
<<A>>
>>A<<
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18
19.
Removal steps
PCV hose connection
Injector connector
Emission control equipment hose
connector
connection
O-ring
Fuel return hose connection
Fuel hose
Delivery pipe pressure regulator
O-ring
Fuel delivery pipe and fuel injector
assembly
Insulators
Fuel injector assembly
O-ring
Fuel injector sheets
Insulators
Fuel injectors
Fuel delivery pipe

<<A>> FUEL DELIVERY PIPE AND FUEL INJECTOR ASSEMBLY REMOVAL
CAUTION
Do not drop the injector.
Remove the fuel delivery pipe with the fuel injector
assembly attached to it.
INSTALLATION SERVICE POINT

>>A<< FUEL INJECTOR ASSEMBLY/DELIVERY
PIPE PRESSURE REGULATOR/FUEL HIGHPRESSURE HOSE INSTALLATION
CAUTION
Do not let the engine oil get into the delivery pipe
will be damaged.
1. Apply a drop of new engine oil to the O-ring.
13A-319
2. Turn the fuel injector assembly. To the right and

left to install to the fuel delivery pipe. Repeat for
delivery pipe pressure regulator and fuel highpressure hose. Be careful not to damage the Oring. After installing, check that the item turns
smoothly.
3. If it dose not turn smoothly, the O-ring may be
trapped, remove the item, re-install it into the fuel
delivery pipe and check again.
4. Tighten the delivery pipe pressure regulator and

fuel high-pressure hose to the specified torque.
Tightening torque:
8.9 1.9 Nm <Delivery pipe pressure regulator>
5.0 1.0 Nm <Fuel high-pressure hose>

M1131007700544
315).
315).
Engine Coolant Supplying (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement 314).
Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service - Accelerator Cable Adjustment 317).
7
2
5.0 1.0 Nm
19 3 Nm
N8
3
4
5
1.
2.
3.
4.
5.
Removal steps
Water return hose connection
Water feed hose connection
6.
>>A<<
7.
8.
AC300416AB

Emission vacuum hose
connection
Throttle body assembly
Throttle body gasket
13A-320
INSTALLATION SERVICE POINT

>>A<< THROTTLE BODY GASKET INSTALLATION
Install the throttle body gasket as shown in the illustration.
CAUTION
Poor idling etc. may result if the throttle body
gasket is installed incorrectly.
Up
Towards front
of vehicle
AC200313AB
THROTTLE BODY ASSEMBLY DISASSEMBLY AND REASSEMBLY

M1131009700409
5
6
2.0 0.5 Nm
2.0 0.5 Nm
1
2
3
4
AK203824 AB
<<A>>
<>
>>A<<
1.
2.
3.
4.
Removal steps
O-ring
Throttle body

5. Speed adjusting screw
6. O-ring
13A-321
NOTE: .
The speed adjusting screw is correctly adjusted
at the factory and should not be removed.
If the speed adjusting screw should happen to
have been removed, carry out speed adjusting
screw adjutment.
DISASSEMBLY SERVICE POINTS

<<A>> THROTTLE POSITION SENSOR DISASSEBLY
1. Do not disassemble the sensor and motor.
2. Do not clean the sensor and motor by dipping
them into cleaning solvent. Clean them with shop
towel.
<> THROTTLE BODY DISASSEMBLY
1. Do not disassemble the throttle body.
2. Check if the vacuum port or passage is clogged.
Use compressed air to clean the vacuum
passage.
REASSEMBLY SERVICE POINT

>>A<< THROTTLE POSITION SENSOR (TPS)
INSTALLATION
AK203835AB
1. Install the throttle position sensor to the throttle

body as shown in the illustration.
2. Turn the throttle position sensor 90 degrees
counterclockwise to set it, and tighten the screws.
Throttle position
sensor power
Earth
Throttle position
sensor output
AK200203 AB
3. Connect an ohmmeter between terminals 2

(output) and 4 (earth), or between terminals 1
(power) and 2 (output).
Then, make sure that the resistance changes
smoothly when the throttle valve is slowly moved
to the fully open position.
13A-322
ENGINE ECU
ENGINE ECU
M1131033800036
Pre-removal and Post-installation Operation

Cowl Side Trim (RH) Removal and Installation (Refer to
GROUP 52A, Instrument Panel Assembly 352A).
3
5.0 1.0 Nm
5.0 1.0 Nm
AC300630AB
1.
REMOVAL STEPS
Engine-ECU connector
2.
3.
REMOVAL STEPS&RQWLQXHG

Engine-ECU
Engine-ECU bracket
13B-1
GROUP 13B
MULTIPORT FUEL
INJECTION (MPI)
<4G69>
CONTENTS
13B-2
FUEL PUMP OPERATION CHECK . . . . . . 13B-428

COMPONENT LOCATION . . . . . . . . . . . . . 13B-428
13B-6

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-429
SEALANT. . . . . . . . . . . . . . . . . . . . . .
13B-6
FUEL PUMP RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-430
SPECIAL TOOLS. . . . . . . . . . . . . . . .
13B-7
THROTTLE VALVE CONTROL SERVO RELAY

CONTINUITY CHECK . . . . . . . . . . . . . . . . . 13B-430
TROUBLESHOOTING . . . . . . . . . . . .
13B-10

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-430
13B-10
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . .
13B-10
ENGINE COOLANT TEMPERATURE SENSOR

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-431
INSPECTION CHART FOR DIAGNOSIS

CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13B-20
ACCELERATOR PEDAL POSITION SENSOR

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-431
INSPECTION PROCEDURE FOR DIAGNOSIS

CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13B-23
ACCELERATOR PEDAL POSITION SWITCH

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-432
INSPECTION CHART FOR TROUBLE

SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13B-281
OXYGEN SENSOR CHECK . . . . . . . . . . . . 13B-432
SYMPTOM PROCEDURES . . . . . . . . . . . . 13B-285
INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13B-435
CHECK AT THE ECU TERMINALS . . . . . . 13B-411
THROTTLE VALVE CONTROL SERVO

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-436
INSPECTION PROCEDURE USING

OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13B-418
OIL CONTROL VALVE CHECK . . . . . . . . . 13B-436
ON-VEHICLE SERVICE. . . . . . . . . . . 13B-425

THROTTLE BODY (THROTTLE VALVE AREA)
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . 13B-425
ACCELERATOR PEDAL POSITION SWITCH AND
ACCELERATOR PEDAL POSITION SENSOR (APS)
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13B-425
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13B-426
FUEL PUMP CONNECTOR DISCONNECTION
(HOW TO REDUCE PRESSURIZED FUEL
LINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-428
INJECTOR . . . . . . . . . . . . . . . . . . . . . 13B-437
REMOVAL AND INSTALLATION . . . . . . . . 13B-437
THROTTLE BODY ASSEMBLY . . . . . 13B-438

ENGINE ECU AND

ENGINE-A/T-ECU . . . . . . . . . . . . . . . . 13B-439
13B-2
MULTIPORT FUEL INJECTION (MPI) <4G69>

GENERAL INFORMATION
GENERAL INFORMATION
M1131000101016
The Multipoint Fuel Injection System consists of

sensors which detect the engine conditions, the
engine-ECU <M/T> or engine-A/T-ECU <A/T> which
controls the system based on signals from these
sensors, and actuators which operate under the
control of the engine-ECU <M/T> or engine-A/T-ECU
<A/T>. The engine-ECU <M/T> or engine-A/T-ECU
FUEL INJECTION CONTROL
The injector drive times and injection timing are
controlled so that the optimum air/fuel mixture is
supplied to the engine to correspond to the
continually-changing engine operation conditions.
A single injector is mounted at the intake port of each
cylinder. Fuel is sent under pressure from the fuel
tank by the fuel pump, with the pressure being
regulated by the fuel pressure regulator. The fuel
thus regulated is distributed to each of the injectors.
Fuel injection is normally carried out once for each
cylinder for every two rotations of the crankshaft. The
firing order is 1-3-4-2. This is called sequential fuel
injection. The engine-ECU <M/T> or
engine-A/T-ECU <A/T> provides a richer air/fuel
<A/T> carries out activities such as fuel injection

control, idle speed control and ignition timing control.
In addition, the engine-ECU <M/T> or
engine-A/T-ECU <A/T> is equipped with several
diagnosis modes which simplify troubleshooting
when a problem develops.
mixture by carrying out "open-loop" control when the

engine is cold or operating under high load
conditions in order to maintain engine performance.
In addition, when the engine is warm or operating
under normal conditions, the engine-ECU <M/T> or
engine-A/T-ECU <A/T> controls the air/fuel mixture
by using the oxygen sensor signal to carry out
"closed-loop" control in order to obtain the theoretical
air/fuel mixture ratio that provides the maximum
cleaning performance from the three way catalyst.
THROTTLE VALVE OPENING CONTROL

This system electrically controls the opening of the
throttle valve. The engine-ECU <M/T> or
engine-A/T-ECU <A/T> detects the amount of travel
of the accelerator pedal via the accelerator pedal
position sensor, and controls the actuation of the
throttle actuator control motor, which is mounted on
the throttle body, in order to attain the target throttle
valve opening that has been predetermined in
accordance with driving conditions.
IDLE AIR CONTROL
The idle speed is kept at the optimum speed by
controlling the amount of air that passes through the
throttle valve in accordance with changes in idling
conditions and engine load during idling.
The engine-ECU <M/T> or engine-A/T-ECU <A/T>
drives the throttle valve control servo to keep the
engine running at the pre-set idle target speed in
accordance with the engine coolant temperature and
A/C and other electrical load. In addition, when the
IGNITION TIMING CONTROL
The power transistor located in the ignition primary
circuit turns ON and OFF to control the primary
current flow to the ignition coil. This controls the
ignition timing in order to provide the optimum
ignition timing with respect to the engine operating
conditions. The ignition timing is determined by the
air conditioning switch is turned off and on while the

engine is idling, the throttle valve control servo
adjusts the throttle valve passes through air amount
according to the engine load conditions to avoid
fluctuations in the engine speed.
engine-ECU <M/T> or engine-A/T-ECU <A/T> from

the engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.

GENERAL INFORMATION
SELF-DIAGNOSIS FUNCTION
sensors or actuators related to emission control,
the engine warning lamp (check engine lamp)
illuminates as a warning to the driver.
sensors or actuators, a diagnosis code
corresponding to the abnormality is output.
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control
Turns the fuel pump relay ON so that current is
supplied to the fuel pump while the engine is
cranking or running.
2. A/C Relay Control
Turns the compressor clutch of the A/C ON and OFF.
3. Oil Control Valve Control
effects duty cycle control on the engine oil control
valve, in accordance with the engine speed. This
regulates the supply of engine oil to the intake
rocker shaft, which switches the cams.
4. Fan Motor Control
13B-3
The RAM data inside the engine-ECU <M/T> or

engine-A/T-ECU <A/T> that is related to the
sensors and actuators can be read by means of
the MUT-II/III. In addition, the actuators can be
force-driven under certain circumstances.
The revolutions of the radiator fan and condenser fan

are controlled in response to the engine coolant
temperature and vehicle speed.
5. Alternator Output Current Control
Prevents alternator output current from increasing
suddenly and idle speed from dropping at times
such as when the headlamp are turned on.
6. Purge Control Solenoid Valve Control
(Refer to P.17-17, GROUP 17 Engine And
Emission Control Evaporative Emission Control
System).
7. EGR Control Solenoid Valve Control
[Refer to P.17-22, GROUP 17 Engine And
Emission Control Exhaust Gas Recirculation
(EGR) System].
13B-4
GENERAL INFORMATION
Items
Throttle body
Specifications
Throttle bore mm
60
Hall element type
Throttle valve control servo
DC motor type, having broshes
engine-ECU
<M/T>
Identification No.
E6T38973
Engine-A/T-E
CU <A/T>
Identification No.
E6T41592 <L. H. drive vehicles>

E6T41593 <R. H. drive vehicles>
Sensors
Air flow sensor
Heat sensitizing type
Barometric pressure Sensor
Semiconductor type
Thermistor type
Thermistor type
Oxygen sensor
Zirconia type
Accelerator pedal position sensor
Variable resistor type
Accelerator pedal position switch
Contact switch type
Vehicle speed sensor <M/T>
Magnetic resistive element type
Inhibitor switch <A/T>
Contact switch type
Magneto resistance element type
Crank angle sensor
Magneto resistance element type
Detonation sensor
Piezoelectric type
Manifold absolute pressure sensor
Semiconductor type
Contact switch type
Engine control relay type
Contact switch type
Fuel pump relay type
Contact switch type
Injector type and number
Electromagnetic type, 4
Injector identification mark
IDH322S
Throttle actuator control motor relay
Contact switch type
Oil control valve
EGR valve
Stepper motor
Actuators
Fuel pressure Regulator pressure kPa

regulator
324
13B-5
GENERAL INFORMATION
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM

1 Cylinder 1, 4 oxygen
sensor (front)
sensor (front)
sensor (rear)
sensor (rear)
5 Camshaft position
sensor
6 Engine coolant
temperature sensor
8 Detonation sensor
(main)
(sub)
11 Intake air temperature
sensor
12 Air flow sensor
13 Manifold absolute
pressure sensor
Power supply
Ignition switch-IG
Ignition switch-ST
A/C switch
A/C load signal
A/C pressure
sensor
Power steering
fluid pressure switch
Alternator FR
terminal
Accelerator pedal
position switch
Accelerator pedal
position sensor
(main)
Accelerator pedal
position sensor
(sub)
Vehicle speed
sensor <M/T>
Inhibitor switch
<A/T>
Engine-ECU
<M/T> or
Engine-A/TECU <A/T>
Barometric
pressure
sensor
1 Oil control valve

2 Throttle valve
control servo
3 Injector
4 EGR valve
(Stepper motor)
5 Purge control solenoid
valve

Fuel pump relay
Throttle valve control
servo relay
Ignition coil
Fan controller
Engine warning lamp
Diagnosis output
Tachometer
Cylinder 1, 4 oxygen
sensor (front)
sensor (front)
sensor (rear)
sensor (rear)
9 Throttle position sensor (main)

10 Throttle position sensor (sub)
5 Camshaft position sensor
sensor (front)
2 Throttle valve
control servo
13 Manifold absolute
pressure sensor
sensor (front)
1 Oil control valve
11 Intake air temperature sensor

12 Air flow sensor
Air
M
From
fuel pump
4 EGR valve
(stepper motor)
Canister
Catalytic
converter
3 Injector
6 Engine coolant
temperature sensor
5 Purge control
solenoid valve
8 Detonation sensor
sensor (rear)
sensor (rear)
Catalytic
converter
AK302916 AB
13B-6

M1131000300675
Items
Specifications
Intake air temperature sensor 20C

resistance k
0C
13 17

sensor resistance k
5.3 6.7
20C
2.3 3.0
40C
1.0 1.5
60C
0.56 0.76
80C
0.30 0.42
20C
14 17
0C
5.1 6.5
20C
2.1 2.7
40C
0.9 1.3
60C
0.48 0.68
80C
0.26 0.36
Oxygen sensor output voltage (at racing) V
0.6 1.0

resistance (at 20C)
front
4.5 8.0
rear
11 18
Fuel pressure kPa
Approximately. 324 at curb idle
Injector coil resistance (at 20C)
10.5 13.5
Throttle valve control servo coil resistance (at 20C)
0.3 80
Oil control valve (at 20C)
6.9 7.9
SEALANT
M1131000500419
Item
Specified sealant
Remark

Threaded portion
3M Nut Locking Part No. 4171 or equivalent
Drying sealant

SPECIAL TOOLS
13B-7
SPECIAL TOOLS
M1131000600580
Tool
Number
Name
Use
MB991502
MUT-II sub
assembly

MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826
MUT-III sub
assembly
A: Vehicle
communicatio
n interface
(V.C.I.)
B: MUT-III USB
cable
C: MUT-III main
harness A
(Vehicles with
CAN
communicatio
n system)
D: MUT-III main
harness B
(Vehicles
without CAN
communicatio
n system)
E: MUT-III
measurement
adapter
F: MUT-III trigger
harness

MB991348
Test harness set

troubleshooting
B991502
MB991824
MB991827
DO NOT USED
MB991910
MB991911
MB991825
MB991826
MB991955
MB991348
13B-8
SPECIAL TOOLS
Tool
Number
Name
Use
MB991709
Test harness

troubleshooting
MB991316
Test harness
(4-pin, square)

Troubleshooting
MD998464
Test harness
(4-pin, square)

Troubleshooting
MB991658
Test harness

Troubleshooting
Inspection of data list
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Check at the ECU terminals

A: Connector pin contact inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester connection
MB991658
MB991223

SPECIAL TOOLS
Tool
13B-9
Number
Name
Use
MD998709
Adaptor hose
MD998742
Hose adaptor
MB991637
Fuel pressure
gauge set
MD998706
Injector test set
MB991607
Injector test
harness
MD998741
Injector test
adaptor
MB991976
Injector test
holder assembly
MB991637
MD998706
MB991607
MD998741
MB991976
Checking the spray condition of

injectors
13B-10
TROUBLESHOOTING
TROUBLESHOOTING
M1131150000568
Refer to P.00-6, GROUP 00 How to Use

Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
M1131155500212
ENGINE WARNING LAMP (CHECK

ENGINE LAMP)
If an abnormality occurs in any of the following items

related to the Multipoint Fuel Injection (MPI) system,
the engine warning lamp will illuminate.
If the lamp remains illuminated or if the lamp
illuminates while the engine is running, check the
diagnosis code output.
Engine warning lamp

(check engine lamp)
AK300251AB
ENGINE WARNING LAMP INSPECTION ITEMS

Code No.
Diagnosis item
Engine-ECU <M/T> or engine-A/T-ECU <A/T>
P0100
P0105
Manifold absolute pressure sensor system
P0110
P0115
P0122*
Throttle position sensor (main) circuit low input
P0123*
Throttle position sensor (main) circuit high input
P0125*
P0130
Cylinder 1, 4 oxygen sensor (front) system
P0135
Cylinder 1, 4 oxygen sensor (front) heater system
P0136
Cylinder 1, 4 oxygen sensor (rear) system
P0141
Cylinder 1, 4 oxygen sensor (rear) heater system
P0150
P0155
P0156
P0161
P0170
Abnormal fuel system (cylinder 1,4)
P0173
P0201
No.1 injector system
P0202
P0203
P0204

TROUBLESHOOTING
13B-11
Code No.
Diagnosis item
P0222*
Throttle position sensor (sub) circuit low input
P0223*
Throttle position sensor (sub) circuit high input
P0300*
Random/multiple cylinder misfire detected
P0301*
No.1 cylinder misfire detected
P0302*
P0303*
P0304*
P0325
P0335
P0340
P0403
Exhaust gas recirculation control system
P0421
Warm up catalyst malfunction (cylinder 1,4)
P0431
Warm up catalyst malfunction (cylinder 2,3)
P0443
P0500
Vehicle speed sensor system <M/T>
P0505
Idle speed control (ISC) system
P0513
Immobilizer malfunction
P0551*
P0606*
Engine-ECU <M/T> or engine-A/T-ECU <A/T> main processor malfunction
P0622
P0638*
Throttle valve control servo circuit range/performance problem
P0642*
Throttle position sensor power supply
P0657*
Throttle valve control servo relay circuit malfunction
P0705
Inhibitor switch system
P0710
A/T fluid temperature sensor system
P0715*
Input shaft speed sensor system
P0720*
Output shaft speed sensor system
P0740*
Torque converter clutch solenoid valve system
P0750*
Low-reverse solenoid valve system
P0755*
Underdrive solenoid valve system
P0760*
Second solenoid valve system
P0765*
Overdrive solenoid valve system
P1010
Oil control valve system
P1602*
Communication malfunction (between engine-ECU <M/T> or engine-A/T-ECU <A/T>

main processor and system LSI)
P1603*
Battery backup circuit malfunction
P1751*
A/T control relay system
P2100*
Throttle valve control servo circuit (open)
P2101*
Throttle valve control servo magneto malfunction
P2102*
Throttle valve control servo circuit (shorted low)
13B-12

TROUBLESHOOTING
Code No.
Diagnosis item
P2103*
Throttle valve control servo circuit (shorted high)
P2121*
Accelerator pedal position sensor (main) circuit range/performance problem
P2122*
Accelerator pedal position sensor (main) circuit low input
P2123*
Accelerator pedal position sensor (main) circuit high input
P2126*
Accelerator pedal position sensor (sub) circuit range/performance problem
P2127*
Accelerator pedal position sensor (sub) circuit low input
P2128*
Accelerator pedal position sensor (sub) circuit high input
P2135*
Throttle position sensor (main and sub) range/performance problem
P2138*
Accelerator pedal position sensor (main and sub) range/performance problem
P2173*
Abnormal intake air amount
NOTE: .
If the engine warning lamp illuminates because of a malfunction of the engine-ECU <M/T> or
engine-A/T-ECU <A/T>, communication between MUT-II/III and the engine-ECU <M/T> or
engine-A/T-ECU <A/T> is impossible. In this case, the diagnosis code cannot be read.
After the engine-ECU <M/T> or engine-A/T-ECU <A/T> has detected a malfunction, the engine warning
lamp illuminates when the engine is next turned on and the same malfunction is re-detected.However, for
items marked with a "*" in the diagnosis code number column, the engine warning lamp illuminates only
on the first detection of the malfunction.
After the engine warning lamp illuminates, it will be switched off under the following conditions.
When the engine-ECU <M/T> or engine-A/T-ECU <A/T> monitored the power train malfunction three
times* met set condition requirements, it detected no malfunction.
*: In this case, "one time" indicates from engine start to stop.
For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
Sensor 1 indicates, the sensor mounted at a position closest to the engine, and sensor 2 indicates the
sensor mounted at the position second closest to the engine.
METHOD OF READING AND ERASING

DIAGNOSIS CODES
Refer to P.00-6, GROUP 00 How to Use
Troubleshooting/Inspection Service Points.
DIAGNOSIS USING DIAGNOSIS 2 CODES

1. Switch the diagnosis mode of the engine control
unit to DIAGNOSIS 2 mode using the MUT-II/III.
2. Carry out a road test.
3. Take a reading of the diagnosis code and repair
the problem location.
4. Turn the ignition switch to OFF and then back to
ON again.
NOTE: By turning the ignition switch to OFF, the
ENGINE-ECU <M/T> or ENGINE-A/T-ECU
<A/T> will switch the diagnosis mode from
DIAGNOSIS 2 mode to DIAGNOSIS 1 mode.
5. Erase the diagnosis codes.
INSPECTION USING MUT-II/III DATA LIST

AND ACTUATOR TESTING
1. Carry out inspection by means of the data list and
the actuator test function, if there is an
abnormality, check and repair the chassis harness
and components.
2. After repairing, re-check using the MUT-II/III and
check that the abnormal input and output have
returned to normal as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II/III, and then start the engine
again and carry out a road test to confirm that the
problem has disappeared.
13B-13
TROUBLESHOOTING
FREEZE FRAME DATA

When the engine-ECU <M/T> or engine-A/T-ECU
<A/T> detects a malfunction and stores a diagnosis
code, it also stores a current status of the engine.
This function is called "Freeze frame data". By
analyzing this "Freeze frame" data with the
MUT-II/III, an effective troubleshooting can be
performed.
The display items of freeze frame data are shown

below.
DISPLAY ITEM LIST

Item No.
Data
Unit
12
Air flow sensor
13
r/min
21
22
Crank angle sensor
r/min
24
Vehicle speed
km/h
44
Ignition advance
km/h
81
Long-term fuel compensation (cylinder 1, 4)
82
Short-term fuel compensation (cylinder 1, 4)
83
Long-term fuel compensation (cylinder 2, 3)
84
Short-term fuel compensation (cylinder 2, 3)
88

(cylinder 1, 4)
Open loop
OL
Closed loop
CL
OL-DRV.
OL-SYS.
CL- H02S
Open loop
OL
Closed loop
CL
OL-DRV.
OL-SYS.
CL- H02S
89

(cylinder 2, 3)
87
Calculation load value
8A
Throttle position sensor (main)
Diagnosis code during data recording
NOTE: If malfunctions have been detected in

multiple systems, store one malfunction only, which
has been detected first.
13B-14
TROUBLESHOOTING
DRIVE CYCLE
The following five drive cycle patterns are performed on the diagnosis codes monitored during the vehicle
driving. The vehicle driving requires the patterns to identify the fault. In other words, doing such a drive allows
to regenerate any kind of trouble which involves illuminating the engine warming lamp (check engine lamp)
and to verify the repair procedure has eliminated the trouble [the engine warming 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
diagnosis code if it has been output.
DRIVE CYCLE PATTERN LIST
Procedure
Monitor item
Diagnosis code
Catalytic converter monitor
P0421, P0431
Oxygen sensor (front) monitor
P0130, P0150
Other monitor
P0135, P0136, P0141,

P0155, P0156, P0161,
P0201, P0202, P0203,
P0204, P0300, P0301,
P0302, P0303, P0304,
P0325, P0501, P0551,
P0638
13B-15
TROUBLESHOOTING
Procedure 1
Catalytic converter monitor
Diagnosis
code No.
P0421, P0431
Drive cycle
pattern
One trip monitor [from start to ignition switch to "LOCK" (OFF) position] will be completed
while traveling with the following drive cycle pattern. It will take 16 minutes or more.
6 minutes or more
90 km/h or more
(3)
Vehicle
speed
10 minutes or more
(4)
(2)
55 - 80 km/h
(5,6)
Stopping and braking
permitted
(1)
Engine Start
(7)
Time
Ignition switch :
"LOCK" (OFF)
position
AK301815 AB
Inspection
condition
Atmospheric temperature: 10C or more
Test
procedure
1. Engine: start
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.
13B-16
TROUBLESHOOTING
Procedure 2
Oxygen sensor (front) monitor
Diagnosis
code No.
P0130, P0150
Drive cycle
pattern
16 minutes or more
55 - 80 km/h
(3)
Vehicle
speed
(2)
Stopping and braking

permitted
(1)
Engine Start
(4)
Time
Ignition switch :
"LOCK" (OFF)
position
AK301816AB
Inspection
conditions
Engine coolant temperature: After engine warm up

Test
procedure
1. Engine: start
2. Accelerate until the vehicle speed is 55 80 km/h.
3. While keeping the acceleator 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.
13B-17
TROUBLESHOOTING
Procedure 3
Other monitor
Diagnosis
code No.
P0135, P0136, P0141, P0155, P0156, P0161, P0201, P0202, P0203, P0204, P0300,
P0301, P0302, P0303, P0304, P0325, P0501, P0551, P0638
Drive cycle
pattern
16 minutes or more
55 km/h or more
(3)
Vehicle
speed
(2)
5 minutes or more
Engine: Idling
(4)
(1)
(5)
Time
Engine Start
Ignition switch :
"LOCK" (OFF)
position
AK301817AB
Inspection
conditions
Engine coolant temperature: After engine warm up

Test
procedure
1. Engine: start
2. Accelerate until the vehicle speed is 55 km/h.
3. While keeping the acceleator 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

monitors the following main diagnosis items, judges
if these items are in good condition or not, and the
stores its history. this history can be read out by
using MUT-II/III. (If the ECU has judged a item
before, the MUT-II/III displays "Complete").
In addition, if diagnosis codes are erased or the

battery cable is disconnected, this history will also be
erased (the memory will be reset).
Catalyst: P0421, P0431
Oxygen sensor: P0130, P0136, P0150, P0156
Oxygen sensor heater: P0135, P0141, P0155,
P0161
13B-18

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
Air flow sensor
Uses the throttle position sensor signal and engine speed signal (crankshaft
position sensor signal) for basic injector drive time and basic ignition timing from
the pre-set mapping.

sensor
Controls as if the intake air temperature is 25C.
Barometric pressure
sensor
Controls as if the barometric pressure is 101 kPa.

