2008 Lancer Service Manual

00-1
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

NOTES
00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 00-2 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . 00-6

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 00-8
TARGETS OF DEVELOPMENT . . . . 00-2 ACTIVE SAFETY. . . . . . . . . . . . . . . . . . . . . 00-9
PASSIVE SAFETY . . . . . . . . . . . . . . . . . . . 00-10
PRODUCT FEATURES . . . . . . . . . . . 00-2 ENVIRONMENTAL PROTECTION . . . . . . . 00-12
SERVICEABILITY AND RELIABILITY . . . . 00-12
TECHNICAL FEATURES. . . . . . . . . . 00-3
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 VEHICLE IDENTIFICATION . . . . . . . . 00-13
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4
BODY DIMENSIONS AND SPACIOUS GENERAL DATA AND
CABIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5 SPECIFICATIONS . . . . . . . . . . . . . . . 00-15
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5
00-2 GENERAL
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

M2000029000758
ABBREVIATIONS M/T:Indicates manual transaxle, or models equipped

The following abbreviations are used in this manual with manual transaxle.
for classification of model types. CVT: Indicates the continuously variable transmis-
2.0 L Engine:1.998 liter <4B11> engine, or a model sion.
equipped with such an engine. FWD: 2-wheel drive vehicles.
MFI: Multiport fuel injection, or engines equipped SWS: Simplified wiring system
with multiport fuel injection. A/C: Air conditioning.
PCM: Powertrain control module
TARGETS OF DEVELOPMENT
M2000004001215
Since first launched in 1973, the LANCER has
always been acknowledged as a motor sport based
vehicle in the sporty sedan market. Keeping with the
tradition of these LANCERS, the new LANCER has
been developed aiming at acquiring additional
LANCER users, and even more, Mitsubishi custom-
ers.
PRODUCT FEATURES
M2000005000594
STYLING COMFORT
The global standard body size has been adopted to The Rockford Fosgate premium sound system
match the market trend. has been installed.
The comfort equipment such as keyless opera-
DRIVING PERFORMANCE tion system (KOS)*1, HDD navigation, handsfree
The newly-developed aluminum block engine phone for Bluetooth*2 has been adopted.
and CVT have been adopted to achieve excellent
NOTE: .
power and performance.
1. The power and performance greatly exceeds *1: In this manual, F.A.S.T.-key (Free-hand
that of the previous LANCER. Advanced Security Transmitter) is described
as Keyless Operation System (KOS). Refer to
2. The fuel efficiency in cruising range has been
greatly improved from the previous LANCER, P.42B-2.
both for M/T and CVT. *2: Refer to P.54A-29.
High rigidity of body and suspension has been
achieved. SAFETY
With fine tuning of suspension, sporty steering, The impact safety body aiming at high score in
flat cornaring and superior driving comfort have New Car Assessment Program (NCAP) has been
been achieved. developed.
The paddle shift has been adopted to achieve With consideration of Insurance Institute for High-
"Fun to Drive." way Safety (IIHS), going ahead of competitors,
the knee air bag has been equipped as a stan-
dard feature in addition to the driver's and pas-
senger's (front) air bags, side-air bag, and curtain
air bag.
GENERAL
TECHNICAL FEATURES
00-3
TECHNICAL FEATURES
EXTERIOR
M2000017000966
DESIGN FEATURES
The robust styling to create the image of LANCER
EVOLUTION, the symbol of Mitsubishi Motors sport
DNA, has been established.
12
10, 11
1
3, 8
6 5
2,7
9
AC607908AC
. .
BETTER APPEARANCE BETTER USER-FRIENDLINESS

1. Radiator grille integrated front bumper 10. Electric remote-controlled door mirrors
2. Side air dams 11. Heated door mirrors
3. Rear spoiler .
5. Air dam skirt panels BETTER PRODUCT PACKAGE

.
12. Vehicle speed sensitive intermittent time variable
BETTER AERODYNAMIC windshield wiper
CHARACTERISTICS .
4. Aerodynamic front bumper SUPPORT RECYCLING OF RESOURCES

5. Air dam skirt panels Uses PP (polypropylene) materials that are easy to
6. Engine room under cover with bulges at left and recycle and easy to stamp material symbols on the
right (Refer to P.51-3) plastic (resin) parts.
7. Side air dams
8. Rear spoiler
9. Aerodynamic rear bumper
00-4 GENERAL
TECHNICAL FEATURES
INTERIOR
M2000018000969
DESIGN FEATURES
Functionality, interior comfort, and safety have been
emphasized, giving interior design for elegance and
relaxation. Various measures have been taken to
protect the environment and recycle resources.
AC609922
Quality improvement Side-airbag

Two-tone interior Curtain air bag
Full interior trim ELR 3-point seat belt (driver side)
ELR/ALR 3-point seat belt (front passenger side)
Usability improvement
ELR/ALR 3-point seat belt (rear)
Armrest (floor console, rear seat, front door trim,
Seat belt retractor with a driver's side preten-
rear door trim)
sioner and variable force limiter
Cup holder (floor console, rear seat armrest)
Seat belt retractor with a passengers side pre-
Bottle holder (front door trim)
tensioner and force limiter
Convenient storage Headliner energy absorption rib
Glove box
Consideration for the optimum driving position
Card holder (Glove box)
Seat height adjustment (drivers seat)
Seatback pocket [front seat (driver side)]
Headrestraint with height adjustment (front, rear)
Floor console box
Seat slide adjustment (front)
Door pocket (front door trim, rear door trim)
Tissue paper holder (floor console) Measures for resource recycling
Aggressively use PP materials that are easy to
Safety improvement
recycle and easy to stamp material symbols on
Front and rear collision protection seat mecha-
the plastic (resin) parts.
nism (front seat)
ISO-FIX lower anchor (rear seat outside) Reduction of chemical material (formaldehyde*,
Upper tether anchor (rear shelf) organic solvent)
deivers and passengers (front) air bags NOTE: *: Clear and colourless, toxic, irritating odour
Knee air bag
GENERAL
TECHNICAL FEATURES
00-5
BODY DIMENSIONS AND SPACIOUS CABIN
M2000019000285
8 9 10
2 3 4 7
1 6
AC609780 AB
No. Item Dimension

1 Overall length mm (in) 4,570 (180.0)
2 Front overhang mm (in) 955 (37.6)
3 Wheel base mm (in) 2,635 (103.7)
4 Rear overhang mm (in) 980 (38.7)
5 Overall height mm (in) 1,490 (58.7)
6 Overall width mm (in) 1,760 (69.4)
7 Tread mm (in) 1,530 (60.2)
8 Front head room mm (in) 1,005 (39.6)
9 Rear head room mm (in) 935 (36.9)
10 Interior width mm (in) 1,390 (54.7)
ENGINE
M2000020000717
The newly-developed 4B11 MIVEC engine has been
adopted. For the 4B11 engine, the aluminum die-cast
cylinder block has been adopted to achieve the top
level of this class in high performance, good fuel effi-
ciency, while being compact and lightweight.
Technology and purpose for 4B11 engine adoption

Item High Compact and Low exhaust Low vibration Reliability
performance lightweight gas improvement
/good fuel
efficiency
Aluminum die-cast cylinder block X

Cylinder head cover made of resin X
Direct injection DOHC valve drive X X X
Intake/exhaust continuously variable valve X X X
timing (MIVEC)
Timing chain cam drive X X
Serpentine auxiliary drive X
00-6 GENERAL
TECHNICAL FEATURES
Item High Compact and Low exhaust Low vibration Reliability

performance lightweight gas improvement
/good fuel
efficiency
Isometric long port intake manifold made of X X
resin
Exhaust manifold made of stainless steel X X X
(double structure)
Rear exhaust engine layout X X
Ultra fine injection X
EGR system <California only> X X
Water pump with shroud-integrated resin X
impeller
Returnless fuel system X
Iridium spark plug X X
TRANSAXLE
M2000021000732
MANUAL TRANSAXLE saxle mechanism by steel belt & pulley" to achieve

F5MBB type (5M/T) has been adopted. "high driving performance" and "better fuel econ-
omy." Depending on the driving conditions, the com-
CONTINUOUSLY VARIABLE TRANSAXLE fortable gear ratio is automatically and continuously
selected from low to overdrive, ensuring
(CVT)
driver-intended smooth driving without shift shocks
The new CVT has been developed to achieve excel- related to acceleration pedal operation.
lent fuel economy, driving ease, and fun. This CVT
achieves quick and smooth acceleration suitable for
LANCER from any speeds. The CVT combines
"torque converter" and "continuously variable tran-
GENERAL
TECHNICAL FEATURES
00-7
PADDLE SHIFT <Vehicle with sports mode (CVT) >
Down shift lever
AC609992
Up shift lever
Down shift
Up shift
(operate it for 2 seconds or more to return to D range.)
AC611129AB
For some models, the paddle-shaped up shift/down

shift lever has been fitted just behind the steering
wheel to allow the driver to operate up shift or down
shift with his/her hands kept on the steering wheel.
00-8 GENERAL
TECHNICAL FEATURES
SUSPENSION
M2000023000590
<REAR SUSPENSION>
Shock absorber
Upper arm
Coil spring
Stabilizer bar <GTS, ES>
<FRONT SUSPENSION>
Coil spring
Stabilizer link
Toe control arm
Stabilizer bar Rear crossmember
Stay
Front Trailing arm

suspension strut
Lower arm
Front axle crossmember

AC609418AD
A MacPherson strut type suspension is adopted Flexible steering stability is achieved, along with
for the front suspension. comfortable driving, secure handling, and flat cor-
A trailing arm type multi-link suspension is nering.
adopted for the rear suspension.
GENERAL
TECHNICAL FEATURES
00-9
ACTIVE SAFETY
M2000031000700
BRAKING SYSTEM <VEHICLES WITH ABS>

ABS warning light ABS warning light <Vehicles for rear drum brake>
Brake warning light Wheel speed sensor
SERVICE
REQUIRED
Brake warning light
Magnetic encoder for

Data link connector wheel speed detection
CHECK Stoplight switch
Hydraulic unit,
ABS control unit (ABS-ECU)
Wheel speed sensor

Wheel speed sensor wheel speed detection
wheel speed detection <Vehicles with rear disc brake> AC608518AC
The ABS that ensures directional stability and con- The magnetic encoder for detecting the wheel
trollability during hard braking. ABS is standard speed has been installed instead of the rotor as
equippment on the ES and GTS models but is the wheel speed sensor.
optional. For wiring harness simplification and secure data
This ABS uses a 4-sensor system that controls all communication, CAN *2 bus has been adopted as
four wheels independently of each other, and has the a tool of communication with another ECU.
following features:
NOTE: .
EBD *1 (Electronic Brake-force Distribution sys-
*1: EBD (Electronic Brake-force Distribution)
tem) control that can obtain ideal rear wheel
brake force has been employed. *2: For more information about CAN (Controller
Area Network), refer to GROUP 54C P.54C-2.
00-10 GENERAL
TECHNICAL FEATURES
PASSIVE SAFETY
M2000032000769
SRS AIR BAGS

Driver's air bag module Passenger's (front)
Seat belt with air bag module
pre-tensioner
Side-airbag module
Curtain air bag module
Knee air bag module
AC609360 AB
Driver's and passenger's (front) air bags, side-air The curtain air bag is activated simultaneously
bags, knee air bag, curtain air bags and seat with the side-air bag upon a side collision to pro-
belts with pre-tensioner are installed on all the tect the heads of the front seat and second seat
vehicles as standard. passengers.
The SRS is a system that is effective with the All the air bag modules are equipped with the
seat belt fastened, and it is designed as a supple- inflator that does not contain toxic sodium azide.
mental system of the seat belt. The seat belt pre-tensioner is activated simulta-
The advanced air bag system is adopted to the neously with the deployment of driver's and pas-
driver's and passenger's (front) sides. When a senger's (front) air bags in case of a frontal
frontal impact exceeds the threshold upon a fron- collision. Seat belts are pulled in to eliminate the
tal collision, or depending on the seat position slack upon a collision, thus improving the initial
(driver's seat side), the air bag inflates the cush- occupant restraint, and reducing the travel dis-
ion air bag in two stages, improving the protection tance of the occupants. For the driver's seat, in
for the front seat passengers. When a frontal addition to the seat belt pre-tensioner for the
impact exceeds the threshold, the knee air bag is shoulder side, the lap pre-tensioner has been
instantaneously inflated to protect the passen- installed on the outer seat belt lower anchor side
ger's feet (knee and leg). in order to improve the restraining performance in
The side-air bag is activated when an impact the waist and the chest areas.
exceeds the threshold upon a side collision, and
the cushion air bag is instantaneously inflated to
protect the chest area of the front seat passen-
gers.
GENERAL
TECHNICAL FEATURES
00-11
BODY CONSTRUCTION
4 Section A - A
6
5
Crush box
A
2
1 3
AB609784AB
The front and rear structures to absorb high energy, 6. The roof bow and roof rail and the side outer
and the strong and sturdy cabin structure is adopted panel have been jointed by the brace to improve
to reduce the risk of passenger injuries at front-, driving stability.
rear-, and side-impact collisions, secure the space
for life protection, and facilitate rescuing passengers. SAFETY-ENHANCED FRONT SEATS
The structures also have the following features: The front seats are designed to minimize the risk of
1. The crush box structure is adopted for the front whiplash in a collision from the rear.
end of the sidemember to reduce the vehicle The head restraints have been ideally angled for-
repair cost in a low speed collision. ward, while the seat frame was moved toward the
2. An annular construction is used for the side struc- rear.
ture reinforcement to improve collision safety and
vehicle body rigidity. OTHER SAFETY FEATURES
3. The front frame structure is supported in three Brake pedal recede-control device
directions by the dash crossmember center, dash Collapsible steering column
crossmember lower, and front sidemember rear Child-protection rear door locks
in order to improve the frontal collision character- Front fog lamps
istics, and increase the vehicle body rigidity. Passengers seat weight sensor system
4. The crush box structure has been changed to 3-point ELR seat belts <Drivers seat, rear seat
straight type with an octagon cross-section so on each side>
that the structure can effectively absorb energy 3-point ELR/ALR seat belts <Passenger's seat,
from the impact at the time of collision. rear seat center>
5. The closed section structure has been adopted Tire pressure monitoring system (TPMS)
for the roof bow and roof rail to improve driving
stability and reduce vibration and noise.
00-12 GENERAL
TECHNICAL FEATURES
ENVIRONMENTAL PROTECTION
M2000027000473
Mitsubishi has given careful consideration to protec-
tion of natural resources and the environment in the
vehicle. Environmentally friendly features are shown
below.
Items Dealing with Environmental Protection
Prevention of Parts name Features
atmospheric
pollution
Adoption of easy Bumper, Instrument panel, Door trim, Interior Adoption of thermoplastic resin
recycling material trim and soon
Expansion of Bumper, Instrument panel, Door trim, Radiator Re-use of material discarded in plant
recycled material grille
Sound absorbing material in dash panel and Re-use of discarded material in other
roof, Oil level gauge industry
Reduction of Fuel tank, Radiator, Heater core, Battery cable Adoption of lead free material
hazardous terminal, Balance weight for wheel, Pressure
substances hose for power steering, Glass ceramics print,
Harness, Electrostatic coating, Intake valve
sheet, Crank bearing metal, Connecting rod
bearing metal, Connecting rod
SERVICEABILITY AND RELIABILITY

M2000028000647
ENHANCED DIAGNOSIS SYSTEM ETACS

Diagnosis functions have been included for the fol- Radio and CD player and visual information
lowing systems, so that it is possible to use the scan equipment etc.
tool to read the diagnosis codes and service data Heater and air conditioning
and to carry out actuator tests. In addition, it is also
possible to read the diagnosis codes by the flashing ADAPTATION OF BOLTS AND NUTS
of the warning light in some systems. WITH STABILIZER FOR COEFFICIENT OF
MFI
Auto-cruise control system
FRICTION *
CVT The bolts and nuts with stabilizer for coefficient of
ABS friction are used for the connections such as the sus-
Power window pension arm and crossmember in order to stabilize
Keyless operation system (KOS) the axial force and to ensure the high axial force at
bolt/nut connections, resulting in improved reliability.
NOTE: In this manual, F.A.S.T.-key (Free-hand
Advanced Security Transmitter) is described as NOTE: *: The bolts and nuts with stabilizer for coeffi-
Keyless Operation System (KOS). cient of friction mean that the bolts and nuts with sur-
SRS air bag face treatment to stabilize and reduce the coefficient
Immobilizer of friction, allowing to achieve the stable axial force
Combination meter and to secure the high axial force with low tightening
Headlight auto leveling device torque.
GENERAL
VEHICLE IDENTIFICATION
00-13
M2000001002662
.
VEHICLE IDENTIFICATION NUMBER LOCATION

The vehicle identification number (VIN) is located on a plate
attached to the left top side of the instrument panel.
AC611242
VEHICLE IDENTIFICATION CODE CHART PLATE

All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
No. Item Content
1 Country J: Japan
J A 3 AU 2 6 U _ 8 U 0 0 0 0 0 1
2 Make A: Mitsubishi
12 3 Vehicle type 3: Passenger car
1 2 3 4 5 6 7 8 9 10 11 4 Others Restraint system
AC609472AB A: Driver and passenger air bags
5 Line U: LANCER
6 Price class 1: Economy
2: Low
8: Sports
7 Body 6: 4-door sedan
8 Engine U: 2.0 L (4B11) MIVEC
9 Check digits* 0, 1, 2, 3, -----------9, X
10 Model year 8: 2008 year
11 Plant U: Mizushima
12 Serial number 000001 to 999999
NOTE: *: Check digit means a single number, or letter X, used

to verify the accuracy of transcription of vehicle identification
number.
00-14 GENERAL
VEHICLE IDENTIFICATION NUMBER LIST

.
VEHICLES FOR USA
(VEHICLES FOR FEDERAL EMISSION REGULATION)

VIN Brand Engine Model code
(Except sequence number) displacement
JA3AU16U_8U MITSUBISHI 2.0L CY4ASNLHL2M
LANCER CY4ASTLHL2M
JA3AU26U_8U CY4ASNSHL2M
CY4ASTSHL2M
JA3AU86U_8U CY4ASNXHL2M
CY4ASTXHL2M
(VEHICLES FOR CALIFORNIA EMISSION REGULATION)

LANCER CY4ASTLHL7M
CY4ASTSHL7M
CY4ASTXHL7M
.
VEHICLES FOR PUERTO RICO

LANCER CY4ASTLHL2M
CY4ASTSHL2M
CY4ASTXHL2M
.
VEHICLES FOR CANADA

LANCER CY4ASTLHL3M
CY4ASTSHL3M
CY4ASTXHL3M
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-15
M2000030001034
.
GENERAL SPECIFICATIONS
2 4 7 5 6 9
1 3
AC608677AB
Item CY4ASNLHL2M/ CY4ASTLHL2M/ CY4ASNSHL2M/

3M/7M 3M/7M 3M/7M
Vehicle Overall width 1 1,760 (69.4) 1,760 (69.4) 1,760 (69.4)
dimension mm Tread-front 2 1,530 (60.2) 1,530 (60.2) 1,530 (60.2)
(in)
Overall length 3 4,570 (180.0) 4,570 (180.0) 4,570 (180.0)
Overhang-front 4 955 (37.6) 955 (37.6) 955 (37.6)
Wheelbase 5 2,635 (103.7) 2,635 (103.7) 2,635 (103.7)
Overhang-rear 6 980 (38.7) 980 (38.7) 980 (38.7)
Ground clearance 7 147 (5.8) 147 (5.8) 147 (5.8)
Overall height (unladen) 8 1,490 (58.7) 1,490 (58.7) 1,490 (58.7)
Tread-rear 9 1,530 (60.2) 1,530 (60.2) 1,530 (60.2)
Vehicle weight Curb weight 1,325 (2,922) 1,360 (2,999) 1,335 (2,944)
kg (lb) Gross vehicle weight rating 1,850 (4,079) 1,850 (4,079) 1,850 (4,079)
Gross axle weight rating-front 1,010 (2,227) 1,010 (2,227) 1,010 (2,227)
Gross axle weight rating-rear 910 (2,007) 910 (2,007) 910 (2,007)
Seating capacity 5 5 5
Engine Model No. 4B11 4B11 4B11
Piston displacement cm3 (cu in) 1,998 (121.9) 1,998 (121.9) 1,998 (121.9)
Maximum output kW/r/min 113/6,000 (152/6,000) <Except California>,
(HP/r/min) 107/6,000 (143/6,000) <California>
Maximum torque N m/r/min 198/4,250 (146/4,250) <Except California>,
(ft-lb/r/min) 194/4,250 (143/4,250) <California>
Fuel system Fuel supply system Electronic controlled multiport fuel injection
Transaxle Model No. F5MBB F1CJA F5MBB
Type 5-speed manual CVT 5-speed manual
Turning radius m (ft) 5.0 (16.4) 5.0 (16.4) 5.0 (16.4)
00-16 GENERAL
2 4 7 5 6 9
1 3
AC608677AB
ITEM CY4ASTSHL2M/ CY4ASNXHL2M/ CY4ASTXHL2M/

3M/7M 3M/7M 3M/7M
Vehicle Overall width 1 1,760 (69.4) 1,760 (69.4) 1,760 (69.4)
dimension mm Tread-front 2 1,530 (60.2) 1,530 (60.2) 1,530 (60.2)
(in)
Overall length 3 4,570 (180.0) 4,570 (180.0) 4,570 (180.0)
Overhang-front 4 955 (37.6) 955 (37.6) 955 (37.6)
Wheelbase 5 2,635 (103.7) 2,635 (103.7) 2,635 (103.7)
Overhang-rear 6 980 (38.7) 980 (38.7) 980 (38.7)
Ground clearance 7 147 (5.8) 147 (5.8) 147 (5.8)
Overall height (unladen) 8 1,490 (58.7) 1,490 (58.7) 1,490 (58.7)
Tread-rear 9 1,530 (60.2) 1,530 (60.2) 1,530 (60.2)
Vehicle weight Curb weight 1,370 (3,021) 1,375 (3,032) 1,410 (3,109)
kg (lb) Gross vehicle weight rating 1,850 (4,079) 1,850 (4,079) 1,850 (4,079)
Gross axle weight rating-front 1,010 (2,227) 1,010 (2,227) 1,010 (2,227)
Gross axle weight rating-rear 910 (2,007) 910 (2,007) 910 (2,007)
Seating capacity 5 5 5
Engine Model No. 4B11 4B11 4B11
Piston displacement cm3 (cu in) 1,998 (121.9) 1,998 (121.9) 1,998 (121.9)
Maximum output kW/r/min 113/6,000 (152/6,000) <Except California>,
(HP/r/min) 107/6,000 (143/6,000) <California>
Maximum torque N m/r/min 198/4,250 (146/4,250) <Except California>,
(ft-lb/r/min) 194/4,250 (143/4,250) <California>
Fuel system Fuel supply system Electronic controlled multiport fuel injection
Transaxle Model No. F1CJA F5MBB F1CJA
Type CVT 5-speed manual CVT
with sport mode
Turning radius m (ft) 5.0 (16.4) 5.0 (16.4) 5.0 (16.4)
00E-1
GROUP 00E
GENERAL
<ELECTRICAL>
CONTENTS
HARNESS CONNECTOR INSPECTION INSTRUMENTS . . . . . . . . . . 00E-8

INSPECTION . . . . . . . . . . . . . . . . . . . 00E-2 CHECKING FUSES. . . . . . . . . . . . . . . . . . . 00E-9
CHECKING SWITCHES . . . . . . . . . . . . . . . 00E-10
HOW TO DIAGNOSE. . . . . . . . . . . . . 00E-6 CHECKING RELAYS . . . . . . . . . . . . . . . . . 00E-11
HOW TO DIAGNOSE . . . . . . . . . . . . . . . . . 00E-6 CABLE AND WIRE CHECK . . . . . . . . . . . . 00E-12
TROUBLESHOOTING STEPS . . . . . . . . . . 00E-6 BATTERY HANDLING . . . . . . . . . . . . . . . . 00E-12
INFORMATION FOR DIAGNOSIS . . . . . . . 00E-6 GENERAL ELECTRICAL SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 00E-7 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E-13
00E-2 GENERAL <ELECTRICAL>
HARNESS CONNECTOR INSPECTION

M1001003900201
CONNECTOR CONTINUITY AND VOLTAGE TEST

Required Special Tools:
MB991219: Test Harness Set
MD998459: Test Harness
Follow the steps below to avoid causing poor connector contact
and/or reduced waterproof performance of connectors when
checking continuity and/or voltage at waterproof connectors.
CAUTION
MD998459
Never backprobe a waterproof connector. Backprobing a
connector may cause the terminals to corrode, deteriorat-
ing circuit performance.
1. If the circuit to be checked is a closed state, use a special
tool like MD998459.
AC000014 AB
CAUTION
Forcing the probe into the terminal may open the terminal,
causing intermittent or poor contact and creating an open
circuit.
2. If the connector is disconnected for checking and the facing
part is the female pin side, use an appropriate male terminal
for checking the contact pressure of connector pins (like
MB991219 MB991219).
CAUTION
Do not simultaneously contact more than one terminal
AC000015 AB with the probe. Contacting two or more terminals at the
same time may damage a circuit, possibly to the point of
starting an electrical fire.
3. If the facing part is the male pin side, either carefully touch
the probe to the pin so it does not accidently contact other
pins, or use an appropriate female terminal.
IMPROPER TERMINAL ENGAGEMENT CHECK

Terminals inside a connector may not engage properly even if
the connectors engage. Make sure that each terminal does not
come out of the connector when gently pulling each harness
wire. If it does, repair or replace the terminal and/or connector.
AC000016
TSB Revision
GENERAL <ELECTRICAL>
00E-3
CONNECTOR TERMINAL ENGAGEMENT AND
DISENGAGEMENT
Loosely engaged terminals can be repaired by removing the
female terminal from the connector housing and raising its
lance to establish better engagement. Removal of the connec-
tor terminal used for MFI and INVECS-II A/T control circuit can
be done in the following manner.
.
COMPUTER CONNECTOR
1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in
the figure, disengage the front holder, and remove it.
FRONT
HOLDER
FRONT HOLDER
ACX00904AB
2. Push the harness wire of the terminal to be repaired deep

into the connector from the harness side and hold it there.
ACX00905
3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width]

HOUSING LANCE
into the connector as shown in the figure, gently push the
housing lance down with the tip, and pull out the terminal.
AC310118AB
4. Insert a needle through the hole provided on the terminal

and raise the contact point. Lightly squeeze the outer edge
NEEDLE so the flats are parallel with the bottom.
NEEDLE
ACX00907 AB
TSB Revision
ROUND WATERPROOF CONNECTOR

1. Remove the waterproof cap by using a screwdriver.
2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0
mm (0.08 inch) width] into the connector as shown in the
figure, raise the housing lance slightly with the tip, and pull
out the terminal.
HOUSING LANCE
ACX00908 AB
3. Insert a screwdriver through the hole provided on the

terminal and raise the contact point. Lightly squeeze the
outer edge so the flats are parallel with the bottom.
ACX00909
RECTANGULAR WATERPROOF CONNECTOR

1. Disengage the front holder with a screwdriver and remove it.
FRONT
HOLDER
FRONT HOLDER
ACX00910AB
2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into

the connector as shown in the figure, push it lightly to raise
the housing lance, and pull out the terminal.
HOUSING LANCE
ACX00911AB
TSB Revision
00E-5
3. Press the contact point to the male terminal down by holding
a screwdriver [1.4 mm (0.06 inch) width] as shown in the
figure. Lightly squeeze the outer edge so the flats are
parallel with the bottom.
ACX00912
INJECTOR CONNECTOR
1. Remove the waterproof cap.
WATERPROOF
CAP
ACX00913AB
2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into

TERMINAL LANCE the connector as shown in the figure, press in the terminal
lance, and pull out the terminal.
AC310304AB
CAUTION
Make sure the lance is pressed in before the terminal is
inserted into the connector.
3. Press the contact point to the male terminal down by holding
a screwdriver [1.4 mm (0.06 inch) width] as shown in the
figure.
AC310313
TSB Revision
HOW TO DIAGNOSE
HOW TO DIAGNOSE
HOW TO DIAGNOSE
M1001004300086
The most important point in troubleshooting is to
determine "Probable Cause." Once the probable
causes are determined, parts to be checked can be
limited to those associated with such probable
causes. The determination of the probable causes
must be based on a theory and be supported by facts
and must not be based on intuition only.
TROUBLESHOOTING STEPS
M1001004400049
If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symp-
toms could become more complicated, resulting in failure to determine the causes correctly and making
incorrect repairs. The four steps below should be followed in troubleshooting.
Observe the symptom carefully. Check if there are also

1 Observation of Problem Symptoms other problems.
In determining the probable causes, it is necessary to

study the wiring diagram to understand the circuit as a
2 Determination of Probable Causes system. Knowledge of switches, relays and other parts is
necessary for accurate analysis. The causes of similar
problems in the past must be taken into account.
Troubleshooting is carried out by making step-by-step

Checking of Parts Associated with checks until the cause is found.
3 Probable Causes and Determination
of Faulty Parts
After the problems are corrected, be sure to check that the

system operates correctly. Also check that new problems
4 Repair and Confirmation have not been caused by the repair.
ACX00915 AC
INFORMATION FOR DIAGNOSIS