(main)
Controls the throttle valve position through the use of the throttle position sensor
(sub) signal.
Renders the amount of accelerator pedal travel as being approximately one-half
the normal opening angle.
Prohibits the operation of the engine speed feedback control.
Cuts off fuel when the engine speed exceeds 3,000 r/min.
Suppresses the engine output by stopping the electronically controlled throttle
valve system if the throttle position sensor (sub) is also malfunctioning.

(sub)
Controls the throttle valve position through the use of the throttle position sensor
(main) signal.
valve system if the throttle position sensor (main) is also malfunctioning.
Accelerator pedal
position sensor (main)
Detects the amount of the accelerator pedal travel through the use of the
accelerator pedal position sensor (sub) signal, but rendering it only as being
approximately one-half the normal opening angle.
valve system if the accelerator pedal position sensor (sub) is also
malfunctioning.
Accelerator pedal
position sensor (sub)
Detects the amount of the accelerator pedal travel through the use of the
accelerator pedal position sensor (main) signal, but rendering it only as being
approximately one-half the normal opening angle.
valve system if the accelerator pedal position sensor (main) is also
malfunctioning.
Engine coolant
temperature sensor
Controls as if the engine coolant temperature is 80C. (This control will be

continued until the ignition switch is turned to the "LOCK" (OFF) position even
though the sensor signal returns to normal.)
Camshaft position
sensor
Injects fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
ignition switch is turned to the "ON" position, the No. 1 cylinder top dead center is
not detected at all.)
Oxygen sensor <front> Air/fuel ratio closed loop control is not performed.
Oxygen sensor <rear> Performs the closed loop control of the air/fuel ratio by using only the signal of the
oxygen sensor (front) installed on the front side of the catalytic converter.

TROUBLESHOOTING
13B-19
Malfunctioning item
Detonation sensor
Switches the ignition timing from ignition timing for high octane to ignition timing for
standard octane fuel.
Ignition coil
(incorporating power
transistor)
Cuts off the fuel supply to cylinders with an abnormal ignition.
Alternator FR terminal
Does not control the output of the alternator according to an electrical load. (works
as a normal alternator)
Misfiring
If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be
shut down.
Throttle valve position

feedback

valve system.
Throttle valve control

servo

valve system.
Engine-ECU <M/T> or
engine-A/T-ECU <A/T>
main processor

valve system.
Communication
between powertrain
control module main
processor and system
LSI

Intake air monitor

valve system.
Prohibits the operation of engine speed feedback.
Oil control valve
Do not switch to high-speed cam.

Cut off fuel when the engine speed exceeds 5,000 r/min.
13B-20
TROUBLESHOOTING
INSPECTION CHART FOR DIAGNOSIS CODE

M1131151000776
Code No.
Diagnosis item
Reference page
P0100
P.13B-23
P0105
Manifold absolute pressure sensor system
P.13B-28
P0110
P.13B-37
P0115
P.13B-44
P0122*
Throttle position sensor (main) circuit low input
P.13B-51
P0123*
Throttle position sensor (main) circuit high input
P.13B-55
P0125*
P.13B-57
P0130
P.13B-64
P0135
P.13B-70
P0136
P.13B-76
P0141
P.13B-83
P0150
P.13B-90
P0155
P.13B-97
P0156
P.13B-104
P0161
P.13B-111
P0170
P.13B-118
P0173
P.13B-121
P0201
P.13B-125
P0202
P.13B-130
P0203
P.13B-135
P0204
P.13B-140
P0222*
Throttle position sensor (sub) circuit low input
P.13B-145
P0223*
Throttle position sensor (sub) circuit high input
P.13B-149
P0300*
Random/multiple cylinder misfire detected
P.13B-152
P0301*
P.13B-154
P0302*
P.13B-157
P0303*
P.13B-160
P0304*
P.13B-163
P0325
P.13B-166
P0335
P.13B-169
P0340
P.13B-179
P0403
Exhaust gas recirculation control system
P.13B-188
P0421
Warm Up Catalyst Malfunction (cylinder 1,4)
P.13B-194
P0431
Warm Up Catalyst Malfunction (cylinder 2,3)
P.13B-195
P0443
P.13B-196
P0500
Vehicle speed sensor system <M/T>
P.13B-201

TROUBLESHOOTING
13B-21
Code No.
Diagnosis item
Reference page
P0505
Idle speed control (ISC) system
P.13B-204
P0513
Immobilizer malfunction
P.13B-205
P0551*
P.13B-207
P0606*
Engine-ECU <M/T> or engine-A/T-ECU <A/T> main processor

malfunction
P.13B-213
P0622
P.13B-214
P0638*
Throttle valve control servo circuit range/performance problem
P.13B-218
P0642*
Throttle position sensor power supply
P.13B-221
P0657*
Throttle valve control servo relay circuit malfunction
P.13B-222
P0705
Inhibitor switch system
A/T DTC No. 27 (Inhibitor switch

system: open circuit)
A/T DTC No. 28 (Inhibitor switch
system: short circuit)
P.23A-53,
P.23A-61
P0710
A/T fluid temperature

sensor system
A/T DTC No. 15 (A/T fluid temperature P.23A-19,

sensor system: open circuit)
P.23A-25
A/T DTC No. 16 A/T (fluid temperature
sensor system: short circuit)
P0715*
Input shaft speed sensor

system
A/T DTC No. 22 (Input shaft speed

sensor system)
P.23A-28
P0720*
Output shaft speed

sensor system
A/T DTC No. 23 (Output shaft speed

sensor system)
P.23A-37
P0740*
Torque converter clutch

solenoid valve system
A/T DTC No. 36 (Torque converter

clutch solenoid valve system)
P.23A-82
P0750*
Low-reverse solenoid
valve system
A/T DTC No. 31 (Low-reverse solenoid P.23A-65

valve system)
P0755*
Underdrive solenoid valve

system
A/T DTC No. 32 (Underdrive solenoid

valve system)
P.23A-70
P0760*
Second solenoid valve

system
A/T DTC No. 33 (Second solenoid

valve system)
P.23A-74
P0765*
Overdrive solenoid valve

system
A/T DTC No. 34 (Overdrive solenoid

valve system)
P.23A-78
P1010
Oil control valve circuit
P.13B-229
P1602*
Communication malfunction (between engine-ECU <M/T> or

engine-A/T-ECU <A/T> main processor and system LSI)
P.13B-234
P1603*
Battery backup circuit malfunction
P.13B-235
P1751*
A/T control relay system
P.23A-89
P2100*
Throttle valve control servo circuit (open)
P.13B-238
P2101*
Throttle valve control servo magneto malfunction
P.13B-242
P2102*
Throttle valve control servo circuit (shorted low)
P.13B-245
P2103*
Throttle valve control servo circuit (shorted high)
P.13B-248
P2121*
Accelerator pedal position sensor (main) circuit range/performance

problem
P.13B-251
A/T DTC No. 54 (A/T control relay

system)
13B-22
TROUBLESHOOTING
Code No.
Diagnosis item
Reference page
P2122*
Accelerator pedal position sensor (main) circuit low input
P.13B-254
P2123*
Accelerator pedal position sensor (main) circuit high input
P.13B-259
P2126*
Accelerator pedal position sensor (sub) circuit range/performance

problem
P.13B-262
P2127*
Accelerator pedal position sensor (sub) circuit low input
P.13B-265
P2128*
Accelerator pedal position sensor (sub) circuit high input
P.13B-269
P2135*
Throttle position sensor (main and sub) range/performance problem
P.13B-272
P2138*
Accelerator pedal position sensor (main and sub) range/performance P.13B-274

problem
P2173*
Abnormal intake air amount
P.13B-280
NOTE: .
Do not replace the engine-ECU <M/T> or engine-A/T-ECU <A/T> until a through terminal check reveals
there are no short/open circuit.
Check that the engine-ECU <M/T> or engine-A/T-ECU <A/T> earth circuit is normal before checking for
the cause of the problem.
After the engine-ECU <M/T> or engine-A/T-ECU <A/T> 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.
13B-23
TROUBLESHOOTING
INSPECTION PROCEDURE FOR

DIAGNOSIS CODES
Code No. P0100: Air Flow Sensor System
Air flow sensor circuit

Battery
W-B
W-B
4
B-17X
1
Engine
control
relay
1
R
4
J/C (2)
C-17
12
R
2
B-08
1
Air flow
sensor
Heat
sensitizing
resistance
2 3 4
3
BR
11
J/C (1)
C-16
W-R
6
BR
C-141
(MU803804)
63
96
6162
6364
656667686970717273
747576777879808182
8384 858687 8889
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
Engine-ECU <M/T>
Engine-A/T-ECM <A/T>
Wire colour code
AK304118AB
13B-24

TROUBLESHOOTING
OPERATION
Power is supplied by the engine control relay
(terminal No. 1) to the air flow sensor (terminal
No. 2), and the air flow sensor (terminal No. 4) is
grounded through the Engine-ECU <M/T> or
Engine-A/T-ECU <A/T> (terminal No. 96).
The air flow sensor (terminal No. 3) outputs a
sensor signal, which is input into the Engine-ECU
<M/T> or Engine-A/T-ECU <A/T> (terminal No.
63).
FUNCTION
The air flow sensor outputs amperage that varies
in accordance with the intake air volume.
The Engine-ECU <M/T> or Engine-A/T-ECU
<A/T> uses the amperage output by the air flow
sensor and the engine speed signal in order to
determine the basic injection duration of the
injector.
TROUBLE JUDGMENT
Check Conditions
After 3 seconds have passed since the ignition
switch was turned to "ON" position.
Judgment Criteria
Air flow sensor output voltage has continued to
be 0.2 V or lower for 2 seconds.
Or
Air flow sensor output voltage has continued to
be 4.9 V or higher for 2 seconds.
PROBABLE CAUSE
Open/short circuit in air flow sensor circuit or
Failed engine-ECU <M/T>
Failed engine-A/T-ECU <A/T>
DIAGNOSIS PROCEDURE
STEP 1. MUT-II/III data list
Refer to Data list reference table P.13B-401.
00 How to Use
P.00-6).
NO : Go to Step 2 .
connector
Connector: B-08
B-08 (B)
4 3 2 1
Harness
side connector
AK303649 AB

NO : Repair.
STEP 3. Perform voltage measurement at B-08 air

Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13B-25
TROUBLESHOOTING

relay connector
STEP 5. Check at B-08 air flow sensor connector.

Connector: B-08
Connector: B-17X
B-17X
B-08 (B)
Relay boxs
triangle marks
4 3 2 1
Harness
side connector
Harness
side connector
AK304152 AB
Connector: B-08

OK: 2 or less
NO : Go to Step 6 .
B-08 (B)
4 3 2 1
Harness
side connector
AK303649 AB
AK303649 AB


flow sensor connector and B-17X (terminal
No. 1) engine control relay connector.
open/short circuit.
NO : Repair.

<M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-142
<L. H. Drive Vehicle>
C-142 (GR)
<R. H. Drive Vehicle>

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-26
TROUBLESHOOTING

(terminal No. 96) engine-ECU <M/T> connector or
engine-A/T-ECU <A/T> connector.
Connector: B-08
NO : Repair.

Refer to Data List Reference Table P.13B-401.
B-08 (B)
00 How to Use
P.00-6).
NO : Replace engine-ECU <M/T> or
engine-A/T-ECU <A/T>.
4 3 2 1
Harness
side connector
AK303649 AB

connector.
Connector: C-142
Connector: C-141
C-142 (GR)
C-141(GR)
C-142 (GR)
C-141 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

Check earthing line for open circuit.
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

NO : Repair.
13B-27
TROUBLESHOOTING

Connector: B-08

relay connector
Connector: B-17X
B-17X
Relay boxs
triangle marks
B-08 (B)
2
Harness
side connector
4 3 2 1
Harness
side connector
AK303649 AB
Connector: C-141
AK304152 AB

NO : Repair.

No. 2) air flow sensor connector and B-17X
C-141(GR)
Connector: B-08
B-08 (B)
C-141 (GR)
4 3 2 1
Harness
side connector
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
Connector: B-17X
B-17X

AK304154 AB
Check output line for open/short circuit and

damage.
NO : Repair.
AK303649 AB
Relay boxs
triangle marks
Harness
side connector
AK304152 AB

NO : Repair.
13B-28
TROUBLESHOOTING

STEP 14. Replace air flow sensor.

trouble symptoms.


YES : Replace the engine-ECU <M/T> or
00 How to Use
P.00-6).
NO : Check end.
Code No. P0105: Manifold Absolute Pressure Sensor System
Manifold absolute pressure sensor circuit
B-103
(MU802723)
Manifold absolute
pressure sensor
1 2 3
Y-B
C-142
(MU803805)
L-B
97
BR
101
96
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
5V
Engine-ECU <M/T>
Engine-A/T-ECU <A/T>
Wire colour code
AK304119AB
OPERATION
A power voltage of 5 V is applied to the manifold
absolute pressure sensor power terminal
(terminal No. 3) from the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (terminal No. 97) and
earthed to the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (terminal No. 96) from the

manifold absolute pressure sensor (terminal No.
2).

TROUBLESHOOTING

<M/T> or engine-A/T-ECU <A/T> (terminal No.
101) from the manifold absolute pressure sensor
FUNCTION
The manifold absolute pressure sensor converts
the manifold absolute pressure into a voltage
signal and inputs the signal to the engine-ECU
<M/T> or engine-A/T-ECU <A/T>.
In response to the signal, the engine-ECU <M/T>
or engine-A/T-ECU <A/T> corrects the fuel
injection amount, etc.
13B-29
00 How to Use
P.00-6).
NO : Go to Step 2 .
STEP 2. Connector check: B-103 Manifold
absolute pressure sensor connector
Connector: B-103
C-103 (B)
TROUBLE JUDGMENT
Check Conditions
in "ON" position or the engine has started up
Judgment Criteria
The sensor output voltage is 4.5V or more
(barometric pressure above 114kPa or
equivalent) for 4 seconds.
Or
The sensor output voltage is 0.2V or less
(barometric pressure below 53kPa or equivalent)
for 4 seconds.
PROBABLE CAUSE
Failed Manifold absolute pressure sensor
Open/short circuit in Manifold absolute pressure
DIAGNOSIS PROCEDURE
a. Item 32: Manifold absolute pressure sensor
3 2 1
Harness side
connector
AK304038AB

NO : Repair.
STEP 3. Perform voltage measurement at B-103

manifold absolute pressure sensor connector.
Connector: B-103
C-103 (B)
3 2 1
Harness side
connector
AK304038AB

Ignition switch: ON
OK: 4.9 5.1 V
NO : Go to Step 4 .
13B-30
TROUBLESHOOTING
STEP 4. Perform voltage measurement at C-142

engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.

connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Measure engine-ECU <M/T> or engine-A/T-ECU

<A/T> terminal voltage.
Ignition switch: ON
OK: 4.9 5.1 V
NO : Go to Step 6 .
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
AK304153 AB
Connector: B-103
C-103 (B)
3 2 1
Harness side
connector
AK304038AB

(terminal No. 3) manifold absolute pressure

97) engine-ECU <M/T> connector or
circuit.
NO : Repair.
13B-31
TROUBLESHOOTING

connector
Connector: C-142

No. 3) manifold absolute pressure sensor
<A/T> connector.
Connector: B-103
C-142 (GR)
C-103 (B)
3 2 1
Harness side
connector
C-142 (GR)
AK304038AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.

a. Item No. 32: Manifold absolute pressure
sensor
13B-32

TROUBLESHOOTING
00 How to Use
P.00-6).

connector
Connector: C-142

C-142 (GR)
Connector: B-103
C-103 (B)

C-142 (GR)
3 2 1
Harness side
connector
AK304038AB

Ignition switch: ON
OK: 2 or less
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.

TROUBLESHOOTING

engine-ECU <M/T> connector or C-124
13B-33
NO : Repair.

Connector: B-103
Connector: B-103
C-103 (B)
C-103 (B)
3 2 1
3 2 1
Harness side
connector
AK304038AB
C-142 (GR)

C-142 (GR)
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

AK304038AB
Use special tool test harness (MB991348) to

connect connector and measure at pick-up
harness.
Ignition switch: ON
OK: 4.9 5.1 V
Connector: C-142
959493
Harness side
connector

13B-34
TROUBLESHOOTING

connector

Connector: B-103
Connector: C-142
C-103 (B)
C-142 (GR)
3 2 1
Harness side
connector

connect connector, and measure at pick-up
harness.
Ignition switch: ON
OK:
Altitude 0m: 3.7 4.3 V
Altitude 1,200m: 3.2 3.8 V
Altitude 1,800m: 2.9 3.5 V

C-142 (GR)
959493
AK304038AB
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-103


connector
C-103 (B)
Connector: C-142
3 2 1
Harness side
connector

AK304038AB

(terminal No. 3) manifold absolute pressure

NO : Repair.
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
13B-35
TROUBLESHOOTING
NO : Repair.
YES : Replace manifold absolute pressure sensor.

NO : Repair.

<A/T> connector.

<A/T> connector.
Connector: C-142
Connector: B-103
C-103 (B)
C-142 (GR)
3 2 1
Harness side
connector
AK304038AB
C-142 (GR)
Connector: C-142
959493
C-142 (GR)
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

Ignition switch: ON
OK:
Altitude 1,200m: 3.2 3.8 V
Altitude 1,800m: 2.9 3.5 V

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB


13B-36
TROUBLESHOOTING

connector

connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-103
AK304153 AB
Connector: B-103
C-103 (B)
C-103 (B)
3 2 1
Harness side
connector
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
3 2 1
AK304038AB

YES : Check and repair check harness between
B-103 (terminal No. 1) manifold absolute

(terminal No. 101) engine-ECU <M/T>
connector or engine-A/T-ECU <A/T>
connector.
damage.
NO : Repair.
Harness side
connector

NO : Repair.
AK304038AB
13B-37
TROUBLESHOOTING
Code No. P0110: Intake Air Temperature Sensor System
Intake air temperature sensor circuit
B-08
1

(Integrated in air flow sensor)
2 3 4
4
BR
11
J/C/ (1)
C-16
Y-L
6
BR
96
99
C-142
(MU803805)
9192
939495
96979899100 101102103 104
5V
105106
107108109
110111112
113114
115116117
118119120
Engine-ECU <M/T>
Wire colour code
AK304120AB
OPERATION
A power voltage of 5 V is applied to the intake air
temperature sensor output terminal (terminal No.
engine-ECU <M/T> or engine-A/T-ECU <A/T>
(terminal No. 99).
<M/T> or engine-A/T-ECU (terminal No. 96) from
the air flow sensor (terminal No. 4).
FUNCTION
The intake air temperature sensor converts the
intake air temperature into a voltage and inputs
the voltage signal to the engine-ECU <M/T> or
or engine-A/T-ECU <A/T> corrects the fuel
injection amount, etc.
The intake air temperature sensor is a kind of

resistor, which has characteristics to reduce its
resistance as the intake air temperature rises.
Therefore, the sensor output voltage varies with
the intake air temperature, and becomes lower as
the intake air temperature rises.
TROUBLE JUDGMENT
Check Conditions
Judgment Criteria
The sensor output voltage is 4.6V or more (intake
air temperature of below -45C or equivalent) for
4 seconds.
Or
13B-38
TROUBLESHOOTING
The sensor output voltage is 0.2V or less (intake

air temperature of above 125C or equivalent) for
4 seconds.

Connector: B-08
PROBABLE CAUSE
Open/short circuit in intake air temperature
B-08 (B)
4 3 2 1
DIAGNOSIS PROCEDURE
Harness
side connector

00 How to Use
P.00-6).
NO : Go to Step 2 .
AK303649 AB

side.
OK: 2 or less
NO : Go to Step 5 .

connector
Connector: C-142

connector
Connector: B-08
C-142 (GR)
B-08 (B)

4 3 2 1
Harness
side connector
C-142 (GR)
AK303649 AB

NO : Repair.
STEP 3. Check intake air temperature sensor

itself.
Check intake air temperature sensor itself (Refer
to P.13B-430).
NO : Replace air flow sensor.
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-39
TROUBLESHOOTING

Connector: B-08
B-08 (B)
NO : Repair.

a. Item No. 13: Intake air temperature sensor
4 3 2 1
Harness
side connector
AK303649 AB
00 How to Use
P.00-6).
Connector: C-142

Connector: B-08
C-142 (GR)
B-08 (B)

C-142 (GR)
4 3 2 1
Harness
side connector
959493

side.
Ignition switch: ON
OK: 4.5 4.9 V
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

AK303649 AB

YES : Replace engine-ECU <M/T> or
NO : Go to Step 9 .
13B-40
TROUBLESHOOTING

<A/T> connector.

connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-08
B-08 (B)
4 3 2 1
4 3 2 1
AK303649 AB

Disconnect B-08 air flow sensor connector.
Ignition switch: ON
OK: 4.5 4.9 V
AK304153 AB
Connector: B-08
B-08 (B)
Harness
side connector
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
Harness
side connector
AK303649 AB


connector.
NO : Repair.
13B-41
TROUBLESHOOTING

connector
Connector: C-142

Connector: B-08
B-08 (B)
C-142 (GR)
4 3 2 1
Harness
side connector
C-142 (GR)
AK303649 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-42
TROUBLESHOOTING

air flow sensor connector.
Connector: B-08

connector
Connector: C-142
B-08 (B)
C-142 (GR)
4 3 2 1
Harness
side connector
AK303649 AB

connect only terminal No. 1 and No. 4, and then
Ignition switch: ON
OK:
Ambient temperature at 20C: 3.8 4.4 V

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.

TROUBLESHOOTING

Connector: B-08
B-08 (B)
4 3 2 1
Harness
side connector
AK303649 AB
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-43
13B-44
TROUBLESHOOTING
Code No. P0115: Engine Coolant Temperature Sensor System
Engine coolant temperature sensor circuit
B-108
(MU802406)
Engine coolant
temperature sensor
1 2
2
BR
Y-G
96
98
C-142
(MU803805)
Engine-ECU <M/T>
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
5V
Wire colour code

AK304121AB
OPERATION
A power voltage of 5 V is applied to the engine
coolant temperature sensor output terminal
(terminal No. 1) from the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (terminal No. 98).
96) from the engine coolant temperature sensor
(terminal No. 2).
FUNCTION
The engine coolant temperature sensor converts
the engine coolant temperature into a voltage
signal, and inputs the voltage to the engine-ECU
or engine-A/T-ECU <A/T> controls the fuel
infection amount and the fast idle speed when the
engine is cold state.
The engine coolant temperature sensor is a kind

of resistor, which has characteristics to reduce its
resistance as the engine coolant temperature
rises. Therefore, the sensor output voltage varies
with the engine coolant temperature, and
becomes lower as the engine coolant
temperature rises.
TROUBLE JUDGMENT
Check Conditions
in "ON" position or just after the engine has
started up.
Judgment Criteria
The sensor output voltage is 4.6V or more (water
temperature of below -45C or equivalent) for 4
seconds.
Or
13B-45
TROUBLESHOOTING
The sensor output voltage is 0.1V or less (water

temperature of above 140C or equivalent) for 4
seconds.
Check Conditions
Judgment Criteria
The sensor output voltage rises 1.6V or more
(engine coolant temperature below 40C or
equivalent) from 1.6V or less (engine coolant
temperature above 40C or equivalent).
PROBABLE CAUSE
Open/short circuit in engine coolant temperature
DIAGNOSIS PROCEDURE
OK:
Engine hot state: At 80 120C
00 How to Use
P.00-6).
NO : Go to Step 2 .
STEP 2. Connector check: B-108 engine coolant
temperature sensor connector
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK304156 AB
NO : Repair.
STEP 3. Perform resistance measurement at

B-108 engine coolant temperature sensor
connector.
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK304156 AB

side.
OK:
Engine coolant temperature at 20C: 14 17
k
Engine coolant temperature at 0C: 5.1 6.5
k
k
k
Engine coolant temperature at 60C: 0.48
0.68 k
Engine coolant temperature at 80C: 0.26
0.36 k
NO : Replace engine coolant temperature
sensor.
13B-46
TROUBLESHOOTING

engine coolant temperature sensor connector.
Connector: B-108
2 1
Harness side
connector

<A/T> connector.
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK304156 AB

side.
OK: 2 or less
NO : Go to Step 5 .
B-108 (B)
AK304156 AB
Connector: C-142
C-142 (GR)

connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
AK304153 AB
C-142 (GR)

NO : Repair.
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
NO : Repair.
13B-47
TROUBLESHOOTING

OK:
Engine hot state: At 80 120 C

<A/T> connector.
Connector: C-142

00 How to Use
P.00-6).
C-142 (GR)

C-142 (GR)

Connector: B-108
2 1
Harness side
connector
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
B-108 (B)
Connector: B-108
2 1
Harness side
connector
AK304156 AB

side.
Ignition switch: ON
OK: 4.5 4.9 V
NO : Go to Step 9 .
B-108 (B)
AK304156 AB

Disconnect B-108 engine coolant temperature
sensor.
Ignition switch: ON
OK: 4.5 4.9 V
13B-48
TROUBLESHOOTING

connector
Connector: C-142
C-142 (GR)
(terminal No. 1) engine coolant temperature

NO : Repair.
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

C-142 (GR)

AK304153 AB
Connector: B-108
2 1
Harness side
connector
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
B-108 (B)
AK304156 AB

NO : Repair.
13B-49
TROUBLESHOOTING

<A/T> connector
NO : Repair.