M1001004500132
This manual contains the harness diagrams as well as the individual circuit drawings, operational explana-
tions, and troubleshooting hints for each component. The information is presented in the following manner:
1. Connector diagrams show the connector 3. Operational explanations include circuit drawings
positions, etc., on the actual vehicle as well as the of current flow when the switch is operated and
harness path. how the component reacts.
2. Circuit diagrams show the configuration of the
circuit with all switches in their normal positions.
TSB Revision
HOW TO DIAGNOSE
00E-7
4. Troubleshooting hints include numerous
examples of problems which might occur, traced
backward in a common-sense manner to the
origin of the trouble. Problems whose origins may
not be found in this manner are pursued through
the various system circuits.
NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer
to a relevant group which includes details of these components.
INSPECTION
M1001004600139
1. Sight and sound checks
Check relay operation, blower motor rotation, light
CLICK illumination, etc. Listen for a "click" when some relay covers
are pushed down.
ACX00936 AB
2. Simple checks
For example, if a headlight does not come on and a faulty
fuse or poor grounding is suspected, replace the fuse with a
new one. Or use a jumper wire to ground the light to the
body. Determine which part(s) is/are responsible for the
problem.
ACX00937
3. Checking with instruments

Use an appropriate instrument in an adequate range and
POINTER
read the indication correctly.
SELECTOR KNOB ACX00938AB
TSB Revision
HOW TO DIAGNOSE
INSPECTION INSTRUMENTS
M1001004700040
For inspection, use the following instruments:
CAUTION
Never use a test light for checking ECU-related circuits or
ECUs.
1. Test light
A test light consists of a 12V bulb and lead wires. It is used
to check voltages or short circuits.
ACX00939
2. Self-powered test light

A self-powered test light consists of a bulb, battery and lead
wires connected in series. It is used to check continuity or
grounding.
ACX00940
CAUTION
Never use a jumper wire to connect a power supply
directly to a load.
3. Jumper wire
A jumper wire is used to close an open circuit.
ACX00941
4. Voltmeter
POWER LINE A voltmeter is used to measure the circuit voltage. Normally,
the positive (red lead) probe is applied to the point of voltage
BLACK LEAD WIRE measurement and the negative (black lead) probe to the
body ground. Use a digital voltmeter to check for voltage
drop before or after a component.
RED LEAD WIRE
GROUND
ACX00942AB
TSB Revision
HOW TO DIAGNOSE
00E-9
5. Ohmmeter
An ohmmeter is used to check continuity or measure
resistance of a switch or coil. If the measuring range has
been changed, the zero point must be adjusted before
measurement.
ACX00943
CHECKING FUSES
M1001005000141
A blade type fuse has test taps provided to allow checking of
the fuse itself without removing it from the fuse block. The fuse
FUSE BLOCK is okay if the test light comes on when its one lead is connected
to the test taps (one at a time) and the other lead is grounded.
Remember to turn the ignition switch to ON to ensure all cir-
cuits are live.
TEST TAPS
ACX00951AB
CAUTIONS IN EVENT OF BLOWN FUSE

When a fuse is blown, there are two probable causes. One is
that it is blown due to flow of current exceeding its rating. The
other is that it is blown due to repeated on/off current flowing
through it. Which of the two causes is responsible can be easily
determined by visual check as described below.
1. Fuse blown due to current exceeding rating
STATE OF FUSE BLOWN DUE TO The illustration shows the state of a fuse blown due to this
OVERCURRENT cause. In this case, do not replace the fuse with a new one
hastily since a current heavy enough to blow the fuse has
flowed through it. First, check the circuit for shorts and check
for abnormal electric parts. After correcting shorts or
replacing parts, use only a fuse of the same capacity as a
replacement. Never use a fuse of larger capacity than the
original fuse. If a larger capacity fuse is used, electric parts
ACX00952 AB or wiring could be damaged, or could start a fire.
2. Fuse blown due to repeated turning current on and off
STATE OF FUSE BLOWN DUE TO The illustration shows the state of a fuse blown due to
THERMAL FATIGUE
repeated current on/off. Normally, this type of problem
occurs after a fairly long period of use and is less frequent
than above. In this case, simply replace with a new fuse of
the same capacity.
ACX00953 AB
TSB Revision
HOW TO DIAGNOSE
CHECKING SWITCHES
M1001004800177
In a circuit diagram, a switch is shown in the idle state.
1. Normally open or normally closed switch
NORMALLY OPEN (NO) TYPE
Switches are classified into those which open the circuit and
OFF ON those which close the circuit when off.
Switches are shown in their normal state unless specified
otherwise.
CURRENT DOES CURRENT FLOWS

NOT FLOW
NORMALLY CLOSED (NC) TYPE

OFF ON
CURRENT CURRENT DOES

FLOWS NOT FLOW
ACX00944AC
2. Switch connection
6 This figure illustrates a complex switch. The continuity
between terminals at each position is as indicated in the
table below.
SWITCH TESTER SPECIFIED
POSITION CONNECTION CONDITION
OFF 1ST 2ND 3RD 4TH STAGE
OFF
1st stage 156 Continuity
5 4 3 2 1
2nd stage 146 Continuity
3rd stage 136 Continuity
4th stage 126 Continuity
ACX00945 AB
TSB Revision
HOW TO DIAGNOSE
00E-11
CHECKING RELAYS
M1001004900152
POWER SUPPLY 1. By using a relay, a heavy current can be turned on and off by
a switch using much less current. For example, in the circuit
shown here, when the switch is turned on (closed), current
RELAY flows to the coil of the relay. Then, its contact is turned on
ON
(closed) and the light comes on. The current flowing through
OFF
the switch is much less than that for the light.
FUSE
SWITCH
LIGHT ON
OFF
ACX00948 AB
NORMALLY OPEN (NO) TYPE 2. When current flows through the coil of a relay, its core is
ENERGIZED STATE magnetized to attract the iron piece, closing (ON) the
COVER contact at the tip of the iron piece. When the coil current is
SPRING
turned off, the iron piece returns to its original position by a
COIL spring, opening the contact (OFF).
IRON
CORE
IRON
PIECE
CONTACT
AC308621 AB
NORMALLY OPEN (NO) TYPE 3. Relays may be classified as the normally open-type or the
DEENERGIZED STATE ENERGIZED STATE normally closed-type, depending on their contact
construction.
3 1 3 1 NOTE: The deenergized state means that no current is flow-
ing through the coil. The energized state means that current
is flowing through the coil.
(1) The normally open-type
4 2 4 2
CURRENT DOES CURRENT FLOWS When a normally open relay as illustrated here is
NOT FLOW checked, there should be no continuity between terminals
AC310636AB 3 and 4 when the relay is deenergized. There should be
continuity between terminals 3 and 4 when battery
NORMALLY CLOSED (NC) TYPE
voltage and ground are applied to terminals 1 and 2. The
DEENERGIZED STATE ENERGIZED STATE
relay condition is determined by this check.
NOTE: Check the relay in both situation which is ener-
3 1 3 1
gized and is not energized.
(2) The normally closed-type
When a normally closed relay as illustrated here is
4 2 4 2 checked, there should be continuity between terminals 3
CURRENT FLOWS CURRENT DOES
NOT FLOW and 4 when the relay is deenergized. There should be no
AC310637 AB continuity between terminals 3 and 4 when battery
voltage and ground are applied to terminals 1 and 2. The
relay condition is determined by this check.
NOTE: Check the relay in both situation which is ener-
gized and is not energized.
TSB Revision
HOW TO DIAGNOSE
CABLES AND WIRES CHECK

M1001005100041
1. Check connections for looseness, rust, and stains.
2. Check terminals and wires for corrosion.
3. Check terminals and wires for open circuit or impending
open circuit.
4. Check wire insulation and coating for damage, cracks, and
wear.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
ACX00954 AB
6. Check grounding parts to verify that there is complete
continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that harnesses are secured to prevent contact with
sharp edges and corners or hot parts (exhaust manifold,
pipe, etc.).
9. Check that harnesses are secured firmly to provide enough
clearance from the fan pulley, fan belt, and other rotating or
moving parts.
10.Check that the harnesses between fixed parts (such as the
ACX00955AB
vehicle body) and vibrating parts (such as the engine) are
long enough to allow for vibration and movement.
BATTERY HANDLING
M1001005200048
WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
When checking or servicing does not require power from the
vehicle battery, be sure to disconnect the cable from the battery
() terminal. This will prevent problems that could be caused by
a short circuit. Disconnect the () battery terminal first and
reconnect it last.
AC000017
TSB Revision
HOW TO DIAGNOSE
00E-13
GENERAL ELECTRICAL SYSTEM CHECK
M1001005300045
A circuit consists of the power supply, switch, relay, load,
ground, etc. There are various methods to check a circuit
including an overall check, voltage check, short-circuit check,
and continuity check. Each of the methods briefly described
below applies only to circuits similar to the illustration.
1. VOLTAGE CHECK
POWER SUPPLY (1) Ground one lead wire of the test light. If a voltmeter is
used instead of the test light, ground the grounding side
lead wire.
FUSE
(2) Connect the other lead wire of the test light to the power
side terminal of the switch connector. The test light
ON (2) should come on or the voltmeter should indicate a
voltage.
SWITCH
(3) Then, connect the test light or voltmeter to the motor
connector. The test light should not come on, or the
voltmeter should indicate no voltage. When the switch is
turned ON in this state, the test light should come on, or
OFF the voltmeter should indicate a voltage, with the motor
(3)
starting to run.
MOTOR (4) The circuit illustrated here is normal. If there is any
problem, such as the motor failing to run, check voltages
TEST LIGHT beginning at the connector nearest to the motor until the
(OR faulty part is identified.
VOLTMETER)
(1) 2. SHORT-CIRCUIT CHECK
Because the fuse has blown, it is probable that there is a
ACX00956AB
short circuit. Follow the procedures below to narrow down
the short-circuit location.
STEP 1. Remove the blown fuse and connect the test light
across the fuse terminals (Circuit switch: OFF).
Q: Does the test light illuminate?
YES : Short-circuit exists between the fuse block and the
POWER SUPPLY
switch. Repair the harness between the fuse block
and the switch.
FUSE BLOCK
(REMOVE NO : Go to Step 2.
THE FUSE)
SHORT-CIRCUIT
TEST
LOCATION
LIGHT
SWITCH
OFF
ILLUMINATION
LIGHT
ACX00957 AB
TSB Revision
HOW TO DIAGNOSE
STEP 2. Turn the switch ON and disconnect the

illumination light connector.
Q: Does the test light illuminate?
YES : Short-circuit exists between the switch and the
POWER SUPPLY connector. Repair the harness between the switch
and the connector.
FUSE BLOCK NO : Short-circuit exists between the connector and the
(REMOVE
THE FUSE) illumination light. Repair the harness between the
connector and the illumination light.
TEST
LIGHT
SWITCH
ON
SHORT-CIRCUIT
LOCATION
DISCONNECT
THE LOAD
ILLUMINATION
LIGHT
ACX00958AB
POWER SUPPLY
FUSE BLOCK
(REMOVE
THE FUSE)
TEST
LIGHT
SWITCH
ON
DISCONNECT
THE LOAD
SHORT-CIRCUIT
LOCATION
ILLUMINATION
LIGHT
ACX00959AB
TSB Revision
HOW TO DIAGNOSE
00E-15
3. CONTINUITY CHECK
(1) When the switch is in the "OFF" position and the contact
SELF-POWERED TEST 1 4 points of terminals 1 and 2 are connected, the self-
LIGHT (OR OHMMETER) powered test light should illuminate or the ohmmeter
ON should read 0 ohm.
ON (2) When the switch is the "ON" position and the contact
OFF
OFF
points of terminals 3 and 4 are connected, the self-
2 3 powered test light should come on or the ohmmeter
should read 0 ohm.
ACX00960 AB
TSB Revision
NOTES
1-1
GROUP 1
BODY
CONSTRUCTION
CONTENTS
BODY COMPONENTS. . . . . . . . . . . . 1-2 SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-17
BODY MAIN CROSS-SECTIONAL ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4 UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-19
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
MAINTENANCE, SERVICEABILITY . 1-6
SILENCER APPLICATION
BODY CONSTRUCTION LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-24
CHARACTERISTICS . . . . . . . . . . . . . 1-8
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8 FOAMING MATERIAL USAGE
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-25
1-2 BODY CONSTRUCTION
BODY COMPONENTS
BODY COMPONENTS
M4010001000771
37 38
31 32
36
29
63 39
28
30 35
33 40
27 68 64
60* 34*
26 66*
61*
67* 41
65
73
59* 75
25
24
74
23 62 72 42
22
58 69*
21 90
70 71*
76**
18
16* 89
57
77**
15 17 20 88
19 78 80 43
79
13 14 87*
12
10 6* 54 81*
7
11 53 56 44*
9 5 82 83
55*
84* 46 45*
8* 52 86*
4
3
2 51
50 85
47**
1* 49 48
: Anti-corrosion steel panels
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)
(**: Indicates 980MPa-ultra-high-tensile steel panels.)
AB601700AB
TSB Revision
BODY CONSTRUCTION
BODY COMPONENTS
1-3
1. Front bumper back beam 46. Rear floor sidemember upper
2. Front end crossmember 47. Front floor side sill inner
3. Headlight support panel 48. Front fender
4. Front end upper bar 49. Battery bracket front
5. Front sidemember inner 50. Battery bracket rear
6. Front sidemember rear 51. Backbone crossmember front
7. Front sidemember outer 52. Backbone crossmember rear
8. Front sidemember outer front 53. Front floor pan
9. Front fender shield front 54. Backbone reinforcement
10. Front wheel house panel inner 55. Front floor crossmember front
11. Front end upper bar side 56. Front floor crossmember rear
12. Front fender bracket upper front 57. Side sill inner support front
13. Engine mounting gusset 58. Front pillar reinforcement lower
14 Front upper frame inner 59. Front pillar inner upper
15 Front upper frame outer 60. Roof side rail inner
16. Dash panel crossmember upper 61. Center pillar inner upper
17. Dash panel crossmember lower 62. Center pillar inner lower
18. Dash panel 63. Rear wheel house panel inner
19. Brake pedal support reinforcement 64. Rear wheel house shield plate front
20. Brake pedal support bracket 65. Rear quarter inner panel lower (Left side)
21. Front deck 66. Roof side rail support
22. Front deck crossmember 67. Front pillar support
23. Front pillar inner lower 68. Roof side rail reinforcement rear
24. Front pillar inner center 69. Roof side rail reinforcement front
25. Hood inner panel 70. Rear door hinge reinforcement support
26. Hood outer panel 71. Rear door hinge reinforcement
27. Front door inner panel 72. Center pillar reinforcement
28. Front door side door beam 73. Rear door catch reinforcement
29. Front door outer panel 74. Rear pillar reinforcement lower
30. Rear door side door beam 75. Rear pillar reinforcement
31. Rear door outer panel 76. Side sill outer reinforcement rear
32. Rear door inner panel 77. Side sill outer reinforcement front
33. Roof panel 78. Front upper frame outer rear
34. Roof center bow lower 79. Front fender bracket lower
35. Roof center bow upper 80. Rear floor crossmember rear
36. Rear shelf panel 81. Rear floor crossmember front
37. Trunk lid inner panel 82. Seat belt rear floor reinforcement (Right side)
38. Trunk lid outer panel 83. Seat belt rear floor reinforcement (Left side)
39. Curtain air bag bracket 84. Rear floor (rear seat) crossmember
40. Quarter inner panel 85. Front floor reinforcement lower
41. Quarter inner extension front 86. Front floor sidemember front
42. Fuel filler door panel 87. Rear floor extension
43. Rear end panel 88. Rear floor pan front
44. Rear floor sidemember extension 89. Rear floor pan rear
45. Rear floor sidemember lower 90. Side outer panel
TSB Revision
BODY MAIN CROSS-SECTIONAL VIEWS

M4010002000785
B C
F
D
E
A
AB601072AB
A Front end D Front door hinge

crossmember upper reinforcement lower
Front pillar
inner lower
Side outer
Front pillar panel
Front end reinforcement
crossmember lower AB601099AB lower AB601103AB
B E Side sill outer

Roof panel reinforcement
front
Roof front
rail upper
Front floor side Side outer panel
Roof front rail sill inner
lower AB601100AB AB601104AB
C Side outer panel F Side sill outer

reinforcement
rear
Center pillar
reinforcement
Roof side rail
reinforcement
front Roof side rail
support
Roof side Front floor side Side outer panel
rail inner AB601101AB
sill inner
AB601105AB
TSB Revision
BODY CONSTRUCTION
1-5
AB601073
G
H I
J
L
AB601492AB
G J
Front pillar Rear shelf panel
Roof side front support
reinforcement
front
Front pillar
Side outer inner upper
panel
Rear shelf reinforcement
AB601106AB AB601108AB
H Center pillar inner upper K Rear pillar reinforcement lower
Rear door hinge Rear wheel

reinforcement Side outer house panel
support panel inner
Center pillar
reinforcement
Side outer Rear wheel

panel house shield
Rear door hinge plate front
reinforcement AB601102AB
Quarter inner panel
AB601109AB
I Roof side rail L

reinforcement rear Rear bumper
center
reinforcement
Rear end
crossmember
Roof side Side outer inner
rail inner panel
Rear end
crossmember
outer
AB601107AB AB601110AB
TSB Revision
MAINTENANCE, SERVICEABILITY
M4010003000670
FENDER SHIELD
A positioning hole, lug, marking, and cut-out have
been added on the front side member, front side
member rear, and headlamp support panel to
improve assembling workability during panel
replacement.
AB601196AB
SIDE STRUCTURE
A panel positioning notch has been added on the
door opening to improve assembling workability
when replacing the panel.
Panel positioning notch AB201388AB
TSB Revision
BODY CONSTRUCTION
1-7
AB601194AB
SIDE OUTER PANEL

The extra parts are supplied in 4 different cut forms
as a result of employing the integrated side-frame
side outer panel.
Center pillar outer
Front pillar outer
Rear quarter
outer panel
Floor side sill outer
AB601082AB
TSB Revision
BODY CONSTRUCTION CHARACTERISTICS

FRONT BODY
M4010010000810
HEADLIGHT SUPPORT The bolt-on hood lock stay, and bolt-on front end
The crush box structure, which has an octagonal upper bar are used to improve maintainability.
cross-section at the front end of the front side-
member, has been adopted. This structure can
effectively absorb energy upon frontal impact and
reduces the vehicle repair cost caused by a light
collision.
9.0 2.0 Nm
80 17 in-lb
3 9.0 2.0 Nm
80 17 in-lb
2
9
7 4 8
9.0 2.0 Nm
80 17 in-lb 5
16
6
1 10
15
11
A
14
13 12
AB601683AB
1. Front bumper back beam

A
2. Bumper support bracket side
3. Front end upper bar
4. Radiator bracket upper
5. Bumper support bracket center Crush box
6. Front sensor reinforcement
7. Hood lock stay
8. Front end crossmember upper
9. Front end crossmember gusset
10. Radiator bracket lower A
11. Radiator bracket lower B AB601701AB
12. Front end crossmember lower
The crush box structure has been changed to
13. Shipping reinforcement front
straight type with an octagon cross-section so that
14. Shipping hook front
15. Front No. 2 crossmember pipe the structure can effectively absorb energy from the
16. Front end crossmember bulkhead impact at the time of collision.
TSB Revision
BODY CONSTRUCTION
1-9
FENDER SHIELD
The front frame structure is supported in three The padding structure of the fender has been
directions by the dash crossmember center, dash adopted to efficiently absorb energy upon impact
crossmember lower and front sidemember rear in and improve the pedestrian protection capability.
order to improve the frontal collision characteris-
tics, and increase the vehicle body rigidity.
Right side
8 12
10 9 13 Left side
12 10
9
15 16
6 15 14
7 17 16
11 6
14 8 7
26 25 17
11
24 29
18 30
5 23 25
21
19 23 5
4 22 20
28 27
3 4 2
2
3
1
AB600956AB
1. Front sidemember 16. Spring house corner gusset

2. Front fender gusset 17. Spring house panel rear
3. Front fender lower bracket front inner 18. Horn bracket
4. Upper side bar front 19. Spring house harness bracket
5. Front end upper bar side 20. Suction hose bracket
6. Front fender bracket upper front 21. Engine mounting bracket upper
7. Upper frame bulkhead front 22. Condense tank reinforcement
8. Upper frame bulkhead center 23. Front fender shield
9. Upper frame bulkhead rear 24. Engine mounting gusset
10. Front upper frame outer 25. Spring house panel
11. Front upper frame inner 26. Power steering reservoir tank bracket
12. Fender bracket upper center 2 27. Engine-ECU bracket
13. Harness bracket 28. Clutch tube bracket
14. Spring house bracket reinforcement 29. Relay box bracket
15. Spring house bracket front 30. Transmission mounting gusset
TSB Revision
FRONT SIDEMEMBER REINFORCEMENT

The 590-MPa class high tensile strength steel panels
have been adopted for the front sidemember outer
front, front sidemember reinforcement rear lower,
front sidemember rear bulkhead, and front sidemem-
ber rear to improve the body rigidity.
Right side
12*
11
4 9 13*
8 10
7
6 14*
5 17
3*
16
15
19
2 18
20
1
22
21
*: Indicates 590MPa-high-tensile steel panels. AB600952AB
12 14
17
5 A 8
18 B
11 13
AB600954AB
1. Front sidemember plate rear 12. Front sidemember reinforcement rear lower
2. Headlight bracket lower 13. Front sidemember rear bulkhead
3. Front sidemember outer front 14. Front sidemember rear
4. Front sidemember outer 15. Dash crossmember extension lower
5. Front sidemember bulkhead front 16. Front sidemember brace lower
6. Engine mounting bulkhead 17. Front sidemember inner
7. Front brake hose bracket 18. Front suspension crossmember bracket front
8. Front suspension crossmember bulkhead 19. Pipe nut
9. Front sidemember brace upper 20. Engine mount bracket
10. Tie down reinforcement front 21. Engine mount reinforcement
11. Height sensor bracket 22. Headlight support panel
A B
20
4 9
4 5
17 17
8
AB601112AB AB601113AB
TSB Revision
BODY CONSTRUCTION
1-11
Left side 14*

17 19
15*
16
18
4 20 22*
13*
12 21
8
10 1
11 9 7 3
24 4 Nm 2
18 3 ft-lb 6
*: Indicates 590MPa-high-tensile steel panels.
5
AB600953AB
21
13 14
4
18 A
B
10
15 AB600955AB
1. Headlight bracket lower 12. Front sidemember brace lower

2. Front sidemember plate rear 13. Front sidemember rear
3. Headlight support panel 14. Front sidemember reinforcement rear lower
4. Front sidemember inner 15. Front sidemember rear bulkhead
5. Connecter bracket 16. Tie down reinforcement front
6. Battery bracket front 17. Front sidemember brace upper
7. Battery bracket rear 18. Front suspension crossmember bulkhead
8. Pipe nut 19. Front sidemember outer
9. Transmission mounting bracket 20. Front brake hose bracket
10. Front suspension crossmember bracket front 21. Transmission mounting bulkhead
11. Dash crossmember extension lower 22. Front sidemember outer front
A B
17
19
19
4
4 18
21
AB601225AB AB601115AB
TSB Revision
FRONT DECK
The impact absorbing opening on the cowl top outer
reinforcement has been added to efficiently absorb
energy upon impact and improve the pedestrian pro-
tection capability.
6
5
4
9
3 8
7
2
10
14
13
1 11
12 AB601010AB
1. Cowl top panel lower 8. Brake pedal support bracket

2. Wiper B bracket 9. Deck crossmember stay bracket
3. Cowl top stay bracket rear 10. Fender bracket upper rear
4. Cowl top outer reinforcement upper 11. Upper frame to front pillar brace
5. Cowl top panel inner 12. Upper frame extension inner
6. Cowl top panel outer 13. Cowl top outer reinforcement lower
7. Clutch pedal support bracket <M/T> 14. Brake pedal support reinforcement
TSB Revision
BODY CONSTRUCTION
1-13
DASH PANEL
The front frame structure is supported in three The 590-MPa class high tensile strength steel
directions by the dash crossmember center, dash panels have been adopted for the dash panel
crossmember lower and front sidemember rear in crossmember center to improve the body rigidity.
order to improve the frontal collision characteris-
tics and increase the vehicle body rigidity.
8
5 7
9
4
3 6
10
15 11
14
2*
1 12
13
*: Indicates 590MPa-high-tensile steel panels. AB601684AB
1. Brake tube bracket 9. Dash crossmember lower bulkhead

2. Dash panel crossmember center 10. Steering shaft bracket
3. Dash crossmember extension 11. Clutch pedal reinforcement lower <M/T>
4. Dash heat protector bracket 12. Dash crossmember side
5. Backbone reinforcement front 13. Dash panel
6. Accelerator pedal bracket 14. Dash panel reinforcement
7. Dash panel lower 15. Canister bracket
8. Dash crossmember lower
TSB Revision
SIDE BODY
M4010011000705
SIDE STRUCTURE
or 980-MPa class ultra high tensile strength steel
panels have been adopted for the front pillar, center
pillar, side sill, and roof side rail to improve the body
rigidity.
58 59
56 57
55 13
54
53 14
12 52
51 50
11* 42
43
49
48 46
10* 60* 15 16 17
40 44 61 18
39 41*
47
45 19
9 63 62
37 38 64 20
8
35*
36
34*
7 5
6 65
4
21
3 33
31
2 32*
30 66
1
28
22**
29
*: Indicates 590MPa-high-tensile steel panels. 23**

**: Indicates 980MPa-ultra-high-tensile steel panels. 27 26 24
25 AB601011AB
1. Front pillar outer extension lower 11. Roof side rail inner
2. Front pillar outer extension upper 12. Bracket C
3. Front door hinge reinforcement lower 13. Curtain air bag bracket
4. Front pillar reinforcement center bulkhead 14. Quarter inner panel
5. Front door hinge reinforcement upper 15. Quarter inner extension front
6. Front pillar inner lower 16. Roof side rail reinforcement rear
7. Harness bracket 17. Quarter outer upper extension
8. Deck crossmember bracket (Right side) 18. Quarter outer upper side extension
9. Front pillar inner center 19. Rear combination light housing
10. Front pillar inner upper 20. Quarter corner panel
TSB Revision
BODY CONSTRUCTION
1-15
21. Fuel filler neck bracket (Left side)
22. Side sill outer reinforcement rear
23. Side sill outer reinforcement front
24 Side sill inner support front
25. Front fender bracket lower
26. Cowl side trim bracket
27. Fender bracket
28. Fender bracket
29. Front upper frame outer rear
30. Front pillar reinforcement lower
31. Deck support pipe (Left side)
32. Rear door hinge reinforcement
33. Rear door hinge reinforcement support
34. Roof side rail reinforcement front
35. Front pillar support
36. Cowl side trim bracket (Right side)
37. Hood opener bracket
38. Center inner pillar lower
39. Roof rail front extension
40. Roof rail center extension
41. Center inner pillar upper
42. Roof rail rear extension
43. Center pillar seat belt reinforcement upper
44. Center pillar seat belt reinforcement lower
45. Rear wheel house shield plate front
46. Rear quarter inner panel lower (Left side)
47. Filler pipe MTG bracket (Left side)
48. Head restraint bracket (Left side)
49 Harness bracket (Right side)
50. Rear wheel house panel inner
51. Rear seat back brace front
52 Rear seat back brace rear
53. Harness bracket (Left side)
54. Plate rear seat back reinforcement
55. Rear seat hook A
56. Rear shelf upper brace
57. Brace rear seat back bulkhead
58. Rear seat belt reinforcement
59. Subwoofer upper bracket <GTS>
60. Roof side rail support
61. Rear pillar reinforcement
62. Nut plate
63. Rear pillar reinforcement lower
64. Rear door catch reinforcement
65. Center pillar reinforcement
66. Side outer panel
TSB Revision
SIDE STRUCTURE REINFORCEMENT

The ring structure of the side structure reinforcement
has been adopted to improve the collision character-
istics and the rigidity of the whole vehicle.
Side roof rail rear reinforcement
Roof side rail front reinforcement
Rear pillar reinforcement
Rear pillar reinforcement lower
Side sill outer reinforcement rear
Front pillar Center pillar reinforcement

reinforcement lower
Side sill outer reinforcement front
AB601202AB
TSB Revision
BODY CONSTRUCTION
1-17
REAR BODY
M4010012000582
REAR DECK
5.0 1.0 Nm 4
44 9 in-lb
2
5
6
5.0 1.0 Nm
44 9 in-lb
1
AB601685AB
1. Seat belt reinforcement center 4. Rear shelf panel

2. Rear shelf extension 5. Rear seat hook A
3. Rear shelf reinforcement 6. Rear seat back reinforcement
REAR END CROSSMEMBER

5
4 5.0 1.0 Nm
44 9 in-lb
1
AB601686AB
1. Rear bumper side bracket 4. Rear end crossmember outer

2. Rear end crossmember inner 5. Rear bumper center reinforcement
3. Trunk lid striker reinforcement
TSB Revision
ROOF
M4010013000853
The closed section structure has been adopted to The 590-MPa class high tensile strength steel
the front roof rail, roof bow center and rear roof panels have been adopted for the roof center
rail to reduce vibration and noise and to improve bow lower to improve the body rigidity.
the rigidity.
Without sunroof 6
4 7
3 9
8*
2
*: Indicates 590MPa-high-tensile steel panels. 1 AB601687AB
Sunroof 6
10
4
11
3 12
13
2 14
1 AB601688AB
1. Sunvisor bracket 8. Roof center bow lower

2. Maplamp bracket 9. Room light bracket
3. Roof front rail lower 10. Roof panel reinforcement
4. Roof front rail upper 11. Bracket A
5. Roof panel 12. Set rear bracket
6. Roof rear rail 13. Bracket B
7. Roof center bow upper 14. Set front bracket
TSB Revision
BODY CONSTRUCTION
1-19
UNDER BODY
M4010014000812
FRONT FLOOR
have been adopted for the front floor sidemember
front and front floor crossmember front, and the
980-MPa class ultra high tensile strength steel pan-
els for the front floor sidemember front, to improve
the body rigidity.
13
4
5 6
2 8 7*
1
9
12*
10
*: Indicates 590MPa-high-tensile steel panels. 11**
**: Indicates 980MPa-ultra-high-tensile steel panels.
AB601689AB
1. Backbone crossmember front 8. Front floor crossmember rear

2. Front floor pan 9. Seat belt reinforcement
3. Parking brake lever reinforcement 10. Front floor side sill inner reinforcement center
4. Backbone reinforcement 11. Front floor side sill inner
5. Parking brake cable reinforcement 12. Front floor crossmember front
6. Backbone crossmember rear 13. Front floor reinforcement lower (Right side)
7. Front floor sidemember front
TSB Revision
REAR FLOOR
have been adopted for the rear floor extension, rear
floor crossmember front, and rear seat crossmember
to improve the body rigidity.
5 6
5.0 1.0 Nm 7
44 9 in-lb 4
3
10
8
21 11
12*
2* 13
14
5.0 1.0 Nm
20 44 9 in-lb
1
4
18 19*
15
*: Indicates 590MPa-high-tensile steel panels. 17 16
AB601690AB
1. Extension rear floor reinforcement side 12. Rear floor crossmember front
2. Rear floor extension 13. Rear floor crossmember extension
3. Rear floor pan front 14. Fuel tank rear bracket
4. Rear spring house reinforcement 15. Rear spring house panel
5. Rear floor pan rear 16. Rear spring house bracket
6. Jack bracket 17. Sidemember front floor extension
7. Spare tire bracket 18. Rear seat crossmember bulkhead inner
8. Rear floor crossmember extension rear upper 19. Rear seat crossmember
9. Rear floor crossmember extension rear 20. Seat belt rear floor reinforcement (Left side)
10. Rear floor crossmember rear 21. Seat belt rear floor reinforcement (Right side)
11. Rear floor sidemember
TSB Revision
BODY CONSTRUCTION
1-21
REAR FLOOR SIDEMEMBER
REINFORCEMENT
have been adopted for the rear floor side sill inner,
rear floor sidemember reinforcement, rear floor side-
member extension, and rear floor sidemember bulk-
head to improve the body rigidity.
8*
6 10
11*
9
12
7
17
18 16
5 19
24
4
13
3 20 21
25 22 14
2 23 15
26*
1*
*: Indicates 590MPa-high-tensile steel panels.
AB601581AB
8 22 17 6 12
1
26
25 16 11
B 23
2
5
3
A
AB601691AB
1. Rear floor side sill inner 15. Rear shipping hook

2. Rear floor sidemember extension front 16. Rear suspension bracket rear
3. Rear tie down plate 17. Rear floor sidemember bulkhead rear
4. Front No. 2 crossmember pipe 18. Rear parking brake cable rear bracket (Right side)
5. Trailing arm bracket 19. Rear parking brake cable rear bracket (Left side)
6. Rear floor sidemember upper 20. Rear brake hose bracket
7. Canister bracket 21. Rear floor sidemember rear reinforcement (Right
8. Rear floor sidemember reinforcement side)
9. Pipe nut 22. Rear floor sidemember rear reinforcement (Left side)
10. Muffler hanger rear 23. Rear suspension bracket front
11. Rear floor sidemember extension 24. Pipe nut
12. Rear floor sidemember extension bulkhead 25. Rear floor sidemember lower
13. Rear bumper support 26. Rear floor sidemember bulkhead
14. Rear shipping hook reinforcement
TSB Revision
A 6 B 6
22
26 1
25 23
3
AB601117AB AB601116AB
DOOR
M4010015000633
An uneven thickness steel sheet* has been used for NOTE: *: A steel sheet of varying thickness that is
the front and rear door inner panels to make the for- welded into one steel sheet.
ward part of the vehicle thicker for reduction in vehi-
cle weight and higher rigidity.
Front door 5 6
8
9 10
7 11
4
12
3 2
1 13
14
AB601048AB
TSB Revision
BODY CONSTRUCTION
1-23
Rear door 22
23
21
24
19
15 25
20 26
17
18 27
16 28
14
AB601049AB
1. Front door checker reinforcement 15. Rear door inside handle bracket
2. Front door mirror reinforcement 16. Rear door side door beam
3. Front door window sash front 17. Rear door beltline inner reinforcement
4. Front door outer panel 18. Rear door latch reinforcement
5. Front door window sash upper 19. Rear door beltline bracket
6. Front door window sash rear 20. Rear door window sash front
7. Front door inside handle bracket 21. Rear door outer panel
8. Front door beltline outer reinforcement 22. Rear door window sash upper
9. Front door beltline inner reinforcement 23. Rear door beltline outer reinforcement
10. Front door latch reinforcement 24. Rear door stat corner bracket
11. Front door outer stiffner 25. Rear door sash reinforcement
12. Front door side door beam 26. Rear door window sash lower bracket
13. Front door inner panel 27. Nut plate
14. Nut plate 28. Rear door inner panel
TSB Revision
SILENCER APPLICATION LOCATIONS
SILENCER APPLICATION LOCATIONS

M4010005000836
A silencer (MD-12) has been affixed on the upper NOTE: MD-12 is a high-performance sheet made of
surface of the floor for vibration damping. asphalt, to which mica, heat cured resin, and so on
are added to improve damping performance.
: 3.2 mm thick MD-12 [Place two 1.6 mm melting sheet one on top of another.]
AB601192AB
NOTE: ( ) indicates the number of melting sheets

that are used for repair.
TSB Revision
BODY CONSTRUCTION
FOAMING MATERIAL USAGE LOCATIONS
1-25
FOAMING MATERIAL USAGE LOCATIONS

M4010006000099
The sound dampening foam material have been CAUTION
adopted to the upper and lower sections of the front The sound dampening foam material may burn
pillar, center pillar lower section, side roof rail and when heated. Always observe the following
wheel house arch inside to shield from external instructions:
noise.
Never use a gas burner to burn the areas
where sound dampening foam material are
used.
When cutting the parts which are provided
with sound dampening foam material, ensure
to use tools (air saw, etc.) that do not gener-
ate fire.
If there are residual sound dampening foam
material remaining on the cut section (body
side), remove the sound dampening foam
material from periphery of the welding area
before welding work.
AB601548
Sound dampening foam material
Sound dampening foam material AB601682AB
TSB Revision
NOTES
2-1
GROUP 2
BODY DIMENSIONS
CONTENTS
BODY DIMENSIONS AND MEASUREMENT TYPE B (ACTUAL-MEASUREMENT

METHODS . . . . . . . . . . . . . . . . . . . . . 2-2 DIMENSIONS). . . . . . . . . . . . . . . . . . . 2-10
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 2-10
TYPE A (PROJECTED DIMENSIONS) SUSPENSION INSTALLATION DIMENSIONS
................................. 2-4 ...................................... 2-12
UNDER BODY . . . . . . . . . . . . . . . . . . . . . . 2-4 FRONT BODY . . . . . . . . . . . . . . . . . . . . . . . 2-14
SUSPENSION INSTALLATION DIMENSIONS SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
...................................... 2-7 REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 2-20
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-2 BODY DIMENSIONS
BODY DIMENSIONS AND MEASUREMENT METHODS

M4020001000448
Projected dimension Type A (projected dimensions) is the dimension when a

measurement location is projected onto the plane.
NOTE: The height indicates a distance from the assumed
Height standard line established 100 mm below the lowest mea-
Probe surement point.
AB302138AE
Type B (actual-measurement dimensions) is the actual dis-

Ac
dim tual tance between the measurement points.Measure using a
en -me tracking gauge or a measuring tape, etc.
sio as
n ur ed
A NOTE: .
Make the lengths of the tracking gauge probes the same
A'
(A=A).
Do not bend or twist the measuring tape.
AB302139AE
Insert the tracking gauge probes securely into the measure-

ment holes.
Center of hole When the standard dimensions in the illustration are
enclosed by rectangle, this indicates that the symmetrical
left and right positions have the same dimensions.
AB302140AF
When using a notch for dimension measurement, set the

measuring point at the center of the notch.
AB302141AD
TSB Revision
BODY DIMENSIONS
2-3
When measuring the suspension mounting arm, or link
Bolt
mounting position, use the suspension mounting bolt, etc.
(Type B only)
The body center points are shown for the purpose of check-
ing the position of the left and right symmetry location.
Measurement point
AB302142AE
TSB Revision
2-4 BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)

UNDER BODY
M4020005001636
mm (in)
76 616 833
(3.0) (24.3) (32.8)
2 540 667 929

510 (26.3) 718 (36.6)
(21.3) (20.1) 624 (28.3)
(24.6)
967 910 7 462 1,262 1,022 990
(35.8) 875 (18.2) (40.2) 877
(38.1) (34.4) (49.7) (34.5) (39.0)
894 894
960 (35.2) (35.2)
(37.8) 564 375
(22.2) 6 (14.8)
350 9 393 545
(13.8) (15.5)
1 3 4 5 8 344 440 12 (21.5)
(13.5) (17.3) 11 13
76 10
(3.0) 1,050 197
(41.3) (7.8)
Center line of the vehicle
1,138
(44.8)
1,079 641
2 (42.5) (25.2)
969 763 1,218 1,025

(38.1) 960 (48.0) 1,369
1,120 (30.0) (40.4) (53.9)
(44.1) 7 (37.8)
1,124
(44.3)
544 1,195 1,342
964 1,028 (21.4) (47.0) (52.8)
(38.0) (40.5) 6 1,080
1,394 1,254 (42.5)
(54.9) (49.4) 1,117
686 (44.0)
(27.0)
1 3 4 5 8 9 12
11 13
10

AB600969AB
No. Standard measurement point Hole shape Size mm (in)

1 Center of front end crossmember lower water draining hole (left side) Round 8 (0.31)
2 Center of front end crossmember lower water draining hole (right side) Round 8 (0.31)
3* Center of front sidemember inner positioning hole Round 25 (0.98)
4* Center of front suspension crossmember mounting hole Round 15.5 (0.61)
5* Center of front sidemember rear water draining hole Round 16 (0.63)
6 Center of center bearing mounting hole (left side) Round 11 (0.43)
7 Center of center bearing mounting hole (right side) Round 11 (0.43)
8* Center of front floor sidemember front positioning hole Round 16 (0.63)
TSB Revision
BODY DIMENSIONS
2-5
10* Center of rear floor sidemember lower positioning hole Oblong 33.9 18
(1.335 0.71)
11* Center of rear suspension bracket front water draining hole Round 16 (0.63)
12* Center of rear floor sidemember lower positioning hole Round 25 (0.98)
13* Center of rear floor extension sidemember water draining hole Round 14 (0.55)
NOTE: The * mark indicates the mounting position for the frame centering gauge.
mm (in)
486 230
(19.1) (9.1)
1 12 13
3 4 11
2 7
5 9 10
348 6 8
(13.7) 259 347 357
287 (13.7)
280 (10.2) 155 (11.3) (14.1)
(11.0) 295 100 158 106 106
(11.6) (3.9) (6.2) (4.2) (4.2) (6.1)
510 716
(20.1) (28.2)
1,049 715
(41.3) 350 (28.1)
(13.8)
1,125 1,101
(44.3) 291 (43.3)
(11.5)
Standard line 1,644
(64.7)
AB600970AB
NOTE: The assumed standard line is established 100 mm (3.9in) below the measurement point No.5.
1, 3 2 4
1
3
AB600994AB AB600995AB AB600996AB
5 6, 7 8, 9
6 8
7
AB600998 AB AB600999AB 9 AB601000AB
TSB Revision
2-6 BODY DIMENSIONS
10 11 12
AB601001AB AB601006AB AB601002AB
13
AB601003AB
TSB Revision
BODY DIMENSIONS
2-7
SUSPENSION INSTALLATION DIMENSIONS
M4020013001222
mm (in)
510 787 289 694

(20.1) (31.0) (11.4) (27.3)
570
(22.4)
1,092
1,130 1,288 (43.0)
886 (50.7) 903
(44.5) (34.9) (35.6)
910 875 894 1,000 1,092

(35.2) 254 (39.4) 441 (43.0)
(35.8) (34.4) (10.0) (17.4)
4 15 9 18 20
544 17
5 (21.4)
14 19
293 217 16
98
(11.5) (8.5) (3.9) 714
(28.1)
1,128 1,215
945 (44.4) (47.8) 1,047
1,212 (41.2)
(37.2) (47.7)
907
(35.7) 1,171 1,294
1,028 (46.1) (50.9)
(40.5) 9
4 18
15 5 17 20
14 1,230 19
(48.4) 16
1,075
(42.3)
AB601172 AB
No. Satndard measurement point Hole shape Size mm (in)

4 Center of front suspension crossmember mounting hole Round 15.5 (0.61)
5 Center of front sidemember rear water draining hole Round 16 (0.63)
9 Center of front floor sidemember front positioning hole Round 16 (0.63)
14 Center of front shock absorber mounting hole Round 80 (3.15)
16 Center of trailing arm mounting hole Round 14 (0.55)
18 Center of rear suspension crossmember mounting hole Round 15 (0.59)
19 Center of rear shock absorber mounting hole Round 64 (2.52)
TSB Revision
2-8 BODY DIMENSIONS
A Vehicle center B Vehicle center

654
630
539 mm (in)
(21.2)
306 1,086
(42.8)
A
14 B
19 0
16
4 18
17 20
15
5 9
779 356 459
(30.7)
296
164 224 286 (14.0) (18.1)
(11.7)
(6.5)
100 107 (8.8) (11.3)
(3.9) (4.2)
217 1,066 535

(8.5) (42.0) (21.1)
510 785
Standard line (20.1) (30.9)
1,223
(48.1) AB601173 AC
NOTE: The assumed standard line is established 100 mm (3.9in) below the measurement point No.5.
4 5 9
AB600996AB AB600998 AB AB601180AB
14 15 16, 17
16
17
AB601004AB AB601181AB AB601008AB
TSB Revision
BODY DIMENSIONS
2-9
18 19 20
AB601182AB AB601005AB AB601007AB
TSB Revision
2-10 BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

UNDER BODY
M4020005001647
mm (in)
102 616 856

(4.0) (24.3) (33.7)
2 222
542 (8.7) 669 740 932
546 (26.3) (29.1) (36.7)
(21.3) (21.5) 644
(25.4) 487
910 (19.2)
967 1,262 1,022 990
(35.8) 875 (40.2) 877
(38.1) (34.4) (49.7) (34.5) (39.0)
7
894 894
960 (35.2) (35.2)
(37.8) 567 378
(22.3) 6 (14.9)
350 9 399 545
(13.8) (15.7)
1 3 4 5 8 348 460 12 (21.5)
(13.7) (18.1) 11 13
101 10
(4.0) 1,079
(42.5)
1,081 1,138
2 (42.6) (44.8)
643 1,225
(25.3) (48.2) 1,027 1,371
971 1,120 (40.4)
(38.2) 960 (54.0)
(44.1) 765 7
(30.1) (37.8)
1,124 1,415 1,209
(44.3) (55.7) 1,356
1,046 566 (47.6) (53.4)
966 (41.2) 1,080
(22.3) (42.5)
(38.0) 6 1,255
(49.4) 1,118
704 (44.0)
1 3 4 5 (27.7) 8 9 12
11 13
10
AB600969AC

1 Center of front end crossmember lower water draining hole (left side) Round 8 (0.31)
2 Center of front end crossmember lower water draining hole (right side) Round 8 (0.31)
3* Center of front sidemember inner positioning hole Round 25 (0.98)
4* Center of front suspension crossmember mounting hole Round 15.5 (0.61)
5* Center of front sidemember rear water draining hole Round 16 (0.63)
6 Center of center bearing mounting hole (left side) Round 11 (0.43)
7 Center of center bearing mounting hole (right side) Round 11 (0.43)
TSB Revision
BODY DIMENSIONS
2-11
10* Center of rear floor sidemember lower positioning hole Oblong 33.9 18
(1.335 0.71)
11* Center of rear suspension bracket front water draining hole Round 16 (0.63)
12* Center of rear floor sidemember lower positioning hole Round 25 (0.98)
13* Center of rear floor extension sidemember water draining hole Round 14 (0.55)
NOTE: The * mark indicates the mounting position for the frame centering gauge.
1, 3 2 4
1
3
AB600994AB AB600995AB AB600996AB
5 6, 7 8, 9
6 8
7
AB600998 AB AB600999AB 9 AB601000AB
10 11 12
AB601001AB AB601006AB AB601002AB
13
AB601003AB
TSB Revision
SUSPENSION INSTALLATION DIMENSIONS

M4020013001233
mm (in)
547 807 295 707

(21.5) (31.8) (11.6) (27.8)
582
(22.9)
1,092
1,288 (43.0)
886 (50.7) 903
(34.9) (35.6)
910 875 894 1,000

(35.2) 262 (39.4) 446
(35.8) (34.4) (10.3) (17.6)
4 15 9 18 20
557 17
5 (21.9)
322 226 16
98
(12.7) (8.9) (3.9) 727
(28.6)
1,134 1,221
954 (44.6) (48.1) 1,050
1,219 (41.3)
(37.6) (48.0)
909
(35.8) 1,173 1,300
1,046 (46.2) (51.2)
(41.2) 9
4 18
15 5 17 20
1,243
(48.9) 16
1,077
(42.4)
AB601190AB

5 Center of front sidemember rear water draining hole Round 16 (0.63)
9 Center of front floor sidemember front positioning hole Round 16 (0.63)
TSB Revision
BODY DIMENSIONS
2-13
4 5 9
AB600996AB AB600998 AB AB601180AB
15 16, 17 18
16
17
AB601181AB AB601008AB AB601182AB
20
AB601007AB
TSB Revision
FRONT BODY
M4020006000829
1,106
(43.5) mm (in)
39 Body center point
40
994
(39.1)
1,174 1,630
(46.2) (64.2)
1,508 37
509 (59.4)
(20.0)
1,072
38
(42.2)
1,438 425
(16.7)
394 (56.6) 1,485 36
(15.5) 901 (58.5)
(35.5) 1,486 35
33 (58.5) 877 34
1,494 (34.5)
32 (58.8) 401
913
(35.9) (15.8)
29 901
327 31
(12.9) 891 (35.5)
27 (35.1) 30
26 28
391
(15.4) 1,060 25 329
336 (41.7) (13.0)
(13.2)
23 392
(15.4)
22 24
Body center point 21
781
(30.7) 37
732 38
855 810 (28.8)
(33.7) (31.9)
822 896 36
(32.4) (35.3) 1,558
1,458 (61.3)
864 35
33 (57.4) 1,449 (34.0)
(57.0)
32 819 34
(32.2)
29
27
1,032 31
26 (40.6)
30
713 1,042 28
(28.1) (41.0)
25
714
23 (28.1) 24
22
AB600979AB
TSB Revision
BODY DIMENSIONS
2-15
mm (in)
601 37
(23.7) 1,556
38
873 555 (61.3)
(34.4) (21.9)
857 831 36
(33.7) (32.7)
953 937
33 (37.5) (36.9) 35
860 341
32 980 (33.9) 34 (13.4)
(38.6) 31
29
27 1,026 30
(40.4)
549
26 (21.6) 782 774
(30.8) (30.5) 543 28
(21.4) 25
23 24
22
AB601191AC

21 Center of front end crossmember positioning notch (Body center
point)
22 Center of inter cooler bracket mounting hole Round 9 (0.35)
23 Center of inter cooler bracket mounting hole Round 9 (0.35)
24 Center of front bumper beam mounting hole Round 9 (0.35)
28 Center of front sidemember inner positioning notch
29 Center of front sidemember inner positioning notch
30 Center of front end upper bar mounting hole Round 6.6 (0.26)
34 Center of front end upper bar side positioning hole Round 6 (0.24)
35 Center of front fender mounting hole Round 6.6 (0.26)
36 Center of front strut mounting hole Round 11.5 (0.45)
37 Center of cowl top lower panel front mounting hole Round 6.6 (0.26)
38 Center of hood hinge mounting hole Round 9 (0.35)
39 Center of roof panel positioning notch (Body center point)
40 Corner of roof panel
TSB Revision
21, 22 23 24, 25 25
21 22
24
AB601012 AB AB601013 AB AB601014 AB
26, 27 28 29
27
26
AB601015 AB AB601018 AB AB601019 AB
30, 31 32, 33 34, 35 35

31 33 34
30 32
AB601016 AB AB601017 AB AB601020 AB
36 37 38
AB601021 AB AB601022 AB AB601023 AB
TSB Revision
BODY DIMENSIONS
2-17
39 40
AB601235 AB AB601024 AB
TSB Revision
SIDE BODY
M4020007000769
mm (in)
43 47
41 45 49
762 970
(30.0) (38.2)
1,159 1,044
863 (45.6)
(34.0) 867 (41.1)
657 (34.1)
(25.9) 635 712
(25.0) 1,290 (28.0)
1,076 (50.8)
(42.4)
822 776
(32.4) (30.6)
42 46 50
44 48
43 47
1,048 640
(41.3) (25.2)
53
51 1,096 781
(43.1) 1,176 (30.7)
1,106
364 (43.5) (46.3) 355
(14.0) 835 55
(14.3) (32.9)
1,072
(42.2) 54
52
AB600980AB

41 Front pillar positioning notch (upper)
42 Front pillar positioning notch (lower)
43 Side roof rail positioning notch (front)
44 Side sill positioning notch (front)
45 Center pillar positioning notch (upper)
46 Center pillar positioning notch (lower)
47 Side roof rail positioning notch (rear)
48 Side sill positioning notch (rear)
49 Quarter panel positioning notch (upper)
50 Quarter panel positioning notch (lower)
51 Center of front door hinge mounting hole (upper) Round 11 (0.43)
52 Center of front door hinge mounting hole (lower) Round 11 (0.43)
53 Center of rear door hinge mounting hole (upper) Round 11 (0.43)
54 Center of rear door hinge mounting hole (lower) Round 11 (0.43)
55 Center of rear door switch mounting hole Round 5 (0.20)
TSB Revision
BODY DIMENSIONS
2-19
41 42, 52 43, 45
42
52
43
45
AB601025AB AB601026AB AB601027AB
44 46, 54 47
46
54
AB601028AB AB601030AB AB601031AB
48 49 50, 55
55
50
AB601032AB AB601033AB AB601034AB
51 53
AB601035AB AB601029AB
TSB Revision
REAR BODY
M4020008000803
mm (in)
1,056
56 (41.6)
1,365 1,509
(53.7) 742 1,011
(59.4) (29.2) (39.8)
198
1,244 (7.8)
(49.0) 1,251
(49.3)
58 1,232
(48.5)
59
61 1,458
60 (57.4)
1,267
(49.9) 63
656 62
(25.8)
606
(23.9) 990
1,100 (39.0) 117
(43.3) (4.6)
64
1,050
(41.3)
65

296
(11.7)
58 648
1,189
(25.5)
(46.8)
59 1,188 505 778

(46.8) (19.9) (30.6)
61 507
60 761 (20.0)
(30.0)
1,346 62 63
(53.0)
64
65 AB600983AC
TSB Revision
BODY DIMENSIONS
2-21

56 Corner of roof panel
57 Body center point of rear shelf panel
58 Center of trunk lid hinge mounting hole Round 9 (0.35)
59 Center of trunk lid hinge mounting hole Round 9 (0.35)
60 Corner of side outer panel
61 Center of rear combination lamp mounting hole Round 8 (0.31)
62 Center of striker mounting hole (left side) Round 6.6 (026)
63 Center of striker mounting hole (right side) Round 6.6 (026)
64 Center of rear bumper mounting hole Round 15 (0.59)
65 Center of rear bumper mounting hole Round 15 (0.59)
56 57 58, 59
58
59
AB601054AB AB601056AB AB601055AB
60, 61 62, 63 64, 65
64
60
65
63
61
62
AB601218 AB AB601183AB AB601059AB
TSB Revision
INTERIOR
M4020009000873
mm (in)
1,193 1,171
(47.0) (46.1) 47
1,357 1,375 43 1,330 49
(53.4) (54.1) (52.4)
41 45
1,430 1,430
1,430 (56.3) (56.3)
(56.3)
50
1,430
1,429 46 (56.3)
42 (56.3) 48
44
43 47
49
41 45 1,128
66 Body center point 1,136 (44.4)
(44.7) 1,189
1,059 (46.8)
1,179 (41.7)
(46.4) Body center point 67
50
784
735 (30.9)
1,073
(42.2) (28.9)
46
42 48
44
720
833 (28.3)
(32.8)
AB600982AB
mm (in)
593
(23.3)
1,093 679
(43.0) (26.7)
1,117
68 (44.0)
720
(28.3)
69
AB601145AB
TSB Revision
BODY DIMENSIONS
2-23

41 Front pillar positioning notch (upper)
42 Front pillar positioning notch (lower)
43 Side roof rail positioning notch (front)
44 Side sill positioning notch (front)
45 Center pillar positioning notch (upper)
46 Center pillar positioning notch (lower)
47 Side roof rail positioning notch (rear)
48 Side sill positioning notch (rear)
49 Quarter panel positioning notch (upper)
50 Quarter panel positioning notch (lower)
57 Body center point of rear shelf panel
66 Center of backbone reinforcement positioning hole (Body center point) Round 11 (0.43)
67 Body center point of rear floor pan front (Body center point)
68 Center of rear shock absorber mounting hole Round 14 (0.55)
69 Center of rear end trim mounting hole Round 8.5 (0.335)
41 42 43, 45
43
45
AB601025AB AB601026AB AB601027AB
44 46 47
AB601028AB AB601030AB AB601031AB
TSB Revision
48 49 50
AB601032AB AB601033AB AB601034AB
66 67 68
AB601063AB AB601064 AB AB601065AB
69
AB601058AB
mm (in)
1,401 1,397
(55.2) (55.0)
70 1,392
(54.8) 72
140
(5.5) 130
(5.1)
1,392
71 (54.8)
73
AB600984AB

70 Center of deck crossmember mounting hole (left-upper) Round 13 (0.51)
71 Center of deck crossmember mounting hole (left-lower) Round 13 (0.51)
72 Center of deck crossmember mounting hole (right-upper) Round 9 (0.35)
73 Center of deck crossmember mounting hole (right-lower) Round 9 (0.35)
TSB Revision
BODY DIMENSIONS
2-25
70, 71 70 72, 73
72
71
73
AB601067AB AB601066AB
TSB Revision
NOTES
3-1
GROUP 3
WELDED PANEL
REPLACEMENT
CONTENTS
ULTRA HIGH STRENGTH STEEL REAR END PANEL. . . . . . . . . . . . . . . 3-35

PLATE . . . . . . . . . . . . . . . . . . . . . . . . 3-2
REAR FLOOR. . . . . . . . . . . . . . . . . . . 3-36
FRONT END CROSSMEMBER . . . . . 3-3
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
FENDER SHIELD. . . . . . . . . . . . . . . . 3-4
QUARTER INNER. . . . . . . . . . . . . . . . 3-40
FRONT SIDEMEMBER (PARTIAL
REPLACEMENT) . . . . . . . . . . . . . . . . 3-8 QUARTER INNER
(PARTIAL REPLACEMENT) . . . . . . . 3-44
FRONT PILLAR . . . . . . . . . . . . . . . . . 3-10
FRONT DOOR OUTER PANEL
FRONT PILLAR (WELDED TYPE) . . . . . . . . . . . . . . . . 3-46
(PARTIAL REPLACEMENT) . . . . . . . 3-16
FRONT DOOR OUTER PANEL
CENTER PILLAR . . . . . . . . . . . . . . . . 3-21 (ADHESION TYPE). . . . . . . . . . . . . . . 3-47
SIDE SILL. . . . . . . . . . . . . . . . . . . . . . 3-26 REAR DOOR OUTER PANEL

(WELDED TYPE) . . . . . . . . . . . . . . . . 3-48
QUARTER OUTER . . . . . . . . . . . . . . 3-32
REAR DOOR OUTER PANEL
(ADHESION TYPE). . . . . . . . . . . . . . . 3-49
3-2 WELDED PANEL REPLACEMENT
ULTRA HIGH STRENGTH STEEL PLATE
ULTRA HIGH STRENGTH STEEL PLATE

M4030002800073
ADVANTAGES OF ULTRA HIGH For the part in which the ultra high strength steel
STRENGTH STEEL PLATE plate is used, do not repair it by cutting and bond-
ing to avoid the reduction in strength by heat.
The ultra high strength steel plate has the following
Instead, replace the whole assembly including
advantages as compared with conventional high
the part.
strength steel plate.
Be careful with rough extending work, because
It has tensile strength approximately 1.7 times
the ultra high strength steel plate has higher ten-
higher than the conventional high strength steel
sile strength and a higher yielding point than high
sheet.
strength steel plate and general steel plate. Care-
It has a higher yielding point and yielding ratio
less work will cause symptom such as over-pull-
(yielding point/tensile strength).
ing and springback. Do not extend it completely
These advantages allow thinner and lighter plates
at a time. Do it gradually while removing the dis-
and better fuel efficiency than the high strength steel
tortion by sheet metal processing with a hammer.
plate.
Plug welding of 8 mm (0.31 inch) diameter plug
for repair ensures the strength equivalent to spot
PRECAUTION UPON MAINTENANCE OF
welding for 2 steel sheets. For 3 sheets, weld 2
ULTRA HIGH STRENGTH STEEL PLATE sheets each time instead of welding from one
Use a spot cutter for ultra high strength steel side to give sufficient welding strength.
plate to ensure that the spot-welded area is cut
off.
TSB Revision
WELDED PANEL REPLACEMENT
FRONT END CROSSMEMBER
3-3
FRONT END CROSSMEMBER
M4030003100022
SYMBOL OPERATION DESCRIPTION

Spot welding
MIG plug welding : indicates two panels to be welded
( : indicates three panels to be welded )
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB601227AB
REPAIR WELDS
A B
AB601317AB
TSB Revision
FENDER SHIELD
FENDER SHIELD
M4030004000761