Connector: B-108
Connector: B-108
2 1
2 1
Harness side
connector
Harness side
connector
B-108 (B)
B-108 (B)
AK304156 AB
AK304156 AB
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113


AK304153 AB


harness.
Ignition switch: ON
OK:
V
Engine coolant temperature at 0C: 3.2 3.8 V
V
V
V
V
13B-50
TROUBLESHOOTING

connector
Connector: C-142

<A/T> connector.
Connector: B-108
2 1
Harness side
connector
C-142 (GR)
B-108 (B)

C-142 (GR)
AK304156 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-51
TROUBLESHOOTING
Code No. P0122: Throttle Position Sensor (Main) Circuit Low Input
Throttle position sensor (main) circuit
(main)
Hall IC
B-06
Electronically
controlled
throttle valve
1 2 3 4 5 6
B
106
115
105
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
5V
Engine-ECU <M/T>
Wire colour code

AK304122 AB
OPERATION
A power voltage of 5 V is applied to the
electronically controlled throttle valve (terminal
No. 5) from the engine-ECU <M/T> or
Engine-A/T-ECU <A/T> (terminal No. 106).
105) from the electronically controlled throttle
valve output terminal (terminal No. 4).
FUNCTION
The throttle position sensor converts the throttle
valve position into voltage and inputs it into the
Engine-ECU <M/T> or Engine-A/T-ECU <A/T>.

<A/T> controls the throttle valve position.
TROUBLE JUDGMENT
Check Conditions
Ignition switch is in "ON" position.
Judgment Criteria
Throttle position sensor (main) output voltage is
0.35 V or less for 0.5 second.
PROBABLE CAUSE
Failed throttle position sensor (main)
Open/short circuit in throttle position sensor
13B-52
TROUBLESHOOTING
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
a. Item 79: Throttle position sensor (main)
00 How to Use
P.00-6).
NO : Go to Step 2 .

connector
Connector: C-142
C-142 (GR)
STEP 2. Connector check: B-06 electronically

controlled throttle valve connector
Connector: B-06
C-142 (GR)
B-06 (B)
6 5 4 3 2 1
AK304259 AB
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

NO : Repair.
AK304153 AB

electronically controlled throttle valve connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1
AK304259 AB

side.
Ignition switch: ON
OK: 4.9 5.1 V

NO : Repair.
13B-53
TROUBLESHOOTING

No. 5) electronically controlled throttle valve
connector.

00 How to Use
P.00-6).
Connector: B-06
B-06 (B)
6 5 4 3 2 1
AK304259 AB

connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)

C-142 (GR)
C-142 (GR)
959493
92 91
103102 101100 99 98 97 96
104
112111110
120119118
109108107
117116115
106105
114113
AK304153 AB
AK304153 AB

NO : Repair.
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
959493

NO : Repair.
13B-54
TROUBLESHOOTING

<A/T> connector.
Connector: B-06

<A/T> connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Connector: C-142
Connector: C-142
AK304259 AB
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
AK304153 AB

damage.
NO : Repair.
STEP 10. Replace the electronically controlled

throttle valve
After replacing the electronically controlled
throttle valve, re-check the trouble symptoms.
YES : Check end.
13B-55
TROUBLESHOOTING
Code No. P0123: Throttle Position Sensor (Main) Circuit High Input
Throttle position sensor (main) circuit
(main)
Hall IC
B-06
Electronically
controlled
throttle valve
1 2 3 4 5 6
B
106
115
105
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
5V
Engine-ECU <M/T>
Wire colour code

AK304122 AB
OPERATION
FUNCTION

TROUBLE JUDGMENT
Check Conditions
Judgment Criteria
4.8 V or more for 0.5 second.
PROBABLE CAUSE
Failed throttle position sensor (main)
13B-56
TROUBLESHOOTING
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
00 How to Use
P.00-6).
NO : Go to Step 2 .

connector
Connector: C-142
C-142 (GR)

Connector: B-06
C-142 (GR)
B-06 (B)
6 5 4 3 2 1
AK304259 AB
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

NO : Repair.
AK304153 AB
STEP 3. Perform resistance measurement at B-06

Connector: B-06
B-06 (B)
6 5 4 3 2 1
AK304259 AB

side.
OK: 2 or less

NO : Repair.

TROUBLESHOOTING

<A/T> connector.
Connector: B-06
13B-57
NO : Repair.

B-06 (B)
00 How to Use
P.00-6).
6 5 4 3 2 1
AK304259 AB
Connector: C-142
C-142 (GR)

throttle valve
YES : Check end.
NO : Replace the engine-ECU <M/T> or

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

Code No. P0125: Feedback System Monitor

OPERATION
Refer to Code No. P0201 No. 1 Injector System
P.13B-125.
P.13B-130.
P.13B-135.

P.13B-140.
Refer to Code No. P0130 Cylinder 1, 4 Oxygen
Sensor (Front) Circuit P.13B-64.
Refer to P0150 Cylinder 2, 3 Oxygen Sensor
(Front) Circuit P.13B-70.
13B-58

TROUBLESHOOTING
FUNCTION
The engine-ECU <M/T> or engine-A/T-ECU
<A/T> effects air-fuel ratio feedback control in
accordance with the signals from the oxygen
sensor (front).
If the oxygen sensor (front) has deteriorated,
corrections will be made by the oxygen sensor
(rear).
Diagnosis code P0125 becomes stored in
memory if a failure is detected in the above
air/fuel ratio feedback control system.
TROUBLE JUDGMENT
Check Conditions
The engine coolant temperature approximately.
82C or more.
Within the range of air-fuel ratio feedback
operation.
Not in low speed operation.
Judgment Criteria
The oxygen sensor output voltage is not deviated
from 0.5 V for 30 seconds.
PROBABLE CAUSE
Harness damage in oxygen sensor (front) circuit
NOTE: When the oxygen sensor (front) begins to
deteriorate, the oxygen sensor output voltage will
deviate from the voltage when the sensor was new
(normally 0.5 volt at stoichiometric ratio). This
deviation will be corrected by the oxygen sensor
(rear).If the oxygen sensor (rear) responds poorly
because it has deteriorated, it will improperly correct
the oxygen sensor (front). Thus, even when closed
loop control is being effected, the fluctuation of the
oxygen sensor (front) output voltage decreases,
without intersecting with 0.5 volt. As a result, there is
a possibility of diagnosis code P0125 becoming
registered.
Failed fuel system
Failed exhaust system
DIAGNOSIS PROCEDURE
STEP 1. MUT-II/III diagnosis code
Q: Is any other diagnosis code than P0170 or P0173
output?
to P.13B-20).
NO : Go to Step 2 .
STEP 2.MUT-II/III data list

c. Item 59: Cylinder 1, 4 oxygen sensor (front)
d. Item 69: Cylinder 2, 3 oxygen sensor (rear)

Chart for Diagnosis Code P.13B-20).
STEP 3: MUT-II/III data list
STEP 4.Check for intake of air from intake hose
and inlet manifold.
NO : Repair.

NO : Repair.
STEP 6.Check throttle body (throttle valve

(Refer to P.13B-425).
13B-59
TROUBLESHOOTING
STEP 7. Connector check: B-39 cylinder 1, 4

oxygen sensor (front) connector, C-142
<A/T> connector.
Connector: B-39
NO : Replace cylinder 1, 4 oxygen sensor (front).

No. 4) cylinder 1, 4 oxygen sensor (front)
<A/T> connector.
Connector: B-39
1
3
B-39 (GR)
sensor (front)
AK304260 AB
2
Connector: C-142
B-39 (GR)
sensor (front)
AK304260 AB
1
3
Connector: C-142
C-142 (GR)
C-142 (GR)
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
STEP8. Check cylinder 1, 4 oxygen sensor (front)

itself.
Check cylinder 1, 4 oxygen sensor (front) itself
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-60
TROUBLESHOOTING

oxygen sensor (front) connector, C-142
<A/T> connector.

Connector: B-112
sensor (front)
2
4
1
3
Harness
side connector
B-112 (GR)
AK304264 AB
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
STEP 11. Check cylinder 2, 3 oxygen sensor

(front) itself.
13B-61
TROUBLESHOOTING

<A/T> connector.

Connectors: B-01, B-02, B-04, B-05
B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR)
Connector: B-112
2 1
Harness
side connector
sensor (front)
a.
b.
c.
d.
AK304261 AB


NO : Repair.
2
4

Check Injector itself (Refer to P.13B-435).
1
3
Harness
side connector
B-112 (GR)
AK304264 AB
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.

13B-62
TROUBLESHOOTING

relay connector and C-139 engine-ECU <M/T>
connector or engine-A/T-ECU <A/T> connector.

Connector: B-17X
Connector: B-17X
B-17X
B-17X
Relay boxs
triangle marks
Relay boxs
triangle marks
Harness
side connector
Harness
side connector
AK304152 AB
AK304152 AB

Connector: C-139
B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR)
C-139 (GR)
2 1
Harness
side connector
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Repair.
AK304261 AB

NO : Repair.

TROUBLESHOOTING

B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR)
NO : Repair.
STEP 18. Fuel pressure measurement.

Fuel pressure measurement (Refer to
P.13B-426).
YES : Repair.
M
2 1
Harness
side connector
AK304261 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

13B-63
13B-64
TROUBLESHOOTING
Code No. P0130: Cylinder 1, 4 Oxygen Sensor (Front) System
Cylinder 1, 4 oxygen sensor circuit (front)
B-39
MU802665
1
3
sensor (front)
2
4
2
R
4
G
To engine-ECU <M/T>
To engine-A/T-ECM <A/T>
B
7
9
J/C (2)
C-17
J/C (1)
C-16
BR
96
109
Engine-ECU <M/T>
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
Wire colour code

AK304123 AC
OPERATION
109) from the cylinder 1, 4 oxygen sensor (front)
The cylinder 1, 4 oxygen sensor (front) (terminal
No. 2) is earthed with engine-ECU <M/T> or
FUNCTION
The cylinder 1, 4 oxygen sensor (front) converts
the concentration of oxygen in the exhaust
emission into a voltage and inputs the signal to
the engine-ECU <M/T> or engine-A/T-ECU
<A/T>.
When the air-fuel ratio is richer than the
theoretical air-fuel ratio, the cylinder 1, 4 oxygen
sensor (front) outputs a voltage of about 1 V.
When it is leaner than the theoretical air-fuel
ratio, it outputs a voltage of about 0 V.
13B-65
TROUBLESHOOTING

infection amount so that the air-fuel ratio can be
equivalent to the theoretical air-fuel ratio.
TROUBLE JUDGMENT
Check Conditions
started up.
The engine coolant temperature is approx. 82C
or higher.
Judgment Criteria
When the cylinder 1, 4 oxygen sensor (front)
output voltage is 0.2 V or less and a power
voltage of 5 V is applied to the cylinder 1, 4
oxygen sensor (front) in the engine-ECU <M/T>
or engine-A/T-ECU <A/T>, the sensor output
voltage is 4.5V or more.
To be monitored once per driving cycle.
Check Conditions
The engine speed is 1200 3000 r/min.
or higher.
Volumetric efficiency is 20 60 %.
During the air-fuel ratio feedback control
00 How to Use
P.00-6).
NO : Go to Step 2 .
oxygen sensor (front) connector
Connector: B-39
1
3
B-39 (GR)
sensor (front)
AK304260 AB

NO : Repair.

cylinder 1, 4 oxygen sensor (front) connector.
Connector: B-39
Judgment Criteria
output frequency is 6 or less for 10 seconds on
the average.
2
PROBABLE CAUSE
Failed cylinder 1, 4 oxygen sensor (front)
Open/short circuit in cylinder 1, 4 oxygen sensor
(front) circuit or loose connector contact
DIAGNOSIS PROCEDURE
a. Item 11: Cylinder 1, 4 oxygen sensor (front)
1
3
B-39 (GR)
sensor (front)
AK304260 AB

side.
OK: 2 or less
NO : Go to Step 4 .
13B-66
TROUBLESHOOTING

connector
Connector: C-142

<A/T> connector.
Connector: B-39
C-142 (GR)
2
C-142 (GR)
1
3
B-39 (GR)
sensor (front)
AK304260 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-67
TROUBLESHOOTING

00 How to Use
P.00-6).

connector
Connector: C-142
C-142 (GR)

C-142 (GR)
Connector: B-39
959493
1
3
B-39 (GR)
sensor (front)
AK304260 AB

harness.
Transmission: Neutral <M/T> or P range <A/T>.
OK:
When the engine is 2,500 r/min, the output
voltage should repeat 0 to 0.8 V alternately.
NO : Go to Step 8 .

(front) itself.
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-39
1
3
B-39 (GR)
sensor (front)
AK304260 AB

(terminal No. 4) Cylinder 1, 4 oxygen sensor

(front) connector and C-142 (terminal No.
NO : Repair.
13B-68
TROUBLESHOOTING

<A/T> connector.

connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

Transmission: Neutral <M/T> or P range <A/T>
OK:
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
AK304153 AB
Connector: B-39
1
3
B-39 (GR)
sensor (front)
AK304260 AB


engine-ECU <M/T> connector or
NO : Repair.

TROUBLESHOOTING

connector
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-69
13B-70
TROUBLESHOOTING
Code No. P0135: Cylinder 1, 4 Oxygen Sensor (Front) Heater System
Cylinder 1, 4 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4
Cylinder 1, 4 oxygen sensor (front)
B-17X
1
B-39
MU802665
Engine
control
relay
1
1
3
2
1
2
4
To engine-ECU <M/T>
P-L
25
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304124AC
13B-71
TROUBLESHOOTING
OPERATION
(terminal No. 1) of the Cylinder 1, 4 oxygen
sensor (front) connector from the engine control
The heater (terminal No. 3) of the Cylinder 1, 4
oxygen sensor (front) connector is controlled by
the power transistor in the engine-ECU <M/T> or
FUNCTION
The power supply to the cylinder 1, 4 oxygen
sensor (front) heater is controlled by the ON/OFF
control of the power transistor in the engine-ECU
Heating the cylinder 1, 4 oxygen sensor (front)
heater enables the cylinder 1, 4 oxygen sensor
(front) to provide good response even when the
exhaust emission temperature is low.
TROUBLE JUDGMENT
Check Conditions
60 seconds have elapsed since the previous
monitoring started.
Engine coolant temperature is 20C or higher.
While cylinder 1, 4 oxygen sensor (front) heater is
on.
Battery positive voltage is 11 16 V.
Judgment Criteria
Cylinder 1, 4 oxygen sensor (front) heater current
has continued to be 0.16 A or lower, or 7.5 A or
higher for 4 seconds.
PROBABLE CAUSE
Failed cylinder 1, 4 oxygen sensor (front) heater
DIAGNOSIS PROCEDURE
Connector: B-39
1
3
B-39 (GR)
sensor (front)
AK304260 AB

NO : Repair.

Connector: B-39
1
3
B-39 (GR)
sensor (front)
AK304260 AB

side.
OK: 4.5 8.0
13B-72
TROUBLESHOOTING

Connector: B-39
1
3
B-39 (GR)
sensor (front)
AK304260 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
(terminal No. 1) cylinder 1, 4 oxygen sensor

(front) connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
<A/T> connector.
Connector: C-139
C-139 (GR)

relay connector
C-139 (GR)
Connector: B-17X
B-17X
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
Relay boxs
triangle marks
2
6
15
22

AK304262 AB
Harness
side connector
AK304152 AB
Connector: B-39

Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .
1
3
B-39 (GR)
sensor (front)
AK304260 AB
1
5
14
21
13B-73
TROUBLESHOOTING

connector
Connector: C-139

<A/T> connector.
Connector: B-39
C-139 (GR)
2
1
3
B-39 (GR)
sensor (front)
AK304260 AB
C-139 (GR)
Connector: C-139
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
C-139 (GR)

AK304262 AB

NO : Repair.
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Repair.
13B-74
TROUBLESHOOTING

connector
Connector: C-139

No. 1)cylinder 1, 4 oxygen sensor (front)
Connector: B-39
C-139 (GR)
2
1
3
B-39 (GR)
sensor (front)
AK304260 AB
Connector: B-17X
C-139 (GR)
B-17X
Relay boxs
triangle marks
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Repair.
Harness
side connector
AK304152 AB

NO : Repair.

TROUBLESHOOTING

<A/T> connector.
Connector: B-39
13B-75
NO : Repair.

00 How to Use
P.00-6).
2
1
3
B-39 (GR)
sensor (front)
AK304260 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

13B-76
TROUBLESHOOTING
Code No. P0136: Cylinder 1, 4 Oxygen Sensor (Rear) System
Cylinder 1, 4 oxygen sensor (rear) circuit
B-38
MU802605
sensor (rear)
1 2
3 4
2
BR
4
Y
To engine-ECU <M/T>
B
8
10
J/C (2)
C-17
J/C (1)
C-16
BR
96
117
Engine-ECU <M/T>
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
Wire colour code

AK304125 AC
OPERATION
117) from the cylinder 1, 4 oxygen sensor (rear)
The cylinder 1, 4 oxygen sensor (rear) (terminal
FUNCTION
The cylinder 1, 4 oxygen sensor (rear) converts
<A/T>.
sensor (rear) outputs a voltage of about 1 V.

TROUBLESHOOTING
Based on this signal, the Engine-ECU <M/T> or

Engine-A/T-ECU <A/T> corrects the deviation in
the signal that is output by the cylinder 1, 4
oxygen sensor (rear).
TROUBLE JUDGMENT
13B-77
DIAGNOSIS PROCEDURE
a. Item 59: Cylinder 1, 4 oxygen sensor (rear)
Check Conditions
started up.
or higher.

Judgment Criteria
When the cylinder 1, 4 oxygen sensor (rear)
output voltage is 0.2V or less and a power
voltage of 5V is applied to the cylinder 1, 4
oxygen sensor (rear) in the engine-ECU <M/T>

oxygen sensor (rear) connector
Check Conditions
2 seconds later after lack of circuit continuity is
detected.
When the front oxygen sensor is normally
operated.
Judgment Criteria
When the air-fuel ratio is rich, the cylinder 1, 4
oxygen sensor (front) output voltage is 0.5 V or
more.
The cylinder 1, 4 oxygen sensor (rear) output
voltage is less than 0.1 V.
The maximum and maximum of the cylinder 1, 4
oxygen sensor (rear) output is 0.078 V or less.
PROBABLE CAUSE
Failed cylinder 1, 4 oxygen sensor (rear)
(rear) circuit or loose connector contact
00 How to Use
P.00-6).
NO : Go to Step 2 .
Connector: B-38
sensor (rear)
2 1
4 3
B-38 (B)
Harness
side connector

NO : Repair.
AK304263 AB
13B-78

TROUBLESHOOTING

cylinder 1, 4 oxygen sensor (rear) connector.
Connector: B-38
NO : Go to Step 4 .

connector
Connector: C-142
sensor (rear)
C-142 (GR)

C-142 (GR)
2 1
4 3
B-38 (B)
Harness
side connector
AK304263 AB

side.
OK: 2 or less
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.

TROUBLESHOOTING

No. 2) cylinder 1, 4 oxygen sensor (rear)
<A/T> connector.
Connector: B-38
13B-79
NO : Repair.

00 How to Use
P.00-6).
sensor (rear)

Connector: B-38
sensor (rear)
2 1
4 3
B-38 (B)
Harness
side connector
AK304263 AB
Connector: C-142
C-142 (GR)
2 1
4 3
B-38 (B)
Harness
side connector

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

Check earthing line for open circuit.
AK304263 AB
Use special tool test harness (MD998464) to

harness.
OK:
voltage should repeat 0 to 0.8 V alternately
NO : Go to Step 8 .
13B-80

TROUBLESHOOTING
STEP 8. Check Cylinder 1, 4 oxygen sensor (rear)

itself.
Check cylinder 1, 4 oxygen sensor (rear) itself
NO : Replace cylinder 1, 4 oxygen (rear) sensor.

connector
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-38
sensor (rear)
2 1
4 3
B-38 (B)
Harness
side connector
AK304263 AB
13B-81
TROUBLESHOOTING

(rear) connector and C-142 (terminal No.
NO : Repair.

connector
Connector: C-142

<A/T> connector.
C-142 (GR)
Connector: B-38
C-142 (GR)
sensor (rear)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-38
2 1
4 3
B-38 (B)
Harness
side connector
sensor (rear)
AK304263 AB

OK:
2 1
4 3
B-38 (B)
Harness
side connector
AK304263 AB
13B-82

TROUBLESHOOTING

NO : Repair.

connector
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-83
TROUBLESHOOTING
Code No. P0141: Cylinder 1, 4 Oxygen Sensor (Rear) Heater System
Cylinder 1,4 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4
Cylinder 1, 4 oxygen sensor (rear)
B-17X
1
B-38
MU802605
Engine
control
relay
1
1 2
3 4
2
1
To engine-ECU <M/T>
V-W
24
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304126 AC
13B-84

TROUBLESHOOTING
OPERATION
(terminal No. 1) of the cylinder 1, 4 oxygen
sensor (rear) connector from the engine control
The heater (terminal No. 3) of the cylinder 1, 4
oxygen sensor (rear) connector is controlled by
FUNCTION
sensor (rear) heater is controlled by the ON/OFF
Heating the cylinder 1, 4 oxygen sensor (rear)
(rear) to provide good response even when the

DIAGNOSIS PROCEDURE
Connector: B-38
sensor (rear)
TROUBLE JUDGMENT
Check Conditions
monitoring started.
While cylinder 1, 4 oxygen sensor (rear) heater is
on.
Judgment Criteria
Cylinder 1, 4 oxygen sensor (rear) heater
currents have continued to be 0.16 A or lower, or
5.0 A or higher for 4 seconds.
PROBABLE CAUSE
Failed cylinder 1, 4 oxygen sensor (rear) heater
2 1
4 3
B-38 (B)
Harness
side connector

NO : Repair.
AK304263 AB

TROUBLESHOOTING


Connector: B-38
Connector: B-38
sensor (rear)
sensor (rear)
2 1
4 3
2 1
4 3
B-38 (B)
Harness
side connector
AK304263 AB

side.
OK: 11 18
NO : Replace cylinder 1, 4 oxygen sensor (rear).
13B-85
B-38 (B)
Harness
side connector
AK304263 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13B-86
TROUBLESHOOTING

relay connector
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector

(rear) connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
<A/T> connector.
AK304152 AB
Connector: C-139
Connector: B-38
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2 1
4 3
2
6
15
22
1
5
14
21

AK304262 AB
B-38 (B)
Harness
side connector
AK304263 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .
13B-87
TROUBLESHOOTING

connector
Connector: C-139

<A/T> connector.
Connector: B-38
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Repair.
2 1
4 3
B-38 (B)
Harness
side connector
AK304263 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Repair.
13B-88
TROUBLESHOOTING

connector
Connector: C-139

Connector: B-38
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
2 1
4 3

AK304262 AB

NO : Repair.
B-38 (B)
Harness
side connector
AK304263 AB
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB

NO : Repair.

TROUBLESHOOTING

<A/T> connector.
Connector: B-38
13B-89
NO : Repair.

00 How to Use
P.00-6).
sensor (rear)
2 1
4 3
B-38 (B)
Harness
side connector
AK304263 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

13B-90
TROUBLESHOOTING
Code No. P0150: Cylinder 2, 3 Oxygen Sensor (Front) System
Cylinder 2, 3 oxygen sensor (front) circuit
B-112
MU802665
1
3
sensor (front)
2
4
To engine-ECU <M/T>
B
2
7
J/C (2)
C-17
J/C (1)
C-16
BR
96
108
Engine-ECU <M/T>
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
Wire colour code

AK304123 AB
OPERATION
108) from the cylinder 2, 3 oxygen sensor (front)
The front cylinder 2, 3 oxygen sensor (front)

(terminal No. 2) is earthed with engine-ECU
96).

TROUBLESHOOTING
FUNCTION
The cylinder 2, 3 oxygen sensor (front) converts
<A/T>.
sensor (front) outputs a voltage of about 1 V.
infection amount so that the air-fuel ratio can be
equivalent to the theoretical air-fuel ratio.
TROUBLE JUDGMENT
Check Conditions
started up.
or higher.
Judgment Criteria
voltage of 5 V is applied to the cylinder 2, 3
oxygen sensor (front) in the engine-ECU <M/T>
13B-91
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
00 How to Use
P.00-6).
NO : Go to Step 2 .
Connector: B-112
sensor (front)
Check Conditions
The engine speed is 1200 3000 r/min.
or higher.
Volumetric efficiency is 20 60 %.
During the air-fuel ratio feedback control.
Judgment Criteria
output frequency is 6 or less for 10 seconds on
the average
2
4
1
3
Harness
side connector
B-112 (GR)

NO : Repair.
AK304264 AB
13B-92
TROUBLESHOOTING

Connector: B-112
NO : Go to Step 4 .

connector
Connector: C-142
sensor (front)
C-142 (GR)

C-142 (GR)
2
4
1
3
Harness
side connector
B-112 (GR)
AK304264 AB

side.
OK: 2 or less
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.

TROUBLESHOOTING

<A/T> connector.
Connector: B-112
13B-93
NO : Repair.

00 How to Use
P.00-6).
sensor (front)

Connector: B-112
2
4
1
3
sensor (front)
Harness
side connector
B-112 (GR)
AK304264 AB
Connector: C-142
C-142 (GR)
2
4
Harness
side connector
C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

1
3
B-112 (GR)
AK304264 AB

harness.
OK:
NO : Go to Step 8 .
13B-94

TROUBLESHOOTING

(front) itself

connector
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-112
sensor (front)
2
4
1
3
Harness
side connector
B-112 (GR)
AK304264 AB
13B-95
TROUBLESHOOTING

NO : Repair.

connector
Connector: C-142

<A/T> connector.
C-142 (GR)
Connector: C-142
C-142 (GR)
C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

C-142 (GR)

AK304153 AB
Connector: B-112
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
sensor (front)

OK:
2
4
1
3
Harness
side connector
B-112 (GR)
AK304264 AB
13B-96

TROUBLESHOOTING

NO : Repair.

connector
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-97
TROUBLESHOOTING
Code No. P0155: Cylinder 2, 3 Oxygen Sensor (Front) Heater System
Cylinder 2, 3 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4
Cylinder 2, 3 oxygen sensor (front)
B-17X
1
B-112
MU802665
Engine
control
relay
1
1
3
2
1
2
4
To engine-ECU <M/T>
Y-R
10
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304124 AB
OPERATION
sensor (front) connector from the engine control

oxygen sensor (front) connector is controlled by
13B-98

TROUBLESHOOTING
FUNCTION
sensor (front) heater is controlled by the ON/OFF
Heating the cylinder 2, 3 oxygen sensor (front)
(front) to provide good response even when the
DIAGNOSIS PROCEDURE
Connector: B-112
TROUBLE JUDGMENT
Check Conditions
monitoring started.
While cylinder 2, 3 oxygen sensor (front) heater is
on.
Judgment Criteria
Cylinder 2, 3 oxygen sensor (front) heater
currents has continued to be 0.16 A or lower, or
PROBABLE CAUSE
Failed oxygen sensor heater
sensor (front)
2
4
1
3
Harness
side connector
B-112 (GR)

NO : Repair.
AK304264 AB

TROUBLESHOOTING

B-112 cylinder 2, 3 oxygen sensor (front)
connector.
13B-99

Connector: B-112
Connector: B-112
sensor (front)
sensor (front)
2
2
4
1
3
Harness
side connector
1
3
Harness
side connector
B-112 (GR)
AK304264 AB

side.
OK: 4.5 8.0
B-112 (GR)
AK304264 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13B-100
TROUBLESHOOTING

relay connector
Connector: B-17X
B-17X
Relay boxs
triangle marks

(front) connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
<A/T>.
Harness
side connector
AK304152 AB
Connector: C-139
Connector: B-112
C-139 (GR)
sensor (front)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
4
1
5
14
21
1
3
Harness
side connector
2
6
15
22
AK304262 AB
B-112 (GR)
AK304264 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .
13B-101
TROUBLESHOOTING

connector
Connector: C-139

<A/T> connector.
Connector: B-112
C-139 (GR)
sensor (front)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
2
AK304262 AB

NO : Repair.
1
3
Harness
side connector
B-112 (GR)
AK304264 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Repair.
13B-102
TROUBLESHOOTING

connector
Connector: C-139

Connector: B-112
C-139 (GR)
sensor (front)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
4
AK304262 AB

NO : Repair.
1
3
Harness
side connector
B-112 (GR)
AK304264 AB
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB

NO : Repair.