Spot welding
MIG spot welding
Braze welding
AB601228AB
REPAIR WELDS
A
AB601427AB
NOTE: Refer to the Front End Crossmember section on P.3-3 for the welding point with front end crossmem-
ber.
TSB Revision
FENDER SHIELD
3-5
E
B
I
C
C
AB601428AC
TSB Revision
FENDER SHIELD
D
(With the front upper frame outer removed) E
G 3 points
on left
side only
H J
AB601429AB
TSB Revision
FENDER SHIELD
3-7
Front NOTE: Partial replacement of the front upper frame is possible
upper frame depending on the range of damage. When performing partial
inner
replacement, cut the front upper frame outer front 152 mm (6.0
25 mm
(1.0 in)
inches) forward of the positioning hole center, and cut the front
upper frame inner 25 mm (1.0 inches) forward of the position-
ing hole center.
152 mm
(6.0 in)
Front upper frame outer front AB601431AB
NOTE ON REPAIR WORK

.
REMOVAL
Front sidemember Turn up the front sidemember outer as shown to cut off the
inner welded point between the front sidemember inner and the front
sidemember brace lower.
Front sidemember
outer
Front sidemember
brace lower
AB601422 AB
INSTALLATION
1. When installing the new front sidemember, align the hole of
Front
the front sidemember brace lower with the front sidemember
sidemember outer to make a hole because the front sidemember outer
outer prevents the front sidemember inner and front sidemember
brace lower from being welded.Then, weld the front
sidemember outer, front sidemember inner, and front
sidemember brace lower.
Front
sidemember
inner
AB601423AB
TSB Revision
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

M4030000100454

Spot welding
MIG spot welding
Braze welding
AB601229AB
REPAIR WELDS
Right side Left side
A
B
275 mm 315 mm
(10.8 in) (12.4 in)
135 mm 210 mm
(5.3 in) (8.3 in)
A B
AB601532AB
NOTE: .
Refer to the Front End Crossmember section on P.3-3 for the welding point with front end crossmember.
Refer to the Fender Shield section on P.3-4 for the welding points with the front fender Shield front.
TSB Revision
3-9
NOTES
TSB Revision
FRONT PILLAR
FRONT PILLAR
M4030005001165

Spot welding
MIG spot welding
Braze welding
AB601230AB
REPAIR WELDS
H A
Cutting position
A
40 mm
B (1.57 in)
Sound dampening
foam material
B
230 mm
(9.1 in)
D I
Cutting position
Sound dampening C C
E
foam material
(With the front upper frame outer rear removed) AB601387AB
CAUTION
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the front upper frame outer
rear.
TSB Revision
FRONT PILLAR
3-11
Cutting position
F Cutting position
D E F
Sound dampening
foam material
(With the side outer panel removed)
Sound dampening
foam material
Cutting position G
I
AB601388AB
TSB Revision
FRONT PILLAR
NOTE ON REPAIR WORK

.
REMOVAL
After removing the front pillar, cut the side outer panel 140 mm
140 mm (5.5 inches) behind the positioning notch to remove the side sill
Front inner pillar lower (5.5 in)
reinforcement outer front, side sill inner support front, and front
inner pillar lower remaining on the body side.
Side sill inner
support front
Side outer panel

Side sill reinforcement outer front AB601206AB
INSTALLATION
Side outer 1. To reinforce the strength in the front pillar cut area, cut the
panel 50 mm side outer panel 100 mm (3.9 inches) above the cut area
(1.97 in) and cut the front inner pillar upper 50 mm (1.97 inches)
above the cut area.
2. Assemble the new front pillar inner lower parts.
3. Assemble the new front pillar inner upper part.
Front pillar
inner upper
100 mm Roof side rail
(3.9 in) front reinforcement
AB601213AB
4. Assemble the new side sill reinforcement front parts. After

that, cover the hole with aluminum tape to prevent the sound
Side sill reinforcement front
dampening foam material from dropping when the material
is filled into the front pillar in the next process.
Aluminum tape AB601208AB
TSB Revision
FRONT PILLAR
3-13
5. Align the new roof side rail reinforcement to the body side to
cut and install.After that, machine the body loose panel
A
cushion (MR535301 or MR435765) as shown and apply it to
the body side to prevent the sound dampening foam
50 mm
(2.0 in) material from dropping when the material is filled into the
front pillar in the next process.
20 mm
(0.8 in)
40 mm
(1.6 in)
Front pillar reinforcement lower
Front pillar
inner upper
A
: Body loose panel cushion AB601297AB
AB601297
6. When installing the new front pillar lower reinforcement is

installed, remove the front pillar outer lower extension and
front pillar outer upper extension in advance, and install the
Front pillar outer front pillar lower reinforcement because there are some
upper extension points which cannot be welded on the body side.After that,
install the front pillar outer lower extension and front pillar
outer upper extension.
Front pillar outer

lower extension
AB601220AB
TSB Revision
FRONT PILLAR
65 mm
7. When installing the new front pillar outer, machine the body
20 mm
(2.6 in) loose panel cushion (MR535301 or MR435765) as shown
(0.8 in) and apply it to the body side to prevent the sound
25 mm is filled into the front pillar upper in the next process (for front
(1.0 in) 35 mm
(1.4 in) pillar upper).
15 mm
(0.6 in)
A
Side outer panel
Front pillar
reinforcement lower
A AB601733AB
35 mm 8. When installing the new front pillar outer, machine the body
80 mm
(1.4 in) loose panel cushion (MR535301 or MR435765) for
10 mm (3.1 in) replacement as shown and apply it to the body side because
(0.4 in) 90 mm the sound dampening foam material is filled into the front
(3.5 in)
pillar (for front pillar lower).
30 mm
(1.2 in) B
110 mm
(4.3 in)
B Side outer
panel
TSB Revision
FRONT PILLAR
3-15
9. When installing the new front pillar outer, apply the body
sealant to the areas as shown in advance.
: Body sealant AB601221AB
10.Assemble the front pillar outer, bolt and tape the hole and
flange with aluminum tape, then fill the hole with sound
dampening foam material as shown in the figure of the
instructions.
SOUND DAMPENING FOAM MATERIAL: 3M AAD
ULTRAPRO Panel foam-Yellow
AB601214
Front pillar
reinforcement lower
Front inner
pillar lower A
: Sound dampening foam material
AB601246AB
11.Wait 2 hours after filling the sound dampening foam material

to remove the bolt and aluminum tape, then melt the sound
dampening foam material with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with sound
dampening foam material.
AB100787
TSB Revision
FRONT PILLAR (PARTIAL REPLACEMENT)

M4030001200045

Spot welding
MIG spot welding
Braze welding
AB601231AB
REPAIR WELDS
Cutting position 110 mm

(4.3 in)
B
A Sound dampening
foam material
230 mm
(9.1 in)
D G
Cutting position
C A
E Cutting position
Sound dampening
foam material
(With the front upper frame outer rear removed)
B C
AB601401AC
CAUTION
NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the front upper frame outer
rear.
TSB Revision
3-17
Cutting position
Cutting position
F G

AB601448AB
NOTE ON REPAIR WORK

.
REMOVAL
After removing the front pillar, cut the side outer panel 140 mm
140 mm (5.5 inches) behind the positioning notch to remove the side sill
Front inner pillar lower (5.5 in)
reinforcement outer front, side sill inner support front, and front
inner pillar lower remaining on the body side.
Side sill inner
support front
Side outer panel

Side sill reinforcement outer front AB601206AB
TSB Revision
INSTALLATION
Side outer 1. To reinforce the strength in the front pillar cut area, cut the
panel side outer panel 50 mm (1.97 inches) above the cut area.
2. Assemble the new front pillar inner lower parts.
50 mm
(1.97 in)
AB601207AB
3. Assemble the new side sill reinforcement front parts. After

that, cover the hole with aluminum tape to prevent the sound
Side sill reinforcement front
is filled into the front pillar in the next process.
Aluminum tape AB601208AB
4. When installing the new front pillar lower reinforcement is

installed, remove the front pillar outer lower extension and
front pillar outer upper extension in advance, and install the
Front pillar outer front pillar lower reinforcement because there are some
upper extension points which cannot be welded on the body side.After that,
install the front pillar outer lower extension and front pillar
outer upper extension.
Front pillar outer

lower extension
AB601220AB
TSB Revision
3-19
5. When installing the new front pillar outer, machine the body
35 mm loose panel cushion (MR535301 or MR435765) for
(1.4 in)
80 mm replacement as shown and apply it to the body side because
10 mm (3.1 in)
(0.4 in) 90 mm the sound dampening foam material cannot be filled into the
(3.5 in) front pillar.
30 mm
(1.2 in) A
110 mm
A
(4.3 in)
A Side outer
panel
6. When installing the new front pillar outer, apply the body
sealant to the areas as shown in advance.
TSB Revision
7. Assemble the front pillar outer, bolt and tape the hole and
instructions.
Front pillar
reinforcement lower
A
Front inner
pillar lower
AB601590AB
8. Wait 2 hours after filling the sound dampening foam material

AB100787
TSB Revision
CENTER PILLAR
3-21
CENTER PILLAR
M4030006000693

Spot welding
MIG spot welding
Braze welding
AB601232AB
REPAIR WELDS
190 mm
(7.5 in)
Cutting position
Sound dampening
A foam material
B
The same position as the The same position as the
new center outer part new center outer part
Sound dampening
C foam material D
C D AB601417AB
CAUTION
TSB Revision
CENTER PILLAR
NOTE ON REPAIR WORK

.
REMOVAL
Side outer 1. To cut the welding points between the side sill center pillar
panel reinforcement and side sill reinforcement outer rear, cut the
Center pillar side outer panel as shown.
reinforcement
Side sill reinforcement

outer rear AB601418AB
2. After removing the center pillar, remove the center pillar

inner upper left on the body side.
Center pillar inner upper

AB601247AB
INSTALLATION
1. To reinforce the strength in the center pillar cut area, cut the
side outer panel 100 mm (3.9 inches) above the cut area
and cut the center pillar reinforcement 50 mm (1.97 inches)
Side outer above the cut area.
Center pillar panel
reinforcement
100 mm
50 mm (3.9 in)
(1.97 in)
AB601248 AB
2. Remove the center pillar inner lower from the new center
inner pillar, and install the center inner pillar to the body.
Center pillar
inner lower
AB601249AB
TSB Revision
CENTER PILLAR
3-23
CAUTION
Rear door hinge Weld and repair if the rear door hinge reinforcement is
reinforcement 50 mm damaged.
(1.97 in)
3. Cut the new center pillar reinforcement parts by aligning
them with the cut area of center pillar reinforcement in the
100 mm body-side. Then, cut only the center pillar reinforcement 100
(3.9 in)
mm (3.9 inches) below from the cut area to create a cover,
and then cut the rear door hinge reinforcement 50 mm (1.97
inches) below from the cut area.
Center pillar
reinforcement
AB601250 AB
4. Weld the rear door hinge reinforcement then weld the cover
of the center pillar reinforcement.
Cover
Rear door hinge

reinforcement
Center pillar
reinforcement
AB601251AB
50 mm 5. When installing the new center pillar outer, machine the

(2.0 in) body loose panel cushion (MR535301 or MR435765) for
50 mm 35 mm 50 mm replacement as shown and apply it to the body side because
(2.0 in) (1.4 in) (2.0 in)
20 mm the sound dampening foam material cannot be filled into the
(0.8 in) front pillar.
75 mm
(3.0 in)
75 mm
(3.0 in)
40 mm 450 mm A
(1.6 in) (17.7 in)
Center pillar
reinforcement
A
Side outer
panel
TSB Revision
CENTER PILLAR
6. Assemble the center pillar outer, bolt and tape the hole and
instructions.
Center pillar reinforcement
A
outer rear
AB601255AB

AB100787
TSB Revision
CENTER PILLAR
3-25
NOTES
TSB Revision
SIDE SILL
SIDE SILL
M4030007000878

Spot welding
MIG spot welding
Braze welding
AB601233AB
REPAIR WELDS Sound dampening

foam material
65 mm
(2.56 in)
50 mm B
(1.97 in) 40 mm
(1.57 in)
A
C
Sound dampening Sound dampening

foam material foam material
A B C
AB601516AB
CAUTION
TSB Revision
SIDE SILL
3-27
D Sound dampening
foam material
D
AB601517AB
NOTE: Partial replacement is possible depending on the range

of damage. Cut the side sill reinforcement outer rear 50 mm
outer rear (1.97 inches) away from the cut area of the side outer panel.
(With the side outer

panel removed)
: Cuttable range AB601311AB
TSB Revision
SIDE SILL
NOTE ON REPAIR WORK

.
REMOVAL
1. When installing the side sill reinforcement outer rear, cut the
80 mm center pillar reinforcement 80 mm (3.15 inches) downward
(3.15 in)
from the installation hole of the rear door hinge because the
center pillar reinforcement interferes with it.For the rear
wheel house, remove the rear wheel house shield plate front
and quarter inner extension front because the quarter inner
extension front interferes with the rear wheel house shield
plate front.
Center pillar
reinforcement
Rear wheel house

shield plate front
Quarter inner extension front

AB601298AB
2. After removing the side sill reinforcement outer rear, remove

Center pillar
the center pillar inner lower.
inner lower
AB601307 AB
TSB Revision
SIDE SILL
3-29
INSTALLATION
1. Remove the center pillar inner upper from the new center
inner pillar, and install the center inner pillar to the body.
Center pillar
inner upper
AB601249 AC
2. Remove the side sill reinforcement outer front from the new
side sill reinforcement, and install the side sill reinforcement
Side sill reinforcement outer front to the body.
AB601309AB
35 mm 3. When installing the new floor side sill outer, machine the
80 mm
10 mm (3.1 in) replacement as shown and apply it to the body side because
(0.4 in) 90 mm the sound dampening foam material cannot be filled into the
(3.5 in)
front pillar.
30 mm
(1.2 in) A
110 mm
(4.3 in)
A Side outer
panel
TSB Revision
SIDE SILL
50 mm 4. When installing the new floor side sill outer, machine the
50 mm 35 mm 50 mm replacement as shown and apply it to the body side because
(2.0 in) (1.4 in) (2.0 in)
20 mm the sound dampening foam material cannot be filled into the
75 mm (0.8 in)
(3.0 in) center pillar.
75 mm
(3.0 in)
40 mm 450 mm A
(1.6 in) (17.7 in)
Center pillar
reinforcement
A
Side outer
panel
5. Assemble the floor side sill outer, bolt and tape the hole and
instructions.
Center pillar reinforcement
A
outer rear
AB601255AB
TSB Revision
SIDE SILL
3-31
AB100787
TSB Revision
QUARTER OUTER
QUARTER OUTER
M4030008000718
Symbol Operation description

Spot welding
MIG spot welding
Braze welding
AB601695 AB
REPAIR WELDS
3 points on
B left side only
320 mm C
(12.6 in) E
Sound dampening
foam material
Sound dampening D
foam material
35mm
(1.38 in)
Right side
A B C AB601476AB
CAUTION
TSB Revision
QUARTER OUTER
3-33
D E
AB601477AB
NOTE ON REPAIR WORK

.
INSTALLATION
1. When installing the new rear quarter outer panel, machine
40 mm the body loose panel cushion (MR535301 or MR435765) for
(1.6 in)
175 mm replacement as shown and apply it to the body side because
(6.9 in) the sound dampening foam material cannot be filled into the
25 mm
(1.0 in) wheel arch.
Side outer
panel
Roof side rail

reinforcement rear
A
TSB Revision
QUARTER OUTER
2. When installing the new rear quarter outer panel, machine

the body loose panel cushion (MR535301 or MR435765) for
185 mm
(7.3 in) replacement as shown and apply it to the body side because
the sound dampening foam material cannot be filled into the
40 mm wheel arch.
(1.6 in)
30 mm
(1.2 in)
Rear pillar
reinforcement lower
Quarter inner
panel
Side outer
panel
A
3. When installing the new rear quarter outer panel, apply the
body sealant in advance to the areas as shown.
Left side only
NOTE: Partial replacement is possible depending on the range

of damage.
: Cuttable range AB601692 AB
TSB Revision
REAR END PANEL
3-35
REAR END PANEL
M4030009000302

Spot welding
MIG spot welding
Braze welding
AB601489 AB
REPAIR WELDS
A
AB601442 AB
TSB Revision
REAR FLOOR
REAR FLOOR
M4030010000782

Spot welding
MIG spot welding
Braze welding
AB601490 AB
REPAIR WELDS
B
A
D
E
C
A
(With the rear floor pan rear removed) AB601443AB
NOTE: Refer to the Rear End Panel section on P.3-35 for the welding points with the rear end panel.
TSB Revision
REAR FLOOR
3-37
B C
D E
AB601444AC
NOTE ON REPAIR WORK

.
REMOVAL
(With the rear floor pan rear removed) 1. When removing the rear floor sidemember upper, cut it 290
mm (11.4 inches) behind the installation hole of the child
restraint bracket.
290 mm
(11.4 in)
AB601242 AB
TSB Revision
ROOF
ROOF
M4030011000871

Spot welding
MIG spot welding
Braze welding
AB601234AB
REPAIR WELDS
Vehicles without
sunroof
Vehicles with
sunroof
: Adhesive AB601308AB
ADHESIVE: Urethane body sealer BRAND: 3M AAD Part No.8542 or equiva-

lent
TSB Revision
ROOF
3-39
NOTES
TSB Revision
QUARTER INNER
QUARTER INNER
M4030012000733

Spot welding
MIG spot welding
Braze welding
AB601696 AB
REPAIR WELDS Sound dampening

foam material
Sound dampening
foam material
Sound dampening
foam material B
B
Left side
A only
Sound dampening
foam material
F
G
(With the quarter outer removed)
AB601518AB
CAUTION
NOTE: Refer to the Quarter Outer section on P.3-32 for the welding points with the quarter outer.
TSB Revision
QUARTER INNER
3-41
Right side
only
E
Right side only
Right side
Right side
only
C
D
Right side
Right side
Left side
only
(With the rear pillar reinforcement and the rear pillar reinforcement lower removed)
E
Left side D
only
Left side
C only
AB601519AB
TSB Revision
QUARTER INNER
Right side
only
Left side Right side

F only G only
H
(With the rear wheel house
shield plate front removed)
AB601591AB
NOTE ON REPAIR WORK

.
INSTALLATION
1. When installing the new rear quarter inner panel, machine
the body loose panel cushion (MR535301 or MR435765) as
A
shown and apply it to the body side to prevent the sound
125 mm
is filled into the rear pillar in the next process.
(4.9 in)
70 mm
(2.8 in)
20 mm
(0.8 in)
Roof side rail

reinforcement rear
Quarter inner
panel
A
TSB Revision
QUARTER INNER
3-43
2. When installing the new rear pillar reinforcement lower,
85 mm
(3.3 in)
machine the body loose panel cushion (MR535301 or
MR435765) for replacement as shown and apply it to the
body side because the sound dampening foam material
cannot be filled into the rear pillar reinforcement lower.
20 mm 40 mm
(0.8 in) (1.6 in)
Quarter inner
panel
Rear pillar
reinforcement lower
3. Assemble the rear quarter inner panel, bolt and tape the
hole and flange with aluminum tape, then fill the hole with
sound dampening foam material as shown in the figure of
the instructions.
AB601338AB

AB100787
TSB Revision
QUARTER INNER (PARTIAL REPLACEMENT)

M4030000200097

Spot welding
MIG spot welding
Braze welding
AB601697 AB
REPAIR WELDS
(With the rear pillar reinforcement and the rear pillar reinforcement lower removed)
Rear wheel house C

shield plate front C
B (With the rear wheel house
shield plate front removed) AB601487AB
NOTE: .
Refer to the Quarter Outer Section on P.3-32 for the welding points with the quarter outer.
Refer to the Quarter Inner Section on P.3-40 for the welding points with the rear pillar reinforcement and
the rear pillar reinforcement lower.
TSB Revision
3-45
NOTE ON REPAIR WORK
.
REMOVAL
1. Adhere tape along the wheel arch of the quarter inner panel
as shown in the figure of the instructions, use the tape as a
guide so about 20 mm (0.79 inch) of the flange remains,
then cut and remove.
Tape
AB601343 AB
INSTALLATION
1. For the new rear quarter inner panel parts, cut the wheel
arch end are so that it overlaps with the flange on the
body-side.
AB601344
2. Overlap, assemble and weld the rear quarter inner panel

with the body-side flange. Weld at a pitch of 40 mm (1.57
inches).
40 mm (1.57 in)
AB601342AB
3. Weld the rear quarter inner panel then apply a body sealing
in the area shown in the figure of the instructions.
Body sealing
AB601426AB
TSB Revision
FRONT DOOR OUTER PANEL (WELDED TYPE)
FRONT DOOR OUTER PANEL (WELDED TYPE)

M4030001500239

Spot welding
MIG spot welding
Braze welding
AB601288AB
REPAIR WELDS
50 mm
(1.97 in)
: Adhesive AB601280AB
ADHESIVE: Urethane body sealer BRAND: 3M AAD Part No.8542 or equiva-

lent
NOTE: After hemming the front door outer panel, MIG spot weld the flange overlap section at a pitch of 50
mm (1.97 inches).
TSB Revision
FRONT DOOR OUTER PANEL (ADHESION TYPE)
3-47
FRONT DOOR OUTER PANEL (ADHESION TYPE)
M4030001700233

Spot welding
MIG spot welding
Braze welding
AB601289AB
REPAIR WELDS
A
: Adhesive 1
: Adhesive 2 AB601281AB
ADHESIVE 1: Urethane body sealer NOTE ON REPAIR WORK

BRAND: 3M AAD Part No.8542 or equiv- .
alent INSTALLATION
ADHESIVE 2: Epoxyayresin adhesive 1. When installing the front door outer panel, grind
BRAND: 3M AAD Part No.8115 or equiv- the bonding surface and remove the paint to
alent improve adhesion. Then, degrease the front door
outer panel.
2. Install the front door outer panel and hem it. Then,
wipe off the adhesive that squeezed out.
TSB Revision
REAR DOOR OUTER PANEL (WELDED TYPE)
REAR DOOR OUTER PANEL (WELDED TYPE)

M4030001600184

Spot welding
MIG spot welding
Braze welding
AB601290AB
REPAIR WELDS
50 mm
(1.97 in)
A
: Adhesive AB601282 AB
ADHESIVE: Urethane body sealer BRAND: 3M ATD Part No.8542 or equivalent

NOTE: After hemming the rear door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm
(1.97 inches).
TSB Revision
REAR DOOR OUTER PANEL (ADHESION TYPE)
3-49
REAR DOOR OUTER PANEL (ADHESION TYPE)
M4030001800188

Spot welding
MIG spot welding
Braze welding
AB601291AB
REPAIR WELDS
: Adhesive 1 A
: Adhesive 2 AB601283AB
ADHESIVE 1: Urethane body sealer NOTE ON REPAIR WORK

BRAND: 3M ATD Part No.8542 or equiva- .
lent INSTALLATION
ADHESIVE 2: Epoxyayresin adhesive 1. When installing the rear door outer panel, grind
BRAND: 3M ATD Part No.8115 or equivalent and remove the paint, etc. from the bonded
surface of the outer panel to ensure the bonding
strength. After the removal, degrease it.
2. Install the outer panel and hem it. Wipe off the
excessive adhesive and finish it.
TSB Revision
NOTES
5-1
GROUP 5
SYNTHETIC-RESIN
PARTS
CONTENTS
LOCATION OF SYNTHETIC-RESIN
PARTS . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 SYNTHETIC-RESIN PARTS
LOCATION OF SYNTHETIC-RESIN PARTS

M4050001000980
The location and material of each of the principal
synthetic-resin parts are shown below.
4
41 3
2, 5 12
6
32 13
7
1
27
26 9
25
29
24 28
23 AB601424AB
15 35 31 16
36
30 17
14
34
33
18
10
19
21 20
11 37
22
38
40 39
AB601425AB
SYNTHETIC-RESIN PARTS
5-3
NO. PART NAME NAME OF RESIN ABBREVIATION HEAT-
RESISTANT
TEMP
[ C ( F)]
1 Radiator grille Acrylonitrile butadiene styrene ABS 80 (176)
2 Door mirror cover (colour)
3 Rear spoiler
4 Roof antenna base Acrylonitrile ethylene styrene AES 80 (176)
5 Door mirror cover (black) Acrylonitrile styrene acrylate ASA(AAS) 80 (176)
6 Door mirror
7 Headlight Polycarbonate PC 120 (248)
8 Rear door outside handle Polycarbonate+Polyethylene PC+PET 120 (248)
9 Front door outside handle terephthalate
10 Rear splash shield High density polyethylene PE-HD 70 90
11 Front splash shield (HDPE) (158 194)
12 High-mounted stoplight Polymethyl methacrylate PMMA 80 (176)
13 Trunk lid light
14 Front door trim lower Polypropylene PP 80 (176)
15 Inside rear view mirror
16 Rear door trim
17 Rear shelf trim
18 Rear end trim
19 Rear scuff plate
20 Front scuff plate
21 Cowl side trim
22 Fender protector
23 Fog light bezel <With fog light> Rubber denatured polypropylene PP+E/P 80 (176)
24 Air intake bezel <Without fog light>
25 Front bumper face
26 Under grille
27 Rear bumper face
28 Front air dam
29 Side air dam Talc filled rubber modified PP+E/P-TD20 110 (230)
polypropylene (20%)
30 Front door trim upper Talc filled polypropylene (10%) PP-TD10 110 120
31 Center pillar trim lower (PPF) (230 248)
5-4 SYNTHETIC-RESIN PARTS
NO. PART NAME NAME OF RESIN ABBREVIATION HEAT-

RESISTANT
TEMP
[ C ( F)]
32 Front deck garnish Talc filled polypropylene (20%) PP-TD20 120 130
33 Instrument panel (PPF) (248 266)
34 Front pillar trim
35 Center pillar trim upper
36 Rear pillar trim
37 Cup holder
38 Floor console
39 Floor console panel
40 Console side cover
41 Roof drip molding Polyvinyl chloride PVC 80 (176)
NOTE: .
If the material symbols designated by the ISO differ from the old symbols, both are given, with the old
symboling enclosed in brackets.
ISO: International Standardization Organization.
A slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus
sign (+) indicates that the two different materials mix each other.
The indicated heat-resistant temperature for parts which are composed of two or more types of material is
the value for the material with the lowest heat-resistant temperature.
The material symbols for synthetic-resin parts are embossed on the parts in hidden places.
6-1
GROUP 6
BODY COLOR
CONTENTS
BODY COLOR CODE . . . . . . . . . . . . 6-2 BODY COLORING . . . . . . . . . . . . . . . 6-3

RADIATOR GRILLE . . . . . . . . . . . . . . . . . . 6-3
BODY COLOR CHARTS . . . . . . . . . . 6-2 WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2 BODY COLOR
BODY COLOR CODE
BODY COLOR CODE

M4060001000679
Body color code is stamped on the name plate, which is
attached on the underside of the center pillar (Right side).
Body color code
AB601277AB
BODY COLOR CHARTS

M4060002001396
Check the vehicles body color code, and then use
this body color chart to determine the refinishing
paint supplier from which the color can be pur-
chased.
Color Color code Color number Color name (Previous name) Composition of film
SILVER A31 CMA10031 Cool Silver Metallic Metallic
MEDIUM A39 CMA10039 Medium Purplish Gray Mica Metallic +
PURPLISH GRAY Interferenced Pearl
GREENISH A86 CMA10086 Greenish Silver Metallic Metallic +
SILVER Interferenced Pearl
BLUE T70 CMT10070 Blue Mica Pearl
BEIGE S18 CMS10018 Platinum Beige Metallic Metallic +
Interferenced Pearl
BLACK X42 AC11342 Black Mica (Amethyst Black) Interferenced Pearl
WHITE W37 CMW10037 White Solid Solid
RED P26 CMP10026 Red Metallic Metallic
NOTE: .
It is a solid, but clear coating is applied.
For painting, inner panel colors should be similar to the outer panel colors.
BODY COLOR
BODY COLORING
6-3
BODY COLORING
RADIATOR GRILLE
M4060007000592
ES, GTS DE
1 Chrome plating Dark gray (CMH18031)
2 Material color Material color
AB601174AB
WHEELHOUSE
M4060012000327
: Black (AC10657) AB601150AB

AB601150
NOTES
9-1
GROUP 9
BASE OF BODY
REPAIR
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . 9-2 USING A FRAME STRAIGHTENER . . . . . . 9-27

FRAME REPAIR PROCEDURES . . . . . . . . 9-28
WELDING. . . . . . . . . . . . . . . . . . . . . . 9-2 NOTES REGARDING REPAIR WORK . . . . 9-31
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 HEAT-WITHSTAND TEMPERATURES OF
ELECTRIC RESISTANCE SPOT RESIN-PLASTIC PARTS . . . . . . . . . . . . . . 9-34
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 HOW TO DISTINGUISH TYPES OF
GAS SHIELD ARC WELDING . . . . . . . . . . 9-8 PLASTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
OTHER TYPES OF WELDING . . . . . . . . . . 9-12
CORROSION PROTECTION . . . . . . . 9-37
BODY REPAIR. . . . . . . . . . . . . . . . . . 9-14 ANTICORROSION TREATMENT AT THE
FACTORY . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
STANDARD BODY REPAIR
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 9-14 ANTICORROSION TREATMENT AT THE
TIME OF BODY REPAIR WORK . . . . . . . . 9-40
THEFT PROTECTION . . . . . . . . . . . . . . . . 9-22
ATTACHMENT OF SILENCERS . . . . . . . . 9-24
REPAIR OF SYNTHETIC-RESIN
POSITIONING DIMENSIONS FOR
PARTS . . . . . . . . . . . . . . . . . . . . . . . . 9-43
OPENINGS . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
SYNTHETIC-RESIN PARTS REPAIR
STANDARD PROCEDURES FOR SHEET
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 9-43
METAL WORK . . . . . . . . . . . . . . . . . . . . . . 9-26
9-2 BASE OF BODY REPAIR
GENERAL
GENERAL
M4090000100018
Group 9 is applicable for all models.
WELDING
WELDING
M4090001000047
Welding is the partial joining of two or more metals
by deposition; the welding methods used for body
maintenance and repair can be classified into the fol-
lowing methods.
Fusion methods Shielded arc welding