TROUBLESHOOTING

<A/T> connector.
Connector: B-112
13B-103
NO : Repair.

00 How to Use
P.00-6).
sensor (front)
2
4
1
3
Harness
side connector
B-112 (GR)
AK304264 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

13B-104
TROUBLESHOOTING
Cylinder 2, 3 oxygen sensor (rear) circuit
B-38
MU802605
sensor (rear)
1 2
3 4
2
P
4
Y
To engine-ECU <M/T>
B
3
10
J/C (2)
C-17
J/C (1)
C-16
BR
96
116
Engine-ECU <M/T>
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
Wire colour code

AK304125 AB
OPERATION
116) from the cylinder 2, 3 oxygen sensor (rear)
The cylinder 2, 3 oxygen sensor (rear) (terminal
FUNCTION
The cylinder 2, 3 oxygen sensor (rear) converts
<A/T>.
sensor (rear) outputs a voltage of about 1 V.
13B-105
TROUBLESHOOTING
Based on this signal, the Engine-ECU <M/T> or

Engine-A/T-ECU <A/T> corrects the deviation in
the signal that is output by the cylinder 2, 3
oxygen sensor (front).
TROUBLE JUDGMENT
DIAGNOSIS PROCEDURE
Check Conditions
started up.
or higher.

Judgment Criteria
When the cylinder 2, 3 oxygen sensor (rear)
voltage of 5V is applied to the cylinder 2, 3
oxygen sensor (rear) in the engine-ECU <M/T>

00 How to Use
P.00-6).
NO : Go to Step 2 .
Connector: B-113
Check Conditions
2 seconds later after lack of circuit continuity is
detected.
When the cylinder 2, 3 oxygen sensor (rear) is
normally operated.
Judgment Criteria
When the air-fuel ratio is rich, the cylinder 1, 4
oxygen sensor (front) output voltage is 0.5 V or
more.
The cylinder 1, 4 oxygen sensor (rear) output
voltage is less than 0.1 V.
The maximum and maximum of the cylinder 1, 4
oxygen sensor (rear) output is 0.078 V or less.
PROBABLE CAUSE
sensor (rear)
B-113 (B)
2 1
4 3
Harness
side connector

NO : Repair.
AK304265 AB
13B-106
TROUBLESHOOTING

Connector: B-113
NO : Go to Step 4 .

connector
Connector: C-142
sensor (rear)
C-142 (GR)
B-113 (B)
C-142 (GR)
2 1
4 3
Harness
side connector
AK304265 AB

side.
OK: 2 or less
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-107
TROUBLESHOOTING

<A/T> connector.
Connector: B-113
NO : Repair.

sensor (rear)
00 How to Use
P.00-6).
Connector: B-113
B-113 (B)
2 1
4 3
sensor (rear)
Harness
side connector
AK304265 AB
Connector: C-142
B-113 (B)
C-142 (GR)
2 1
4 3
Harness
side connector
C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

AK304265 AB
Use special tool test harness (MD998464) to

harness.
OK:
NO : Go to Step 8 .
13B-108

TROUBLESHOOTING
STEP 8. Check cylinder 2, 3 oxygen sensor (rear)

itself
Check cylinder 2, 3 oxygen sensor (rear) itself

connector
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-113
sensor (rear)
B-113 (B)
2 1
4 3
Harness
side connector
AK304265 AB
13B-109
TROUBLESHOOTING

NO : Repair.

connector
Connector: C-142

<A/T> connector.
C-142 (GR)
Connector: C-142
C-142 (GR)
C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

C-142 (GR)

AK304153 AB
Connector: B-113
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
sensor (rear)

OK:
B-113 (B)
2 1
4 3
Harness
side connector
AK304265 AB
13B-110

TROUBLESHOOTING

NO : Repair.

connector
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-111
TROUBLESHOOTING
Cylinder 1,4 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4
Cylinder 1, 4 oxygen sensor (rear)
B-17X
1
B-38
MU802605
Engine
control
relay
1
1 2
3 4
2
1
To engine-ECU <M/T>
V-W
24
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304126 AC
OPERATION
sensor (rear) connector from the engine control

oxygen sensor (rear) connector is controlled by
13B-112

TROUBLESHOOTING
FUNCTION
sensor (rear) heater is controlled by the ON/OFF
Heating the cylinder 2, 3 oxygen sensor (rear)
(rear) to provide good response even when the
DIAGNOSIS PROCEDURE
Connector: B-113
TROUBLE JUDGMENT
Check Conditions
monitoring started.
While cylinder 2, 3 oxygen sensor (rear) heater is
on.
Judgment Criteria
Cylinder 2, 3 oxygen sensor (rear) heater
currents have continued to be 0.16 A or lower, or
PROBABLE CAUSE
Failed cylinder 2, 3 oxygen sensor (rear) heater
sensor (rear)
B-113 (B)
2 1
4 3
Harness
side connector

NO : Repair.
AK304265 AB
13B-113
TROUBLESHOOTING

Connector: B-113

Connector: B-113
sensor (rear)
sensor (rear)
B-113 (B)
B-113 (B)
2 1
4 3
Harness
side connector
2 1
4 3
AK304265 AB

side.
OK: 11 18
Harness
side connector
AK304265 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 4 .
13B-114
TROUBLESHOOTING

relay connector
Connector: B-17X
B-17X
Relay boxs
triangle marks

(rear) connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
<A/T>.
Harness
side connector
AK304152 AB
Connector: C-139
Connector: B-113
C-139 (GR)
sensor (rear)
C-139 (GR)
B-113 (B)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
1
5
14
21
2 1
4 3
Harness
side connector
2
6
15
22
AK304262 AB
AK304265 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .
13B-115
TROUBLESHOOTING

connector
Connector: C-139

<A/T> connector.
Connector: B-113
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
B-113 (B)
1
5
14
21

AK304262 AB

NO : Repair.
2 1
4 3
Harness
side connector
AK304265 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Repair.
13B-116
TROUBLESHOOTING

connector
Connector: C-139

Connector: B-113
C-139 (GR)
sensor (rear)
C-139 (GR)
B-113 (B)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
2 1
4 3

AK304262 AB

NO : Repair.
Harness
side connector
AK304265 AB
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB

NO : Repair.

TROUBLESHOOTING

<A/T> connector.
Connector: B-113
13B-117
NO : Repair.

00 How to Use
P.00-6).
sensor (rear)
B-113 (B)
2 1
4 3
Harness
side connector
AK304265 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

13B-118

TROUBLESHOOTING
Code No. P0170: Abnormal Fuel System (Cylinder 1,4)

OPERATION
Refer to Code No. P0201: No. 1 Injector System
P.13B-125.
P.13B-140.
FUNCTION
If the fuel system goes out of order, the fuel
correction valve will become larger.
<A/T> checks whether the fuel trim value is within
a specified range.
TROUBLE JUDGMENT
Check Conditions
In learning the air-fuel ratio.
Judgment Criteria
Long-term fuel trim has continued to be +12.5 %
or higher for 10 seconds.
Or
Long-term fuel trim has continued to be -12.5 %
PROBABLE CAUSE
Failed injector
Air drawn in from gaps in gasket, seals, etc.
Failed manifold absolute pressure sensor
Exhaust leak
Incorrect fuel pressure
DIAGNOSIS PROCEDURE
to P.13B-20).
NO : Go to Step 2 .

d. Item 95: Manifold absolute pressure sensor

and inlet manifold.
NO : Repair.

NO : Repair.
13B-119
TROUBLESHOOTING

Connectors: B-01, B-05
B-01 (GR)

connector or engine-A/T-ECU <A/T> connector
B-05 (GR)
Connector: B-17X
B-17X
Relay boxs
triangle marks
2 1
Harness
side connector
AK304261 AG
a. B-01 (No. 1 injector connector).

b. B-05 (No. 4 injector connector).
NO : Replace.
Harness
side connector
AK304152 AB
Connector: C-139

C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Replace.
13B-120
TROUBLESHOOTING

B-05 (GR)
B-01 (GR)

connector and C-139 engine-ECU <M/T>
B-05 (GR)
B-01 (GR)
2 1
Harness
side connector
AK304261 AG
2 1
Harness
side connector
AK304261 AG
Connector: B-17X
Connector: C-139
B-17X
Relay boxs
triangle marks
Harness
side connector
C-139 (GR)
AK304152 AB

NO : Replace.
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Replace.

TROUBLESHOOTING

itself.
to GROUP 17 Emission Control System
Evaporative Emission Control System Purge
Control Solenoid Valve P.17-20).
13B-121

P.13B-426).
NO : Repair.

Code No. P0173: Abnormal Fuel System (cylinder 2, 3)

OPERATION
P.13B-130.
P.13B-135.
FUNCTION
If the fuel system goes out of order, the fuel
correction valve will become larger.
<A/T> checks whether the fuel trim value is within
a specified range.
TROUBLE JUDGMENT
Check Conditions
In learning the air-fuel ratio.
DIAGNOSIS PROCEDURE
to P.13B-20).
NO : Go to Step 2 .

d. Item 95: Manifold absolute sensor
Judgment Criteria
Long-term fuel trim has continued to be +12.5 %
Or
Long-term fuel trim has continued to be -12.5 %

PROBABLE CAUSE
Failed injector
Air drawn in from gaps in gasket, seals, etc.
Failed manifold absolute pressure sensor
Exhaust leak
Incorrect fuel pressure



13B-122
TROUBLESHOOTING

and inlet manifold.
NO : Repair.

Connector: B-17X
B-17X

NO : Repair.
Relay boxs
triangle marks
Harness
side connector
AK304152 AB

Connector: B-113

B-02 (GR) B-04 (GR)
sensor (rear)
2 1
Harness
side connector
AK304261 AH
a. B-02 (No. 2 injector connector).

b. B-04 (No. 3 injector connector).
B-113 (B)

NO : Replace.

2 1
4 3
Harness
side connector

NO : Replace.
AK304265 AB
13B-123
TROUBLESHOOTING


connector and C-139 engine-ECU <M/T>
B-02 (GR) B-04 (GR)
B-02 (GR) B-04 (GR)
2 1
Harness
side connector
AK304261 AH
2 1
Harness
side connector
AK304261 AH
Connector: B-17X
Connector: C-139
B-17X
Relay boxs
triangle marks
Harness
side connector
C-139 (GR)
AK304152 AB

NO : Replace.
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Replace.
13B-124

TROUBLESHOOTING

itself.
Control Solenoid Valve P.17-20).

P.13B-426).
NO : Repair.
13B-125
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
Engine
control
relay
2
1
R
R
Injector
No. 1
R
1
Injector
No. 2
R
1
Injector
No. 3
R
1
Injector
No. 4
B-01
B-02
B-04
B-05
1 2
1 2
1 2
1 2
W-G
R-W
R-B
14
21
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code
AK304127 AB
13B-126

TROUBLESHOOTING
OPERATION
<A/T> (terminal No. 1) makes the power
transistor in the unit be in "ON" position, and that
makes currents go on the injector (terminal No.
2).
FUNCTION
<A/T> controls the power supply interval of the
injector.
TROUBLE JUDGMENT
Check Conditions
While engine is running.
Judgment Criteria
Injector coil surge voltage (battery positive
voltage + 2 V) has not been detected for 2
seconds.
PROBABLE CAUSE
Open/short circuit in injector circuit or loose
connector contact

connector
Connector: B-01
B-01 (GR)
2 1
Harness
side connector
AK304261 AC

NO : Repair.
STEP 3. Check No. 1 injector itself.

Check No. 1 Injector itself (Refer to P.13B-435).

No. 1 injector connector.
Connector: B-01
B-01 (GR)
DIAGNOSIS PROCEDURE
STEP 1. MUT-II/III actuator test
Refer to Actuator Test Reference Table List
P.13B-410.
00 How to Use
P.00-6).
NO : Go to Step 2 .
2 1
Harness
side connector
AK304261 AC

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13B-127
TROUBLESHOOTING

relay connector
Connector: B-17X

relay connector
Connector: B-17X
B-17X
B-17X
Relay boxs
triangle marks
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
AK304152 AB

NO : Repair.
Connector: B-01
B-01 (GR)

2 1
Harness
side connector
Harness
side connector
Connector: B-17X
B-17X
AK304261 AC


injector connector.
open/short circuit.
NO : Repair.
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: B-01
B-01 (GR)
2 1
Harness
side connector
AK304261 AC

NO : Repair.
13B-128
TROUBLESHOOTING

connector
Connector: C-139

Connector: B-01
B-01 (GR)
C-139 (GR)
2 1
Harness
side connector
AK304261 AC
Connector: C-139
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
C-139 (GR)

AK304262 AB

NO : Repair.
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

damage.
NO : Repair.

TROUBLESHOOTING
STEP 10. Perform signal wave pattern

measurement at C-139 engine-ECU <M/T>
(Using an oscilloscope).
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB
Engine: Idling
OK: Waveforms should be display on
13B-129
00 How to Use
P.00-6).
13B-130
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
Engine
control
relay
2
1
R
R
Injector
No. 1
R
1
Injector
No. 2
R
1
Injector
No. 3
R
1
Injector
No. 4
B-01
B-02
B-04
B-05
1 2
1 2
1 2
1 2
W-G
R-W
R-B
14
21
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code
AK304127 AB

TROUBLESHOOTING
OPERATION
<A/T> connector (terminal No. 5) makes the
and that makes currents go on the injector
(terminal No. 2).
FUNCTION
injector.
TROUBLE JUDGMENT
Check Conditions
Judgment Criteria
seconds.
PROBABLE CAUSE
connector contact
13B-131

connector
Connector: B-02
B-02 (GR)
2 1
Harness
side connector
AK304261 AD

NO : Repair.


Connector: B-02
B-02 (GR)
DIAGNOSIS PROCEDURE
P.13B-410.
00 How to Use
P.00-6).
NO : Go to Step 2 .
2 1
Harness
side connector
AK304261 AD

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13B-132
TROUBLESHOOTING

relay connector
Connector: B-17X

relay connector
Connector: B-17X
B-17X
B-17X
Relay boxs
triangle marks
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
AK304152 AB

NO : Repair.
Connector: B-02
B-02 (GR)

2 1
Harness
side connector
Harness
side connector
Connector: B-17X
B-17X
AK304261 AD


injector connector.
NO : Repair.
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: B-02
B-02 (GR)
2 1
Harness
side connector
AK304261 AD

NO : Repair.
13B-133
TROUBLESHOOTING

connector
Connector: C-139

Connector: B-02
B-02 (GR)
C-139 (GR)
2 1
Harness
side connector
AK304261 AD
Connector: C-139
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
C-139 (GR)

AK304262 AB

NO : Repair.
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

damage.
NO : Repair.
13B-134
TROUBLESHOOTING

Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB
Engine: Idling
OK: Waveform should be display on
00 How to Use
P.00-6).
13B-135
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
Engine
control
relay
2
1
R
R
Injector
No. 1
R
1
Injector
No. 2
R
1
Injector
No. 3
R
1
Injector
No. 4
B-01
B-02
B-04
B-05
1 2
1 2
1 2
1 2
W-G
R-W
R-B
14
21
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code
AK304127 AB
13B-136

TROUBLESHOOTING
OPERATION
2).
FUNCTION
injector.
TROUBLE JUDGMENT
Check Conditions
Judgment Criteria
seconds.
PROBABLE CAUSE
connector contact
Failed engine-ECU<M/T>
Failed engine-A/T-ECU<A/T>

connector
Connector: B-04
B-04 GR)
2 1
Harness
side connector
AK304261 AE

NO : Repair.


Connector: B-04
B-04 GR)
DIAGNOSIS PROCEDURE
Refer to Actuator test reference table list
P.13B-410.
00 How to Use
P.00-6).
NO : Go to Step 2 .
2 1
Harness
side connector
AK304261 AE

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13B-137
TROUBLESHOOTING

relay connector
Connector: B-17X

relay connector
Connector: B-17X
B-17X
B-17X
Relay boxs
triangle marks
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
AK304152 AB

NO : Repair.
Connector: B-04
B-04 GR)

2 1
Harness
side connector
Harness
side connector
Connector: B-17X
B-17X
AK304261 AE


injector connector.
open/short circuit.
NO : Repair.
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: B-04
B-04 GR)
2 1
Harness
side connector
AK304261 AE

NO : Repair.
13B-138
TROUBLESHOOTING

connector
Connector: C-139

Connector: B-04
B-04 GR)
C-139 (GR)
2 1
Harness
side connector
AK304261 AE
Connector: C-139
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
C-139 (GR)

AK304262 AB

NO : Repair.
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

damage.
NO : Repair.

TROUBLESHOOTING

(Using on oscilloscope).
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB
Engine: Idling
13B-139
00 How to Use
P.00-6).
13B-140
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
3
4
B-17X
1
Engine
control
relay
2
1
R
R
Injector
No. 1
R
1
Injector
No. 2
R
1
Injector
No. 3
R
1
Injector
No. 4
B-01
B-02
B-04
B-05
1 2
1 2
1 2
1 2
W-G
R-W
R-B
14
21
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code
AK304127 AB

TROUBLESHOOTING
OPERATION
2).
FUNCTION
<A/T> connector controls the power supply
interval of the injector.
TROUBLE JUDGMENT
Check Conditions
Judgment Criteria
seconds.
PROBABLE CAUSE
connector contact
13B-141

connector
Connector: B-05
B-05 (GR)
2 1
Harness
side connector
AK304261 AF

NO : Repair.

Check No. 4 Injector (Refer to P.13B-435) itself.

Connector: B-05
B-05 (GR)
DIAGNOSIS PROCEDURE
P.13B-410.
00 How to Use
P.00-6).
NO : Go to Step 2 .
2 1
Harness
side connector
AK304261 AF

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
13B-142
TROUBLESHOOTING

relay connector
Connector: B-17X

relay connector
Connector: B-17X
B-17X
B-17X
Relay boxs
triangle marks
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: B-05
B-05 (GR)
AK304152 AB

YES : Go to Step 7.
NO : Repair.

2 1
Harness
side connector
Harness
side connector
Connector: B-17X
B-17X
AK304261 AF


injector connector.
NO : Repair.
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: B-05
B-05 (GR)
2 1
Harness
side connector
AK304261 AF

NO : Repair.
13B-143
TROUBLESHOOTING

connector
Connector: C-139

Connector: B-05
B-05 (GR)
C-139 (GR)
2 1
Harness
side connector
AK304261 AF
Connector: C-139
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21
C-139 (GR)

AK304262 AB

NO : Repair.
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

damage.
NO : Repair.
13B-144
TROUBLESHOOTING

Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB
Engine: Idling
00 How to Use
P.00-6).
13B-145
TROUBLESHOOTING
Code No. P0222: Throttle Position Sensor (Sub) Circuit Low Input
Throttle position sensor (sub) circuit
(sub)
Hall IC
B-06
Electronically
controlled
throttle valve
1 2 3 4 5 6
B
106
113
105
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
5V
Engine-ECU <M/T>
Wire colour code

AK304122AC
OPERATION
FUNCTION

TROUBLE JUDGMENT
Check Conditions
Judgment Criteria
Throttle position sensor (sub) output voltage is
2.25 V or less for 0.5 second.
PROBABLE CAUSE
Failed throttle position sensor (sub)
Open/short circuit in throttle position sensor (sub)
13B-146
TROUBLESHOOTING
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
a. Item 14: Throttle position sensor (sub)
00 How to Use
P.00-6).
NO : Go to Step 2 .

connector
Connector: C-142
C-142 (GR)

Connector: B-06
C-142 (GR)
B-06 (B)
6 5 4 3 2 1
AK304259 AB
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

NO : Repair.
AK304153 AB

Connector: B-06
B-06 (B)
6 5 4 3 2 1
AK304259 AB

side.
Ignition switch: ON
OK: 4.9 5.1 V

NO : Repair.
13B-147
TROUBLESHOOTING

<A/T> connector.

00 How to Use
P.00-6).
Connector: B-06
B-06 (B)
6 5 4 3 2 1
AK304259 AB

connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)

C-142 (GR)
C-142 (GR)
959493
92 91
103102 101100 99 98 97 96
104
112111110
120119118
109108107
117116115
106105
114113
AK304153 AB
AK304153 AB

NO : Repair.
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
959493

NO : Repair.
13B-148
TROUBLESHOOTING

<A/T> connector.
Connector: B-06

<A/T> connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Connector: C-142
Connector: C-142
AK304259 AB
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
AK304153 AB

damage.
NO : Repair.

throttle valve
YES : Check end.
13B-149
TROUBLESHOOTING
Code No. P0223: Throttle Position Sensor (Sub) Circuit High Input
Throttle position sensor (sub) circuit
(sub)
Hall IC
B-06
Electronically
controlled
throttle valve
1 2 3 4 5 6
B
106
113
105
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
5V
Engine-ECU <M/T>
Wire colour code

AK304122AC
OPERATION
FUNCTION

TROUBLE JUDGMENT
Check Conditions
Judgment Criteria
4.8 V or more for 0.5 second.
PROBABLE CAUSE
Failed throttle position sensor (sub)
Open/short circuit in throttle position sensor (sub)
13B-150
TROUBLESHOOTING
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
00 How to Use
P.00-6).
NO : Go to Step 2 .

connector
Connector: C-142
C-142 (GR)

Connector: B-06
C-142 (GR)
B-06 (B)
6 5 4 3 2 1
AK304259 AB
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

NO : Repair.
AK304153 AB

Connector: B-06
B-06 (B)
6 5 4 3 2 1
AK304259 AB

side.
OK: 2 or less

NO : Repair.

TROUBLESHOOTING

<A/T> connector.
Connector: B-06
13B-151
NO : Repair.

B-06 (B)
00 How to Use
P.00-6).
6 5 4 3 2 1
AK304259 AB
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB


throttle valve
YES : Check end.
13B-152

TROUBLESHOOTING
Code No. P0300: Random/Multiple Cylinder Misfire Detected

OPERATION
Refer to Code No. P0201: No. 1 injector system
P.13B-125.
P.13B-130.
P.13B-135.
P.13B-140.
FUNCTION
<A/T> checks for such changes in engine speed.
TROUBLE JUDGMENT
Check Conditions
Engine speed is 500 6,500 r/min.
Barometric pressure is 76 kPa or higher.
Volumetric efficiency is between 30% and 55 %.
Adaptive learning is complete for the vane which
generates a crankshaft position signal.
While the engine is running, excluding gear
shifting, deceleration, sudden
acceleration/deceleration and A/C compressor
switching.
The throttle deviation is 0.06 V/10 ms to +0.06
V/10 ms.
Judgment Criteria (change in the angular
acceleration of the crankshaft is used for
misfire detection).
Misfire has occurred more frequently than the
limit during the last 200 revolutions (when the
catalyst temperature has been 950C or higher).
Or
Misfire has occurred 15 times or more in the last
1,000 revolutions (that has been equivalent to
approximately 1.5 times the emission standard).
PROBABLE CAUSE
Incorrect air-fuel ratio
Skipping of timing belt teeth.
EGR system and EGR valve failed
DIAGNOSIS PROCEDURE
Item 22: Crank angle sensor
OK: Keep the engine speed constant to make
the pulse width of output waveform
constant.
Code No. P0335 P.13B-169).

b. Item 81: Long-term fuel compensation
c. Item 82: Short-term fuel compensation

Inspection Procedure 31 P.13B-386).

TROUBLESHOOTING
13B-153
NO : Repair.

B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR)

and inlet manifold.
NO : Repair.
2 1
Harness
side connector
a.
b.
c.
d.
STEP 8. Check for skipped timing belt teeth.

AK304261 AB
B-01 (No. 1 injector connector)


NO : Repair.

NO : Repair.
STEP 9. Check EGR valve (stepper motor) itself.

Check EGR valve (stepper motor) itself [Refer to
GROUP 17 Exhaust Gas Recirculation (EGR)
System EGR Valve (Stepper Motor) Check
<4G69> P.17-25].


NO : Replace EGR valve (stepper motor)


Fuel pressure measurement (Refer to Fuel
Pressure Test P.13B-426)

00 How to Use
PointsP.00-6).
13B-154

TROUBLESHOOTING
Code No. P0301: No. 1 Cylinder Misfire Detected

OPERATION
P.13B-125.
FUNCTION
TROUBLE JUDGMENT
Check Conditions
switching.
V/10 ms.
misfire detection).
Or
PROBABLE CAUSE

DIAGNOSIS PROCEDURE
Inspection procedure 31 P.13B-386)

STEP 2.Connector check: B-01 No. 1 injector
connector
Connector: B-01
B-01 (GR)
2 1
Harness
side connector
AK304261 AC

NO : Repair.
STEP 3.Check No. 1 injector itself.

13B-155
TROUBLESHOOTING

NO : Repair.

Connector: B-17X
B-17X
Relay boxs
triangle marks
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: C-139
Harness
side connector
AK304152 AB
Connector: B-01
C-139 (GR)
B-01 (GR)
2 1
Harness
side connector
C-139 (GR)
AK304261 AC
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22

NO : Repair.
1
5
14
21

AK304262 AB
13B-156
TROUBLESHOOTING
STEP 6. Check harness between B-01(terminal

engine-A/T-ECU <A/T> connector
Connector: B-01
B-01 (GR)
NO : Repair.

Fuel pressure measurement (Refer to fuel
pressure test P.13B-426).
YES : Go to Step 8
NO : Repair.
2 1
Harness
side connector
AK304261 AC
Connector: C-139
00 How to Use
P.00-6).
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23

2
6
15
22
1
5
14
21

AK304262 AB

13B-157
TROUBLESHOOTING

OPERATION
P.13B-130.
FUNCTION
TROUBLE JUDGMENT
Check Conditions
switching.
V/10 ms.
misfire detection).
Or
PROBABLE CAUSE

DIAGNOSIS PROCEDURE

STEP 2. Check connector: B-02 No. 2 injector
connector
Connector: B-02
B-02 (GR)
2 1
Harness
side connector
AK304261 AD

NO : Repair.

13B-158
TROUBLESHOOTING

NO : Repair.

No. 1) engine control relay connector and
B-02(terminal No. 1) No. 2 injector connector.
Connector: B-17X
B-17X
Relay boxs
triangle marks
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: C-139
Harness
side connector
AK304152 AB
Connector: B-02
B-02 (GR)
C-139 (GR)
2 1
Harness
side connector
C-139 (GR)
AK304261 AD
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22

NO : Repair.
1
5
14
21

AK304262 AB

TROUBLESHOOTING

Connector: B-02
B-02 (GR)
13B-159
NO : Repair.

pressure test P.13B-426)
NO : Repair.
2 1
Harness
side connector
AK304261 AD
Connector: C-139
00 How to Use
P.00-6).
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23

2
6
15
22
1
5
14
21

AK304262 AB

13B-160

TROUBLESHOOTING

OPERATION
P.13B-135.

Failed engine-A/T-ECU
FUNCTION
DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT
Check Conditions
switching.
V/10 ms.
misfire detection).
Or
PROBABLE CAUSE


connector
Connector: B-04
B-04 GR)
2 1
Harness
side connector
AK304261 AE

NO : Repair.

13B-161
TROUBLESHOOTING

NO : Repair.

Connector: B-17X
B-17X
Relay boxs
triangle marks
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: C-139
Harness
side connector
AK304152 AB
Connector: B-04
B-04 GR)
C-139 (GR)
2 1
Harness
side connector
C-139 (GR)
AK304261 AE
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22

NO : Repair.
1
5
14
21

AK304262 AB
13B-162
TROUBLESHOOTING

Connector: B-04
B-04 GR)
NO : Repair.

pressure test P.13B-426)
NO : Repair.
2 1
Harness
side connector
AK304261 AE
Connector: C-139
00 How to Use
P.00-6).
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23

2
6
15
22
1
5
14
21

AK304262 AB


TROUBLESHOOTING
13B-163

OPERATION
P.13B-140.
FUNCTION
TROUBLE JUDGMENT
Check Conditions
switching.
V/10 ms.
misfire detection).
Or
PROBABLE CAUSE

DIAGNOSIS PROCEDURE
STEP 1. Check the ignition coil spark.

connector
Connector: B-05
B-05 (GR)
2 1
Harness
side connector
AK304261 AF

NO : Repair.

13B-164
TROUBLESHOOTING

NO : Repair.

Connector: B-17X
B-17X
Relay boxs
triangle marks
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: C-139
Harness
side connector
AK304152 AB
Connector: B-05
B-05 (GR)
C-139 (GR)
2 1
Harness
side connector
C-139 (GR)
AK304261 AF
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22

NO : Repair.
1
5
14
21

AK304262 AB

TROUBLESHOOTING

Connector: B-05
B-05 (GR)
13B-165
NO : Repair.

Fuel pressure measurement (Refer to Fuel
Pressure Test P.13B-426)
NO : Repair.
2 1
Harness
side connector
AK304261 AF
Connector: C-139
00 How to Use
PointsP.00-6).
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23

2
6
15
22
1
5
14
21

AK304262 AB

13B-166

TROUBLESHOOTING
Code No. P0325: Detonation Sensor System
Detonation sensor circuit
C-141
(MU803804)
Engine-ECU <M/T>
6162
6364
656667686970717273
747576777879808182
8384 858687 8889
89
W
B
B-102
MU802661
2
1 2
Detonation sensor
Wire colour code

AK304128 AB
OPERATION
89) from the detonation sensor (terminal No. 1).
FUNCTION
The detonation sensor detects the vibration of the
cylinder block caused by detonation waves, and
inputs a signal to the engine-ECU <M/T> or
or engine-A/T-ECU <A/T> provides controls to
retard the ignition timing when the detonation
occurs.
TROUBLE JUDGMENT
Check Conditions
After 2 seconds have passed since the engine
starting sequence was completed.
Engine speed is 2,500 r/min or higher.
Judgment Criteria
Change of detonation sensor output voltage
(detonation sensor peak voltage in each 1/2 turn
of the crankshaft) has not been 0.06 V or more in
the last consecutive 200 periods.
PROBABLE CAUSE
Failed detonation sensor
Open/short circuit in detonation sensor circuit or
13B-167
TROUBLESHOOTING

DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-102 detonation
sensor connector
Connector: B-102
(terminal No. 2) detonation sensor

and damage.
Connector: C-141
B-102 (GR)
2 1
C-141(GR)
Detonation sensor
Harness
side connector
AK304266 AB

NO : Repair.

C-141 (GR)

B-102 detonation sensor connector.
Connector: B-102
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
B-102 (GR)
AK304154 AB
2 1
Detonation sensor
Harness
side connector
AK304266 AB

side.
OK: 2 or less

NO : Repair.
13B-168
TROUBLESHOOTING

No. 1) detonation sensor connector and C-141

Connector: B-102
00 How to Use
P.00-6).
B-102 (GR)
2 1
NO : Repair.
Detonation sensor
Harness
side connector
AK304266 AB
STEP 6. Replace detonation sensor.

After replacing the detonation sensor, re-check
Connector: C-141
NO : Check end.
C-141(GR)

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

damage.

TROUBLESHOOTING
13B-169
Code No. P0335: Crank Angle Sensor System
Crank angle sensor circuit

Battery
W-B
W-B
3
4
B-17X
1
Engine
control
relay
1
R
1 B-29
B-29
(MU802064)
1 B-29-1
Crank
angle
sensor
1 2 3
B-29-1
1 2 3
B-W
18
J/C (1)
C-16
G-R
17
B-W
88
70
C-141
(MU803804)
6162
6364
656667686970717273
747576777879808182
8384 858687 8889
5V
Engine-ECU <M/T>
Wire colour code

AK304129 AB
OPERATION
Power is supplied to the crank angle sensor
(terminal No. 1) from the engine control relay
(terminal No. 1) and is earthed to the engine-ECU

88) from the crank angle sensor (terminal No. 3).
13B-170

TROUBLESHOOTING
A power voltage of 5 V is applied to the crank

angle sensor output terminal (terminal No. 2)
from the engine-ECU <M/T> or engine-A/T-ECU
<A/T> (terminal No. 70).
FUNCTION
The crank angle sensor detects the crank angle
(position) and inputs a pulse signal to the
engine-ECU <M/T> or engine-A/T-ECU <A/T>.
or engine-A/T-ECU <A/T> controls the injector,
etc.
STEP 2. Connector check: B-29 crank angle

sensor intermediate connector
Connector: B-29
B-29 (GR)
3 2 1
Harness
side connector
AK304267 AB
TROUBLE JUDGMENT
Check Conditions
While engine is being cranked.
Judgment Criteria
Crank angle sensor output voltage has not been
changed (no pulse signal has been input) for 2
seconds.

NO : Repair.

crank angle sensor intermediate connector.
Connector: B-29
PROBABLE CAUSE
Open/short circuit in crank angle sensor circuit or
DIAGNOSIS PROCEDURE
00 How to Use
P.00-6).
NO : Go to Step 2 .
B-29 (GR)
3 2 1
Harness
side connector
AK304267 AB

side.
Ignition switch: ON
OK: 4.9 5.1 V
NO : Go to Step 4 .
13B-171
TROUBLESHOOTING

Connector: C-141

connector
Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR)

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
AK304154 AB
Connector: B-29
Connector: B-29
B-29 (GR)
B-29 (GR)
3 2 1
Harness
side connector
3 2 1
AK304267 AB

Disconnect B-29 crank angle sensor intermediate
connector.
Ignition switch: ON
OK: 4.9 5.1 V
NO : Go to Step 6 .
Harness
side connector
AK304267 AB


intermediate connector and C-141 (terminal
No. 70) engine-ECU <M/T> connector or
NO : Repair.
13B-172
TROUBLESHOOTING

connector
Connector: C-141

No. 2) crank angle sensor intermediate connector
and C-141 (terminal No. 70) engine-ECU <M/T>
Connector: B-29
B-29 (GR)
C-141(GR)
3 2 1
Harness
side connector

C-141 (GR)
AK304267 AB
Connector: C-141
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
C-141(GR)

AK304154 AB

NO : Repair.

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

NO : Repair.

00 How to Use
P.00-6).
13B-173
TROUBLESHOOTING

crank angle sensor intermediate connector.
Connector: B-29

intermediate connector and B-17X (terminal
open/short circuit.
NO : Repair.
B-29 (GR)

B-29 crank angle sensor intermediate connector.
3 2 1
Connector: B-29
Harness
side connector
AK304267 AB

side.
Ignition switch: ON
OK: System voltage
Connector: B-17X
Relay boxs
triangle marks
Harness
side connector
AK304152 AB
Connector: B-29
B-29 (GR)
3 2 1
Harness
side connector
AK304267 AB
AK304267 AB

side.
OK: 2 or less
B-17X
3 2 1
Harness
side connector

relay connector
B-29 (GR)
13B-174
TROUBLESHOOTING

connector
Connector: C-141

Connector: B-29
B-29 (GR)
C-141(GR)
3 2 1
Harness
side connector

C-141 (GR)
AK304267 AB
Connector: C-141
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
C-141(GR)

AK304154 AB

NO : Repair.

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

NO : Repair.
13B-175
TROUBLESHOOTING
STEP 14. Perform output wave pattern

measurement at B-29 crank angle sensor
intermediate connector (Using an oscilloscope).
NO : Repair.

connector.
Connector: B-29
Connector: B-29
B-29 (GR)
3 2 1
B-29 (GR)
Harness
side connector
AK304267 AB

harness.
Engine: Idling
(Refer to P.13B-418), its maximum value
waveform.
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
Connector: B-17X
B-17X
Relay boxs
triangle marks
3
AK304152 AB

relay connector
AK304267 AB
Harness
side connector

3 2 1
Harness
side connector
AK304152 AB

NO : Repair.
13B-176
TROUBLESHOOTING

<M/T> connectors or engine-A/T-ECU <A/T>
connector
Connector: C-141

Connector: B-29
B-29 (GR)
C-141(GR)
3 2 1
Harness
side connector

C-141 (GR)
AK304267 AB
Connector: C-141
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
C-141(GR)

AK304154 AB

NO : Repair.

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

NO : Repair.
13B-177
TROUBLESHOOTING

STEP 20. Connector check: B-29-1 crank angle

sensor connector
Connector: B-29-1
Connector: B-29
B-29-1 (B)
B-29 (GR)
3 2 1
Harness
side connector
3 2 1
Harness
side connector
AK304267 AB
Connector: C-141
AK304268 AB

NO : Repair.
STEP 21. Check harness between B-29 crank

angle sensor intermediate connector and B-29-1
crank angle sensor connector.
C-141(GR)
Connector: B-29

C-141 (GR)
B-29 (GR)
3 2 1
Harness
side connector
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304267 AB
Connector: B-29-1

AK304154 AB

NO : Repair.
B-29-1 (B)
3 2 1
Harness
side connector
AK304268 AB
Check power supply line open/short circuit and

damage.
Check output line open/short circuit and damage.
Check earthing line for open/short circuit and
damage.
NO : Replace the timing belt cover.
13B-178

TROUBLESHOOTING
STEP 22. Check the crankshaft sensing blade.

NO : Replace the crankshaft sensing blade.

00 How to Use
P.00-6).
NO : Replace crank angle sensor.

TROUBLESHOOTING
13B-179
Code No. P0340: Camshaft Position Sensor System
Camshaft position sensor circuit
Battery
W-B
W-B
3
4
B-17X
1
Engine
control
relay
1
R
B-106
MU802337
Camshaft
position
sensor
1 2 3
2
1
B-W
19
J/C (1)
C-16
L-Y
17
B-W
88
71
C-141
(MU803804)
6162
6364
656667686970717273
747576777879808182
8384 858687 8889
5V
Engine-ECU <M/T>
Wire colour code

AK304130 AB
13B-180
TROUBLESHOOTING
OPERATION
Power is supplied to the camshaft position sensor
(terminal No. 3) from the engine control relay
(terminal No. 1) and is earthed to the engine-ECU
88) from the camshaft position sensor (terminal
No. 1).
A power voltage of 5 V is applied to the camshaft
position sensor output terminal (terminal No. 2)
FUNCTION
The camshaft position sensor detects the top
dead center on the compression stroke of the No.
1 cylinder and inputs a pulse signal to the
engine-ECU <M/T> or engine-A/T-ECU <A/T>.
TROUBLE JUDGMENT
Check Conditions
Engine speed is 50 r/min or higher.
NO : Repair.

camshaft position sensor connector.
Connector: B-106
B-106 (B)
3 2 1
Harness
side connector
AK304269 AB

side.
Ignition switch: ON
OK: System voltage
Judgment Criteria
Camshaft position sensor output voltage has not
been changed (no pulse signal is has been input)
for 2 seconds.

NO : Go to Step 3 .
PROBABLE CAUSE
Open/short circuit in camshaft position sensor

relay connector
Connector: B-17X
B-17X
Relay boxs
triangle marks
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-106 camshaft
position sensor connector
Harness
side connector
AK304152 AB
Connector: B-106
Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
3 2 1
Harness
side connector
Harness
side connector
AK304269 AB
AK304269 AB

13B-181
TROUBLESHOOTING

open/short circuit.
NO : Repair.

<A/T> connector.
Connector: C-141

camshaft position sensor connector.
C-141(GR)
Connector: B-106
C-141 (GR)
B-106 (B)
3 2 1
Harness
side connector
AK304269 AB

side.
Ignition switch: ON
OK: 4.9 5.1 V
NO : Go to Step 5 .
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB
Connector: B-106
B-106 (B)
3 2 1
Harness
side connector
AK304269 AB

Disconnect B-106 camshaft position sensor
connector.
Ignition switch: ON
OK: 4.9 5.1 V
NO : Go to Step 7 .
13B-182
TROUBLESHOOTING

connector
Connector: C-141
C-141(GR)

NO : Repair.
connector
Connector: C-141

C-141 (GR)
C-141(GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

C-141 (GR)

AK304154 AB
Connector: B-106
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
B-106 (B)

3 2 1
Harness
side connector
AK304269 AB
AK304154 AB

NO : Repair.
13B-183
TROUBLESHOOTING

C-141 (terminal No. 71) engine-ECU <M/T>

B-106 camshaft position sensor connector.
Connector: B-106
Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
Harness
side connector
3 2 1
Harness
side connector
AK304269 AB
Connector: C-141
AK304269 AB

side.
OK: 2 or less

C-141(GR)

connector

C-141 (GR)
Connector: C-141
C-141(GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

C-141 (GR)

NO : Repair.

00 How to Use
P.00-6).
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

NO : Repair.
13B-184
TROUBLESHOOTING

STEP 13. Perform output wave pattern

measurement at B-106 camshaft position sensor
connector (Using an oscilloscope).
Connector: B-106
Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
3 2 1
Harness
side connector
Harness
side connector
AK304269 AB
Connector: C-141
C-141(GR)

C-141 (GR)
AK304269 AB

harness.
Engine: Idling
(Refer to P.13B-418), its maximum value
waveform.

relay connector.
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
Connector: B-17X
B-17X
AK304154 AB

NO : Repair.
Relay boxs
triangle marks
Harness
side connector

NO : Repair.
AK304152 AB
13B-185
TROUBLESHOOTING

connector.
Connector: B-106

<M/T> connectors or engine-A/T-ECU <A/T>
connector
Connector: C-141
B-106 (B)
C-141(GR)
3 2 1
Harness
side connector
AK304269 AB

C-141 (GR)
Connector: B-17X
B-17X
Relay boxs
triangle marks
Harness
side connector
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB
AK304152 AB

NO : Repair.

NO : Repair.
13B-186
TROUBLESHOOTING

Connector: B-106

Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
3 2 1
Harness
side connector
Harness
side connector
AK304269 AB
AK304269 AB
Connector: C-141
Connector: C-141
C-141(GR)

C-141 (GR)
C-141(GR)

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

NO : Repair.
AK304154 AB

NO : Repair.

TROUBLESHOOTING

cylinder.
13B-187

YES : Replace camshaft position sensor.
00 How to Use
P.00-6).
13B-188
TROUBLESHOOTING
Code No. P0403: Exhaust Gas Recirculation Control System
EGR valve circuit

Battery
W-B
W-B
4
B-17X
1
Engine
control
relay
2
1
R
R
2
B-105
(MU802056)
Exhaust gas
recirculation
(EGR) valve
1 2 3
4 5 6
1
L-B
L-Y
12
L-R
19
26
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304131AB

TROUBLESHOOTING
OPERATION
Power is supplied to the EGR valve (terminal No.
2 and No. 5) from the engine control relay
(terminal No. 1).
<A/T> (terminal No. 3, No. 12, No. 19 and No. 26)
makes the power transistor in the unit be in "ON",
and that makes currents go on the EGR valve
(terminal No. 1, No. 3, No. 4 and No. 6).
FUNCTION
Based on the signal from engine-ECU <M/T> or
engine-A/T-ECU <A/T>, the EGR valve (stepper
motor) controls the EGR rate.
TROUBLE JUDGMENT
Check Conditions
Battery positive voltage is 10.3 V or higher.
Judgment Criteria
The EGR valve motor coil surge voltage (battery
positive voltage +2 V) is not detected for 3
seconds.
PROBABLE CAUSE
Failed EGR valve
Open/short circuit in EGR valve circuit or loose
connector contact
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-105 EGR valve
connector
Connector: B-105
B-105 (GR)
3 2 1
6 5 4
Harness
side connector
AK304270 AB
13B-189
NO : Repair.

GROUP 17 Emission Control System
Exhaust Gas Recirculation (EGR) System EGR
Valve (stepper motor) Check <4G69> P.17-25.
NO : Replace EGR valve (stepper motor).

EGR valve connector.
Connector: B-105
B-105 (GR)
3 2 1
6 5 4
Harness
side connector
AK304270 AB

side.
Ignition switch: ON
Voltage between terminal No. 2, No. 5 and earth.
OK: System voltage
NO : Go to Step 4 .
13B-190
TROUBLESHOOTING

relay connector
Connector: B-17X

engine-ECU connector or engine-A/T-ECU <A/T>.
Connector: C-139
B-17X
Relay boxs
triangle marks
C-139 (GR)
Harness
side connector
AK304152 AB
Connector: B-105
C-139 (GR)
B-105 (GR)
3 2 1
6 5 4
Harness
side connector
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304270 AB

(terminal No. 2, No. 5) EGR valve connector

and B-17X (terminal No. 1) engine control
relay connector.
open/short circuit.
NO : Repair.
AK304262 AB

side.
Ignition switch: ON
Voltage between terminal No. 3, No. 12, No. 19,
No. 26 and earth.
OK: System voltage
NO : Go to Step 6 .

TROUBLESHOOTING

Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB
Connector: B-105
B-105 (GR)
3 2 1
6 5 4
Harness
side connector
AK304270 AB
13B-191
EGR valve and C-139 engine-ECU <M/T>

connector
a. Check harness between B-105
(terminal No. 1) EGR valve and
<M/T> connector or engine-A/T-ECU
<A/T> connector
b. Check harness between B-105
<A/T> connector
c. Check harness between B-105
<A/T> connector
d. Check harness between B-105
<A/T> connector
open/short circuit.
NO : Repair.
13B-192
TROUBLESHOOTING

connector
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB
NO : Repair.
13B-193
TROUBLESHOOTING
STEP 8. Check harness between B-105 EGR

valve and C-139 engine-ECU <M/T> or
Connector: B-105

NO : Repair.

No. 2, No. 5) EGR valve connector and B-17X
Connector: B-105
B-105 (GR)
3 2 1
6 5 4
Harness
side connector
B-105 (GR)
AK304270 AB
3 2 1
6 5 4
Harness
side connector
Connector: C-139
AK304270 AB
Connector: B-17X
B-17X
C-139 (GR)
Relay boxs
triangle marks
Harness
side connector
C-139 (GR)
AK304152 AB

4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22

1
5
14
21
NO : Repair.

AK304262 AB

EGR valve and C-139 (terminal No. 3)
13B-194

TROUBLESHOOTING
Code No. P0421: Warm Up Catalyst Malfunction (cylinder 1,4)

FUNCTION
The signal from the cylinder 1, 4 oxygen sensor
(rear) differs from the cylinder 1, 4 oxygen sensor
(front). That is because the catalytic converter
purifies exhaust gas. When the catalytic
converter has deteriorated, the signal from the
cylinder 1, 4 oxygen sensor (front) becomes
similar to the cylinder 1, 4 oxygen sensor (rear).
<A/T> compares the output of the cylinder 1, 4
oxygen sensor signals (front and rear).
TROUBLE JUDGMENT
Check Conditions
Engine speed is 3,000 r/min or lower.
The accelerator pedal is open.
Air flow sensor output is 8 gm/s or higher.
3 seconds or more elapsed after the
abovementioned conditions were satisfied.
Intake air temperature is 10C or higher after the
engine is started.
Under the closed loop air/fuel ratio control.
Vehicle speed is 1.5 km/h or higher.
For 10 seconds per cycle, the engine-ECU
<M/T> or engine-A/T-ECU <A/T> monitors 7
cycles of this condition during the drive cycle.
Short-term fuel trim is between 25 % or higher
and +25 % or lower.
The cumulative air flow sensor output is 2,931 g
or higher.
Judgment Criteria
The cylinder 1, 4 oxygen sensor (rear) signal
frequency divided by cylinder 1, 4 oxygen sensor
(front) signal frequency is 0.8 or more.
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
NO : Repair.

b. Item 59: Cylinder 1, 4 oxygen sensor (rear)

OK: 0 0.4 and 0.6 1.0 volt should alternate
NO : Replace the cylinder 1, 4 oxygen sensor
(front).
STEP 4. Replace the cylinder 1, 4 oxygen sensor
(rear).
After replacing the cylinder 1, 4 oxygen sensor
(rear), re-check the trouble symptoms.
YES : Check end.
NO : Go to Step 5 .
STEP 5. Replace the catalytic converter (cylinder

1, 4).
After replacing the catalytic converter (cylinder 1,
4), re-check the trouble symptoms.
YES : Replacing engine-ECU <M/T> or
NO : Check end.

TROUBLESHOOTING
13B-195
Code No. P0431: Warm Up Catalyst Malfunction (Cylinder 2, 3)

FUNCTION
The signal from the cylinder 2, 3 oxygen sensor
(rear) differs from the cylinder 2, 3 oxygen sensor
(front). That is because the catalytic converter
purifies exhaust gas. When the catalytic
converter has deteriorated, the signal from the
cylinder 2, 3 oxygen sensor (front) becomes
similar to the cylinder 2, 3 oxygen sensor (rear).
<A/T> compares the output of the cylinder 2, 3
oxygen sensor signals (front and rear).
TROUBLE JUDGMENT
Check Conditions
Engine speed is 3,000 r/min or lower.
The accelerator pedal is open.
Air flow sensor output is 8 gm/s or higher.
3 seconds or more elapsed after the
abovementioned conditions were satisfied.
Intake air temperature is 10C or higher after the
engine is started.
Under the closed loop air/fuel ratio control.
Vehicle speed is 1.5 km/h or higher.
For 10 seconds per cycle, the engine-ECU
<M/T> engine-A/T-ECU <A/T> monitors 7 cycles
of this condition during the drive cycle.
Short-term fuel trim is between 25 % or higher
and +25 % or lower.
The cumulative air flow sensor output is 2,931 g
or higher.
Judgment Criteria
The cylinder 2, 3 oxygen sensor (rear) signal
frequency divided by cylinder 2, 3 oxygen sensor
(front) signal frequency is 0.8 or more.
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
NO : Repair.

b. Item 69: Cylinder 2, 3 oxygen sensor (rear)

OK: 0 0.4 and 0.6 1.0 volt should alternate
NO : Replace the cylinder 2, 3 oxygen sensor
(front).
STEP 4. Replace the cylinder 2, 3 oxygen sensor
(rear).
After replacing the cylinder 2, 3 oxygen sensor
(rear), re-check the trouble symptoms.
YES : Check end.
NO : Go to Step 5 .
STEP 5. Replace the catalytic converter (cylinder

2, 3).
After replacing the catalytic converter (cylinder 2,
3), re-check the trouble symptoms.
NO : Check end.
13B-196
TROUBLESHOOTING
Code No. P0443: Purge Control Solenoid Valve System

Purge control solenoid valve circuit
Battery
W-B
W-B
4
B-17X
1
Engine
control
relay
1
2
B-101
MU802779
Purge
control
solenoid
valve
1 2
1
BR
23
C-139
(MU803802)
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304132 AB

TROUBLESHOOTING
OPERATION
Power is supplied to the purge control solenoid
makes currents go on the purge control solenoid
13B-197
00 How to Use
P.00-6).
NO : Go to Step 2 .
STEP 2. Connector check: B-101 purge control
Connector: B-101
FUNCTION
In response to a signal from the engine-ECU
<M/T> or engine-A/T-ECU <A/T>, the purge
control solenoid valve controls the flow rate of the
purge air to be introduced into the surge tank.
TROUBLE JUDGMENT
Check Conditions
Battery positive voltage is 10 V or higher.
Judgment Criteria
The surge voltage (system voltage +2 V) of
solenoid coil is not detected when the purge
control solenoid valve is turned in OFF position
from ON.
PROBABLE CAUSE
Open/short circuit in purge control solenoid value
DIAGNOSIS PROCEDURE
2 1
Harness
side connector
AK304271 AB

NO : Repair.
STEP 3: Perform resistance measurement at

B-101 purge control solenoid valve connector.
Connector: B-101
2 1
Harness
side connector

Item 08: Purge control solenoid valve
valve vibrates
B-101 (B)
B-101 (B)
AK304271 AB

valve side.
OK: 30 34 (at 20C)
13B-198
TROUBLESHOOTING

purge control solenoid valve connector.
Connector: B-101
2 1

circuit.
NO : Repair.
<A/T> connector.
B-101 (B)
Harness
side connector
AK304271 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
Connector: C-139
C-139 (GR)

relay connector
C-139 (GR)
Connector: B-17X
B-17X
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
Relay boxs
triangle marks
2
6
15
22

AK304262 AB
Harness
side connector
AK304152 AB
Connector: B-101

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 7 .
2 1
1
5
14
21
B-101 (B)
Harness
side connector
AK304271 AB
13B-199
TROUBLESHOOTING

connector
Connector: C-139
C-139 (GR)

circuit.
NO : Repair.
connector
Connector: C-139

C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB
C-139 (GR)
Connector: B-101
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

2 1
B-101 (B)
Harness
side connector
AK304262 AB
AK304271 AB

NO : Repair.
13B-200
TROUBLESHOOTING

Connector: B-101
2 1

connector.
Connector: B-101
2 1
B-101 (B)
Harness
side connector
AK304271 AB
B-101 (B)
Harness
side connector
AK304271 AB
Connector: B-17X
Connector: C-139
B-17X

Relay boxs
triangle marks
C-139 (GR)
Harness
side connector
AK304152 AB

NO : Repair.
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22

Item 08: purge control solenoid valve
valve vibrates
1
5
14
21

AK304262 AB

NO : Repair.