Temperature: 1,130 1,550C CO2 gas arc welding
(2,066 2,822F)
Gas welding
Welding methods
Pressure methods Electric resistance spot welding
[Temperature approximatery 1,500C (2,732F) or higher at weld area]
Brazing methods Brazing

Temperature: 620 950C
(1,148 1,742F)
Soldering
Temperature: 183 310C
(361 590F)
AB301447AB
FUSION WELDING BRAZING

Fusion welding is a method of welding in which the Brazing is a method of welding in which the weld
weld connection is made by forming or supplying the connection is made by supplying a filler metal (which
weld metal at the part where the weld is to be made. is molten at a temperature lower than the melting
temperature of the base metal) at the place where
PRESSURE WELDING the joining is to be made without melting the base
Pressure welding is a method of welding in which the metal itself.
weld connection is made by applying external pres-
sure while the part where the weld is to be made is in
a molten or semi-molten condition.
ELECTRIC RESISTANCE SPOT WELDING
M4090002000039
Electric resistance spot welding is a method for fus- ADVANTAGES OF ELECTRIC
ing metal parts together. Two or three metal sheets RESISTANCE SPOT WELDING
are positioned between two copper-alloy electrode
Because the time required for welding at each
tips, and pressure and a large current are then
point is brief, the work can be done quickly and at
applied, thus causing the contacting surfaces to heat
reduced cost.
up and fuse together because of the electric contact
Because both metals are fused and pressure
resistance.
applied to make the weld, the strength and reli-
ability are both high.
Because the time required to make the welds is
short, there is little occurrence of distortion of the
panel due to heat.
.
BASE OF BODY REPAIR
WELDING
9-3
PROCEDURE
There are three basic stages in electric resistance spot weld-
ing.
1. Initial pressure application stage
This stage precedes the current application. Applying
pressure to the steel panels through the electrode tips
ensures a uniform contact resistance and a smoother
current flow.
AB200026
2. Current application stage

While an ample amount of pressure is being applied, the
current is sent through the electrode tips. The contact
resistance causes the contact surfaces of the steel panels to
heat up and fuse together.
AB200027
3. Holding stage
When the current application is finished and a nugget (a
solidified piece of molten metal) forms at the weld, the
pressure application is continued in order to strengthen the
weld. This is the most important stage of electric resistance
spot welding in ensuring the strength of the weld.
AB200028
.
WELDING
NUGGET FORMATION
Cooling water
More than C
D Elect-
1.6 mm rode
Weak Shear strength per point Strong
(0.06 in) Melting point

C' Steel
panel
D'
B'
B 1.6 mm (0.06 in)
or less
Nugget
Elect-
A' A C is the scatter point rode
Small Welding current Large Water 540 1,095 1,650C

Cooling water temperrature (1,000) (2,000) (3,000)F
Max. Heating temperature
AB301468 AC
Generally speaking, the size of the nugget will As the current level increases further, the weld
increase as the welding current increases, and as strength for thick panels [more than 1.6 mm (0.06
the size of the nugget increases, the strength of the inch)] continues to increase proportionately (between
weld will also increase. points B and C); however, for thin panels [1.6 mm
Nugget formation will not begin until the current level (0.06 inch) or less], the weld strength reaches a peak
reaches a certain point; however, once this welding very quickly and will increase only slightly, even if the
current level is passed, the strength will increase rap- current level increases (between points B' and C').
idly (between points A and B). Then, for both thick panels and thin panels, the mol-
ten metal will scatter if the current level increases
past a certain point.
.
BASE OF BODY REPAIR
WELDING
9-5
NOTES REGARDING WELDING
90 120
D : Diameter of the electrode tip
t : Thickness of the panel
AB301455AC
1. Selection of the electrode tips Make the spot welds at the center of the
Select the electrode tips according to the flanges to provide sufficient adhesion. When
thickness of the panels to be welded. welding at an edge, make the spot welds at
D = 2t + 3 mm (D = 2t + 0.1 inch) least 5 mm (0.2 inch) from the edge of the
The angle of the tip should be between 90 flange.
degree angle and 120 degree angle. The number of spot weld points should be the
To always keep the end of tip in the correct same as, or slightly more than the number of
shape, use a tip cutter, file or similar tool to original repair welds.
shape it if it becomes worn. When spot welding three or more panels
2. Alignment of the electrode tips together, if painted surfaces cause a loss of
Adjust the arms so that the upper and lower conductivity, make the welds at the same
electrode tips are in a straight line. places as the factory welds. If this is done,
3. Alignment and length of the arms extra welds will not be necessary, but if extra
Adjust the electrode tips so that the upper and welds are necessary, switch to plug welding.
lower arms are parallel. .
Select an appropriate arm length. Note, how- WELDING REQUIREMENTS

ever, that the arm length should not be more Standard steel plate (SPCC, etc.)
than 350 mm (13.8 inches) in order to ensure CAUTION
nugget strength. If the total thickness of the plates at the weld
4. The weld points places is 3 mm (0.12 inch) or more, use plug
The overall strength will increase as the pitch welding, because spot welding will not provide
decreases; however, if the pitch decreases sufficient welded strength.
too much, the current will be short-circuit
diverted to the previous weld point and the Example
strength of the individual nuggets will be insuf- Center pillar (outer): plate thickness 1.4 mm (0.06
ficient. inch), material SPCC
Center pillar (inner): plate thickness 1.5 mm (0.06
inch), material SPCC
The number of weld points are as below when the
outer and inner center pillars are repaired by weld-
ing.
WELDING
Factory welds (F) Repair welds (R)
8 Points 8 Points 11 Points 11 Points
As shown by the Welding Requirements table, the number of repair welds is as follows.
8 (points) 130 (%) = 10.4 (points)
The number of weld points should, therefore, be ten or eleven.
If, however, a pitch of 26 mm (1.0 inch) or more cannot be maintained, the plug
welding method (eight weld points) should be used.
AB200031AC
PANEL NUMBER OF REPAIR WELD (PERCENTAGE OF FACTORY WELD)

THICKNESS*
[mm (in)]
SAFETY 1.0 (0.04) or 100% Same number as factory welds
EQUIPM less
ENT 1.2 (0.05) 150% Maintain pitch of at least 22 mm (0.9 inch); if not possible, plug weld.
AREA
1.4 (0.06) or 100% Same number as factory welds; plug welding
more
OTHER 1.2 (0.05) or 100% Same number as factory welds
AREA less
1.4 (0.06) 130% Maintain pitch of at least 26 mm (1.0 inch); if not possible, plug weld.
more
NOTE: *: For welding steel plates of different thickness, conform to the welding conditions for the thinner
plate.
.
BASE OF BODY REPAIR
WELDING
9-7
Galvanized steel plate (SECC)
CAUTION
If the total thickness of the plates at the weld
places is 3 mm (0.1 inch) or more, use plug weld-
ing, because spot welding will not provide suffi-
cient welded strength.
PANEL NUMBER OF REPAIR WELD (PERCENTAGE OF FACTORY WELD)
THICKNESS*
[mm (in)]
SAFETY 0.9 (0.04) or 100% Same number as factory welds
EQUIPM less
ENT 1.0 (0.04) 200% Maintain pitch of at least 18 mm (0.7 inch); if not possible, plug weld.
AREA
more
OTHER 0.9 (0.04) or 100% Same number as factory welds
AREA less
1.0 (0.04) 140% Maintain pitch of at least 18 mm (0.7 inch); if not possible, plug weld.
more
NOTE: *: For welding steel plates of different thicknesses, conform to the welding conditions for the thinner
plate.
.
USING A TEST PIECE TO CHECK NUGGET

FORMATION
Weld a test piece of the same type of steel plate as the panels
to be welded. Try to twist the piece, and also check the nugget
Weld point 1 diameter.
Using the weld point as an axis, apply force in the direction indi-
cated by the arrows in the illustration, and determine the
2
strength of the weld.
1. Good (The welded part remains at one side).
3 2. and 3.
The weld conditions are unsatisfactory; adjust the welding
AB200032AC current, the current application time, and/or the applied
pressure.
.
WELDING
CHECKING NUGGET STRENGTH FOLLOWING

SPOT WELDING
CAUTION
Stop wedging the tip or the chisel or flat-tipped screw-
driver as soon as the size of the nuggets can be deter-
3 mm (0.1 in) mined; do not wedge it in more than 30 mm (1.2
inches).
After checking the nugget diameter, correct the place
where the checking was done.
Wedge the tip of a chisel or flat-tipped (-) screwdriver into the
space between two weld points.
The nuggets should not break apart.
AB200033AB The nugget diameter should be 3 mm (0.1 inch) or more.
GAS SHIELD ARC WELDING

M4090003000032
Wire
Nozzle
Contact tip
Metal vapor
Shield gas
AB301456 AC
Gas shielded arc welding is one method of arc weld- fuse the area. There are two types of gas shielded
ing. In this method, while the area to be welded is arc welding, classified according to the gas they use
shielded from the air by a layer of inert gas (such as as the shield gas: carbon dioxide (CO2) gas shielded
argon) or carbon dioxide gas, the filler metal (wire) is arc welding, and MIG welding, which uses an inert
fed from the torch nozzle at a constant rate and an gas (such as argon).
electric arc is generated between the tip of the wire However, herein we will refer to all gas shielded arc
and the area being welded, thus generating heat to welding as MIG welding.
MIG SPOT WELDING
Wire
Gas cup
Gas outlet
AB200036 AD
BASE OF BODY REPAIR
WELDING
9-9
This welding method is used in areas where regular 2. Being sure that the two prongs are not leaning to
spot welding cannot be done. The two panels are either side, set them in direct contact with the
stacked together, the tip of the torch (one designed panel to the welded.
for use in MIG spot welding) is positioned on one 3. Welding will begin when the torch trigger is
side, an arc is generated for a short time, and a par- squeezed, and will stop automatically when the
tial melting is done to obtain a spot weld. weld is complete.
.
Procedure .
CAUTION
Make sure that the area to be welded is per-
fectly clean; remove oxidation film, scales,
rust, dirt, etc.
The two panels to be welded must be in per-
fect contact with each other.
The number and pitch of the weld points
should be approximately the same as for the
factory welds.
1. Position the tip of the nozzle at a right angle to the
surface to be welded.
FEATURES OF MIG SPOT WELDING

In comparison to resistance spot welding, MIG spot
welding has the following advantages and disadvan-
tages.
ITEM MIG SPOT WELDING ELECTRIC RESISTANCE SPOT WELDING
Working Light weight Although the torch with separate
characteristics Welding possible at various transformer is lightweight, the torch
positions (no limit upon welding combined with transformer type is heavy.
positions) The arm must be exchanged to conform
to the weld location.
Weld time/point Slow (0.5 second or more) Fast (0.5 second or less)
Treatment after Necessary (grinding by grinder, Unnecessary
welding etc.)
Power High voltage, low current Low voltage, high current
(15 30 V, 50 200 A) (2 4 V, 4 10 kA)
Flux material CO2 (carbonic acid gas) Unnecessary
Weld wire
Weld points/10 25 points or less 50 60 points
minutes Arc instability and contact tip Welding rod deformation and transformer
(rate of use) burn if rate of use is exceeded. overheating if rate of use is exceeded.
Distortion caused by Occurs easily Rare
welding
WELDING
ITEM MIG SPOT WELDING ELECTRIC RESISTANCE SPOT WELDING

Welding strength Depends on strength of welding Same as base material
wire itself. Little oxidation
Uniform welding quality
Weld traces Button head (slightly convex) Slight concave
(Almost no indentation if swivel tip
used.)
Swivel tip
AB200037AC
Re-repairability Difficult Easy

(cutting away welded (Much welding trace High hardness (Can be separated by spot cutter.)
area) of weld points)
.
The MIG welding done around the doors, wheelhouse arches,

etc., to prevent the flanges from coming undone after hemming
work is also called MIG spot welding.
AB200038 AB
PLUG WELDING
CAUTION
In order to prevent the formation of blowholes, fill in each
hole completely in one pass.Be sure that the two panels
5 6 mm
(0.2 in) are in perfect contact.Be sure that the penetration goes all
Torch the way to the bottom panel.
Diameter hole
Plug welding is done by making holes 5 6 mm (0.2 inch) in
diameter in one of the panels to be welded together, positioning
Perfect contact the torch at a right angle to the holes and then filling in the
holes one at a time.
AB301460AC
BASE OF BODY REPAIR
WELDING
9-11
CONTINUOUS WELDING
There are several types of continuous welding: fillet (lap joint)
welding, butt welding, T joint welding, gap welding, etc.; these
are called short-circuit arc welding, and provide a stable arc at
a relatively low current.
AB200041
Torch angle and welding technique

There are two welding techniques: forehand welding and back-
hand welding.
Forehand welding: Penetration is shallow and the bead is flat.
Backhand welding: Penetration is deep and the bead has a
convex shape.
The angle of the torch should be 15 30 degree angle for either
technique, and the tip should be maintained at a distance of 6
15 30 15 30 10 mm (0.2 0.4 inch) from the surface being welded.
Furehand Backhand
technique technique
AB301457AC
Preventing warping
1. Backhand technique
Anti-warp welding techniques
Because the direction for each weld pass and that for the
5 4 3 2 1 fusion progression are opposite, the residual stress is
1.
Backhand technique
evenly distributed.
4 2 1 3
2. Symmetrical technique
2. Because the welds are made in symmetrical positions in
Symmetrical technique relation to the center of the joint, the residual stress is also
1 4 2 5 3 symmetrical.
3.
"Stepping stone" technique 3. "Stepping stone" technique
AB200043 AC Because the welds are made at random positions, the
residual stress is the most evenly distributed; however, the
possibility of flaws at the starting and stopping points is rela-
tively high.
WELDING
NOTES REGARDING MIG WELDING 3. Select a welding current to match the thickness of
Note the following notes regarding MIG welding. the panels being welded.
1. The surface to be welded must be perfectly 4. For continuous welding, maintain a constant weld
clean; be sure to remove any non-conductive speed and keep both the height and the width of
paint. the bead constant.
2. If the end of the wire forms into a ball, it will In addition, the tack welding pitch and the welding
adversely affect the formation of the arc; cut the bead should be shorter as the thickness of the
end off with a pair of wire snips or a similar tool. panels being welded decreases.
OTHER TYPES OF WELDING

M4090004000035
BRAZING 1. Brass filler metal (brass solder)

In brazing, a filler metal is melted into the joint of the Brass filler metal is an alloy consisting of 60%
panels to be welded at a comparatively low tempera- copper and 40% zinc with a melting temperature
ture to fuse them together without melting the panels of approximately 850 1,050 C (1,562
themselves. In other words, through the aid of a flux 1,922 F), and it is the most commonly used braz-
and because of the capillarity phenomenon, the mol- ing filler metal used for body repair.
ten filler metal will flow into the joint between the two The filler metal itself is coated with flux to facili-
panels which are in contact with each other and tate penetration between the panels to be joined.
spread along the metal surfaces. When this molten 2. Silver alloy filler metal (silver solder)
filler metal cools and solidifies, it will from a strong Silver alloy filler metal consists of silver, copper,
joint of the two panels. Note that, if two panels of dif- zinc or cadmium, nickel, and tin, or other metals.
ferent kinds of metal are brazed, the electrolysis gen- This filler metal is most applicable for the brazing
erated between the two metals will cause moisture to of steel and non-ferrous alloy other than alumi-
from, which will result in corrosion. num, magnesium, and others with low melting
Panels should not be connected together by brazing points.
at any place except those places indicated. The fol-
lowing materials (filler metals) are usually used for
brazing.
Notes with regard to brazing work
Examples of brazed joints

AB200044 AD
Use a wire brush, sandpaper, file etc., to remove When doing brass brazing, if the panels and the
any oxide film grease, dirt, etc., from the surfaces filler metal are heated excessively, a weak
of the panels to be brazed. iron-copper alloy will form, which could crack
easily. Be careful not to apply excessive heat.
The joint of the panels must overlap as indicated
in the illustration.
BASE OF BODY REPAIR
WELDING
9-13
GAS WELDING
Oxy-acetylene Gas welding is a method in which a high temperature flame is
flame used to melt both a welding rod and the base metal (panels) to
make a fused joint. Oxy-acetylene is the most common type of
gas welding. However, because of the extremely high tempera-
Welding rod ture of the fused joint, the strength of the steel plate deterio-
Deposite rates, and there is a higher possibility of warping. This method,
therefore, is not very suitable for body repair.
Base metal AB200049 AC
The flame in gas welding can be classified according

to the ratio of acetylene and oxygen.
1. Carburizing flame 2. Standard flame 3. Peroxide flame
Flame core Flame core Flame core
Acetylene core Outer flame Outer flame

Outer flame
AB200050 AD
1. Carburizing flame (acetylene-rich flame)

.
Notes with regard to gas welding

This flame has an excess of acetylene or a defi-
ciency of oxygen. The incomplete combustion 1. Handle the oxygen and acetylene tanks carefully.
gives off a black smoke, and two flame cores can 2. Adjust the flame in accordance with the type of
be seen inside the deformed yellow flame. The metal being welded.
flame itself is large, but the temperature is rela- 3. Select a nozzle to match the work to be done.
tively low, making this flame unsuitable for weld- Avoid overheating and adhesion of foreign matter
ing. (dirt, etc.)
2. Standard flame (neutral-mixture flame) 4. The following points are particularly important
This flame has approximately equal amounts of when welding mild steel plate.
acetylene and oxygen. The length is shorter than Melt a sufficient amount of welding rod, but be
that of the carburizing flame; the flame core is careful not to melt the base metal. Use the
rounded; and it is clear and bright. same amount of welding rod on both sides.
The carbon in the acetylene is burned completely, Use the correct amount of welding rod in
resulting in the maximum obtainable temperature. accordance with the melting point of the base
This is the flame most commonly used for weld- metal.
ing. Avoid welding over places which have been
3. Peroxide flame (oxygen-rich flame) welded before.
This flame has an excess of oxygen or a defi- In order to avoid warping, do only the amount
ciency of acetylene. The flame core is shorter of tack welding that is absolutely required.
and sharper, and the entire flame has a black-
ish-purplish color. The combustion is unstable,
and the flame flickers continuously.
BODY REPAIR
BODY REPAIR
STANDARD BODY REPAIR PROCEDURES
M4090006000064
The following is an explanation of the standard repair STANDARD PROCEDURES FOR
procedures for the monocoque body and the REPLACEMENT OF WELDED PANELS
frame-type body. Furthermore, please refer to the
In order to maintain the proper levels of strength,
replacement of welded panels for the applicable
rigidity, and precision when making welded panel
model for information concerning the procedures for
replacements, it is essential to first gain a thorough
replacement of panels (as classified by position) for
understanding of the body structure, and then to per-
the various models.
form all repair operations carefully and correctly. In
NOTE: That reference should be made to page addition, when performing the operations, be sure to
P.9-27 concerning repair procedures for the frame of use the proper protective equipment for each opera-
frame-type vehicles. tion.
.
CAUTION
Select an appropriate location for the cutting operation,
and perform the work carefully, so as not to cut into the
reinforcements located inside the pillars, panels which
are not be replaced, or any other such parts.
There are harnesses, hoses, and other such parts
routed inside the front pillar, the rear pillar, the fender
shield, the side sill, etc.; perform the repair work only
after any such material has been removed.
For overlap cutting, allow an overlap of approximately
AB200051 30 50 mm (1.2 2.0 inches) when performing the cut-
ting operation.
1. Rough cutting of panels
First make a rough cutting of a portion of the panel to be
replaced, and then remove that portion, thus making it
easier to break the spot welds.
2. Removal of the paint coat from spot-welded points
In order to clearly identify the spot-welded points, remove
the paint coat from areas where it is difficult to determine the
spot welds.
AB200052
3. Cutting and separation of spot-welded points

In order to perform cutting and separation of spot-welded
points, use a spot weld cutter which is larger than the size of
the nugget to make a hole only in the panels to be replaced.
When cutting and separating spot-welded points in places
where the surrounding panel or other parts interfere with the
spot weld cutter, or if the operation is hampered by a lack of
space, bend back the flanges in order to make the work
easier.
AB200053 If a spot-weld cutter cannot be used at all, cut and separate
the spot welds by using a chisel or similar tool.
BASE OF BODY REPAIR
BODY REPAIR
9-15
NOTE: If a replacement panel is to be mounted by doing
plug welding from the side of the panel remaining on the
body, either a hole can be made in the panel on the body, or
a hole can be made right through both the panel which is to
remain on the body and the panel to be replaced.
CAUTION
When performing this operation, warping of the surround-
ing panels may occur if an excessive amount of heat is
applied; therefore, be careful to avoid doing this.
4. Breaking of brazing and arc welds
Heat only the brazed or arc welded portion (such as the
upper portion of pillars, etc.), and then separate by using a
screwdriver while melting occurs.
AB200054
5. Finishing work of spot welding

Grind and smooth any weld traces which might be left on the
body surface by using an air grinder or similar tool, being
careful not to damage any of the panels which is not to be
replaced. When performing this operation, be sure to wear
safety goggles (dust proof glasses).
AB200055
6. Making of holes in new parts for MIG plug welding

Make holes approximately 5 6 mm (0.2 inch) in diameter at
points where plug welding is to be performed because spot
welding is not possible.
AB200056
AB200057
BODY REPAIR
7. Flange correction for spot weld traces

Correct any flanges that become bent or deformed when
spot welds are broken or during other work.
AB200058
CAUTION
Do not use a flame for paint coat removal because doing
so might damage the paint coat of panels which are not to
be replaced, thus causing corrosion.
8. Removal of the paint coat from new parts and from the
vehicle body
In order to provide for the proper flow of electric current
during spot welding operations, remove the paint coat from
both sides of the new part and the body by using a polisher
wheel or similar tool.
AB200059
9. Rough cutting of new parts

Cut off the unnecessary portions of new parts. Allow an
overlap of approximately 30 50 mm (1.2 2.0 inches) when
performing overlap cutting of the pillars, side sills, or other
locations.
AB200060
CAUTION
Carefully select the location for cutting, taking care not to
cut a reinforcement at the inner side of a pillar, etc. or a
panel that is not to be replaced.
10.Overlap cutting of new parts
For locations in which butt welding is to be done, first
temporarily attach the new parts to the body, and then cut
the two panels simultaneously.
Edge of the
new part NOTE: If a reinforcement or a panel which is not to be
Edge of the replaced is cut accidentally, first repair the mistake by weld-
panel on the body AB200061AC ing before proceeding with the rest of the work.
CAUTION
Perform the operations carefully so that the cut ends fit
together properly.
11.Cutting of new parts by using a measurement marking
BASE OF BODY REPAIR
BODY REPAIR
9-17
If overlap cutting is not possible in a place where butt
welding is to be done, make a measurement marking on the
new part at the exact same measurement which was used
for the cutting of the body panel, and then cut the new part
by using this measurement marking.
Two-layer construction Two-layer construction
When cutting a front pillar or center pillar which has a
two-layer construction but no reinforcement, make the cut-
ting of the inner panel and that of the outer panel approxi-
Outer panel
mately 50 mm (2.0 inches) apart in order to obtain
Approx. 50 mm (2.0 in)
maximum strength.
Inner panel
AB200062AC
Three-layer coustruction Three-layer construction

When cutting a front pillar or center pillar which has a
three-layer (including a reinforcement) construction (dou-
ble-box construction), cut the outer panel and the reinforce-
ment at the same position, and don't forget to butt weld the
Inner panel Inner panel reinforcement. If the inner panel is an assembly replace-
cut line
ment part, cut it at two places in order to provide ample
working space for the butt welding of the reinforcement.
Outer panel and
reinforcemant
cut line Inner panel cut line AB200063AC
12.Application of spot sealer to spot-welded points

Apply an electro-conductive spot sealer to the connecting
surfaces of both the new parts and the vehicle body in order
to provide corrosion protection.
AB200064
BODY REPAIR
CAUTION
During temporary mounting, it is extremely important to
obtain accurate measurements for each component. The
mounting positions for the front and rear suspensions are
especially crucial with regard to safety; therefore, it is nec-
essary that all work concerning these areas be done care-
fully and correctly.
13.Temporary mounting of new parts
(1) In order to bring the new parts into the proper mounting
position, measure each part carefully and make any
AB200065 corrections necessary in order to obtain agreement with
the measurements.
(2) In addition, make temporary welds, and then check to
confirm that the closing and fit of the doors, fenders, etc.,
are correct.
For parts which should be symmetrical to the body
center, measure the distances from the body center point
to both the left part and the right part, and confirm that the
distances are the same.
AB200066
CAUTION
Weld completely so that there are no pinholes.
14.Butt welding
For burr welding, make a 10 15 mm (0.4 0.6 inch) MIG
spot weld, and then, in order to prevent warping which might
be caused by the welding heat, complete the welding by
making welds of the specified width at alternate positions.
AB200067
AB200068
BASE OF BODY REPAIR
BODY REPAIR
9-19
15.Spot welding
When doing spot welding, it is not only important to correctly
position the electrode tips, but also to hold the two panels
securely together with vise-grip pliers or some other type of
clamps, being sure that they are in perfect contact with each
other.
Be sure that the force applied by the arm is sufficient.
Use a test piece to check the secondary current and the
current application time of the spot welder, and adjust the
AB200070
values as appropriate.
16.Plug welding
If spot welds cannot be made, make holes for plug welding
in the new parts, and then MIG weld. Because the quality of
the fusion varies according to the size of the holes, they
should be about 5 6 mm (0.2 inch) in diameter. In addition,
be sure the two surfaces are in complete contact with each
other by using vise-grip pliers to securely hold them.
NOTE: Depending on the working conditions, it might also
be necessary to make holes in the panel remaining on the
AB200070 body
17.Hemming (Adhesion type)

(1) Apply an adhesive to the area to be hemmed of the door
outer panel.
Section
AA
A
AB401282
A
AB500010 AC
(2) For the area to be hemmed of the door outer panel, apply
an adhesive and smooth the panel with a hammer and a
dolly. Then, hem the panel with a hemming tool.
Hemming tool
AB200072 AC
BODY REPAIR
18.Hemming (Welded type)

(1) For the area to be hemmed of the door outer panel, etc.,
smooth the panel with a hammer and a dolly, and hem it
with a hemming tool.
Hemming tool
AB200072 AC
(2) After completing the hemming work, make MIG spot

welds at 50 60 mm (2.0 2.4 inches) intervals on the
inside.
AB200073
CAUTION
Be sure not to grind the panel down too much. Before
welding the outer panel, be sure to apply an anticorrosion
agent.
19.Finishing work for butt welding and plug welding
Do the finishing work to smooth the protruding weld traces.
However, the butt joints of reinforcements and other internal
parts will be stronger if the weld traces are not finished.
AB200074
20.Application of body sealant

Apply a coating of sealant carefully, without breaks, as
described in the section (of the manual corresponding to
that model).
NOTE: After application has been made to any external sur-
faces, perform smooth-finishing work.
AB200076
BASE OF BODY REPAIR
BODY REPAIR
9-21
CAUTION
Wipe off any anticorrosion agent which oozes out onto
surfaces to be painted later; the presence of such anticor-
rosion agent would prevent correct adhesion of the paint
coat.
21.Application of an anticorrosion agent
Apply an ample amount of anticorrosion agent to any
welded areas and to all surfaces from which the paint coat
was removed.
The paint coat of welded areas will have been damaged by
AB200077 the heat; be sure to apply an anticorrosion agent to surfaces
to be repaired.
Use an aerosol-type anticorrosion agent for application to
the side sills, the pillars, and other similar parts which have a
hollow construction, by utilizing the trim mounting holes, etc.
AB200078
22.Application of undercoating
If the underbody is repaired or replaced, carefully apply a
coating of undercoating as described in the section (of the
manual corresponding to that model).
AB200079
CAUTIONS REGARDING BODY REPAIR At the time of repair, it is particularly necessary to

Because each component part of a single-unit con- take measurements at the components noted
struction body makes some contribution, more or below, and to make all welds and installations
less, to the overall strength of that body, it is neces- with special care.
sary to sufficiently understand the actual function of Front sidemember
any part to be repaired before attempting any repair Rear floor sidemember
or welding procedure. Front wheelhouse (inner)
. Rear wheelhouse (inner) (Independent rear
STRENGTH AND RIGIDITY suspension type)
1. The suspension installation part plays an impor- 2. Because the places where the floor panel and
tant role, determining the wheel alignment. Wheel sidemember parts are joined have an important
misalignment is of course potentially very danger- effect upon the rigidity of the entire body, welds in
ous because it can lead to driving instability, these places must be done with particular care.
one-sided braking, abnormal tire wear, abnormal 3. After repairs have been completed, the wheel
vibration, etc. alignment, wheel base, tread, etc., must be care-
fully checked to be sure that there is no deviation.
.
BODY REPAIR
SAFETY At the outer and inner side of any place sub-

1. Procedures related to the installation of any com- jected to heat.
ponent related to safety must be done with partic- 3. Apply a coating of undercoating if the underbody
ular care in order to assure full maintenance of is repaired.
safety. 4. Use spot sealer if spot welds are made.
Suspension installation parts 5. Repair any scratches to panels made by mold-
Fuel pipe ings, sashes, etc.
Brakes 6. Carefully apply body sealant to panel connection
Fuel tank installation parts, etc. joints and other fitting places.
2. Because seat belts are directly related to driver 7. Tape over any unused holes in the panel inner
and passenger safety, any welds of seat belt side by using sealing tape.
anchor points or reinforcements must be done
with particular care in order to maintain strength.
.
VIBRATION AND NOISE

.
1. Prevent any decrease of tensional rigidity caused
PREVENTION OF CORROSION AND OF by welding distortion.
WATER OR DUST ENTRY 2. Carefully apply body sealant to panel connection
1. After any work is completed, it is important to joints and other fitting places.
completely remove any welding residue, particles 3. Tape over any unused holes in the panel inner
or residue from cutting, and any other dirt, etc. side by using sealing tape.
2. Corrosion-prevention material must without fail .
be applied at the following places: CONTACT AND ALIGNMENT