00 How to Use
P.00-6).
13B-201
TROUBLESHOOTING
Code No. P0500: Vehicle Speed Sensor System <M/T>
Vehicle speed sensor circuit
Ignition switch
Engine-ECU
C-141
(MU803804)
C-303
1 2 3
4 5 6
LOCK
6162
6364
656667686970717273
747576777879808182
8384 858687 8889
ST
ACC
IG1 IG2
2
L-B
86
C-203
6
W-L
2 J/B
7.5A
Meter and gauge
C-202
11
C-105
22
B-W
C-106
3
W-L
B-W
1
B-115
1 2 3
2
B 6
J/C (2)
C-17
B
Wire colour code

O: Orange GR: Gray
AK304535 AB
13B-202

TROUBLESHOOTING
OPERATION
A power voltage of 5 V is applied to the vehicle
speed sensor (terminal No. 3) from the
FUNCTION
The vehicle speed sensor converts the vehicle
speed to the voltage, and then input it into the
engine-ECU
TROUBLE JUDGMENT
Check Conditions
Engine speed: 2,500 r/min or more.
Idle switch: OFF
Under the high load operation.
Judgment Criterion
NO : Check the speedometer (Refer to GROUP
54A Combination Meter Assembly

On-vehicle Service Speedmeter Check
P.54A-68).
a. Item 24: Vehicle speed sensor

Service Points P.00-6).
STEP 3.Check connector: C-141 engine-ECU
connector
Connector: C-141
PROBABLE CAUSE
Failed Vehicle speed sensor
Open/short circuit in vehicle speed sensor circuit
Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1.Check the speedometer
C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304536 AB

NO : Repair.

TROUBLESHOOTING
STEP 4.Check harness between C-141 (terminal

No. 79) engine-ECU connector and B-115
(terminal No. 3) Vehicle speed sensor connector.
13B-203
NO : Repair.
STEP 5.Check the trouble symptoms.
Connector: C-141

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304536 AB
Connector: B-115
C-115 (B)
3 2 1
Harness side
connector
AK304537AB

Check output line for open circuit and damage.

13B-204

TROUBLESHOOTING
DTC P0505: Idle Speed Control (ISC) System

FUNCTION
The amount of air taken in during idling is
regulated by the opening and closing of the
throttle valve.
<A/T> checks the difference between the actual
engine speed and the target engine speed.
TROUBLE JUDGMENT
Check Conditions
at least once.
Judgment Criteria
Judgment Criteria
The actual idle speed is lower than the target idle
speed by 100 r/min or more for 10 seconds.
PROBABLE CAUSE
Throttle valve area is dirty.
Intake system vacuum leak.
STEP 1: MUT-II/III diagnosis code
to P.13B-20.)
NO : Go to Step 2 .
Check Conditions
at least once.
The highest ambient temperature at the last drive
is 45C or less.
or higher.
STEP 2: Check throttle body (throttle valve

Judgment Criteria

NO : Repair.
Check Conditions
During the closed-loop idle speed control
or higher.
The power steering switch is in OFF position.
The charging efficiency is 40 % or less.

inlet manifold.

00 How to Use
P.00-6).

TROUBLESHOOTING
13B-205
Code No. P0513: Immobilizer Malfunction
Immobilizer-ECU circuit
Signal
transmission
circuit
C-304-1
Immobilizer-ECU
1
2
3 4 5 6 7
C-304
(MU801547)
V
11
C-104
V
C-141
(MU803804)
6162
6364
656667686970717273
747576777879808182
8384 858687 8889
65
Engine-ECU <M/T>
Engijne-A/T-ECU <A/T>
Wire colour code

AK304151AB
OPERATION
The signals are sent and received between
(terminal No. 65) and immobilizer-ECU (terminal
No. 7).
FUNCTION
sends or receives the control signals to or from
immobilizer-ECU to certify the ignition key.
NOTE: .
If the registered ignition keys are close each
other when starting the engine, radio
interference may cause this code to be
displayed.
This code may be displayed when registering
the key encrypted code.
TROUBLE JUDGMENT
Check Condition
Judgment Criterion
When the communication error between
and the immobilizer-ECU continues for 2 seconds
or more.
PROBABLE CAUSE
Open/short circuit in immobilizer system circuit or
Failed immobilizer-ECU
13B-206
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1. Connector check: C-304
immobilizer-ECU connector and C-141
<A/T> connector.

No. 3) immobilizer-ECU connector and C-141
Connector: C-304
Connector: C-304
C-304
C-304
1
2
76543
Harness
side connector
1
2
76543
Harness
side connector
AK304272 AB
AK304272 AB
Connector: C-141
Connector: C-141
C-141(GR)
C-141(GR)
C-141 (GR)
C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

AK304154 AB

NO : Repair.

damage.
NO : Repair.

TROUBLESHOOTING
13B-207
STEP 4. After replacing the immobilizer-ECU,

re-check the trouble symptoms.


00 How to Use
P.00-6).
NO : Check end.
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-140
(MU803803)
3132
33
353637383940 41 42
444546474849 50
5253 545556 57
Engine-ECU <M/T>
34
43
51
58
47
Y
B-19
1
Y
B-37
(MU801215)
1
OFF
ON
Power steering fluid

pressure switch
Wire colour code

AK304134 AB
CONDITION
The battery voltage is applied to the power
steering fluid pressure switch (terminal No. 1)
FUNCTION
It is detected whether a load is applied on the
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU <M/T> or
engine-A/T-ECU <A/T>. When the power
steering fluid pressure switch "ON" signal (a large
load on the power steering fluid pump) is
inputted, the engine-ECU <M/T> or
engine-A/T-ECU <A/T> provides the idle-up
control.
13B-208
TROUBLESHOOTING
TROUBLE JUDGMENT
Check Conditions
Drive the vehicle of 50 km/h or more for 4
seconds or more. Stop the vehicle (of 1.5 km/h or
less). Repeat 10 times or more.
NO : Repair.

power steering fluid pressure switch connector.
Connector: B-37
Judgment Criteria
Power steering pressure switch continues to be
in "ON".
PROBABLE CAUSE
Failed power steering fluid pressure switch
Open/short circuit in power steering fluid
pressure switch circuit or loose connector contact
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-37 power steering
fluid pressure switch connector
Connector: B-37
B-37 (B)
1
AK304273 AB
B-37 (B)
1
AK304273 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 3 .
13B-209
TROUBLESHOOTING

<A/T> connector.

connector
Connector: C-140
Connector: C-140
C-140 (GR)
C-140 (GR)
C-140 (GR)
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
AK304274 AB
Connector: B-37
B-37 (B)
1
AK304273 AB

(terminal No. 1) power steering fluid

pressure switch connector and C-140
connector.
NO : Repair.
13B-210
TROUBLESHOOTING

connector
Connector: C-140

<A/T> connector.
Connector: B-37
C-140 (GR)
B-37 (B)
1
C-140 (GR)
AK304273 AB
Connector: C-140
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
C-140 (GR)

AK304274 AB

NO : Repair.
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

NO : Repair.
13B-211
TROUBLESHOOTING
STEP 7. MUT-II/III data List

00 How to Use
P.00-6).
NO : Go to Step 9 .

connector
Connector: C-140
C-140 (GR)

<A/T> connector.
Connector: C-140

C-140 (GR)
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

NO : Repair.
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

Engine: Idling
OK:
System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
13B-212
TROUBLESHOOTING

<A/T> connector.
Connector: B-37
YES : Replace power steering fluid pressure
switch.
NO : Repair.

connector
Connector: C-140
B-37 (B)
C-140 (GR)
1
AK304273 AB
Connector: C-140
C-140 (GR)
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB
C-140 (GR)

NO : Repair.
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB


TROUBLESHOOTING
13B-213
DTC P0606: Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Main Processor Malfunction

Failed the engine-A/T-ECU <A/T>
FUNCTION
System LSI checks the engine-ECU <M/T> or
engine-A/T-ECU <A/T> for abnormal conditions.
DIAGNOSIS
TROUBLE JUDGMENT
Check Conditions
Ignition switch is "ON" position.

Judgement Criteria
No surveillance pulse signals is input for 0.5
second.
PROBABLE CAUSE
Failed the engine-ECU <M/T>
00 How to Use
P.00-6).
13B-214

TROUBLESHOOTING
Code No. P0622: Alternator FR Terminal System
Alternator circuit
C-141
(MU803804)
Engine-ECU <M/T>
6162
6364
656667686970717273
747576777879808182
8384 858687 8889
86
Y-B
B-19
2
Y-B
B-30
(MU802046)
1 2 3 4
IC voltage
regulator
Alternator
Wire colour code

AK304135 AB
OPERATION
The energized state of the alternator field coil is
inputted from the alternator (terminal No. 4) to the
(terminal No. 86).
FUNCTION
A signal of the power supply duty ratio for the
alternator field coil is inputted to the engine-ECU
or engine-A/T-ECU <A/T> detects the alternator
output current and controls the idling speed
according to the output current (electric load).
TROUBLE JUDGMENT
Check Condition
Engine speed is 50 r/min or higher.
Judgment Criterion
Input voltage from the alternator FR terminal has
continued to be approximately battery positive
voltage for 20 seconds.
PROBABLE CAUSE
Failed alternator
Open/short circuit in alternator FR terminal circuit
or loose connector
13B-215
TROUBLESHOOTING
NO : Go to Step 3 .
DIAGNOSIS PROCEDURE
connector
Connector: B-30

connector.
Connector: C-141
B-30 (GR)
4 3 2 1
Harness side
connector
C-141(GR)
AK304037AB

NO : Repair.

C-141 (GR)

alternator connector.
Connector: B-30
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

B-30 (GR)

NO : Repair.
4 3 2 1
Harness side
connector
AK304037AB
Disconnect connector, and measure at male

connector side.
Ignition switch: ON
OK: System voltage
AK304154 AB
13B-216
TROUBLESHOOTING

Connector: B-30
B-30 (GR)
00 How to Use
P.00-6).
<A/T> connector.
Connector: C-141
4 3 2 1
Harness side
connector
AK304037AB
Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR)

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

NO : Repair.


Engine: Idle after warm-up
NO : Go to Step 5 .

TROUBLESHOOTING

13B-217
NO : Repair.
STEP 8. Check trouble symptom.

Q: Same symptoms regenerated?
NO : Intermittent malfunction (Refer to Group 00
Connector: C-141
How to Use troubleshooting/Inspection

C-141(GR)

C-141 (GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB
Connector: B-30
B-30 (GR)
4 3 2 1
Harness side
connector

AK304037AB
13B-218

TROUBLESHOOTING
DTC P0638: Throttle Valve Control Servo Circuit Range/Performance Problem
OPERATION
Refer to P2101 Throttle valve control servo
circuit P.13B-242.
FUNCTION
checks the electronic controlled throttle system
for abnormal conditions.
TROUBLE JUDGMENT
Check Conditions
0.35 4.8 V.
Drop of throttle position sensor (main) output
voltage per 100 milliseconds is 0.04 V or more.
Judgement Criteria
Throttle position sensor (main) output voltage has
continued to be above 0.5 V higher than the
target throttle position sensor (main) voltage for
0.5 second.
Check Conditions
0.35 4.8 V.
Judgement Criteria
Difference between throttle position sensor
(main) output voltage and target throttle position
sensor (main) voltage is 1 V or higher for 4
seconds.
PROBALE CAUSE
Failed throttle valve return spring.
Failed throttle valve operation.
Failed throttle valve control servo.
Open/short circuit in throttle valve control servo
connector contact.
Failed engine-ECU <M/T>.
Failed engine-A/T-ECU <A/T>.
DIAGNOSIS
a. Item 9A: Throttle position sensor (main) mid
opening learning value
NO : Replace throttle body assembly.
STEP 2. Check the throttle valve control servo

itself.
Check the throttle valve control servo control
motor itself (Refer to P.13B-436)
13B-219
TROUBLESHOOTING

controlled throttle valve connector and C-138
<A/T> connector
Connector: B-06

<A/T> connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1
B-06 (B)
AK304259 AB
6 5 4 3 2 1
AK304259 AB
Connector: C-138
Connector: C-138
C-138 (GR)
C-138 (GR)

C-138 (GR)
C-138 (GR)
124 123
122121
133 132 131 130 129128127126125

141 140 139 138 137136 135134
146 145
144 143142
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136
146 145
144
135134
143142

AK304275 AB
AK304275 AB

NO : Repair.

NO : Repair.
13B-220
TROUBLESHOOTING

<A/T> connector.
Connector: B-06
NO : Repair.

00 How to Use
P.00-6).
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Connector: C-138
C-138 (GR)

C-138 (GR)
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136
146 145
144
135134
143142

AK304275 AB


TROUBLESHOOTING
13B-221
DTC P0642: Throttle Position Sensor Power Supply
FUNCTION
checks the throttle position sensor power voltage
for abnormal conditions.
PROBALE CAUSE
DIAGNOSIS
TROUBLE JUDGMENT
Check Conditions
Judgement Criteria
Throttle position sensor power voltage is 4.1 V or
less for 0.5 second.

00 How to Use
P.00-6).
13B-222
TROUBLESHOOTING
DTC P0657: Throttle Valve Control Servo Relay Circuit Malfunction

Throttle valve control srvo relay circuit
Battery
W-B
A-14
5 (*1) or
16 (*2)
W-B
W-B
4
B-17X
1
Engine
control
relay
1
2
R
W-B
Y-G
4
J/C (2)
12
To engine-ECU <M/T>
3
B-14X
Throrrle
valve
control
servo
relay
1
R-W
123 124
134135
142143
15
C-139
(MU803802)
Power source
136137 138 139 140 141

144
145 146
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
3
2
C-138
(MU803801)
121122
132
125126127128129 130 131 132 133
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304138 AB
13B-223
TROUBLESHOOTING
OPERATION
Battery voltage is applied to the Throttle valve
control servo relay terminal (terminal No. 4).
Battery voltage is applied to the Throttle valve
control servo relay terminal (terminal No. 3) from
the engine control relay (terminal No. 1).
(terminal No. 15) applies current to the throttle
valve control servo relay coil by turning ON the
power transistor in the unit in order to turn the
relay ON.
When the throttle valve control servo relay turns
ON, battery voltage is supplied by the throttle
valve control servo relay (terminal No. 1) to the
(terminal No. 132).
FUNCTION
When the ignition switch ON signal is input into
<A/T>, the engine-ECU <M/T> or
engine-A/T-ECU <A/T> turns ON the Throttle
valve control servo.
TROUBLE JUDGMENT
Check Condition
Judgement Criteria
The power line voltage of the electronic controlled
throttle system is 4.0 V or less for 1 second.
PROBALE CAUSE
Failed throttle valve return spring
circuit or loose connector contact.
DIAGNOSIS
STEP 1. Connector check: B-14X throttle valve
control servo relay connector
Connector: B-14X
Relay boxs
triangle marks
STEP 3. Perform voltage measurement at B-14X

throttle valve control servo relay connector.
Connector: B-14X
Relay boxs
triangle marks
B-14X
Harness
side connector
AK304276 AB

NO : Repair.
STEP 2. Check throttle valve control servo relay

itself.
Check throttle valve control servo relay (Refer to
P.13B-430).
NO : Repair.
Harness
side connector
B-14X
AK304276 AB

OK: System voltage

throttle valve control servo relay connector
and battery.
open/short circuit.
13B-224
TROUBLESHOOTING
STEP 4. Perform voltage measurement at B-14X

throttle valve control servo relay connector.
Connector: B-14X
Relay boxs
triangle marks
B-14X
Harness
side connector
AK304276 AB

Ignition switch: ON
OK: System voltage

engine control relay connector and B-14X
(terminal No. 3) throttle valve control servo
relay connector.
open/short circuit.
NO : Repair.
connector.
Connector: C-139

NO : Go to Step 6 .
C-139 (GR)

relay connector
Connector: B-17X
B-17X
C-139 (GR)
Relay boxs
triangle marks
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
Harness
side connector
2
6
15
22
1
5
14
21
AK304152 AB
AK304262 AB
Connector: B-14X
Connector: B-14X
Relay boxs
triangle marks
B-14X
Harness
side connector
Relay boxs
triangle marks
B-14X
AK304276 AB
Harness
side connector
AK304276 AB

side.
Ignition switch: ON
OK: System voltage
13B-225
TROUBLESHOOTING

relay connector and C-139 (terminal No. 15)
circuit.
NO : Go to Step 7 .
<A/T> connector.
Connector: C-138

No. 1) throttle valve control servo relay
<A/T> connector.
Connector: B-14X
Relay boxs
triangle marks
B-14X
Harness
side connector
AK304276 AB
Connector: C-138
C-138 (GR)
C-138 (GR)
C-138 (GR)
C-138 (GR)
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136
146 145
144
135134
143142

AK304275 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136
146 145
144
135134
143142

AK304275 AB

NO : Repair.
13B-226
TROUBLESHOOTING

No. 1) engine control relay connector and B-14X
(terminal No. 3) throttle valve control servo relay
connector.
Connector: B-17X
B-17X
Relay boxs
triangle marks

circuit.
NO : Repair.
<A/T> connector
Connectors: C-138, C-139
Harness
side connector
AK304152 AB
Connector: B-14X
Relay boxs
triangle marks
C-138 (GR)
B-14X
C-139 (GR)
Harness
side connector
AK304276 AB
Connector: C-139
C-139 (GR)
C-138 (GR)
124
133
141
146
C-139 (GR)
123
122121
132 131 130 129128127126125
140 139 138 137136 135134
145
144 143142

4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304277 AB
C-139 (GR)

4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
00 How to Use
P.00-6).
1
5
14
21

AK304262 AB

13B-227
TROUBLESHOOTING
STEP 11. Check and repair harness between

B-14X (terminal No. 4) throttle valve control servo
relay connector and battery.
Connector: B-14X
Relay boxs
triangle marks
Harness
side connector
STEP 12. Check and repair harness between

B-14X (terminal No. 1) throttle valve control servo
<A/T> connector.
Connector: B-14X
B-14X
Relay boxs
triangle marks
AK304276 AB

Q: Is the harness connector in good condition?
00 How to Use
P.00-6).
B-14X
Harness
side connector
AK304276 AB
Connector: C-138
C-138 (GR)

C-138 (GR)
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136
146 145
144
135134
143142

AK304275 AB

Q: Is the harness connector in good condition?
00 How to Use
P.00-6).
13B-228

TROUBLESHOOTING
00 How to Use
P.00-6).

TROUBLESHOOTING
13B-229
Code No. P1010: Oil Control Valve Circuit
Engine oil control valve circuit
Battery
W-B
W-B
4
B-17X
1
3
Engine
control
relay
1
R
4
J/C (2)
C-17
11
R
B-104
MU802779
1
Oil control
valve
1 2
2
P-B
C-142
(MU803805)
9192
939495
96979899100 101102103 104
105106
107108109
110111112
113114
115116117
118119120
95
Engine-ECU <M/T>
Wire colour code

AK304140AB
13B-230
TROUBLESHOOTING
OPERATION
Power is supplied to the oil control valve (terminal
No. 1) from the engine control relay (terminal No.
1).
makes currents go on the oil control valve
(terminal No. 2).
FUNCTION
The oil control valve switches the cams to
operate the MIVEC system in the low-speed or
high-speed mode in accordance with the signals
<A/T>.
TROUBLE JUDGMENT
Check Conditions
Ignition switch is "ON" position
Battery positive voltage is higher than 10 V.
MIVEC operating in the low-speed mode.
Judgment Criteria
The engine-ECU terminal voltage of oil control
valve circuit is less than 1.5 V for 2 seconds.
PROBABLE CAUSE
Failed purge oil control valve
Open/short circuit in oil control valve circuit or
NO : Repair.
STEP 2: Perform resistance measurement at

B-104 oil control valve connector.
Connector: B-104
2 1
B-104 (B)
Harness
side connector
AK304278 AB
Disconnect connector, and measure at control

valve side.
OK: 6.9 7.9 (at 20C)
NO : Replace oil control valve.

oil control valve connector.
Connector: B-104
DIAGNOSIS PROCEDURE
2 1
STEP 1. Connector check: B-104 oil control valve

connector
Harness
side connector
AK304278 AB

side.
Ignition switch: ON
OK: System voltage
Connector: B-104
2 1
B-104 (B)

NO : Go to Step 4 .
B-104 (B)
Harness
side connector
AK304278 AB
13B-231
TROUBLESHOOTING

relay connector
Connector: B-17X
Connector: C-142
B-17X
Relay boxs
triangle marks

<A/T> connector.
C-142 (GR)
Harness
side connector
AK304152 AB
Connector: B-104
C-142 (GR)
2 1
Harness
side connector
959493
B-104 (B)
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
AK304278 AB


harness between B-104 (terminal No. 1) oil
control valve connector and B-17X (terminal
circuit.
NO : Repair.

AK304153 AB

side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 6 .
13B-232
TROUBLESHOOTING

connector
Connector: C-142
C-142 (GR)
(terminal No. 2) oil control valve connector

connector.
circuit.
NO : Repair.
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
C-142 (GR)
Connector: B-104
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

2 1
B-104 (B)
Harness
side connector
AK304153 AB
AK304278 AB

NO : Repair.
13B-233
TROUBLESHOOTING

No. 2) oil control valve connector and C-142

No. 2) oil control valve connector and B-17X
Connector: B-104
Connector: B-104
B-104 (B)
2 1
B-104 (B)
2 1
Harness
side connector
Harness
side connector
AK304278 AB
AK304278 AB
Connector: B-17X
Connector: C-142
B-17X
Relay boxs
triangle marks
C-142 (GR)
Harness
side connector
AK304152 AB

C-142 (GR)

NO : Repair.

959493

92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
00 How to Use
P.00-6).
13B-234

TROUBLESHOOTING
DTC P1602: Communication Malfunction (between Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Main
Processor and System LSI)
FUNCTION
checks the communication status for abnormal
conditions.
PROBALE CAUSE
DIAGNOSIS
TROUBLE JUDGMENT
Check Conditions
Ignition switch is "ON" position.
Judgement Criteria
Engine-ECU detects an error in communication
with the throttle actuator control module for 0.07
second.

00 How to Use
P.00-6).

TROUBLESHOOTING
13B-235
Code No. P1603: Battery Backup Circuit Malfunction
Battery backup circuit

Battery
9
20A
Relay
box
W-B
A-14
5 (*1) or
16 (*2)
W-B
58
C-140
(MU803803)
33
3132
35363738394041 42
444546474849 50
5253 545556 57
34
43
51
58
Battery
backup
Engine-ECU <M/T>
NOTE
Wire colour code
AK304139AB
OPERATION
Power is directly supplied to the engine-ECU
58) from the battery.
FUNCTION
<A/T> is check the open circuit of battery backup
line.
13B-236

TROUBLESHOOTING
TROUBLE JUDGMENT
Check Condition
After engine starting sequence is completed.
Battery positive voltage is 10 V or higher.
Judgment Criterion
Battery backup line voltage is 6 V or lower for 2
seconds.
PROBABLE CAUSE
Open/short circuit in battery backup line circuit or

<A/T> connector.
Connector: C-140
C-140 (GR)
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-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

side.
Ignition switch: ON
OK: System voltage

harness between battery and C-140
connector.
open/short circuit.
13B-237
TROUBLESHOOTING
STEP 3. Check harness between battery and

NO : Repair.

connector.
Connector: B-17X
Connector: C-140
B-17X
Relay boxs
triangle marks
C-140 (GR)
Harness
side connector
AK304152 AB

Connector: C-140
C-140 (GR)
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

NO : Repair.
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

00 How to Use
PointsP.00-6).
13B-238
TROUBLESHOOTING
DTC P2100: Throttle Valve Control Servo Circuit (open)
Throttle valve control servo circuit
B-06
Electronically
controlled
throttle valve
1 2 3 4 5 6
L-R
L-Y
133
141
C-138
(MU803801)
121122
123 124
125126127128129 130 131 132 133
GND
134135
142143
GND
145
144
136137 138 139 140 141

144
145 146
Engine-ECU <M/T>
Wire colour code

AK304136 AB
OPERATION
Controls the current that is applied from the
(terminals No. 133, No. 141) to the electronically
controlled throttle valve (terminals No. 1, No. 2).
FUNCTION
varies the direction and the amperage of the
current that is applied to the throttle valve control
servo in order to control the opening of the
throttle valve.
13B-239
TROUBLESHOOTING
TROUBLE JUDGMENT
Check Condition

Connector: B-06
Judgement Criteria
Throttle actuator control motor current is 0.1 A or
less for 0.72 second.
PROBABLE CAUSE
circuit or lose connector contact.
DIAGNOSIS PROCEDURE
Connector: B-06
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Disconnect connector, and measure at

electronically controlled throttle valve side.
OK: 0.3 80 k (at 20 C)

connector
Connector: C-138
B-06 (B)
6 5 4 3 2 1
AK304259 AB

NO : Repair.
C-138 (GR)

C-138 (GR)
124 123
122121
133 132 131 130 129128127126125

141 140 139 138 137136 135134
146 145
144 143142

AK304275 AB

NO : Repair.
13B-240
TROUBLESHOOTING

<A/T> connector.
Connector: C-138

<A/T> connector.
Connector: B-06
C-138 (GR)
B-06 (B)
6 5 4 3 2 1
C-138 (GR)
AK304259 AB
Connector: C-138
124 123
122121
133 132 131 130 129128127126125

141 140 139 138 137136 135134
146 145
144 143142
C-138 (GR)
AK304275 AB

side.
Voltage between terminal No. 144 and earth or
terminal No. 145 and earth.
OK: 2 or less
NO : Check harness between C-138 (terminal
No. 144 or No. 145) engine-ECU <M/T> or

engine-A/T-ECU <A/T> and earth.

C-138 (GR)
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136
146 145
144
135134
143142

AK304275 AB

NO : Repair.

TROUBLESHOOTING

<A/T> connector.
Connector: B-06
13B-241
NO : Repair.

00 How to Use
P.00-6).
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Connector: C-138
C-138 (GR)

C-138 (GR)
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136
146 145
144
135134
143142

AK304275 AB

13B-242
TROUBLESHOOTING
DTC P2101: Throttle Valve Control Servo Magneto Malfunction
B-06
Electronically
controlled
throttle valve
1 2 3 4 5 6
L-R
L-Y
133
141
C-138
(MU803801)
121122
123 124
125126127128129 130 131 132 133

134135
142143
Engine-ECU <M/T>
136137 138 139 140 141

144
145 146
Wire colour code

AK304137AB
TROUBLE JUDGMENT
OPERATION
FUNCTION
check whether the throttle valve control servo
magneto failed.
Check Condition
Judgement Criteria
The coil temperature of the throttle actuator
control motor is 180C or higher for 0.8 second.
PROBABLE CAUSE
circuit or lose connector contact.
13B-243
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: B-06

connector
Connector: C-138
B-06 (B)
C-138 (GR)
6 5 4 3 2 1
AK304259 AB

NO : Repair.