At any place where paint has flaked off or
1. In order to maintain the precision of openings,
peeled away.
make careful measurements as repairs are being
At any surfaces that have been cut.
made.
At the outer and inner side of every welded
place. 2. Make contact/alignment adjustments of door
Within any semi-enclosed structure or compo- hinge, lid, and hood hinge installation parts.
nent (aerosol-type rust inhibitors are effective
for difficult-to-reach places).
THEFT PROTECTION
M4090007000056
In order to prevent theft, following Vehicle Identification Number
Theft protection label (VIN) has been engraved and attached, in the form of a label to
For original parts the engine, transaxle, and main of the outer body:
Engine cylinder block, Transaxle housing, Fender,
Doors, Quarter panel, Hood, Liftgate, Trunk lid,
Bumpers
Furthermore, supplementary parts for the main portions of the
outer body have theft protection labels attached and the sup-
plementary parts for the engine and the transaxle are engraved
with the same details.
For replacement parts
AC211646 AC
BASE OF BODY REPAIR
BODY REPAIR
9-23
PANEL REPAIR CAUTION
1. Take care when respraying the original part to cover the theft
protection label with masking tape prior to respraying. In
addition, remember to peel off the masking tape after
completion of the respray.
2. Because theft protection labels on the supplementary parts
are covered with masking tape already, they can be
resprayed just as they are.
3. Take care not to peel off the theft protection labels from
either the original or the supplementary parts.
HOW TO PEEL OFF THE SURFACE MASKING

FILM FROM THE THEFT-PROTECTION LABEL
CAUTION
Be careful not to damage the paint surface or the label
itself.
Knife
1. Using a sharp knife at the corner of the label surface, lift up
the masking film only.
2. Grasp the masking film and peel it all off.
NOTE: If the masking film tears, repeat from step 1. Use the
Masking film knife, however, to lift the opposite corner of the label, rather
than trying to continue peeling from the place where it tore.
AB200080AC
BODY REPAIR
ATTACHMENT OF SILENCERS
M4090009000041
Dash panel interior side
: Thickness: 1.6 mm (0.06 in)

: Thickness: 3.2 mm (0.13 in) (two 1.6 mm (0.06 in) silencers overlapped) AB200097AC
Silencers (petroleum-asphalt sheets) are attached to welded panel, cut and attach replacement material
the upper surface of the floor and at the interior side (in the shape shown in the figure). For detailed infor-
of the dash panel in order to absorb vibrations and mation concerning the locations where silencers are
shut out exhaust gas heat. If these silencers are to be attached for individual models, refer to the
peeled off in the course of replacement or repair of a manual for that model.
1. Heat the "silencer layer" (petroleum-asphalt sheet) with a
blow drier to soften it.
AB200098
BASE OF BODY REPAIR
BODY REPAIR
9-25
2. Align the silencer layer in the position where it is to be
installed, and then press it down with a roller or a block of
wood so that it adheres well.
NOTE: An infrared light can also be used to heat both the
silencer layer and the body panels (be sure to wear gloves).
AB200099
POSITIONING DIMENSIONS FOR OPENINGS

M4090010000034
Porta power
AB200100 AC
When replacing the panel of the opening of the front

pillar, center pillar and other openings, make a point
to securely bite the poltapower, etc. so the position of
the opening is not off-center. Upon assembling,
adjust the opening dimensions to the standard speci-
fications and then weld.
BODY REPAIR
STANDARD PROCEDURES FOR SHEET METAL WORK

M4090012000029
REPAIRS USING A HAMMER AND DOLLY

It a damaged external panel, etc., can be reused, the
usual way to repair it is by using a hammer and dolly
to hammer out the damaged area. The following
describes these repair procedures.
.
1. Check whether or not there is foreign material (mud, etc.) on

the panel surface. If so, clean it away.
CAUTION
The surface of the hammer and dolly must be free of scars,
etc.
2. Select the appropriate hammer and dolly to be used
according
CAUTIONto the panel shape.
Care should be taken, as far as possible, not to permit the
(1) panel plates to become elongated.
3. Use the hammer and dolly to repair the dents and other
uneven surfaces of the panel.
(1) First repair the larger areas of damage so that they are as
close as possible to the original condition before the
damage occurred.
(2) Next repair the areas of moderate damage.
(3) Finally, smooth the surface out.
(2)
(3)
AB200101
BASE OF BODY REPAIR
BODY REPAIR
9-27
CAUTION
Be careful not to file too much; this will reduce the
strength and rigidity of the panel.
Do not use the file in one direction only; alternate use
in two directions diagonally opposite each other.
4. Next, file the area so that convex and concave parts are no
longer clearly visible, and at the same time remove small
projections.
5. After once again smoothing the clearly visible dents and
projections by using the hammer and dolly, follow step 4
above.
Alternately repeat hammering and filing until there are file
traces over the entire repair area.
6. Make a solder build-up at the repair.
AB200102 7. Finally, finish up the solder build-up using a body file.
USING A FRAME STRAIGHTENER

M4090013000033
For serious and extensive damage, when for exam- 3. Finally, determine what repair methods should be
ple the damage extends to the frame of members, it used.
is necessary to first use a frame straightener to make To what extent will frame straightening and other
a rough, overall repair of the body, and then to pro- overall repairs be necessary in order to restore
ceed to careful repairs of each individual area of the damaged areas to the way they were?
damage. When a frame straightener is used for body At what stage of the repairs should panels adjoin-
repairs, it is a fundamental principle that the pulling ing the components to be frame straightened,
should be in the direction from which the impact was etc., be removed?
sustained, and from the opposite direction. If this is, Decide upon the work steps and restoration
in error, not done, previously undamaged compo- methods to be followed after the rough, overall
nents will be deformed, and repair may become repairs are completed.
impossible. Select the frame straightener based upon the results
It is for that reason that it is important to decide upon of above, and use it to pull in the appropriate direc-
the method of repair, especially regarding the initial tion. More than one direction may be appropriate,
overall repair, by following the steps below. depending upon the damage.
OVERALL ROUGH REPAIRS If the damage is of a moderate degree or less, it may
1. First, analyze the impact. This means analysis be possible to do all that is necessary in one pull.
and consideration of the point of collision, the If, however, the damage is major, that is to say if
speed at the time of collision, and the strength, repairs must be made to components of the passen-
weight and shape of the object hit. ger compartment such as the dash panel, etc., it may
be necessary, after completing the first pull, to set up
2. Then get a complete understanding of the
the frame straightener at a different position and use
condition of the existing damage. In particular, if
it again at that position.
the damage extends to the suspension installation
components, an inspection must be made to
determine whether or not there is any deviation of
the frame or body alignment.
BODY REPAIR
FRAME STRAIGHTENING NOTES

For safety, no one must be standing in the direction of the
Wires for pull.
protection
Wires or chains should be used for protection in the event
of an accident.
For frame straightening of body with frame, care should be
taken regarding the position (body mount) of installation to
the frame. The reason for this is that usually mounting rub-
ber pieces are used at the installation part in order to
improve vibration prevention, and these mounting rubber
AB200103AC
pieces might be deformed if there is a deviation of the
installation position.
If the part to be pulled is made of high-tensile steel (which
has a higher tensional strength and yield point than ordinary
steel), the pulling must be done with care in order to avoid
"over pull" and "spring back". It is particularly important for
the pulling of sidemembers and other reinforcement compo-
nents made of high-tensile steel that the pulling not be all
done at one time; pull gradually while using a hammer to
repair distorted areas as the pulling is done.
FRAME REPAIR PROCEDURES
M4090014000036
The frame is subjected to the following types of These various types of loads are compounded under
loads. various conditions, and are applied to the frame.
Vertical loads: Vertical loads may occur either As a result, it is important, before attempting to repair
while stopped or during travel. the frame, to carefully observe the shape of the dam-
Lateral (horizontal) loads: This type of loads aged part and to in that way fully understand the
occurs during turning, start-off and braking. cause of the damage.
Torsional loads: Torsional loads occur while trav-
eling on roads with poor surface conditions.
CHECKING FOR FRAME CRACKING OR
FLAKING
Check, by using a test hammer, for flaking or cracking of the
welded surface of the sidemembers, crossmembers and brack-
ets.
Test hammer
Sidemember
AB200127AC
BASE OF BODY REPAIR
BODY REPAIR
9-29
REPAIRING CRACKS
If the check reveals a crack(s) in the frame, repair as described
bellow.
Crack-stop hole 1. Remove the components near the crack.
A 2. Make 6 8 mm (0.2 0.3 inch) holes (to prevent further
cracking), by using a drill, at points 7 8 mm (0.3 inch) from
A the crack ends.
Crack
6 8 mm
(0.2 0.3 in)
A : 7 8 mm (0.3 in) AB301469 AC
10 12 mm (0.4 0.5 in) 3. Use a 10 12 mm (0.4 0.5 inch) drill to bevel the hole
openings.
6 8 mm
(0.2 0.3 in)
10 12 mm
(0.4 0.5 in)
AB301470 AB
4. Use a chisel or gouging tool to open up the crack and holes,

Crack and then fill the crack and holes by MIG welding.
Crack-stop hole
Approx.
8 mm
A (0.3 in)
Approx. Approx.90 Approx.
1 mm 1 mm
(00.4 in) (0.04 in)
If a chisel If a gouge
is used is used
A A AB301471AC
CAUTION
Gas welding should be avoided because it causes ther-
mal distortion of the frame.
When using a grinder for finishing, be careful not to
grind the frame excessively.
5. Using a grinder for finishing after welding.
AB200131AB
BODY REPAIR
CAUTION
The reinforcement plate should completely cover the
cracked part.
The reinforcement plate should be the same thickness
and material as the frame.
6. To avoid a concentration of stress, prepare a reinforcement
plate that has been cut to 30 45 degree angle at both ends.
A : 30 45
AB301461AB
CAUTION
Be sure that the edges of the reinforcement plate are not
10 mm (0.4 in) near any place where a concentration of stress of the
crossmember or spring hanger installation part, etc. could
easily occur.
7. Attach the reinforcement plate to the repaired crack area by
MIG welding. In order to avoid a concentration of stress at
the time, weld the reinforcement plate at points about 10 mm
(0.4 inch) from its edges.
Welded point
AB200133 AC
(1)
(2)
AB200134 AB
NOTE: If the crack is at the upper side of the frame, attach

the reinforcement plate facing downward, as shown in (1).
If the crack is at the lower side, attach the reinforcement
plate to face upward, as shown in (2).
8. Finally, apply a coating of chassis black to the repaired area
and to any places where the coating has flaked off.
BASE OF BODY REPAIR
BODY REPAIR
9-31
NOTES REGARDING REPAIR WORK
M4090015000028
SAFETY MEASURES
.
PROTECTIVE GEAR
1
2 3 During body repair work, a work suit, a work cap, and safety
shoes should be worn at all times. Depending on the work
being done, safety glasses, gloves, ear protectors, a dustproof
4 mask, etc., should also be worn as needed.
5 6 1. Safety glasses
2. Work cap
3. Ear protectors
7 8 4. Head protector
5. Work suit
6. Dustproof mask
7. Work apron
8. Welding gloves
9 10 11
9. Foot and ankle protectors
10. Safety shoes
11. Work gloves
AB200104
(6) Never attempt to disassemble or repair the

.
SUPPLEMENTAL RESTRAINT SYSTEM

SRS components (SRS-ECU, air bag module
(SRS) and clock spring). If there is a defect, replace
1. Items to review when servicing SRS the defective part.
(1) Be sure to read Service Manual GROUP 52B, (7) Whenever you finish servicing the SRS, check
Supplemental Restraint System (SRS). For the SRS warning light operation to make sure
safe operation, please follow the directions that the system functions properly.
and heed all warnings. (8) Be sure to deploy the air bag before disposing
(2) Wait at least 60 seconds after disconnecting of the air bag module or disposing of a vehicle
the battery cable before doing any further equipped with an air bag.
work. The SRS system is designed to retain 2. Observe the following when carrying out
enough voltage to deploy the air bag even operations on places where SRS components are
after the battery has been disconnected. installed, including operations not directly related
Serious injury may result from unintended air to the SRS air bag.
bag deployment if work is done on the SRS
(1) When removing or installing parts, do not allow
system immediately after the battery cable is
any impact or shock to occur to the SRS
disconnected.
components.
(3) Warning labels must be heeded when
(2) If heat damage may occur during paint work,
servicing or handling SRS components.
remove the SRS-ECU, the air bag module,
(4) Always use the designated special tools and clock spring, the front impact sensor, the side
test equipment. impact sensor, and the seat belt pre-tensioner.
(5) Store components removed from the SRS in a SRS-ECU, air bag module, clock spring, front
clean and dry place. The air bag module impact sensor, the side impact sensor: 93 C
should be stored on a flat surface and placed (200 F) or more
so that the pad surface is facing upward. Seat belt pre-tensioner: 90 C (194 F) or more
.
BODY REPAIR
SECURING THE VEHICLE

If the vehicle is raised on a jack, be sure to always support it
with jack stands positioned at the specified points.
.
CLEARING THE AREA OF FLAMMABLE

MATERIALS
Because of the presence of many various kinds of flammable
materials, organic solvents, etc., in the work area, there is
always the possibility of a fire or explosion. It is, therefore,
important to keep the work area as clear as possible of such
dangerous materials.
.
HANDLING ELECTRONIC PARTS AND

SEMICONDUCTORS
WARNING
HANDLING.
When the body is used as the ground during welding for body
repairs, be absolutely sure to first disconnect the battery's posi-
tive (+) cable.
CAUTION
Be sure that both the ignition and lighting switches are
"LOCK" (OFF) position before either disconnecting or
reconnecting a battery cable. (If this is not done, equip-
ment containing semiconductors could be damaged).
Note that the memory of electronic equipment having a
AB200105 memory function will be cleared when the battery cable
is disconnected.
NOTE: Vehicles today include a great many electronic parts
and components, and these are in general very susceptible to
adverse effects caused by overcurrent, reverse current, elec-
tromagnetic waves, high temperature, high humidity, impacts,
etc. In particular, such electronic components can be damaged
if there is a large current flow during welding from the body
side, etc.
This is because, for electronic components that incorporate a
back-up circuit (for memory retention) that functions (by a
trickle current) even when the ignition switch is at OFF, an elec-
tronic circuit is formed even when the switch is at OFF.
.
BASE OF BODY REPAIR
BODY REPAIR
9-33
HANDLING COMBUSTIBLE MATERIALS
If welding work is to be done in the area of the fuel tank, the fuel
tank must be removed to prevent the generation of flammable
gases. Also be sure to cap the inlet port and the pipes of the
fuel tank after removal to prevent the escape of any fuel or
flammable gases.
Wipe up any fuel, oil, etc., spilled in the work area as soon as
possible.
Only the amounts of paint to be used for the day's work should
be in the work area; do not keep excessive amounts of paint, or
paint which is not going to be used, in the work area.
HEALTH AND SANITATION PROCEDURES

The following points should be noted for employee health and
sanitation.
The work area should be well ventilated in order to prevent
the inhalation of dust, organic solvent vapors, etc.
All unused paint cans must be securely covered.
Care should be taken to avoid exposure to the skin of adhe-
sives, organic solvents, etc.
If an unavoidable exposure occurs, the exposed area
should be immediately washed with clean water.
VEHICLE PROTECTION
Vehicle covers (fender covers, seat covers, etc.) and tape (if
there is the possibility of damage by tools, equipment, etc.)
should be used to protect painted surfaces, interior/exterior
parts and components, etc., from staining and damage.
AB200106
For welding operations, a heat-resistant protective cover

should be used to protect glass, seats, instrument panel,
carpeting, etc.
AB200107
BODY REPAIR
HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS

M4090016000032
Because resin-plastic parts are deformed by heat,
they should be removed if the heat to be applied is
high enough to cause deformation, as shown by the
table below.
MATERIAL NAME ABBREVIATION HEAT-DEFORMATION WHERE MAINLY USED
TEMPERATURE C ( F)
Acrylonitrile ASA 80 (176) Door mirror, Pillar garnish, License
styrene acrylate garnish, Radiator grille
Acrylonitrile ABS 80 (176) Air spoiler, Console box, Radiator grille,
butadiene styrene Rear garnish, Headlight bezel
Cellulose acetate CA 50 90 (122 194) -
Cellulose acetate CAB 60 100 (140 212) Door trim molding
butylate
Polyamide PA 140 160 (284 320) Harness connector, Wheel cover,
Cooling fan, Fuel strainer
Talc filled PA-TD 190 200 (374 392) Hood garnish, Door outside handle
polyamide
Polybutylene PBT 120 (248) Dome light lens, Headlight lens
terephthalate
Polyethylene PE 100 (212) Heater duct, Fender liner, Washer tank
High density PE-HD (HDPE) 70 90 (158 194) Fuel tank, Splash shield
polyethylene
Phenole PF 170 190 (338 374) Ashtray
formaldehyde
Polymethyl PMMA 80 100 (176 212) Light lens
methacrylate
Polyacetal POM 120 (248) Door regulator handle, Ball joint seat
Polypropylene PP 80 (176) Glove compartment, Bumper face,
Pillar trim, Steering wheel, Heater unit,
Cooling fan
Polyphenylene PPE (PPO) 130 140 (266 284) Accelerator pedal pad, Wheel cover,
ether Speaker garnish
Talc filled PP-TD (PPF) 100 (212) Front deck garnish, Stone guard, Floor
polypropylene console, Instrument panel
Talc filled PP-TD10 (PPF) 110 120 (230 248) Center pillar trim
polypropylene
(10%)
Talc filled PP-TD15 (PPF) 110 120 (230 248) Front pillar trim, Center pillar trim, Rear
polypropylene pillar trim
(15%)
Talc filled PP-TD20 (PPF) 120 130 (248 266) Beltline trim, Front deck garnish, Front
polypropylene pillar trim
(20%)
Talc filled PP-TD30 (PPF) 130 140 (266 284) Quarter trim, Rear side trim
polypropylene
(30%)
BASE OF BODY REPAIR
BODY REPAIR
9-35
MATERIAL NAME ABBREVIATION HEAT-DEFORMATION WHERE MAINLY USED
TEMPERATURE C ( F)
Polyurethane PUR 80 100 (176 212) Bumper, Steering wheel
Polyurethane PUR-E 80 100 (176 212) Seat cushion, Arm rest, Door trim,
(formed) Instrument panel
Glass fiber PUR-GF [RIM] 100 120 (212 248) Air dam panel
reinforced RIM
urethane
Polyvinyl alcohol PVAL *1 -
Polyvinyl butyral PVB -
Polyvinyl chloride PVC 80 (176) Steering wheel, Side protector molding,
Shift lever cover, Window molding
Thermoplastic TPO (TEO) 80 (176) Mud guard, Side air dam
elastomer (olefine)
Urea formaldehyde UF 120 145 (248 293) -
Glass fiber UP-(GT + TD) 200 (392) Rear air spoiler
reinforced [SMC], [BMC]
unsaturated
polyester
Ethylene vinyl E/VAC (EVA) 60 (140) Mud guard
acetate
Talc filled PP + E/P-TD 80 100 (176 212) Bumper face, Side air dam, Side
polypropylene [HMPP] protector molding
Polyvinyl chloride, PVC, PUR-E *2 Instrument panel pad
Polyurethane
Thermoplastic TES, PP-TD 100 120 (212 248) Side splash
elastomer
(styrene), Talc filled
polypropylene
Polycarbonate + PC + ABS 120 125 (248 257) Door outside handle
Acrylonitrile
butadiene
Polycarbonate + PC + PET 120 (248) Door outside handle
Polyethylene
terephthalate
Polycarbonate + PC + PBT 130 140 (266 284) Door outside handle
Polybutylene
terephthalate
Polyphenylene PPE (PPO) + PA6 150 160 (302 320) Wheel cover
ether + Polyamide
6
Polyphenylene PPE (PPO) + 160 170 (320 338) Wheel cover
ether + Polyamide PA66
66
Polyphenylene PPE (PPO) + PS 120 130 (248 266) Wheel cover
ether + Polystyrene
BODY REPAIR
NOTE: .
A slash (/) in the abbreviation indicates that two different materials make two-layer construction.
A plus sign (+) indicates that the two different materials mix each other.
If the new material symbols designated by the ISO differ form the old symbols, both are given, with the old
symbol being enclosed in brackets. ISO: International Organization for Standardization
*1: Temperature differs depending on the ratio of the materials included.
*2: Impossible to fix the temperature due to the multi-layer and foam material structure.
If an infra-red lamp is used for drying, use a heat-resistant cover, etc., to protect parts.
HOW TO DISTINGUISH TYPES OF PLASTICS
M4090017000024
There are various methods that can be employed to
determine types of plastics, among them (1) using a
chemical solvent, etc., to check it chemically, (2)
scratching the material to determine its make-up, (3)
cutting of a small piece (where the scar can't be
seen) and burning it to judge by the way it burns, etc.
The following is an outline of the burning method,
which is a relatively simple method.
PLASTIC ABBREVIATION FLAME COLOR COMBUSTION SELF- ODOR
NAME CONDITIONS EXTINGUISHING
Polyvinyl PVC Yellow flame top Burns to black residue Yes Irritating acid
chloride Blue flame odor
bottom
Polyethylene PE Yellow flame top Burns cleanly while No Candle-like
Blue flame melting odor
bottom
Polypropylene PP Yellow flame top Burns briskly and No Petroleum-
Blue flame drips like odor
bottom Slight white smoke
Polyurethane PUR Orange Crackles as burns; No Rubber odor
TRUR Orange drips
Polycarbonate PC Yellow Cinders remain To some extent Sweet odor
Polyamide PA Yellow flame top Melts and drips Yes Strong formic
(nylon) Blue flame acid odor
bottom
Polyester resin UP Yellow Ashes remain No Styrene odor
Glass-fiber- FRP Yellow Ashes with glass-fiber No Differs
reinforced remnants remain according to
plastic plastic type
Phenol resin PF Yellow Ashes remain Yes Formalin
odor
ABS resin ABS Orange Burns accompanied No Rubber odor
by foaming and black
smoke
BASE OF BODY REPAIR
CORROSION PROTECTION
9-37
ANTICORROSION TREATMENT AT THE FACTORY
M4090019000053
Anticorrosion treatment at the time of production
includes the following measures.
THE USE OF GALVANIZED STEEL PLATE
: locations where galvanized steel

plate is used.
AB200136 AB
Because galvanized steel plate has excellent corro-

sion resistance, it is used in areas which have a high
possibility of painting deficiency.
ZINC PHOSPHATE COATING

In order to improve the adhesive properties of the paint coat on
the steel plate, and also to improve the finish of the paint coat,
1
the entire body is coated with a film of zinc phosphate prior to
2
undergoing the electrodeposition undercoating process.
3
1. Final coat
4
5 2. Intermediate coat
6 3. Anticorrosion primer
4. Undercoat
5. Zinc phosphate film
AB200109 6. Steel plate
CATIONIC ELECTRODEPOSITION UNDERCOATING
Anionic Cationic
coating coating
Alkali
Counteragent Counteragent solution
Anionic electrodeposition Cationic electrodeposition AB200110AC
In the cationic electrodeposition method, the car

body is the negative pole, thus preventing damage to
the zinc plating of the galvanized body panels or to
the chemically formed phosphate crystals. This
method, therefore, maximizes the corrosion resis-
tance and the results obtained are much better than
those from conventional anionic electrodeposition.
BODY SEALING
Sealant has been applied to all body panel joints and seams in
A order to provide resistance to water, dust, and corrosion.
A
Section A A
AB301462 AC
UNDERBODY COATING
An underbody coating has been applied to the underside of the
floor pans, the inside of the doors, etc., in order to provide
resistance to vibration, corrosion, and wear.
AB200112
BASE OF BODY REPAIR
9-39
WAX INJECTION
Wax injection is used at the lower part of the frame, side sill and
hollow panels, etc., in order to obtain a better anticorrosion
effect.
AB200113
ANTICORROSION PRIMER
1
A
1
A
1. Rocker panel primer application AB200114 AC
Anticorrosion primer is used at the side sill outer pan-

els in order to prevent corrosion and to suppress
vibration.
SEALING TAPE
Sealing tape is attached at unused holes, at the inner side of
the panel, for waterproofing and anticorrosion protection.
: Locations for
attachment of sealing tape
AB301463AE
AB301463
ANTICORROSION TREATMENT AT THE TIME OF

BODY REPAIR WORK
M4090020000035
The following procedures should be followed for anticorrosion
protection when making repairs.
AB200116
CORROSION PROTECTION FOR HOLLOW

PARTS
CAUTION
Wipe away any excess anticorrosion agent on the
coated surface, because it can adversely affect the
coating.
When spraying the anticorrosion agent, use holes in
different areas to ensure that all weld surfaces of the
hollow structure are well coated.
The insides of hollow parts (such as the side sill, pillars, etc.)
which have been welded are more susceptible to corrosion.
Spray an aerosol-type anticorrosion agent into these parts by
AB200117 using the trim mounting holes and other openings.
ANTICORROSION TREATMENT OF ROUGH CUTS

An anticorrosion agent should be applied to rough cuts made in
the course of welding, because the surface film has been dam-
aged by the heat of welding.
SPOT SEALER
In order to prevent corrosion from occurring at the contact sur-
faces of panels which are spot welded, apply an electroconduc-
tive spot sealer.
.
SPOT SEALER APPLICATION STEPS

1. Remove all paint, etc., from the areas to be spot welded by
using sandpaper or a pneumatic belt sander.
AB200118
BASE OF BODY REPAIR
9-41
2. Use a brush to apply spot sealer to the contact surfaces of
the panels (both the new panel and the panel remaining on
the body) to be spot welded.
AB200119
3. Do not spot welding.

NOTE: The spot welding can be done as the spot sealer is
dry to the touch.
Dry to the touch: 30 minutes or less at 20 C (68 F)
AB200120
BODY SEALING
Even if a car body is restored to the exact specified dimen-
sions, the body repair work cannot be considered to be com-
plete if an ample amount of sealant is not applied to each of the
panel joints and seams. Insufficient sealant will result in water
leakage, corrosion, etc.
NOTE: Use a piece of clean cloth dampened in lead-free gaso-
line or a similar material to clean parts and areas where sealant
is applied.
When applying sealant to areas at which the external
Clean away appearance is important (areas which can be seen or where
any excess the condition of the paint coat is important), be sure to apply
the sealant so that it is perfectly level with the surrounding
panels.
AB301490AC
Apply the sealant at the fuel port so that it is perfectly level

with the surrounding panel so that drops of fuel will not col-
lect.
AB200122
After applying sealant to the door-stop, etc., clean away any

excess so as to be sure that there is no interference with
installed parts, etc.
AB200123
UNDERCOATING
: Undercoating application locations

AB301464 AC
Be sure to mask any parts installation holes, and If the undercoating application inside the wheel
the area around the place where undercoating is housing, on the under body, etc., is insufficient, it can
to be applied, before applying it. result in corrosion. Be sure, therefore, to apply a
Be sure not to apply the undercoating to tires or good coating of undercoating to such parts after
to the drive shaft and other drive components. repairs are completed.
BASE OF BODY REPAIR
REPAIR OF SYNTHETIC-RESIN PARTS
9-43
SYNTHETIC-RESIN PARTS REPAIR PROCEDURES
M4090000300078
Bumper is taken as a repair work example for expla-
nation.
FLOWCHART
Hole (Diameter 50 mm Crack, tear (Length 200 mm Scratch (Length 200 mm X

(1.97 in) or smaller) width 120 mm (7.8 X 4.7 in)
(7.8 in) or smaller)
or smaller)
1. Cleaning
2. Reshaping of damaged area
3. Fixing of glass cloth (backing)
4. Adhesive application
5. Base surface preparation (surface grinding)
6. Rough grinding
7. Filling (putty application)
8. Surface grinding
9. Surface preparation for primer-surfacer
10. Cleaning and degreasing
11. Masking
12. Primer-surfacer coating
13. Primer-surfacer grinding
14. Coating
AB401319 AD
REPAIR JUDGMENT
.
REPAIRABLE AREA
In case of a hole, the damaged area is reshaped to be a cir-
cle or ellipse for easier filling of the repair agent. The diame-
ter or major diameter should be 50 mm (1.97 inches) or
smaller.
In case of a crack or tear, if the both ends of the crack or
tear are not separated from the body, the length of the area
should be 200 mm (7.8 inches) or smaller. If one of the ends
reaches the bumper edge, the length of the damaged area
should be 200 mm (7.8 inches) or smaller, and also the
width should be a half or less of the bumper width.
In case of a scratch, the area should be 200 x 120 mm (7.8
x 4.7 inches) or smaller.
.
UNREPAIRABLE COMPONENTS
Black-base area is raw urethane base and repairable, however,
its color does not match in color of the repair agent (ash gray).
In this case, the replacement of the bumper is preferable.
.
BUMPER REMOVAL AND CLEANING

The damage of holes, cracks, and tears requires a repair
work from the rear surface. Remove the bumper to clean
the whole surface, degrease the front and rear surfaces of
the repair area using SU Silicone Off, and then repair, hold-
ing the bumper to avoid twisting.
In case of a scratch, a softener is applied to the bumper as
repair paint. The repair area cannot be polished after paint-
ing, and surface/gloss matching is difficult. Therefore, do
not apply gradated topcoat painting, and paint the whole
surface as a rule.
REPAIR PROCEDURE
.
1. CLEANING
Using SU Silicone Off, degrease the repair area, and then
remove the wax and oil completely.
.
AB401311AB
BASE OF BODY REPAIR
9-45
2. RESHAPING OF DAMAGED AREA
CAUTION
The grind surface area should be larger than the resin
putty application area.
Remove burrs on the rear surface reinforcement point, and
grind with a sandpaper #60 to #80, as a surface preparation for
painting. When using a sander #80, grind at a low speed 6000
r/min. For PP, apply PP primer after grinding.
PRIMER : PP PRIMER
BRAND : 3M Automix Polyolefin Adhesion Promoter
5907 or equivalent
AB401317AB .
3. FIXING OF GLASS CLOTH (BACKING)

CAUTION
After applying the instant adhesive, fix the repair area.
For PP, apply PP primer.
Apply the adhesive to the glass cloth fixing area of the repair
part in order to adhere the glass cloth.
TAPE: Glass cloth tape
BRAND: 3M Glass Cloth Tape 6400 or equivalent
ADHESIVE: Urethane adhesive
BRAND: 3M Duramix Plastic Repair Semi-rigid
4040 or equivalent
AB401293AB
AB
.
4. Adhesive application
Apply a resin adhesive to cover the fixing glass cloth and its
surrounding area. Then smooth it, using a spatula, and dry.
AB401312AB
5. BASE SURFACE PREPARATION (SURFACE

GRINDING)
Remove burrs on the surface, and grind with a sandpaper #120
to make the repair area surface lower than the surrounding
Background area. When using a sander #120, grind at a low speed 6000
r/min.
.
Old paint layer

AB401316AC
6. ROUGH GRINDING
Grind the base surface area with a sandpaper #80 as a surface
preparation for painting.
AB401315AB
7. FILLING (PUTTY APPLICATION)

CAUTION
When mixing the two kinds of liquid, be sure that the air is
not mixed in.
1. Using SU Silicone Off, degrease the repair area, and then
remove the wax and oil completely.
2. For scrape, apply putty to the repair area.
PUTTY: Epoxy resin putty
BRAND: 3M Automix EZ Sond Flexble Parts 5887
or equivalent
PUTTY: Epoxy resin putty
AB401291AB BRAND: 3M Resin Putty No.1, 8120 or equivalent
NOTE: .
The amount to be applied at a time is approximately 1.5 mm
(0.06 inches). Therefore, recoat it as needed.
For tear and scratch, apply putty after sanding the surface.
AB401296AB
8. SURFACE GRINDING
After drying, grind with a sandpaper #120.
.
AB401297AB
BASE OF BODY REPAIR
9-47
9. SURFACE PREPARATION FOR
PRIMER-SURFACER
Grind with a sandpaper #180 to #240. Grind the primer-sur-
facer application area as a surface preparation for painting. In
addition, remove the grind mark.
AB401297AB
10. CLEANING AND DEGREASING

Using SU Silicone Off, degrease and wipe off completely.
.
11. MASKING
To avoid splashing of primer-surfacer during the coating, apply
masking.
MASKING: Masking paper tape
BRAND: 3M Scotch Block Masking Paper or equiva-
lent
.
AB401318AB
12. PRIMER-SURFACER COATING
CAUTION
If an excessive amount is applied at a time, or
force-dried in a short time, the coating film may crack.
For color separation, use masking tape.
While taking flash off time, apply 1 to 3 times of double coating,
using a spray gun.
AB401298AB
13. PRIMER-SURFACER GRINDING

1. Grind the base surface with a sandpaper #240 to #320.
AB401299AB
2. Apply the putty to cover pinholes, grind marks, and slight

distortion. Do not apply an excessive amount at a time.
Repeat application of small amount, taking a drying time.
AB401300AB
3. Grind with a sandpaper #240 to #320. If the PP base surface

is exposed, apply PP primer.
PRIMER : PP PRIMER
BRAND : 3M Automix Polyolefin Adhesion Promoter
5907 or equivalent
AB401299AB
CAUTION
If an excessive amount is applied at a time, or force-dried
in a short time, the coating film may crack.
4. While taking flash off time, apply 1 to 3 times of double
coating, using a spray gun.
AB401302AB
5. Dry sand with a sandpaper #240 to #300 or finer. Then, as a

surface preparation for painting, grind lightly so as not to
expose the base surface. Finally, use a sandpaper #600
(#800 for dark color coating) or finer to remove grind marks.
AB401303AB
11-1
GROUP 11
ENGINE
CONTENTS
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

NOTES
11A-1
GROUP 11A
ENGINE
MECHANICAL
CONTENTS
GENERAL INFORMATION . . . . . . . . 11A-2 VALVE STEM SEAL . . . . . . . . . . . . . . 11A-38

REMOVAL AND INSTALLATION . . . . . . . . 11A-38
ENGINE DIAGNOSIS. . . . . . . . . . . . . 11A-3
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A-45
SERVICE SPECIFICATIONS. . . . . . . 11A-4 REMOVAL AND INSTALLATION . . . . . . . . 11A-45
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-48
SEALANTS . . . . . . . . . . . . . . . . . . . . 11A-4
CRANKSHAFT OIL SEAL . . . . . . . . . 11A-49
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-5 REMOVAL AND INSTALLATION . . . . . . . . 11A-49
ON-VEHICLE SERVICE. . . . . . . . . . . 11A-9 CYLINDER HEAD GASKET . . . . . . . . 11A-53

DRIVE BELT TENSION CHECK. . . . . . . . . 11A-9 REMOVAL AND INSTALLATION . . . . . . . . 11A-53
AUTO-TENSIONER CHECK . . . . . . . . . . . 11A-9
VALVE CLEARANCE CHECK AND TIMING CHAIN . . . . . . . . . . . . . . . . . . 11A-63
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-11 REMOVAL AND INSTALLATION . . . . . . . . 11A-63
IGNITION TIMING CHECK . . . . . . . . . . . . . 11A-11
CURB IDLE SPEED CHECK . . . . . . . . . . . 11A-13 OIL PUMP CHAIN. . . . . . . . . . . . . . . . 11A-70
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A-14 REMOVAL AND INSTALLATION . . . . . . . . 11A-70
COMPRESSION PRESSURE CHECK. . . . 11A-16
MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-17 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . 11A-72
CRANKSHAFT PULLEY . . . . . . . . . . 11A-19
REMOVAL AND INSTALLATION . . . . . . . . 11A-19 ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-74
CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11A-22
11A-2 ENGINE MECHANICAL
GENERAL INFORMATION
GENERAL INFORMATION
M1111000101111
The 4B11 (2.0 L) engine is an in-line four-cylinder
engine. The cylinder numbers are assigned as
1-2-3-4 from the front of the engine (timing belt side).
The firing order is 1-3-4-2.
ITEMS SPECIFICATIONS
Type In-line DOHC
Number of cylinders 4
Bore mm (in) 86 (3.39)
Stroke mm (in) 86 (3.39)
Total displacement cm3 (cu. in) 1,998 (121.9)
Compression ratio 10.0
Firing order 1-3-4-2
Valve timing Intake valve Opens (BTDC) 0 25 <FED>
3 28 <CAL>
Closes (ABDC) 48 23 <FED>
45 20 <CAL>
Exhaust valve Opens (BBDC) 44 24 <FED>
41 21 <CAL>
Closes (ATDC) 0 20 <FED>
3 23 <CAL>
Lubrication system Pressure feed, full-flow filtration
Oil pump type Trochoid type
TSB Revision
ENGINE MECHANICAL
ENGINE DIAGNOSIS
11A-3
ENGINE DIAGNOSIS
M1111000700370
SYMPTOMS PROBABLE CAUSE REMEDY

Compression is too Blown cylinder head gasket Replace the gasket.
low Worn or damaged piston rings Replace the rings.
Worn piston or cylinder Repair or replace the piston and/or the
cylinder block.
Worn or damaged valve seat Repair or replace the valve and/or the
seat ring
Drop in engine oil Engine oil level is too low Check the engine oil level.
pressure Malfunction of engine oil pressure switch Replace the engine oil pressure switch.
Clogged oil filter Install a new filter.
Worn oil pump gears or cover Replace the gears and/or the cover.
Thin or diluted engine oil Change the engine oil to the correct
viscosity.
Stuck (opened) oil relief valve Repair the relief valve.
Excessive bearing clearance Replace the bearings.
Engine oil pressure Stuck (closed) oil relief valve Repair the relief valve.
too high
Noisy valves Incorrect valve clearance Adjust valve clearance
Thin or diluted engine oil (low engine oil Change the engine oil.
pressure)
Worn or damaged valve stem or valve Replace the valve and/or the guide.
guide
Connecting rod Insufficient oil supply Check the engine oil level.
noise/main bearing Thin or diluted engine oil Change the engine oil.
noise
Excessive bearing clearance Replace the bearings.
TSB Revision
SERVICE SPECIFICATIONS
M1111000301278
Item Standard value Limit

Drive belt tension Vibration frequency Hz 102 129
(Reference)
Tension N (lb) (Reference) 248 400 (56
90)
Valve clearance (at cold) mm (in) Intake valve 0.20 0.03
(0.008 0.0012)
Exhaust valve 0.03 0.03
(0.012 0.0012)
Basic ignition timing at idle 5 BTDC 3
Actual ignition timing at curb idle Approximately
10 BTDC
CO contents % 0.5 or less
HC contents ppm 100 or less
Curb idle speed r/min 700 100
Compression pressure (200 r/min) kPa (psi) 1,470 (213) Minimum 1,050
(152)
Compression pressure difference of all cylinder kPa (psi) 98 (14)
Intake manifold vacuum at curb idle kPa (in Hg) Minimum 60 (18)
Auto-tensioner rod protrusion amount mm (in) 9.1 13.4 (0.36
0.52)
SEALANTS
M1111000500536
Item Specified sealant Remark

Flywheel bolt LOCTITE 262, Three bond 1324 Semi-drying
or equivalent sealant
Cylinder head cover Three bond 1227D, 1217G or
equivalent
Cylinder block Three bond 1227D, 1217G,
Engine oil pan LOCTITE 5970, 5971, 5900 or
equivalent
Timing chain case assembly
TSB Revision
ENGINE MECHANICAL
SPECIAL TOOLS
11A-5
SPECIAL TOOLS
M1111000601570
Tool Tool number and name Supersession Application
A
MB992080 Tool not available Drive belt tension check
Belt tension meter set
A: MB9912081
B Belt tension meter
B992080 B: MB992082
Mic assembly
MB991958 MB991824-KIT CAUTION
a
Scan tool (M.U.T.-III sub NOTE: MB991826 For vehicles with CAN
assembly) M.U.T.-III Trigger communication, use
A: MB991824 Harness is not M.U.T.-III main harness A
Vehicle communication necessary when to send simulated vehicle
MB991824
interface (V.C.I.) pushing V.C.I. speed. If you connect
b B: MB991827 ENTER key. M.U.T.-III main harness B
M.U.T.-III USB cable instead, the CAN
C: MB991910 communication does not
M.U.T.-III main harness A function correctly.
(Vehicles with CAN Drive belt tension check
MB991827
communication system) Ignition timing check
c
D: MB991911 Curb idle speed check
M.U.T.-III main harness B Idle mixture check
(Vehicles without CAN Erasing the diagnostic
communication system) trouble code
MB991910 E: MB991914
d M.U.T.-III main harness C
(for Daimler Chrysler
DO NOT USE models only)
F: MB991825
M.U.T.-III adapter harness
MB991911
G: MB991826
e M.U.T.-III trigger harness
DO NOT USE
MB991914
MB991825
MB991826
MB991958
TSB Revision
SPECIAL TOOLS

MB990767 MB990767-01 Holding the camshaft
Front hub and flange yoke sprocket
holder
B990767
MD998719 MIT308239
Pin
D998719
MB992103 Camshaft and camshaft

Chain tension release bar sprocket assembly
(exhaust side) removal
B992103
MD998772 General service Valve spring compression

Valve spring compressor tool
MD998772
MB992090
Retainer holder attachment
B992090
MB992089
Retainer holder C
MB992085 Valve stem seal removal

Valve stem seal pliers
MD998737 MD998737-01 Valve stem seal

Valve stem seal installer press-fitting
TSB Revision
ENGINE MECHANICAL
SPECIAL TOOLS
11A-7
MD998727 MD998727-01 Oil pan removal
Oil pan FIPG cutter
D998727
MB991883 General service Supporting the drive plate

Flywheel stopper tool <CVT> or flywheel <M/T>
MB991883
MD998718 MD998718-01 Press-fitting the crankshaft

Crankshaft rear oil seal rear oil seal
installer
MB991448 MB991448-01 Press-fitting the crankshaft

Bush remover and installer front oil seal
base
MB991346 Holding the oil pump

Top Cover Wrench sprocket
B991346
TSB Revision
SPECIAL TOOLS

MB991454 MZ203827-01 When the engine hanger is
Engine hanger balancer used: Supporting the
engine assembly during
removal and installation of
B991454
the transaxle assembly
NOTE: Special tool
MB991895 Tool not available MB991454 is a part of
Engine hanger engine hanger attachment
set MB991453.
MB991895
MB991928 Tool not available

Slide bracket (HI) Engine hanger
A: MB991929
E Joint (50) 2
B: MB991930
Joint (90) 2
F A C: MB991931
D Joint (140) 2
B D: MB991932
C Foot (standard) 4
B991928
E: MB991933
Foot (short) 2
F: MB991934
Chain and hook assembly
MB992201 Transaxle removal
Engine hanger plate
B992201
TSB Revision
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-9
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003101596
1. Remove the radiator condenser tank mounting bolts.
2. Move the radiator condenser tank to a place where it will not
be a hindrance when checking the drive belt tension.
CAUTION
Check the drive belt tension after turning the crankshaft
clockwise one turn or more.
Auto-tensioner 3. Make sure that the indicator mark on the auto-tensioner is
within the area marked with A in the illustration.
4. If the mark is out of the area A, replace the drive belt (Refer
A
to P.11A-19).
NOTE: The drive belt tension check is not necessary as the
auto-tensioner is adopted.
5. Tighten the radiator condenser tank mounting bolts to the
specified torque.
Indicator mark
Tightening torque: 12 2 N m (102 22 in-lb)
AC506730 AC
AUTO-TENSIONER CHECK
M1111003000972
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.11A-19).
Auto-tensioner 3. Rotate the pulley bolt of the auto-tensioner clockwise and
counterclockwise with an offset wrench [45 , a long offset
wrench (5/8 x 11/16 inches) recommended] to check for
binding.
4. If there are any problems in the procedure 1 or 3, replace
the auto-tensioner (Refer to P.11A-63).
5. Install the drive belt (Refer to P.11A-19).
AC506731 AD
FUNCTION CHECK
The auto-tensioner can be checked whether it is in good condi-
tion by checking its tension.
.
<When the vibration frequency is measured:

Recommendation>
MB992080: Belt Tension Meter Set
MB992081: Belt Tension Meter
MB992082: Mic Assembly
1. Check the tension of the drive belt (Refer to P.11A-9).
TSB Revision
ON-VEHICLE SERVICE
2. Check the tension of the drive belt in the following

procedures.
(1) Connect special tool microphone assembly (MB992082)
Belt tension meter set (MB992080)
to special tool belt tension meter (MB992081) of special
MB992081 tool belt tension meter set (MB992080).
(2) Press the "POWER" button to turn on the power supply.
(3) Press the numeral key of "1" and check that "No. 1"
appears on the upper left of the display.
NOTE: This operation is to temporarily set the preset
data such as the belt specifications, because if the mea-
MB992082 surement is taken without input of the belt specifications,
AC507219AD conversion to tension value (N) cannot be made, result-
ing in judgement of error.
(4) Press "Hz" button twice to change the display to the
frequency display (Hz).
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 val-
ues measured by the microphone may not correspond
to actual values.
If the microphone is touching the belt while the mea-
surement is being made, the values measured by the
microphone may not correspond to actual values.
Do not take the measurement while the vehicle's engine
is running.
(5) Hold special tool MB992080 to the middle of the belt
between the pulleys (at the place indicated by arrow)
where it does not contact the belt (approximately 10 15
Power steering
10 15 mm
mm (0.4 0.59 inch) away from the rear surface of the
oil pump pulley
(0.4 0.59 inch) belt) so that it is perpendicular to the belt (within an angle
Idler pulley of 15 degree).
(6) Press the "MEASURE" button.
(7) Gently tap the middle of the belt between the pulleys (the
Gently tap with your finger place indicated by the arrow) with your finger as shown in
the illustration, and check that the vibration frequency of
15 the belt is within the standard value.
15 Standard value: 102 129 Hz
MB992080 NOTE: To take the measurement repeatedly, tap the belt
again.
(8) Press and hold the "POWER" button to turn off the power
supply.
Idler pulley
Alternator 3. If not within the standard value, replace the auto-tensioner
pulley
Crankshaft (Refer to P.11A-63).
pulley
AC607321AC
TSB Revision
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-11
<When using a tension gauge>
1. Check the tension of the drive belt (Refer to P.11A-9).
2. Use a belt tension gauge in the middle of the belt between
Power steering
the pulleys shown in the figure (at the place indicated by the
oil pump pulley
arrow) to check that the belt tension is within the standard
value.
Idler pulley Standard value: 248 400 N (56 90 lb)
3. If not within the standard value, replace the auto-tensioner
(Refer to P.11A-63).
Belt
tension
gauge
Idler pulley
Alternator
Crankshaft pulley
pulley
AC506733 AC
VALVE CLEARANCE CHECK AND ADJUSTMENT

M1111001500681
Refer to GROUP00, General Maintenance service Intake
And Exhaust Valve Clearance (Inspect And Adjust)
IGNITION TIMING CHECK

M1111001701699
Required Special Tool:

MB991958: Scan Tool (M.U.T.-III Sub Assembly)
MB991824: V.C.I.
MB991827: M.U.T.-III USB Cable
MB991910: M.U.T.-III Main Harness A
1. Before inspection, set the vehicle in the following condition:
Engine coolant temperature: 80 95 C (176 203 F)
Lights and all accessories: OFF
Transaxle: Neutral (P range on vehicles with CVT)
NOTE: On vehicles for Canada, the headlight, taillight, etc.
remain lit even when the lighting switch is in "OFF" position
but this is no problem for checks.
TSB Revision
ON-VEHICLE SERVICE
CAUTION
To prevent damage to scan tool MB991958, always turn the
ignition switch to the "LOCK" (OFF) position before con-
Data link connector necting or disconnecting scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
MB991910
MB991824
MB991827 AC608435 AB
Equipment side connector

3. Set the timing light to the power supply line (terminal No. 3)
of the ignition coil No. 1.
No. 1 ignition coil 1 2 3 4. Start the engine and run it at idle.
5. Check that the idle speed is approximately 700 r/min.
Power supply line
(terminal No. 3) 6. Select scan tool MB991958 actuator test "item number 11".
7. Check that basic ignition timing is within the standard value.
Standard value: 5 BTDC 3
8. If the basic ignition timing is not within the standard value,
AK604618 AB check the following items:
Diagnostic output
Timing belt cover and crankshaft position sensor installation
conditions
Crankshaft sensing blade condition
CAUTION
If the actuator test is not canceled, the forced drive will
continue for 27 minutes. Driving in this state could lead to
engine failure.
9. Cancel the setting mode of the scan tool MB991958.
10.Check that the actual ignition timing is at the standard value.
Standard value: Approximately 10 BTDC
NOTE: Ignition timing fluctuates about 7 Before Top Dead
Center, even under normal operating condition.
NOTE: It is automatically further advanced by about 5 to
10 Before Top Dead Center at higher altitudes.
11.Remove the timing light.
TSB Revision
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-13
CAUTION
necting or disconnecting scan tool MB991958.
12.Disconnect scan tool MB991958 from the data link
connector.
CURB IDLE SPEED CHECK

M1111003501561

MB991824: V.C.I.
CAUTION
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
ON-VEHICLE SERVICE

No. 1 ignition coil 1 2 3 4. Start the engine.
5. Run the engine at idle for 2 minutes.
Power supply line
(terminal No. 3) 6. Check the actual ignition timing is at the standard value.
Standard value: Approximately 10 BTDC
7. Check the idle speed. Select item number 2 and take a
reading of the idle speed.
AK604618 AB Curb idle speed: 700 100 r/min
NOTE: The idle speed is controlled automatically by the idle
air control system.
8. If the idle speed is outside the standard value, refer to
GROUP 13A, Multiport Fuel Injection (MFI) Multiport Fuel
Injection (MFI) Diagnosis Symptom Chart P.13A-51.
10 Before Top Dead Center at higher altitudes.
9. Remove the timing light.
CAUTION
connector.
IDLE MIXTURE CHECK

M1111002101087

MB991824: V.C.I.
Transaxie: Neutral (P range on vehicles with CVT)
TSB Revision
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-15
CAUTION
MB991910
MB991824
MB991827 AC608435 AB

No. 1 ignition coil 1 2 3 4. Start the engine and let it run at idle.
5. Check that the actual ignition timing is at the standard value.
Power supply line
(terminal No. 3) Standard value: Approximately 10 BTDC
AK604618 AB 10 Before Top Dead Center at higher altitudes.
6. Run the engine and increase the engine speed to 2,500
r/min for 2 minutes.
7. Set the CO, HC tester.
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, inspect the
MFI system (Refer to GROUP 13A Multiport Fuel Injection
(MFI) Multiport Fuel Injection (MFI) Diagnosis Symptom
Chart P.13A-51)
10.Remove the timing light.
CAUTION
connector.
TSB Revision
ON-VEHICLE SERVICE
COMPRESSION PRESSURE CHECK

M1111002601747

MB991824: V.C.I.
1. Before inspection, check that the engine oil, starter and
battery are normal. Also, set the vehicle in the following
condition:
2. Remove all of the ignition coils and spark plugs.
3. Disconnect the all of the injector connectors.
NOTE: Doing this will prevent the engine control module
Injector from carrying out ignition and fuel injection.
connectors
WARNING
Keep your distance from the spark plug hole when
cranking. Oil, fuel, etc., may spray out from the spark
plug hole and may cause serious injury.
4. Cover the spark plug hole with a shop towel etc., after the
AK502603AE
engine has been cranked, check that no foreign material is
adhering to the shop towel.
Compression gauge 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): 1,470
kPa (213 psi)
Limit (at engine speed of 200 r/min): Minimum 1,050
kPa (152 psi)
7. Measure the compression pressure for all the cylinders, and
check that the pressure differences of the cylinders are
AK502604AE
below the limit.
Limit: Maximum 98 kPa (14 psi)
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 does 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 all of the injector connector.
10.Install the spark plugs and ignition coils.
TSB Revision
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-17
11.Use the scan tool MB991958 to erase the diagnosis codes.
NOTE: This will erase the diagnosis code resulting from the
Data link connector injector connectors being disconnected.
MB991910
MB991824
MB991827 AC608435 AB
MANIFOLD VACUUM CHECK

M1111002701313

MB991824: V.C.I.
TSB Revision
ON-VEHICLE SERVICE
CAUTION
MB991910
MB991824
MB991827 AC608435 AB
3. Disconnect the ventilation hose from the positive crankcase

Vacuum gauge ventilation (PCV) valve, and then connect a vacuum gauge
to the ventilation hose. Plug the PCV valve.
4. Start the engine and check that idle speed is approximately
700 r/min.
PCV valve
5. Check the intake manifold vacuum.
Limit: Minimum 60 kPa (18 in Hg)
Plug
6. Turn off the ignition switch.
AK502601AE 7. Remove the vacuum gauge and then connect the ventilation
hose to the PCV valve.
CAUTION
8. Disconnect scan tool MB991958 from the data link
connector.
TSB Revision
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-19
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001601402
Pre-removal operation Post-installation operation

Engine Room Under Cover Front Removal (Refer to Radiator Condenser Tank Installation (Refer to GROUP
GROUP 51 Under Cover P.51-16). 14 Radiator P.14-26).
Engine Room Side Cover (RH) Removal (Refer to Drive Belt Tension Check (Refer to P.11A-9).
GROUP 51Under Cover P.51-16). Engine Room Side Cover (RH) Installation (Refer to
Radiator Condenser Tank Removal (Refer to GROUP 14 GROUP 51 Under Cover P.51-16).
Radiator P.14-26). Engine Room Under Cover Front Installation (Refer to
GROUP 51 Under Cover P.51-16).
210 Nm
155 ft-lb
(Engine oil)
AC506736 AC
Removal steps Removal steps (Continued)

<<A>> 1. Drive belt <> >>A<< 3. Crankshaft washer
<> >>A<< 2. Crank pulley center bolt <> >>A<< 4. Crankshaft pulley

MB990767: Front Hub and Flange End Yoke MD998719:Pin
Holder
TSB Revision
CRANKSHAFT PULLEY
REMOVAL SERVICE POINTS

.
<<A>> DRIVE BELT REMOVAL

To introduce the serpentine drive system with the drive belt
auto-tensioner, the following operations will be required.
CAUTION
To reuse the Drive belt, draw an arrow indicating the rotat-
ing direction on the back of the belt using chalk to install
the same direction.
Auto-tensioner 1. Rotate the pulley bolt of the auto-tensioner counterclockwise
with an offset wrench [45 , a long offset wrench (5/8 x 11/16
inches) recommended] and insert the hexagon wrench into
the auto-tensioner hole to fix the auto-tensioner.
2. Remove the drive belt.
AC506731 AD
Auto-tensioner
L-shaped
hexagon
wrench
Pulley bolt AC511067AC
<> CRANKSHAFT PULLEY CENTER

BOLT/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT PULLEY REMOVAL
MD998719
1. Hold the crankshaft drive sprocket with special tools
MB990767 and MD998719.
2. Loosen the crankshaft pulley center bolt and remove the
crankshaft pulley washer and crankshaft pulley.
Crankshaft pulley
MB990767 AC506738 AC
TSB Revision
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-21
INSTALLATION SERVICE POINT
.
>>A<< CRANKSHAFT PULLEY/CRANKSHAFT

PULLEY WASHER/CRANKSHAFT PULLEY CEN-
TER BOLT INSTALLATION
1. Wipe off the dirt on the crankshaft and the crankshaft pulley
: Wipe clean with a rag. as shown in the figure using a rag.
: Wipe clean with a rag and degrease.
: Apply a small amount of engine oil. 2. Wipe off the dirt on the crankshaft sprocket, the crankshaft
and the crankshaft pulley as shown in the figure using a rag,
and then degrease them.
NOTE: Degrease them to prevent drop in the friction coeffi-
cient of the pressed area, which is caused by oil adhesion.
Crankshaft
Crankshaft 3. Install the crankshaft pulley.
pulley washer
sprocket
4. Wipe off the dirt on the crankshaft pulley washer and the
crankshaft pulley center bolt as shown in the figure using a
rag.
5. Apply an adequate and minimum amount of engine oil to the
threads of the crankshaft pulley center bolt and the lower
area of the flange.
Crankshaft
Crankshaft
pulley center bolt Crankshaft
pulley
Engine front
AC606441AB
MD998719
6. Hold the crankshaft pulley with special tools MB990767 and
MD998719 in the same manner as removal.
7. Tighten the crankshaft pulley center bolt to the specified
torque.
Tightening torque: 210 N m (155 ft-lb)
Crankshaft pulley
MB990767 AC506738 AC
TSB Revision
CAMSHAFT
CAMSHAFT
M1112007800274
Apply engine oil to all

3.0 1.0 Nm 5.5 0.5 Nm 2
to 5 moving parts before
27 8 in-lb 49 4 in-lb
installation.
3.0 0.5 Nm
27 4 in-lb
12 1 Nm
12 1 Nm
106 9 in-lb
1
106 9 in-lb 3
11
17 3 Nm 30 2 Nm 13
to 19
13 2 ft-lb 22 1 ft-lb
12 21
10 2 Nm 10 4
89 17 in-lb 20
6
8
16 9 18
14
15
17
26
59 5 Nm 29
44 3 ft-lb 27
22 23 10 2 Nm
24 89 17 in-lb
28 N (Engine oil)
10 2 Nm
89 17 in-lb 30
(Engine oil) N 31
7
13 1 Nm
115 9 in-lb
25 4 Nm
18 3 ft-lb
25
AC611613 AB
Camshaft removal steps Camshaft removal steps

Air cleaner assembly (Refer to <> Cylinder No. 1 compression top
GROUP 15 Air Cleaner P.15-4). dead center setting (only at
Strut tower bar (Refer to GROUP removal)
42A Strut Tower Bar P.42A-11). Valve clearance adjustment (Refer
1. Engine upper cover to P.11A-11). (only at installation)
Ignition coil (Refer to GROUP 16 6. Timing chain upper guide
Ignition System, Ignition Coil 7. Service hole bolt
P.16-39). <<C>> Camshaft and camshaft sprocket
2. Breather hose connection assembly (exhaust side) removal
3. PCV hose connection preparatory operation (only at
4. Control wiring harness connection removal)
<<A>> >>G<< 5. Cylinder head cover assembly <<D>> >>F<< 8. Front camshaft bearing cap
assembly
TSB Revision
ENGINE MECHANICAL
CAMSHAFT
11A-23
Camshaft removal steps
>>E<< 9. Camshaft bearing
<<E>> >>D<< 10. Oil feeding camshaft bearing cap
(exhaust side)
<<E>> >>D<< 11. Camshaft bearing cap (exhaust
side)
<<E>> >>D<< 12. Camshaft bearing cap (exhaust
side)
<<E>> >>D<< 13. Thrust camshaft bearing cap
(exhaust side)
<<F>> >>E<< 14. Camshaft and camshaft sprocket
assembly (exhaust side)
<<G>> >>B<< 15. Camshaft sprocket (exhaust side)
<<G>> >>B<< 16. Camshaft (exhaust side)
>>E<< 17. Camshaft bearing
<<E>> >>D<< 18. Oil feeding camshaft bearing cap
(intake side)
<<E>> >>D<< 19. Camshaft bearing cap (intake side)
<<E>> >>D<< 20. Camshaft bearing cap (intake side)
<<E>> >>D<< 21. Thrust camshaft bearing cap
(intake side)
>>C<< 22. Camshaft and camshaft sprocket
assembly (intake side)
<<G>> >>B<< 23. Camshaft sprocket (intake side)
<<G>> >>B<< 24. Camshaft (intake side)
Oil control valve removal steps
Drive belt (Refer to P.11A-19).
<<H>> 25. Power steering oil pump assembly
26. Intake engine oil control valve
connector
<> >>A<< 27. Intake engine oil control valve
>>A<< 28. O-ring
29. Exhaust engine oil control valve
connector
<> >>A<< 30. Exhaust engine oil control valve
>>A<< 31. O-ring
MB992103: Chain Tension Release Bar