C-138 (GR)

124 123
Connector: B-06
122121
133 132 131 130 129128127126125

141 140 139 138 137136 135134
146 145
144 143142

AK304275 AB
B-06 (B)
6 5 4 3 2 1
AK304259 AB

OK: 0.3 80 k (at 20 C)

NO : Repair.
13B-244
TROUBLESHOOTING

<A/T> connector.
Connector: B-06

<A/T> connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Connector: C-138
Connector: C-138
C-138 (GR)
AK304259 AB
C-138 (GR)
C-138 (GR)
C-138 (GR)
124 123
122121
133 132 131 130 129128127126125
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136

146 145
144
141 140 139 138 137136

146 145
144
135134
143142
135134
143142

AK304275 AB

NO : Repair.
AK304275 AB

NO : Repair.

00 How to Use
P.00-6).

TROUBLESHOOTING
13B-245
DTC P2102: Throttle Valve Control Servo Circuit (Shorted Low)
B-06
Electronically
controlled
throttle valve
1 2 3 4 5 6
L-R
L-Y
133
141
C-138
(MU803801)
121122
123 124
125126127128129 130 131 132 133

134135
142143
Engine-ECU <M/T>
136137 138 139 140 141

144
145 146
Wire colour code

AK304137AB
TROUBLE JUDGMENT
OPERATION
engine-ECU <M/T> or engine-A/T-ECU
FUNCTION
throttle valve.
Check Condition
Judgement Criteria
Throttle valve control servo current is 12 A or
higher for 0.8 second.
PROBABLE CAUSE
Short circuit in throttle valve control servo circuit
or lose connector contact.
13B-246
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
Connector: B-06

connector
Connector: C-138
B-06 (B)
C-138 (GR)
6 5 4 3 2 1
AK304259 AB

NO : Repair.

C-138 (GR)

124 123
Connector: B-06
122121
133 132 131 130 129128127126125

141 140 139 138 137136 135134
146 145
144 143142

AK304275 AB
B-06 (B)
6 5 4 3 2 1
AK304259 AB

OK: 0.3 80 (at 20 C)

NO : Repair.
13B-247
TROUBLESHOOTING

<A/T> connector.
Connector: B-06

<A/T> connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Connector: C-138
Connector: C-138
C-138 (GR)
AK304259 AB
C-138 (GR)
C-138 (GR)
C-138 (GR)
124 123
122121
133 132 131 130 129128127126125
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136

146 145
144
141 140 139 138 137136

146 145
144
135134
143142
135134
143142

AK304275 AB

NO : Repair.
AK304275 AB

NO : Repair.

00 How to Use
P.00-6).
13B-248
TROUBLESHOOTING
DTC P2103: Throttle Valve Control Servo Circuit (Shorted High)
B-06
Electronically
controlled
throttle valve
1 2 3 4 5 6
L-R
L-Y
133
141
C-138
(MU803801)
121122
123 124
125126127128129 130 131 132 133

134135
142143
Engine-ECU <M/T>
136137 138 139 140 141

144
145 146
Wire colour code

AK304137AB
TROUBLE JUDGMENT
OPERATION
engine-ECU <M/T> or engine-A/T-ECU
FUNCTION
throttle valve.
Check Condition
Judgement Criteria
Throttle actuator control motor current is 8 A or
higher for 0.8 second.
PROBABLE CAUSE
Short circuit in throttle valve control servo circuit
or loose connector contact.
13B-249
TROUBLESHOOTING
NO : Replace the throttle body assembly.
DIAGNOSIS PROCEDURE
Connector: B-06

connector
Connector: C-138
B-06 (B)
C-138 (GR)
6 5 4 3 2 1
AK304259 AB

NO : Repair.

C-138 (GR)

124 123
Connector: B-06
122121
133 132 131 130 129128127126125

141 140 139 138 137136 135134
146 145
144 143142

AK304275 AB
B-06 (B)
6 5 4 3 2 1
AK304259 AB

OK: 0.3 80 (at 20 C)

NO : Repair.
13B-250
TROUBLESHOOTING

<A/T> connector.
Connector: B-06

<A/T> connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Connector: C-138
Connector: C-138
C-138 (GR)
AK304259 AB
C-138 (GR)
C-138 (GR)
C-138 (GR)
124 123
122121
133 132 131 130 129128127126125
124 123
122121
133 132 131 130 129128127126125
141 140 139 138 137136

146 145
144
141 140 139 138 137136

146 145
144
135134
143142
135134
143142

AK304275 AB

NO : Repair.
AK304275 AB

NO : Repair.

00 How to Use
P.00-6).

TROUBLESHOOTING
13B-251
Code No. P2121: Accelerator Pedal Position Sensor (Main) Circuit Range/Performance Problem
OPERATION
Refer to P2122 accelerator pedal position sensor
(main) circuit P.13B-394.
Refer to inspection procedure 32 accelerator
pedal position switch circuit P.13B-394.
FUNCTION
checks the accelerator pedal position sensor
(main) output signal characteristics for abnormal
conditions.
TROUBLE JUDGMENT
Check Condition
Ignition switch is in "ON" position
Closed throttle position switch: ON
Accelerator pedal position sensor (sub) output
voltage is 1.88 V or less.
NO : Repair.
STEP 2. Check accelerator pedal position sensor

itself.
Check accelerator pedal position sensor itself
NO : Replace accelerator pedal position sensor.

B-116 accelerator pedal position sensor
connector.
Connector: B-116
B-116 (GR)
Judgment Criteria
Accelerator pedal position sensor (main) output
voltage is 1.88 V or higher for 1 second.
PROBABLE CAUSE
Failed accelerator pedal position sensor
Open/short circuit in accelerator pedal position
Failed accelerator pedal position switch
switch circuit or loose connector contact
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-116 accelerator
pedal position sensor connector
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
AK304279 AB
8 7 6 5 4 3 2 1
AK304279 AB

side.
OK: 2 or less
NO : Go to Step 4 .
13B-252
TROUBLESHOOTING

connector
Connector: C-142

No. 1) accelerator pedal position sensor
<A/T> connector.
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
C-142 (GR)
AK304279 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.

00 How to Use Trouble

shooting/Inspection Service Points P.00-6).
13B-253
TROUBLESHOOTING
STEP 7. Check accelerator pedal position switch

itself.
Check accelerator pedal position switch itself

<A/T> connector.
Connector: B-116
B-116 (GR)

connector
Connector: C-140
8 7 6 5 4 3 2 1
AK304279 AB
Connector: C-140
C-140 (GR)
C-140 (GR)
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
C-140 (GR)

AK304274 AB

NO : Repair.
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

NO : Repair.
13B-254

TROUBLESHOOTING
Code No. P2122: Accelerator Pedal Position Sensor (Main) Circuit Low Input
Accelerator pedal position sensor (main) circuit
Accelerator
pedal
position
sensor
(main)
B-116
(MU802073)
1 2 3 4 5 6 7 8
L-W
GR
92
BR-W
114
91
C-142
(MU803805)
9192
939495
96979899100 101102103 104
5V
105106
107108109
110111112
113114
115116117
118119120
Engine-ECU <M/T>
Wire colour code
AK304133AB
OPERATION
accelerator pedal position sensor (terminal No. 2)
91) from the accelerator pedal position sensor
(terminal No. 1).

FUNCTION
The accelerator pedal position sensor (main)
outputs voltage which corresponds to the
accelerator pedal depression.
<A/T> checks whether the voltage is within a
specified range.

TROUBLESHOOTING
TROUBLE JUDGMENT
Check Condition
Judgment Criteria
voltage is 0.2 volt or less for 0.3 second.
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
a. Item 78: Accelerator pedal position sensor
(main)
00 How to Use
P.00-6).
NO : Go to Step 2 .
13B-255

Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
AK304279 AB

NO : Repair.

itself.

accelerator pedal position sensor connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
AK304279 AB
13B-256
TROUBLESHOOTING

connector
Connector: C-142

connector.
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
C-142 (GR)
AK304279 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-257
TROUBLESHOOTING

(main)

<A/T> connector.
Connector: B-116
00 How to Use
P.00-6).
connector
B-116 (GR)
8 7 6 5 4 3 2 1
Connector: C-142
Connector: C-142
AK304279 AB
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
959493
92 91
AK304153 AB
AK304153 AB

NO : Repair.
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

NO : Repair.
13B-258
TROUBLESHOOTING

<A/T> connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
AK304279 AB
Connector: C-142
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-259
TROUBLESHOOTING
Code No. P2123: Accelerator Pedal Position Sensor (Main) Circuit High Input
Accelerator pedal position sensor (main) circuit
Accelerator
pedal
position
sensor
(main)
B-116
(MU802073)
1 2 3 4 5 6 7 8
L-W
GR
92
BR-W
114
91
C-142
(MU803805)
9192
939495
96979899100 101102103 104
5V
105106
107108109
110111112
113114
115116117
118119120
Engine-ECU <M/T>
Wire colour code
AK304133AB
OPERATION
(terminal No. 1).

FUNCTION
The accelerator pedal position sensor (main)
specified range.
13B-260
TROUBLESHOOTING
TROUBLE JUDGMENT
Check Condition
voltage is 0.2 - 2.5 V.
Judgment Criteria
voltage is 4.5 V or higher for is 1 second.
PROBABLE CAUSE
NO : Repair.

itself.

connector.
Connector: B-116
DIAGNOSIS PROCEDURE
B-116 (GR)

(main)
00 How to Use
P.00-6).
NO : Go to Step 2 .
8 7 6 5 4 3 2 1
AK304279 AB

side.
OK: 2 or less
NO : Go to Step 6 .
Connector: B-116

(main)
B-116 (GR)

8 7 6 5 4 3 2 1
AK304279 AB
00 How to Use
P.00-6).
13B-261
TROUBLESHOOTING

connector
Connector: C-142

<A/T> connector.
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
C-142 (GR)
AK304279 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-262
TROUBLESHOOTING
Code No. P2126: Accelerator Pedal Position Sensor (Sub) Circuit Range/Performance Problem
OPERATION
Refer to Code No. P2127 Accelerator Pedal
Circuit Position Sensor (sub) Circuit P.13B-265.
Refer to Inspection Procedure 32: Accelerator
Pedal Position Switch Circuit P.13B-394.
FUNCTION
(sub) output signal characteristics for abnormal
conditions.
TROUBLE JUDGMENT
Check Condition
Closed throttle position switch: ON
Accelerator pedal position sensor (main) failure is
detected.
NO : Repair.

itself.

connector.
Connector: B-116
B-116 (GR)
Judgment Criteria
PROBABLE CAUSE
Failed accelerator pedal position switch
switch circuit or loose connector contact
DIAGNOSIS PROCEDURE
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
AK304279 AB
8 7 6 5 4 3 2 1
AK304279 AB

side.
OK: 2 or less
NO : Go to Step 4 .
13B-263
TROUBLESHOOTING

connector
Connector: C-142

<A/T> connector.
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
C-142 (GR)
AK304279 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-264
TROUBLESHOOTING

00 How to Use Trouble
shooting/Inspection Service Points P.00-6).
STEP 7. Check accelerator pedal position switch
itself.
Check accelerator pedal position switch itself
NO : Repair.

<A/T> connector.
Connector: B-116
B-116 (GR)

8 7 6 5 4 3 2 1

connector
AK304279 AB
Connector: C-140
Connector: C-140
C-140 (GR)
C-140 (GR)
C-140 (GR)
C-140 (GR)
34
43
51
58
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB

AK304274 AB

NO : Repair.
13B-265
TROUBLESHOOTING
Code No. P2127: Accelerator Pedal Position Sensor (Sub) Circuit Low Input
Accelerator pedal position sensor (sub) circuit
Accelerator
pedal
position
sensor
(sub)
B-116
(MU802073)
1 2 3 4 5 6 7 8
Y-R
97
107
96
C-142
(MU803805)
9192
939495
96979899100 101102103 104
5V
105106
107108109
110111112
113114
115116117
118119120
Engine-ECU <M/T>
Wire colour code
AK304133AC
OPERATION
(terminal No. 7).

FUNCTION
The accelerator pedal position sensor (sub)
specified range.
13B-266
TROUBLESHOOTING
TROUBLE JUDGMENT
Check Condition

accelerator pedal position sensor connector.
Connector: B-116
Judgment Criteria
voltage is 0.2 volt or less for 1 second.
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
(sub)
00 How to Use
P.00-6).
NO : Go to Step 2 .
B-116 (GR)
8 7 6 5 4 3 2 1
AK304279 AB

side.
Ignition switch: ON
OK: 4.9 5.1 V
NO : Go to Step 5 .

connector
Connector: C-142

Connector: B-116
C-142 (GR)
B-116 (GR)
C-142 (GR)
8 7 6 5 4 3 2 1
AK304279 AB

NO : Repair.
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

itself.
AK304153 AB

NO : Repair.
13B-267
TROUBLESHOOTING

connector.
Connector: B-116

(sub)
00 How to Use
P.00-6).
B-116 (GR)
8 7 6 5 4 3 2 1
AK304279 AB

connector
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
AK304153 AB

NO : Repair.
13B-268
TROUBLESHOOTING

<A/T> connector.
Connector: B-116

<A/T> connector.
Connector: B-116
B-116 (GR)
B-116 (GR)
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
AK304279 AB
Connector: C-142
Connector: C-142
C-142 (GR)
AK304279 AB
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
AK304153 AB

NO : Repair.
13B-269
TROUBLESHOOTING
Code No. P2128: Accelerator Pedal Position Sensor (Sub) Circuit High Input
Accelerator pedal position sensor (sub) circuit
Accelerator
pedal
position
sensor
(sub)
B-116
(MU802073)
1 2 3 4 5 6 7 8
Y-R
97
107
96
C-142
(MU803805)
9192
939495
96979899100 101102103 104
5V
105106
107108109
110111112
113114
115116117
118119120
Engine-ECU <M/T>
Wire colour code
AK304133AC
OPERATION
(terminal No. 7).

FUNCTION
The accelerator pedal position sensor (sub)
specified range.
13B-270
TROUBLESHOOTING
TROUBLE JUDGMENT
Check Condition
voltage is 0.2 2.5 V.
Judgment Criteria
PROBABLE CAUSE
NO : Repair.

itself.

connector.
Connector: B-116
DIAGNOSIS PROCEDURE
B-116 (GR)

(sub)
00 How to Use
P.00-6).
NO : Go to Step 2 .
8 7 6 5 4 3 2 1
AK304279 AB

side.
OK: 2 or less
NO : Go to Step 6 .
Connector: B-116

(sub)
B-116 (GR)

8 7 6 5 4 3 2 1
AK304279 AB
00 How to Use
P.00-6).
13B-271
TROUBLESHOOTING

connector
Connector: C-142

<A/T> connector.
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
C-142 (GR)
AK304279 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-272

TROUBLESHOOTING
Code No. P2135: Throttle Position Sensor (Main and Sub) Range/Performance Problem
OPERATION
Refer to Code No. P0122: Throttle Position
Sensor (main) Circuit Low Input P.13B-51.
Refer to Code No. P0222: Throttle Position
Sensor (sub) Circuit Low Input P.13B-145.
FUNCTION
checks the throttle position sensor output signal
characteristics for abnormal conditions.
DIAGNOSIS PROCEDURE
connector and B-06 electronically controlled
throttle valve connector
Connector: C-142
TROUBLE JUDGMENT
Check Condition
0.35 2.5 V.
2.25 4.8 V
Judgment Criteria
Using the formula given below, the voltage of 0.3
V or higher is obtained for 0.5 second: V* V**
2V
V*: throttle position sensor (main) output voltage
V**: throttle position sensor (sub) output voltage.
PROBABLE CAUSE
C-142 (GR)

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB
Connector: B-06
B-06 (B)
6 5 4 3 2 1

NO : Repair.
AK304259 AB
13B-273
TROUBLESHOOTING

<A/T> connector.
Connector: B-06

<A/T> connector.
Connector: B-06
B-06 (B)
6 5 4 3 2 1
B-06 (B)
6 5 4 3 2 1
AK304259 AB
Connector: C-142
Connector: C-142
AK304259 AB
C-142 (GR)
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
AK304153 AB

NO : Repair.
STEP 4. Replace throttle body assembly.

After throttle body assembly is replaced, re-check
for trouble symptom.
NO : Check end.
13B-274

TROUBLESHOOTING
Code No. P2138: Accelerator Pedal Position Sensor (Main and Sub) Range/Performance Problem
OPERATION
Refer to Code No. P2122: Accelerator Pedal
Position Sensor (main) Circuit Low Input
P.13B-254.
Refer to Code No. P2127: Accelerator Pedal
Position Sensor (sub) Circuit Low Input
P.13B-265.
DIAGNOSIS PROCEDURE
pedal position connector
Connector: B-116
B-116 (GR)
FUNCTION
output signal characteristics for abnormal
conditions.
8 7 6 5 4 3 2 1
TROUBLE JUDGMENT
Check Condition
Judgment Criteria
voltage minus Accelerator pedal position sensor
(main) output voltage is 1 volt or higher for 1
second.
voltage minus Accelerator pedal position sensor
(sub) output voltage is 1 volt or higher for 0.2
seconds.
PROBABLE CAUSE
AK304279 AB

NO : Repair.

itself.

connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
AK304279 AB

side.
OK: 2 or less
NO : Go to Step 4 .
13B-275
TROUBLESHOOTING

connector
Connector: C-142

<A/T> connector.
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
C-142 (GR)
AK304279 AB
Connector: C-142
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
C-142 (GR)

AK304153 AB

NO : Repair.

C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-276
TROUBLESHOOTING
STEP 6. Check the trouble symptoms

00 How to Use
P.00-6).

connector
Connector: C-142
C-142 (GR)

connector.
Connector: B-116
C-142 (GR)
B-116 (GR)
959493
8 7 6 5 4 3 2 1
AK304279 AB

side.
OK: 2 or less
NO : Go to Step 8 .
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
13B-277
TROUBLESHOOTING

<A/T> connector.
Connector: B-116
NO : Repair.

connector
Connector: C-142
B-116 (GR)
C-142 (GR)
8 7 6 5 4 3 2 1
AK304279 AB

Connector: C-142
C-142 (GR)
C-142 (GR)
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
AK304153 AB
C-142 (GR)

NO : Repair.
959493
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

13B-278
TROUBLESHOOTING

<A/T> connector.
Connector: B-116

<A/T> connector.
Connector: B-116
B-116 (GR)
B-116 (GR)
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
AK304279 AB
Connector: C-142
Connector: C-142
C-142 (GR)
AK304279 AB
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
AK304153 AB

NO : Repair.
13B-279
TROUBLESHOOTING

<A/T> connector.
Connector: B-116

<A/T> connector.
Connector: B-116
B-116 (GR)
B-116 (GR)
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
AK304279 AB
Connector: C-142
Connector: C-142
C-142 (GR)
AK304279 AB
C-142 (GR)
C-142 (GR)
C-142 (GR)
959493
92 91
959493
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113
92 91
104 103102 101100 99 98 97 96

112111110
109108107
106105
120119118
117116115
114113

AK304153 AB

NO : Repair.
AK304153 AB

NO : Repair.
13B-280

TROUBLESHOOTING
DTC P2173: Abnormal Intake Air Amount

FUNCTION
decides the allowable intake air amount in
accordance with the engine speed and the target
opening angle of throttle valve.
checks whether the actual intake air amount is
more than the allowable intake air amount.
TROUBLE JUDGMENT
DIAGNOSIS
to P.13B-20).
NO : Go to Step 2 .
Check Conditions
STEP 2. Replace the air flow sensor.

trouble symptoms.
Judgment Criteria
The actual intake air amount is more than the
allowable in take air amount for 1.5 seconds.

NO : Check end.
TROUBLESHOOTING HINTS (The most likely

causes for this code to be set are: )
Failed air flow sensor.
Throttle valve faulty operation.
STEP 3. Replace the throttle body assembly.

After replacing the throttle body assembly,
re-check the trouble symptoms.
NO : Check end.

TROUBLESHOOTING
13B-281
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1131151500812
Items
Trouble symptom
Inspection
procedure
No.
Communication
with MUT-II/III is
impossible
Communication with engine-ECU <M/T> or engine-A/T-ECU <A/T> only

is not possible
Engine warning
lamp
The engine warning lamp does not illuminate right after the ignition switch 3
is turned the "ON" position
Starting
Starting impossible
(No initial combustion)
The starter is impossible to operate. 5 <M/T>,

6 <A/T>
Starting impossible
(Starter operative but no initial
combustion)
The starter is operative and cranks

the engine, but none of initial
combustion is in the cylinders and
The initial combustion occurs, but

Starting impossible
(Initial combustion but no complete the engine stalls soon due to the
combustion)
incomplete combustion.
Improper idling
Engine stalls
Improper starting
(Long time to start)
It is long cranking to start the engine.
Unstable idling
(Rough idling, hunting)
9
The engine speed is not constant
and changeable during the idling.
Usually, the judgment can be based
on the movement of the tachometer
pointer, also on the vibration
transmitted to the steering wheel, sift
lever, vehicle body and so on.
Improper idling speed
The proper idling speed is not

satisfied.
Engine stalled during idling

(Die out)
The engine stalls during the idling in

no relation to the vehicle movement.
The engine stalls when starting the The engine stalls during the
car
operation, or when the accelerator
(Pass out)
pedal is depressed from the idling.
The engine stalls when
decelerating
10
The engine stalls at the deceleration. 11
13B-282
TROUBLESHOOTING
Items
Trouble symptom
Inspection
procedure
No.
Driving
The engine speed is not higher when 12

the accelerator pedal is depressed.
Hesitation, sag
13
The response of vehicle speed
(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.

when accelerating

the acceleration.
14

when decelerating

the deceleration.
15
Knocking
Sharp sound like a hammer striking

on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
16
The basic ignition timing is deviated

from the datum value.
17
Stopping
Run on (Dieseling)
The engine continues to run after the 18

ignition switch is in "LOCK (OFF)"
position.
Exhaust gas
Odor, white smoke, black smoke,

high-concentration CO/HC during
idling
The exhaust gas is extremely rank

odor, white smoke or black smoke.
The concentration of CO & HC is
high during the idling.
19
Charging
performance
Battery rundown
The battery is soon rundown or the

charging ability of battery is small.
20

TROUBLESHOOTING
13B-283
Items
Trouble symptom
Cooling
performance
Overheating
The temperature of engine cooling

water is extremely high.
21
Abnormal rotation of fan Motor
The fan motor is abnormally rotated

when the ignition switch is in "ON"
position in no relation to the engine
cooling water temperature.
22
Poor A/C Performance
The temperature of air cooling from

A/C is not efficient or very far from
the target temperature.
23
A/C performance
Inspection
procedure
No.
PROBLEM SYMPTOMS TABLE

procedure
No.
Reference
page
P.13B-285
Communication with engine-ECU <M/T> or engine-A/T-ECU <A/T> only is not P.13B-288

possible
The engine warning lamp does not illuminate right after the ignition switch is
turned the "ON" position
P.13B-291
P.13B-298
Starting impossible (No initial combustion) <M/T>
P.13B-301
Starting impossible (No initial combustion) <A/T>
P.13B-306
Starting impossible (Starter operative but no initial combustion)
P.13B-312
Starting impossible (Initial combustion but no complete combustion)
P.13B-314
Starting impossible (Long time to start)

9
Unstable idling (Rough idling, hunting)
P.13B-316
Improper idling speed (Too high or too low)

Engine stalls during idling (Die out)
10
The engine stalls when starting the car (pass out)
P.13B-320
11
The engine stalls when decelerating
P.13B-321
12
P.13B-322
13
Hesitation, sag
P.13B-323
Poor acceleration
Stumble
Surge
14
The feeling of impact or vibration when accelerating
P.13B-324
15
The feeling of impact or vibration when decelerating
P.13B-325
16
Knocking
P.13B-325
17
P.13B-326
18
Run on (Dieseling)
P.13B-327
13B-284
TROUBLESHOOTING

procedure
No.
Reference
page
19
Odor, white smoke, black smoke, high-concentration CO/HC during idling
P.13B-328
20
Battery rundown
P.13B-330
21
Overheating
P.13B-333
22
Abnormal rotation of fan motor
P.13B-334
23
Poor A/C performance
P.13B-337
24
Engine-ECU <M/T> or engine-A/T-ECU <A/T> power supply, engine control

relay, ignition switch-IG1 system
P.13B-338
25
Fuel pump system
P.13B-344
26
Fan control relay system
P.13B-352
27
A/C switch system
P.13B-359
28
A/C compressor relay system
P.13B-364
29
A/C load signal system
P.13B-371
30
A/C pressure sensor system
P.13B-376
31
Ignition circuit system
P.13B-386
32
Accelerator pedal position switch circuit system
P.13B-394

TROUBLESHOOTING
13B-285
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is Not Possible
Diagnosis connector circuit
Fusible link (1)

R
C-116
15 (*1) or
A-14
14 (*2)
R
C-122
2 (*2)
R
C-204
1
15
15A
J/B
12
C-205
W-R
C-24
MU803797
16
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Diagnosis connector
5
4
B
NOTE
Wire colour code
AK304141 AB
13B-286
TROUBLESHOOTING
OPERATION
Battery voltage is applied to diagnosis connector
(terminal No.16).
Diagnosis connector (terminals No. 4 and 5) are
earthed to the vehicle body.
circuit or failed earthing circuit of diagnosis
connector.
NO : Repair.
STEP 2: Perform resistance measurement at C-24

Connector: C-24
<L. H. drive vehicle>
PROBABLE CAUSE
Failed diagnosis connector
Open/short circuit in diagnosis connector circuit
Failed MUT-II/III
DIAGNOSIS PROCEDURE
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
<R. H. drive vehicle>
NOTE: .
*1
: L.H. drive vehicles
STEP 1: Check connector: C-24 diagnosis
connector
Connector: C-24
Harness side
connector
C-24 (B)
AK304280 AB

side.
Resistance between terminal No. 4 and earth,
also between terminal No. 5 and earth.
OK: 2 or less
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Harness side
connector
C-24 (B)
AK304280 AB

NO : Check and repair harness between C-24

body earth, also between C-24 (terminal No.
5) diagnosis connector and body earth.
and damage.
13B-287
TROUBLESHOOTING
STEP 3: Perform voltage measurement at C-24

Connector: C-24

NO : Check end

No. 16) diagnosis connector and battery.
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
STEP 4: Replace MUT-II/III

After replacing the MUT-II/III, re-check the trouble
symptoms.
Connector: C-24
Harness side
connector
C-24 (B)
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Harness side
connector
AK304280 AB
Disconnect connector, and measure at the

harness side.
OK: System voltage
NO : Check intermediate connectors C-116*1,
A-14*2
C-122*2, C-204 and
C-205 and repair

if necessary. If connectors are normal,
check and repair harness between C-24
battery.
open/short circuit.
C-24 (B)
AK304280 AB

connectors C116*1, A-14*2, C-122*2, C-204 and
C-205, and repair if necessary.
(terminal No. 4 and No. 5) diagnosis

NO : Repair.
13B-288
TROUBLESHOOTING
Inspection Procedure 2: Communication with Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Only is

Not Possible.
Diagnosis connector circuit

C-141
(MU803804)
6162
6364
656667686970717273
747576777879808182
8384 858687 8889
Engine-ECU <M/T>
74
O-W
C-04 (*1)
C-105
5
31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
O-L
37
Combination mater
C-04 (*2)
CPU
36
O-W
32 (*1) or
20 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
J/C (3)
C-02
O-L
C-24
29 (*1) or
18 (*2)
7
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
NOTE
Wire colour code
AK304142 AB
OPERATION
There is data communication between diagnosis
connector output terminal (terminal No. 7) and
engine-ECU <M/T> (terminal No. 74).
circuit or failed earthing circuit of engine-ECU
PROBABLE CAUSE
Open/short circuit in engine-ECU <M/T> or
engine-A/T-ECU <A/T> power circuit
Between engine-ECU <M/T> or engine-A/T-ECU
<A/T> and diagnosis connector for short circuit
Failed combination meter
13B-289
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
STEP 1: Check engine warning lamp.
Ignition switch: OFF ON
Q: Is lamp illuminating for few seconds?
NO : Check engine-ECU <M/T> or

No. 7) diagnosis connector and C-141 (terminal
Connector: C-24
engine-A/T-ECU <A/T> power supply,

engine control relay and ignition switch IG1
system (Refer to Inspection Procedure 24
P.13B-338).
connector
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Harness side
connector
Connector: C-141
C-24 (B)
C-141(GR)
AK304280 AB

C-141 (GR)
Connector: C-141
C-141(GR)
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

C-141 (GR)

AK304154 AB

NO : Repair.
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB
NOTE: Before Checking harness, check

intermediate connectors C-02, C-04 and C-105 and
Check communication line for open/short circuit
and damage.
13B-290

TROUBLESHOOTING
NO : Repair.
STEP 4: Replace the combination meter

After replacing the combination meter, re-check
NO : Check end.
STEP 5: Check the trouble symptom.

00 How to Use
P.00-6).
13B-291
TROUBLESHOOTING
Inspection Procedure 3: The Engine Warning Lamp Does Not Illuminate Right after the Ignition Switch
is Turned the "ON" Position
Combination meter circuit
Ignition switch
C-303
1 2 3
4 5 6
LOCK
R
ST
ACC
IG1
IG2
2
L-B
C-203
6
2
7.5A
J/B
25
C-205
C-04 (*1)
B-W
C-04
42
31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
Combination meter
G
C-05 (*1)
C-04 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122
G
C-05
14
C-05 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
R-W
7
C-105
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
R-W
7
C-139
NOTE
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304143 AB
13B-292

TROUBLESHOOTING
OPERATION
(terminal No. 7) makes power transistor in unit be
in "ON" position, and that makes currents go on
engine warning lamp of combination meter
connector (terminal No. 14).
COMMENTS ON TROUBLE SYMPTOM
Engine-ECU <M/T> engine-A/T-ECU <A/T> 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 CAUSE
Engine warming lamp bulb burnt out
Failed ignition switch
Open/short circuit in engine warning lamp circuit
for or loose connector contact
DIAGNOSIS PROCEDURE
STEP 1: Check engine start-up.
Q: Is engine started?
NO : Check engine-ECU <M/T> engine-A/T-ECU
<A/T> power supply, engine control relay

and ignition switch IG1 system (Refer to
STEP 2: Check engine warning lamp for

burnt-out bulb.
NO : Replace engine warning lamp.
STEP 3: Connector check: C-04 combination

meter connector
Connector: C-04
C-04
<L. H. Drive Vehicles>

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

<R. H. Drive Vehicles>
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 4342

AK304333 AB

NO : Repair.
13B-293
TROUBLESHOOTING

combination meter connector.
Connector: C-04

connector
Connector: C-303
C-04
C-303
3 2 1
6 5 4
Connector: C-04
C-04
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G
AK304334 AB

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 4342

AK304333 AB

harness side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 5 .
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 4342

AK304333 AB


No. 42) combination meter connector and
connector.
open/short circuit.
NO : Repair
13B-294
TROUBLESHOOTING

connector

<A/T> connector.
Connector: C-139
Connector: C-139
C-139 (GR)
C-139 (GR)
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
1
5
14
21
2
6
15
22

AK304262 AB

NO : Repair.
1
5
14
21
AK304262 AB

harness side.
Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .

TROUBLESHOOTING
STEP 8: Check connector: C-05 combination

meter connector
Connector: C-05
C-05 (L)
13B-295

connector.
circuit.
NO : Repair
connector
Connector: C-303
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G
C-303

3 2 1
6 5 4
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12

AK304335 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

NO : Repair.
AK304334 AB
13B-296
TROUBLESHOOTING

NO : Repair.

connector
Connector: C-04
C-04
Connector: C-05
C-05 (L)

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312

41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 4342
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12

AK304333 AB
Connector: C-303
AK304335 AB
C-303
3 2 1
6 5 4
AK304334 AB

connectors C-203 and C-205, and repair if
necessary.

NO : Repair.

TROUBLESHOOTING

13B-297

NO : Repair.
Connector: C-05
C-05 (L)

00 How to Use
P.00-6).
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G

11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12

AK304335 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

13B-298
TROUBLESHOOTING
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and Never Goes Out
Combination meter circuit
Ignition switch
C-303
1 2 3
4 5 6
LOCK
R
ST
ACC
IG1
IG2
2
L-B
C-203
6
2
7.5A
J/B
25
C-205
C-04 (*1)
B-W
C-04
42
31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
Combination meter
G
C-05 (*1)
C-04 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122
G
C-05
14
C-05 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
R-W
7
C-105
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
R-W
7
C-139
NOTE
1
5
14
21
2
3 4
6 7 8 9 10111213
15 16 1718 19 20
22 232425 2627
Engine-ECU <M/T>
Wire colour code

AK304143 AB
13B-299
TROUBLESHOOTING
OPERATION
(terminal No. 7) makes power transistor in unit be
in "ON" position, and that makes currents go on
engine warning lamp (terminal No. 14).
has detected failed sensor or failed actuator. Or
failure is possibly caused by short circuit or other
faults.
PROBABLE CAUSE
Short circuit in between engine warning lamp and
circuit.
Failed engine-ECU <A/T>
DIAGNOSIS PROCEDURE

Connector: C-139
C-139 (GR)
C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
1
5
14
21

AK304262 AB

to P.13B-20.)
NO : Go to Step 2 .

NO : Repair
13B-300
TROUBLESHOOTING

<A/T> connector.
Connector: C-139
C-139 (GR)
OK: System voltage


connector or engine-A/T-ECU <A/T>.

C-139 (GR)
4 3
13 12 1110 9 8 7
2019 18 17 16
2726 2524 23
2
6
15
22
00 How to Use
P.00-6).
1
5
14
21

AK304262 AB
Connector: C-05
C-05 (L)
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G

11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12

AK304335 AB

harness side.
Ignition switch: ON
13B-301
TROUBLESHOOTING
Inspection Procedure 5: Starting Impossible (No Initial Combustion) <M/T>
Stating impossible (no initial combustion) <M/T>
Ignition switch
C-303
LOCK
R
ST
IG1
ACC
IG2
1 2 3
4 5 6
Battery
5
B-Y
C-106
16
B-Y
B-L
B-19
4
B-Y
51
B-R
1
3132
33
35363738394041 42
444546474849 50
5253 545556 57
34
43
51
58
Engine-ECU
1
OFF
B-25
C-140
(MU803083)
ON
B-26
(MU801211)
Starter
Wire colour code

AK304155 AB

PROBABLE CAUSE
Failed battery
13B-302
TROUBLESHOOTING
DIAGNOSIS PROCEDURE


OK: 8 V or higher
Connector: C-140

NO : Check battery (Refer to GROUP 54A
C-140 (GR)
Battery On-vehicle Service Battery Test

P.54A-6).
34
43
51
58

OK:
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304455 AB

harness side.
Ignition switch: ST
OK: System voltage

NO : Go to Step 3 .

connector

NO : Go to Step 5 .
Connector: C-140

connector
Connector: C-303
C-140 (GR)
C-303
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
3 2 1
6 5 4

AK304455 AB

NO : Repair.

NO : Repair.
AK304334 AB
13B-303
TROUBLESHOOTING
STEP 6: Check ignition switch.

Connector: C-140
Connector: C-303
C-303
C-140 (GR)
3 2 1
6 5 4
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
AK304334 AB
Connector: B-26

AK304455 AB
Connector: C-303
B-26(B)
C-303
1
3 2 1
6 5 4
AK304334 AB
Check ignition switch (Refer to GROUP 54A

Ignition Switch Ignition Switch Inspection
P.54A-35).

engine-ECU connector and C-303 (terminal
No. 5) ignition switch connector.
open/short circuit.
AK304336 AB


NO : Repair.
STEP 8: Check connector: B-26 starter connector
Connector: B-26
B-26(B)
1

NO : Repair.
AK304336 AB
13B-304
TROUBLESHOOTING
STEP 9: Perform voltage measurement at B-26

starter connector.
Connector: B-26
B-26(B)
1
AK304336 AB

harness side.
Ignition switch: ST
OK: System voltage
YES : Check intermediate connectors B-19 and

damage.
NO : Repair.
connector
Connector: B-25
B-25

1

connector
Connector: C-303
C-303
AK304337 AB

NO : Repair.

starter connector.
Connector: B-25
3 2 1
6 5 4
AK304334 AB
B-25
Connector: B-26
1

harness side.
OK: System voltage
B-26(B)
1
AK304337 AB
AK304336 AB


battery.
open/short circuit.
13B-305
TROUBLESHOOTING

NO : Repair.

Connector: C-303
Connector: B-25
C-303
3 2 1
6 5 4
B-25
AK304334 AB
1
Connector: B-26
AK304337 AB

NO : Repair.
B-26(B)
1
AK304336 AB

connectors B-19 and C-106, and repair if necessary.
13B-306
TROUBLESHOOTING
Inspection Procedure 6: Starting Impossible (No Initial Combustion) <A/T>
Stating impossible (no initial combustion) <A/T>
Ignition switch
C-303
LOCK
R
ST
IG1
ACC
IG2
1 2 3
4 5 6
Battery
5
B-Y
C-106
16
B-Y
B-35
(MU802355)
10
1 2 3 4 5 6
7 8 9 10
B-L
B-R
B-Y
B-19
4
51
33
3132
35363738394041 42
444546474849 50
5253 545556 57
B-R
1
C-140
(MU803803)
34
43
51
58
Engine-A/T-ECU
1
OFF
ON
B-25
Starter
B-26
(MU801215)
Wire colour code

AK304329 AB

PROBABLE CAUSE
Failed battery
Failed inhibitor switch

13B-307
TROUBLESHOOTING
DIAGNOSIS PROCEDURE

engine-A/T-ECU connector.

OK: 8 V or higher
Connector: C-140

NO : Check battery (Refer to GROUP 54A
C-140 (GR)
Battery-On-vehicle Service Battery Test

P.54A-6).

OK:
C-140 (GR)

NO : Go to Step 3 .
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
STEP 3: Connector check: C-140 engine-A/T-ECU

connector
Connector: C-140
C-140 (GR)
AK304274 AB

harness side.
Ignition switch: ST
OK: System voltage
NO : Go to Step 5 .
STEP 5: Connector check: B-35 inhibitor switch

connector
Connector: B-35
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
B-35 (B)
6 5 4 3 2 1
10 9 8 7

AK304274 AB

NO : Repair.

NO : Repair.
AK304338 AB
13B-308
TROUBLESHOOTING

inhibitor switch connector
STEP 8: Check ignition switch

Connector: B-35
Connector: B-35
B-35 (B)
6 5 4 3 2 1
10 9 8 7
B-35 (B)
6 5 4 3 2 1
10 9 8 7
AK304338 AB
AK304338 AB

harness side.
Ignition switch: ST
OK: System voltage
NO : Go to Step 7 .
Connector: C-303
C-303
3 2 1
6 5 4

connector
Connector: C-303
AK304334 AB
Check ignition switch (Refer to GROUP 54A

Ignition switch Ignition Switch Inspection
P.54A-35).
YES : Check intermediate connector C-106 and
C-303
3 2 1
6 5 4

NO : Repair.
AK304334 AB

harness between B-35 (terminal No. 10)
open/short circuit.
13B-309
TROUBLESHOOTING
STEP 9: Check inhibitor switch.

Connector: B-35
Connector: B-35
B-35 (B)
6 5 4 3 2 1
10 9 8 7
B-35 (B)
AK304338 AB
6 5 4 3 2 1
10 9 8 7
AK304338 AB
Connector: C-140
Connector: B-26
C-140 (GR)
B-26(B)
AK304336 AB

YES : Check intermediate connectors B-19, and
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB
Check ignition switch (Refer to GROUP 23A On

vehicle Service A/T Control Component
Check Inhibitor Switch Check P.23A-149).

(terminal No. 51) engine-A/T-ECU
connector.
open/short circuit.

inhibitor switch connector and B-26
NO : Repair.
STEP 11: Check connector: B-26 starter
connector
Connector: B-26
B-26(B)
1

NO : Repair.
AK304336 AB
13B-310
TROUBLESHOOTING

starter connector.
Connector: B-26
B-26(B)
1
AK304336 AB

harness side.
Ignition switch: ST
OK: System voltage

inhibitor switch connector and B-26
damage.
NO : Repair.
connector
Connector: B-25
B-25

1

connector
Connector: B-35
AK304337 AB

NO : Repair.

starter connector.
Connector: B-25
B-35 (B)
6 5 4 3 2 1
10 9 8 7
AK304338 AB
B-25
Connector: B-26
1

harness side.
OK: System voltage
B-26(B)
1
AK304337 AB
AK304336 AB


battery.
open/short circuit.
13B-311
TROUBLESHOOTING

No. 9) inhibitor switch connector and B-26
NO : Repair.

Connector: B-35
Connector: B-25
B-35 (B)
6 5 4 3 2 1
10 9 8 7
B-25
AK304338 AB
1
Connector: B-26
AK304337 AB

NO : Repair.
B-26(B)
1
AK304336 AB

connectors B-19 and repair if necessary.
13B-312

TROUBLESHOOTING
Inspection Procedure 7: Starting Impossible (Starter Operative but No Initial Combustion)

Failure is possibly caused by failed ignition
circuit, failed fuel feed or other faults.
PROBABLE CAUSE
Failed battery
Timing belt broken
Failed idle speed control
Failed fuel system
Failed immobilizer system
Failed inhibitor-switch <A/T>

to P.13B-20)
NO : Go to Step 4 .
STEP 4: MUT-II/III actuator test
Item 07: Fuel pump
heard.
Inspection Procedure 25 P.13B-344)
DIAGNOSIS PROCEDURE
NOTE: .
*2
: R.H. drive vehicles
OK: 8 V or higher
YES : Go to STEP 2 .
NO : Check battery (Refer to GROUP 54

P.54A-6).
STEP 2: Check engine warning lamp for burnt out
bulb.
NO : Check engine-ECU <M/T> or
engine-A/T-ECU <A/T> power supply,

engine control relay and ignition switch IG1
system (Refer to Inspection Procedure 24
P.13B-338).
STEP 5. Check timing belt for breakage.

Engine: Cranking
OK: Camshaft rotates.
NO : Replace timing belt.
STEP 6. Check throttle body (throttle valve)

contamination.
OK:
NO : Go to Step 8 <M/T> , Go to Step 9 <A/T> .
13B-313
TROUBLESHOOTING

connector
Connector: C-140
STEP 9: Connector check: C-140 engine-A/T-ECU

connector
Connector: C-140
C-140 (GR)
34
43
51
58
C-140 (GR)
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304455 AB
C-140 (GR)
Connector: C-303
34
43
51
58
C-303
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB
3 2 1
6 5 4
Connector: C-303
AK304334 AB
C-303

YES : Check intermediate connectors B-19 and

circuit.
NO : Repair.
3 2 1
6 5 4
AK304334 AB


(terminal No. 51) engine-A/T-ECU
connector.
circuit.
NO : Repair.
13B-314

TROUBLESHOOTING

Code No. P0335 P.13B-169).

P.13B-435).
cylinder.
system P.13B-125.)
system P.13B-130.)
system P.13B-135.)
system P.13B-140.)

Inspection Procedure 31)

STEP 13: Fuel pressure measurement.
P.13B-426).
NO : Repair.
STEP 14: Replace engine-ECU <M/T> or

engine-A/T-ECU <A/T>
After replacing the engine-ECU <M/T> or
engine-A/T-ECU <A/T>, re-check the trouble
symptoms.

NO : Check end.
Inspection Procedure 8: Starting Impossible (Initial Combustion But No Complete Combustion),

Improper Starting (Long Time to Start)
Failure is possibly caused by poor ignition,
incorrect air-fuel ratio at cranking, improper fuel
pressure or other faults.
PROBABLE CAUSE
Failed battery
Failed fuel system
Air-fuel ratio control
Failed exhaust gas cleaning system
Timing belt not in place
DIAGNOSIS PROCEDURE
Q: Have the battery terminal been disconnected?
minutes.
NO : Go to Step 2 .

OK: 8 V or higher
NO : Check battery (Refer to GROUP 54

P.54A-6).
to P.13B-20)
NO : Go to Step 4 .

TROUBLESHOOTING


13B-315
cylinder.
(Refer to Code No. P0201: No.1 Injector
System P.13B-125.)
System P.13B-130.)
System P.13B-135.)
System P.13B-140.)



STEP 6: Check throttle body (throttle valve)
contamination.
STEP 7: MUT-II/III actuator test
Item 07: Fuel pump
heard.

inlet manifold.


STEP 12: Check spray condition of injector.
P.13B-435).
STEP 13: Check compression pressure.

11C On-vehicle Service Compression
Pressure Check P.11C-15).
NO : Repair.

NO : Repair.
STEP 14: Check EGR valve (stepper motor) itself.

Valve (stepper motor) Check <4G69> P.17-25].

Check injector for operating sound at engine
cranking (Refer to P.13B-435).

13B-316

TROUBLESHOOTING
STEP 15: Replace engine-ECU <M/T> or

After replacing the engine-ECU <M/T> or
engine-A/T-ECU <A/T>, re-check the trouble
symptoms.

NO : Check end.
Inspection Procedure 9: Unstable Idling (Rough Idling, Hunting), Improper Idling Speed (Too High or
too Low), Engine Stalls during Idling (Die Out)
Probable causes can be widely found in ignition
system, air-fuel ratio control system, idle speed
control system, fuel system, etc. A sudden
engine stall is possibly caused by poor connector
contact.
PROBABLE CAUSE
Failed fuel system
Failed intake/exhaust system
DIAGNOSIS PROCEDURE
Q: Has the battery terminal been disconnected?
minutes.
NO : Go to Step 2 .

to P.13B-20).
NO : Go to Step 3 .

c. Item 14: Throttle position sensor (sub)
d. Item 21: Engine coolant temperature sensor
e. Item 77: Accelerator pedal position sensor
(sub)
f. Item 78: Accelerator pedal position sensor
(main)
g. Item 79: Throttle position sensor (main)

NO : Check power steering fluid pressure switch
circuit (Refer to Code No. P0551

P.13B-207).
13B-317
TROUBLESHOOTING
STEP 6: Check throttle body (throttle valve)

contamination.
inlet manifold.
NO : Repair.

<A/T> connector.
Connector: C-140

P.13B-435).
cylinder.
(Refer to Code No. P0201: No. 1 Injector
System P.13B-125.)
System P.13B-130.)
System P.13B-135.)
System P.13B-140.)
C-140 (GR)
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB
STEP 9: Check timing marks of timing belt.


b. Item 39: Cylinder 2, 3 oxygen sensor (front)
c. Item 59: Cylinder 1, 4 oxygen sensor (rear)

OFF causes the voltage to increase.
13B-318
TROUBLESHOOTING

Connector: C-140

engine-A/T-ECU <A/T> connector and B-30
(terminal No. 1) alternator connector.
Connector: C-140
C-140 (GR)
C-140 (GR)

C-140 (GR)
C-140 (GR)
34
43
51
58
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352
34
43
51
58

AK304274 AB
33
32 31
42 4140 39 38 37 36 35
50 49 4847 46 4544
57 5655 54 5352

AK304274 AB
Connector: B-30
Connector: B-30
B-30 (GR)
B-30 (GR)
4 3 2 1
Harness side
connector

NO : Repair.
4 3 2 1
AK304037AB
Harness side
connector
AK304037AB

damage.
NO : Repair.

TROUBLESHOOTING
STEP 14. Replace alternator

After alternator is replaced, re-check for trouble
symptom.
13B-319
NO : Check A/C load signal system (Refer to

NO : Check end.

<A/T> connector.
Connector: C-141

P.13B-435).
C-141(GR)

11A On-vehicle Service Compression

C-141 (GR)

NO : Repair.
6463
62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483

AK304154 AB

Engine: Idling
A/C switch: ON (A/C compressor ON)
OK:
1 V or less (with outside air temperature
sensor ambient temperature at 18C or
higher and A/C set for maximum air flow at
minimum temperature)
System voltage (with A/C set for minimum air
flow at room temperature)

itself.
Control Solenoid Valve Check P.17-20)

Valve (Stepper Motor) Check <4G69> P.17-25].
13B-320

TROUBLESHOOTING

Item 07: Fuel pump
OK: Operating sounds of fuel pump can be
heard.
STEP 22. Replace engine-ECU <M/T> or

After engine-ECU <M/T> or engine-A/T-ECU
<A/T> is replaced, re-check for trouble symptom.


inspection Procedure 25 P.13B-344).

NO : Check end.
Inspection Procedure 10: The Engine Stalls when Starting the Car (Pass Out)
Engine stall on starting is possibly caused by
misfire due to failed spark plug, improper air-fuel
ratio at accelerator pedal depression or other
faults.

PROBABLE CAUSE

DIAGNOSIS PROCEDURE


to P.13B-20).
NO : Go to Step 2 .
b. Item 77: Accelerator pedal position sensor
(sub)
c. Item 78: Accelerator pedal position sensor
(main)
d. Item 79: Throttle position sensor (main)

inlet manifold.
NO : Repair.


TROUBLESHOOTING
13B-321
Inspection Procedure 11. The Engine Stalls when Decelerating

Engine stall on deceleration is possibly caused by
insufficient air intake, improper air-fuel ratio due
to failed exhaust gas recirculation system or
other faults.
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
to P.13B-20).
NO : Go to Step 2 .

(sub)
(main)


13B-322

TROUBLESHOOTING
Inspection Procedure 12: Engine Does Not Revole Up

Failure is possibly caused by failed fuel system,
throttle valve opening control system ignition
system or other faults.
PROBABLE CAUSE
Failed fuel system
Failed throttle valve opening control system
DIAGNOSIS PROCEDURE
to P.13B-20).
NO : Go to Step 2 .

(sub)
(main)


Fuel pressure measurement P.13B-426).
NO : Repair.

TROUBLESHOOTING
13B-323
Inspection Procedure 13: Hesitation, Sag, Poor Acceleration, Stumble, Surge

Failure is possibly caused by failed ignition
system, improper air-fuel ratio, throttle valve
opening control system improper compression
pressure or other faults.
PROBABLE CAUSE
Failed fuel system
Improper compression pressure

a. Idem 13: Intake air temperature sensor
b. Item 14: Throttle position sensor (sub)
d. Item 77: Accelerator pedal position sensor
(sub)
e. Item 78: Accelerator pedal position sensor
(main)
f. Item 79: Throttle position sensor (main)

DIAGNOSIS PROCEDURE
to P.13B-20).
NO : Go to Step 2 .

P.13B-435).
cylinder.
System P.13B-125).
System P.13B-130).
System P.13B-135).
System P.13B-140).

itself.
Control Solenoid Valve Check P.17-20).

13B-324

TROUBLESHOOTING

b. Item 39: Cylinder 2, 3 oxygen sensor (front)
c. Item 59: Cylinder 1, 4 oxygen sensor (rear)


Measure fuel pressure (Refer to P.13B-426).
NO : Repair.

11C On-vehicle Service Compression
NO : Repair.
Inspection Procedure 14. The Feeling of Impact or Vibration when Accelerating

Failure is possibly caused by failed ignition leak
with rise in spark plug-required voltage at
acceleration, throttle valve opening control
system.
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
to P.13B-20).
NO : Go to Step 2 .

(sub)

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SRS SERVICE PRECAUTIONS . . . . .

SUPPORT LOCATIONS FOR LIFTING

GENERAL DATA AND

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

PRECAUTIONS BEFORE SERVICE.

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR AND

INDICATION OF TIGHTENING TORQUE

Symbols are used to show the locations for lubrication

Multi-purpose grease unless there is a

HOW TO USE THIS MANUAL

For bolts and nuts which do

parts sets are

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

Does not reoccur

After taking note of the

Recheck trouble symptom.

Refer to the INSPECTION CHART

Read the diagnosis code.

Refer to the INSPECTION CHART

2. SYSTEM OPERATION AND SYMPTOM

4. DIAGNOSIS CODE CHART

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

6. TROUBLE SYMPTOM CHART

<Using the MUT-III>

8. SERVICE DATA REFERENCE TABLE

9. CHECK AT ECU TERMINALS

Connect the MUT-II to the diagnosis connector, and

Connect the MUT-III to the 16-pin diagnosis

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

NOTE: The ABS warning lamp may flash when the

ERASING DIAGNOSIS CODE (BY USING NO

<Using the MUT-III>

<Using the MUT-III>

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

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

1. Use the special tool diagnosis code check

HOW TO USE THE INSPECTION

The causes of many of the problems occurring in

Relevant circuit(s) of the component which

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Explains about the basic

CONNECTOR MEASUREMENT SERVICE

IF INSPECTING WITH THE CONNECTOR

Be sure to use special tool harness connector

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

<Ordinary (non-waterproof) Connectors>

Use the special tool inspection harness (MB991219)

Check by inserting the multi-meter test probe from

At this time, be careful not to short the connector

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR INSPECTION SERVICE

Low connection pressure due to rusted terminals

Stretched or broken wires

If the connector pin stopper is damaged, the terminal

Harness wire breakage

Connector is disconnected or improperly connected

Use the special tool inspection harness (MB991219)

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

INSPECTION SERVICE POINTS FOR A

Remove the blown fuse and measure the resistance

HOW TO COPE WITH INTERMITTENT