.
<<A>> CYLINDER HEAD COVER ASSEMBLY

REMOVAL
6 Loosen the cylinder head cover assembly mounting bolts in the
18 13 12 11
5 order of number shown in the figure, and remove the cylinder
head cover assembly.
1 7 14 17 10 4
2 15 16 9 3
8
Engine front AC506743 AD
TSB Revision
CAMSHAFT
<> CYLINDER NO. 1 COMPRESSION TOP

DEAD CENTER SETTING
CAUTION
Turn the crankshaft clockwise.
1. Turn the crankshaft clockwise so that the camshaft sprocket
Cylinder head upper surface
timing marks become horizontal to the cylinder head upper
Paint surface, and set the cylinder No. 1 to the top dead center of
Timing chain markings Timing chain
compression. At this time, check that the crankshaft pulley
mating mark mating mark
timing mark is in the 0-degree position of the ignition timing
indicator of the timing chain case assembly.
2. Put paint marks on both the camshaft sprocket and timing
chain at the position of camshaft sprocket timing chain
Camshaft sprocket mating mark (circular hole).
timing marks AC506744 AC
<<C>> CAMSHAFT AND CAMSHAFT SPROCKET

ASSEMBLY (EXHAUST SIDE) REMOVAL
PREPARATORY OPERATION
Precision flat-tipped 1. Insert a precision flat-tipped screwdriver () through the
screwdriver Crankshaft pulley service hole of the timing chain case, press up the timing
chain tensioner ratchet to unlock, and keep the timing chain
tensioner with that state.
NOTE: Lightly press down the tail end of the precision
flat-tipped screwdriver () to press up the tip of the precision
Service hole flat-tipped screwdriver () inserted to the timing chain ten-
sioner to unlock.
Section A-A
Precision flat-tipped screwdriver
Ratchet
A Service hole
A Timing chain Ratchet

tensioner release hole
Timing chain tensioner
construction diagram
Ratchet
Ratchet
release hole
AC509155AC
TSB Revision
ENGINE MECHANICAL
CAMSHAFT
11A-25
CAUTION
When inserting special tool MB992103 into the timing
chain case assembly inside, pay attention to the posi-
tion of the timing chain to avoid damage to the timing
chain and timing chain tension side guide. Do not
insert the special tool beyond its insertion guideline.
If unlocking the timing chain tensioner is insufficient,
the special tool cannot be inserted to the insertion
guideline. Do not insert the special tool forcibly, follow
Step 1 again to unlock the timing chain tensioner and
insert the special tool.
TSB Revision
CAMSHAFT
2. With the timing chain tensioner unlocked, insert special tool

MB992103
MB992103 inside the timing chain case assembly along the
tension side of the timing chain until the insertion guide line
aligns with the upper surface of the timing chain case
Timing chain assembly (Figure A).
NOTE: With the timing chain tensioner unlocked, insert the
special tool along the tension side of the timing chain,
according to the special tool top shape. The special tool can
be inserted smoothly to the position where the special tool
Insertion standard line
AC507118AC insertion guide line aligns with the timing chain case assem-
bly top surface (Figure B), and the spread timing chain ten-
MB992103 sion side guide can be held (Figure C).
3. With the special tool inserted up to the insertion guide line,
B press the special tool against the intake side camshaft
sprocket and spread and hold the timing chain tension side
guide.
A 4. Remove the flat-tipped precision screwdriver () unlocking
the timing chain tensioner.
Camshaft
sprocket
(intake side)
Valve timing chain
(tension side)
Timing chain
tension
side guide
AC508123
MB992103
Timing chain tension

side guide
AC509159AB
TSB Revision
ENGINE MECHANICAL
CAMSHAFT
11A-27
CAUTION
The timing chain may snag on by other parts. After sag-
ging the timing chain, never rotate the crankshaft.
Hexagon 5. With the timing chain tension side guide spread, hook the
part of special tool over the hexagon part of the camshaft on the
exhaust exhaust side, and turn the camshaft clockwise to apply slack
MB992103 camshaft to the timing chain between the camshaft sprockets.
Timing chain AC506748 AC
<<D>> FRONT CAMSHAFT BEARING CAP

ASSEMBLY REMOVAL
Loosen the mounting bolts of front camshaft bearing cap in the
Front camshaft order of number shown in the figure, and remove the front cam-
bearing cap 4
assembly
shaft bearing cap assembly.
2
3
Engine front AC506745AD
TSB Revision
CAMSHAFT
<<E>> OIL FEEDING CAMSHAFT BEARING

CAP/CAMSHAFT BEARING CAP/THRUST
CAMSHAFT BEARING CAP REMOVAL
CAUTION
When the camshaft bearing cap mounting bolts are loos-
ened at once, the mounting bolts jump out by the spring
force and the threads are damaged. Always loosen the
mounting bolts in four or five steps.
Loosen the mounting bolts of the camshaft bearing caps in the
Engine front
order of number shown in the figure in four or five steps, and
remove the camshaft bearing caps.
Camshaft bearing cap
2 6 8 4
1 5 7 3
1 5 7 3
2 6 8 4
AC506746 AC
<<F>> CAMSHAFT AND CAMSHAFT SPROCKET

ASSEMBLY (EXHAUST SIDE) REMOVAL
1. Raise slightly the transaxle side of the camshaft and
camshaft sprocket assembly (exhaust side) by using the
slack of the timing chain, and remove from the cam bearing.
Camshaft and camshaft

sprocket assembly
AC508124AD
TSB Revision
ENGINE MECHANICAL
CAMSHAFT
11A-29
2. Remove the timing chain from the camshaft and camshaft
sprocket assembly (exhaust side) toward the timing chain
case assembly, and remove the camshaft and camshaft
sprocket assembly (exhaust side) toward the transaxle.
Camshaft and
camshaft sprocket
3. Remove special tool MB992103 inserted into the timing
assembly chain case assembly.
MB992103
Timing chain AC506749 AC
CAUTION
The timing chain may snag on other parts. After removing
the camshaft and camshaft sprocket assembly, never
rotate the crankshaft.
4. After removing the camshaft and camshaft sprocket
Rope Timing chain assembly (exhaust side), hang up the timing chain with a
rope to prevent the timing chain from falling into the timing
chain case assembly.
AC509403AD
<<G>> CAMSHAFT SPROCKET/CAMSHAFT

REMOVAL
Hold the flats of the camshaft with a monkey wrench. Loosen
Hexagon part
the camshaft sprocket mounting bolts and remove the camshaft
of camshaft
sprocket from the camshaft.
AC611532AB
TSB Revision
CAMSHAFT
<<H>> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
1. With the hose installed, remove the power steering oil pump
assembly from the bracket.
2. Tie the removed power steering oil pump assembly with a
string at a position where it will not interfere with the removal
and installation of oil control valve.
.
<> OIL CONTROL VALVE REMOVAL

CAUTION
After removal of the oil control valve, be careful to prevent
dust from getting into the oil passage in the cylinder head.
INSTALLATION SERVICE POINTS

.
>>A<< O-RING/OIL CONTROL VALVE INSTALLA-

TION
CAUTION
When installing the oil control valve, be careful to avoid
damage to the O-ring.
Apply engine oil to the O-ring of the oil control valve and install
the oil control valve to the cylinder head.
.
>>B<< CAMSHAFT/CAMSHAFT SPROCKET

INSTALLATION
1. Use a monkey wrench to secure the flats of the camshaft in
Hexagon part
the same manner as removal.
of camshaft
AC611532AB

Camshaft Camshaft camshaft and camshaft sprocket as shown in the figure.
sprocket
3. Install the camshaft sprocket to the camshaft.
camshaft sprocket bolt.
5. Tighten the camshaft sprocket bolts to the specified torque.
Tightening torque: 59 5 N m (44 3 ft-lb)
Camshaft
sprocket bolt
AC607720AB
TSB Revision
ENGINE MECHANICAL
CAMSHAFT
11A-31
>>C<< CAMSHAFT AND CAMSHAFT SPROCKET
ASSEMBLY (INTAKE SIDE) INSTALLATION
1. Align the intake side paint mark of the timing chain which
Paint markings was put at removal with the paint mark of the intake side
(intake side) camshaft sprocket, and install the camshaft sprocket to the
timing chain.
2. Install the camshaft and camshaft sprocket assembly (intake
side) to the cylinder head.
AC509403AE
>>D<< THRUST CAMSHAFT BEARING

CAP/CAMSHAFT BEARING CAP/OIL FEEDING
CAMSHAFT BEARING CAP/CAMSHAFT
BEARING INSTALLATION
1. Install the camshaft bearing caps to the cylinder heads.
Engine front
NOTE: Because the thrust camshaft bearing cap and cam-
Identification of intake side shaft bearing cap are the same in shape, check the bearing
and exhaust side cap number and additionally its symbol to identify the intake
E 5
and exhaust sides for correct installation.

Bearing cap No.
2. Tighten each camshaft bearing cap mounting bolt to the
specified torque in the order of number shown in the figure
in two or three steps.
Camshaft bearing cap Tightening torque: 12 1 N m (106 9 in-lb)
7 3 1 5
8 4 2 6
8 4 2 6
3 1
7 5
Camshaft bearing cap AC506778AC
>>E<< CAMSHAFT BEARING/CAMSHAFT AND

CAMSHAFT SPROCKET ASSEMBLY (EXHAUST
SIDE) INSTALLATION
CAUTION
Be careful not to drop the camshaft bearing.
1. Install camshaft bearings on the cylinder head.
TSB Revision
CAMSHAFT
Camshaft Camshaft bearing

identification color
Identification Journal diameter
mark mm (in)
1 40.000 - 40.008 Black
(1.5748 - 1.5751)
2 40.008 - 40.016 None
(1.5751 - 1.5754)
3 40.016 - 40.024 Green
(1.5754 - 1.5757)
2. The identification color of the camshaft bearing is painted at

the illustrated position.
Identification
color
AC611233 AB
TSB Revision
ENGINE MECHANICAL
CAMSHAFT
11A-33
Precision flat-tipped 3. In the same manner as removal, insert the precision
screwdriver Crankshaft pulley flat-tipped screwdriver () through the service hole of the
timing chain case, press up the ratchet of timing chain
tensioner to unlock, and hold the unlocked timing chain
tensioner.
NOTE: Lightly press down the tail end of the precision
Service hole flat-tipped screwdriver () to press up the tip of the precision
flat-tipped screwdriver () inserted to the timing chain ten-
sioner to unlock.
Section A-A
Precision flat-tipped screwdriver
Ratchet
A Service hole
A Timing chain Ratchet

tensioner release hole
construction diagram
Ratchet
Ratchet
release hole
AC509155AC
TSB Revision
CAMSHAFT
CAUTION
When inserting special tool MB992103 into the timing
chain case assembly, pay attention to the position of
the timing chain to avoid damage to the timing chain
and timing chain tension side guide. Do not insert the
special tool beyond its insertion guideline.
If unlocking the timing chain tensioner is insufficient,
the special tool cannot be inserted to the insertion
guideline. Do not insert the special tool forcibly, follow
Step 1 again to unlock the timing chain tensioner and
insert the special tool.
TSB Revision
ENGINE MECHANICAL
CAMSHAFT
11A-35
4. With the timing chain tensioner unlocked, insert special tool
MB992103
MB992103 inside the timing chain case assembly along the
tension side of the timing chain until the insertion guide line
aligns with the upper surface of the timing chain case
Timing chain assembly (Figure A).
NOTE: With the timing chain tensioner unlocked, insert the
special tool along the tension side of the timing chain,
according to the special tool top shape. The special tool can
be inserted smoothly to the position where the special tool
Insertion standard line
AC507118AC insertion guideline aligns with the timing chain case assem-
bly top surface, and the spread timing chain tension side
guide can be hold.
Timing chain
(exhaust camshaft and
Camshaft 5. With the special tool inserted up to the insertion guide line,
sprocket press the special tool against the intake side camshaft
camshaft sprocket
(intake side)
assembly side) sprocket (Figure B) and spread and hold the timing chain
tension side guide (Figure C).
6. Remove the flat-tipped precision screwdriver () unlocking
D the timing chain tensioner.
A B
7. Pull up the camshaft and camshaft sprocket assembly
(exhaust side) mounting area of the timing chain (Figure D)
to provide allowance for easy installation of the camshaft
and camshaft sprocket assembly (exhaust side) to the
MB992103 timing chain.
Timing chain
(tension side)
Timing chain
tension
side guide
AC508125
Timing chain MB992103

tensioner
Timing chain
tension side guide
AC509177 AD
TSB Revision
CAMSHAFT
CAUTION
When installing the camshaft and camshaft sprocket
assembly (exhaust side), be careful not to let the camshaft
bearing which is installed to the front cam bearing deviate
from its position.
8. Align the exhaust side paint mark of the timing chain which
Paint markings was put at removal with the paint mark of the exhaust side
(exhaust side) camshaft sprocket, and install the timing chain to the
camshaft sprocket.
9. Install the camshaft and camshaft sprocket assembly
(exhaust side) to the cylinder head.
10.Remove the special tool inserted into the timing chain case
assembly inside.
AC506752 AB
>>F<< FRONT CAMSHAFT BEARING CAP

ASSEMBLY INSTALLATION
CAUTION
When the mounting bolts are tightened with the front cam-
shaft bearing cap tilted, the front camshaft bearing cap is
damaged. Install the front camshaft bearing cap properly
to the cylinder head and camshaft.
Engine front 1. Install the front camshaft bearing cap to the cylinder head,
(2)
(1) and temporarily tighten the camshaft bearing front cap to the
Front specified torque in the order of the figure (1).
4 camshaft 1
bearing Tightening torque: 17 3 N m (13 2 ft-lb)
3 cap 3 2. Tighten the front camshaft bearing cap again to the specified
assembly
torque in the order of the figure (2).
2 4 Tightening torque: 30 2 N m (22 1 ft-lb)
1 2 3. After the front camshaft bearing cap installation, check that
AC511062AC
the paint markings of the camshaft sprocket and the timing
chain and the timing mark of the crankshaft pulley and the
0-degree position of ignition timing indicator are aligned
respectively.
.
>>G<< CYLINDER HEAD COVER ASSEMBLY

INSTALLATION
1. Wipe off the sealant on the mating surface of the cylinder
head cover assembly and the cylinder head and timing
chain case assembly, and degrease the surface where the
sealant is applied by white gasoline or the like.
TSB Revision
ENGINE MECHANICAL
CAMSHAFT
11A-37
2. Apply sealant to the joint between the cylinder head and
Cylinder head
4 mm timing chain case assembly as shown in the figure and
4 mm install the cylinder head cover assembly to the cylinder
( 0.14 in)
( 0.14 in)
head.
Specified sealant: Three bond 1227D or equivalent
NOTE: Install the cylinder head cover assembly within 3
minutes after the application of sealant.
Timing chain case assembly AC506753 AC
13 3. Tighten the cylinder head cover assembly mounting bolts to

1 6 7 8 14 the specified torque in the order of number shown in the
figure.
Tightening torque: 3.0 1.0 N m (27 8 in-lb)
5 9 15
18 12 2 4. Tighten again the cylinder head cover assembly mounting
bolts to the specified torque in the order of number shown in
the figure.
16
17 11 4 3 10 Tightening torque: 5.5 0.5 N m (49 4 in-lb)
Engine front AC506743AE
TSB Revision
VALVE STEM SEAL
VALVE STEM SEAL

M1112008100148
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
Engine Room Under Cover Front Removal (Refer to Engine Oil Pan Installation (Refer to P.11A-45).
GROUP 51 Under Cover P.51-16). Valve Clearance Check (Refer to P.11A-11).
Engine Room Side Cover (RH) Removal (Refer to Cylinder Head Cover Assembly Installation (Refer to
GROUP 51Under Cover P.51-16). P.11A-22).
Cylinder Head Cover Assembly Removal (Refer to Engine Oil Refilling (Refer to GROUP 12 - On-vehicle
P.11A-22). Service, Engine Oil Replacement P.12-4).
Engine Oil Pan Removal (Refer to P.11A-45). Engine Room Side Cover (RH) Installation (Refer to
Engine Room Under Cover Front Installation (Refer to
12 1 Nm 12 1 Nm
106 9 in-lb 6 4 106 9 in-lb
5 12
17 3 Nm 30 2 Nm
to
13 2 ft-lb 22 1 ft-lb 3 11
9
10
1
2
13
7 15*
16* 17* 15*

8 18* 16*
N 19* 17*
14 18*
19* N
25 5 Nm
19 3 ft-ib
Apply engine oil to all

moving parts before
installation.
AC611584AB

<<A>> >>F<< 1. Front camshaft bearing cap <> >>D<< 6. Thrust camshaft bearing cap
assembly (exhaust side)
2. Camshaft bearing >>E<< 7. Camshaft and camshaft sprocket
<> >>D<< 3. Oil feeding camshaft bearing cap assembly (exhaust side)
(exhaust side) 8. Camshaft bearing
<> >>D<< 4. Camshaft bearing cap (exhaust <> >>D<< 9. Oil feeding camshaft bearing cap
side) (intake side)
<> >>D<< 5. Camshaft bearing cap (exhaust <> >>D<< 10. Camshaft bearing cap (intake side)
side) <> >>D<< 11. Camshaft bearing cap (intake side)
TSB Revision
ENGINE MECHANICAL
VALVE STEM SEAL
11A-39
Removal steps (Continued)
<> >>D<< 12. Thrust camshaft bearing cap
(intake side)
13. Camshaft and camshaft sprocket
assembly (intake side)
14. Spark plug
<<C>> >>C<< 15. Valve tappet
<<D>> >>B<< 16. Valve spring retainer lock
17. Valve spring retainer
18. Valve spring
<<E>> >>A<< 19. Valve stem seal
MD998772: Valve Spring Compressor MB992085: Valve Stem Seal Pliers
MB992089: Retainer Holder C MD998737: Valve Stem Seal Installer
MB992090: Retainer Holder Attachment

.
<<A>> FRONT CAMSHAFT BEARING CAP

ASSEMBLY REMOVAL
CAUTION
bearing cap 4
assembly
2
3
TSB Revision
VALVE STEM SEAL
<> OIL FEEDING CAMSHAFT BEARING

CAUTION
Engine front
2 6 8 4
1 5 7 3
1 5 7 3
2 6 8 4
AC506746 AC
<<C>> VALVE TAPPET REMOVAL

CAUTION
Do not use pliers or other tools to remove the valve tap-
pets. Always remove them by hand.
When reusing the removed valve tappet, it has to be
installed in the same position as before. Be sure to put
a tab that shows the original installation position on the
valve tappet when storing it.
Remove all of the valve tappets by hand.
Valve tappet
AC509270 AC
TSB Revision
ENGINE MECHANICAL
VALVE STEM SEAL
11A-41
<<D>> VALVE SPRING RETAINER LOCK
REMOVAL
1. Screw in special tool MB992090 to special tool MD998772
and assemble special tool MB992089.
MD998772
CAUTION
When removing the valve spring retainer lock, leave the
piston of the cylinder in the TDC (Top Dead Center) posi-
tion. The valve may fall into the cylinder if the piston is not
properly in the TDC position.
2. Install special tool MD998772 (with special tools MB992090
and MB992089 attached) to the cylinder head and compress
the valve spring. Then, remove the valve spring retainer
lock.
MB992090
MB992089
AC509271 AC
<<E>> VALVE STEM SEAL REMOVAL

Use special tool MB992085 to grip the base of the stem seal
(where the outside diameter is larger) securely, and remove it
MB992085 by twisting it to the left and right.
Valve stem seal AC608112 AB

.
>>A<< VALVE STEM SEAL INSTALLATION

1. Apply a small amount of engine oil to the valve stem seals.
TSB Revision
VALVE STEM SEAL
CAUTION
Valve stem seals cannot be reused.
Do not damage the wall of the tappet hole when install-
ing the valve stem seal.
Special tool MD998737 must be used to install the valve
stem seal. Improper installation of the valve stem seal
could result in oil leaking past the valve guide.
2. Use special tool MD998737 to press-fit a new valve stem
MD998737 seal in the valve guide using the valve stem area as a guide.
Valve
Valve stem
seal
Valve guide
AC308654AG
>>B<< VALVE SPRING RETAINER LOCK

INSTALLATION
In the same manner as removal, use special tool MD998772
with special tool MB992090 and special tool MB992089
attached to compress the valve spring, and install the valve
MD998772 spring retainer lock.
MB992090
MB992089
AC509271 AC
>>C<< VALVE TAPPET INSTALLATION

1. Apply a small amount of engine oil to the valve tappets.
TSB Revision
ENGINE MECHANICAL
VALVE STEM SEAL
11A-43
CAUTION
Be sure to install the valve tappets in the same position as
before.
2. Install the valve tappet to the cylinder head.
Valve tappet
AC509270 AC

CAMSHAFT BEARING CAP INSTALLATION
Engine front
Identification of intake side shaft bearing cap are the same in shape, check the cap
and exhaust side number and additionally its symbol to identify the intake and
E 5
exhaust sides for correct installation.

Bearing cap No.
2. Tighten each camshaft bearing cap to the specified torque in
the order of number shown in the figure in two or three
steps.
7 3 1 5
8 4 2 6
8 4 2 6
3 1
7 5
>>E<< CAMSHAFT AND CAMSHAFT SPROCKET

ASSEMBLY (EXHAUST SIDE) INSTALLATION
CAUTION
from its position.
.
TSB Revision
VALVE STEM SEAL
>>F<< FRONT CAMSHAFT BEARING CAP

CAUTION
(2)
(1) and temporarily tighten the front camshaft bearing cap to the
4 camshaft 1
assembly
1 2
AC511062AC
TSB Revision
ENGINE MECHANICAL
OIL PAN
11A-45
OIL PAN
M1112002801625

Engine Room Under Cover Front Removal (Refer to Drive Belt Installation (Refer to P.11A-19).
GROUP 51 Under Cover P.51-16). Engine Oil Refilling (Refer to GROUP 12 - On-vehicle
Engine Room Side Cover (RH) Removal (Refer to Service, Engine Oil Replacement P.12-4).
GROUP 51Under Cover P.51-16). Engine Room Side Cover (RH) Installation (Refer to
Engine Oil Draining (Refer to GROUP 12 - On-vehicle GROUP 51 Under Cover P.51-16).
Service, Engine Oil Replacement P.12-4). Engine Room Under Cover Front Installation (Refer to
Drive Belt Removal (Refer to P.11A-19). GROUP 51 Under Cover P.51-16).
5
N4
3 29 2 Nm
22 1 ft-lb
39 5 Nm
29 3 ft-lb
1
10 2 Nm
89 17 in-lb
23 6 Nm
23 6 Nm 17 4 ft-lb
17 4 ft-lb
2
AC608151AB

<<A>> >>C<< 1. A/C compressor and clutch 3. Engine oil pan drain plug
assembly >>B<< 4. Engine oil pan drain plug gasket
2. A/C compressor bracket <> >>A<< 5. Engine oil pan

MD998727: Oil Pan FIPG Cutter
TSB Revision
OIL PAN

.
<<A>> A/C COMPRESSOR AND CLUTCH ASSEM-

BLY REMOVAL
1. Loosen the mounting bolts of A/C compressor and clutch
assembly in the order of number as shown in the figure.
3 2. Remove the A/C compressor and clutch assembly together
with the hose from the bracket.
1 3. Tie the removed A/C compressor and clutch assembly with
a string at a position where they will not interfere with the
removal and installation of engine oil pan.
2 A/C compressor
and clutch assembly
AC506759AD
TSB Revision
ENGINE MECHANICAL
OIL PAN
11A-47
<> ENGINE OIL PAN REMOVAL
1. Remove the engine oil pan mounting bolts.
CAUTION
Do not forcibly drive in special tool MD998727 to avoid
damage to the engine oil pan seal surface of cylinder block
assembly.
<Engine front> 2. Insert special tool MD998727 from the engine oil pan
removal groove of the cylinder block assembly.
Engine oil pan
3. Lightly tap the special tool with a hammer to slide the oil pan
seal surface, cut off the liquid gasket, and remove the
Crankshaft pulley
engine oil pan.
AC506757AC
<Engine rear>
Engine oil pan
Engine oil filter

AC506758AC
MD998727 MD998727
AC102324 AB
TSB Revision
OIL PAN

.
>>A<< ENGINE OIL PAN INSTALLATION

1. Remove thoroughly the liquid gasket from the engine oil pan
and cylinder block assembly with a remover.
2. Apply a bead of the sealant to the mating surface of the
engine oil pan as shown in the figure, and install the engine
1mm (0.04in)
oil pan to the cylinder block assembly.
CAUTION
Do not apply oil or water to the sealant-applied area or
start up the engine within 2 hours after the installation of
2.5 mm (0.1in) the engine oil pan.
AC506756AC
3. Tighten the engine oil pan mounting bolts to the specified
torque.
Tightening torque:
M6: 10 2 N m (89 17 in-lb)
M8: 29 2 N m (22 1 ft-lb)
.
>>B<< ENGINE OIL PAN DRAIN PLUG GASKET

INSTALLATION
Replace the engine oil pan drain plug gasket with a new one.
Install the new gasket in the direction shown in the illustration.
Engine oil
pan side
Engine oil pan

drain plug gasket
AC102325AJ
>>C<< A/C COMPRESSOR AND CLUTCH

Tighten A/C compressor and clutch assembly mounting bolts to
the specified torque in the order of number shown in the illus-
1 tration.
3
2 A/C compressor
and clutch assembly
AC506759 AE
INSPECTION
M1112002900447
Check the oil pan for cracks.
Check the oil pan sealant-coated surface for damage and
deformation.
TSB Revision
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-49
CRANKSHAFT OIL SEAL
M1112003101607
40 Nm 130 Nm
<M/T> to
30 ft-lb 96 ft-lb
N 7
3
40 Nm 130 Nm
to
30 ft-lb 96 ft-lb
<CVT>
6
N1
AC608163AB
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps <CVT>
Crankshaft pulley (Refer to CVT assembly (Refer to GROUP
P.11A-19). 23A - Transaxle Assembly
>>D<< 1. Crankshaft front oil seal P.23A-149).
Crankshaft rear oil seal removal <<A>> >>B<< 4. Drive plate bolts
steps <M/T> >>B<< 5. Drive plate adapter plate
Manual transaxle assembly (Refer >>B<< 6. Drive plate
to GROUP 22A - Transaxle >>A<< 7. Crankshaft rear oil seal
Assembly P.22A-12).
<<A>> >>C<< 2. Flywheel bolts
>>C<< 3. Flywheel
>>A<< 7. Crankshaft rear oil seal
MB991883: Flywheel Stopper MB991448: Bush Remover And Installer Base
MD998718: Crankshaft Rear Oil Seal Installer
TSB Revision
CRANKSHAFT OIL SEAL
REMOVAL SERVICE POINT

.
<<A>> FLYWHEEL BOLTS/DRIVE PLATE BOLTS

REMOVAL
Fix the flywheel or drive plate using special tool MB991883,
Cylinder block and loosen the flywheel bolts or drive plate bolts.
MB991883
AC506761 AD

.
>>A<< CRANKSHAFT REAR OIL SEAL INSTAL-

LATION
1. Apply a small amount of engine oil to the entire inner
diameter of the oil seal lip.
Oil seal 2. Using special tool MD998718, press in the crankshaft rear
oil seal up to the cylinder block assembly end surface.
MD998718
(Engine oil)
Crankshaft
AC506762 AC
>>B<< DRIVE PLATE/DRIVE PLATE ADAPTER

PLATE/DRIVE PLATE BOLT INSTALLATION
1. Remove the engine oil and deposit from the bolt threads of
the drive plate, screw holes of crankshaft, and drive plate.
2. Apply a small amount of engine oil to the drive plate and the
bearing surface of drive plate adapter plate.
3. Fix the flywheel or drive plate using special tool MB991883
Cylinder block in the same manner as removal.
4. Apply a small amount of engine oil to the bolt threads of
drive plate or the screw holes of crankshaft.
MB991883 5. Tighten drive plate bolts to temporarily torque 40 N m (30
ft-lb).
6. Tighten the drive plate bolts to the specified torque.
AC506761 AD
TSB Revision
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-51
>>C<< FLYWHEEL/FLYWHEEL BOLTS
INSTALLATION
1. Remove the sealant, the engine oil, and other adhering
materials from the flywheel assembly installation face, the
crankshaft screw hole, and flywheel bolts.
2. Install the flywheel assembly to the crankshaft.
3. Use special tool MB991883 to secure the flywheel assembly
Cylinder block in the same manner as removal.
MB991883
AC506761 AD
4. Apply the engine oil to the installation face of the flywheel

bolts for the flywheel assembly.
5. Apply specified sealant to the flywheel bolt threads.
Specified sealant: Three bond 1324 or equivalent
AC609795AB
6. Tighten flywheel bolts to temporary torque 40 N m (30 ft-lb)

4 7 in the order shown in the illustration.
7. Tighten flywheel bolts to temporary torque in the order
1 2 shown in the illustration.
6 5
3 AC609796 AB
>>D<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION
1. Apply a small amount of engine oil to the entire inner
diameter of the oil seal lip.
TSB Revision
CRANKSHAFT OIL SEAL
CAUTION
When installing the crankshaft oil seal, be careful to avoid
damage to the crankshaft front oil seal.
Timing chain case
2. Using special tool MB991448, press in the crankshaft front
oil seal up to the chamfered surface of timing chain case.
MB991448
AC506763 AC
TSB Revision
ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-53
M1112004002190

Fuel Line Pressure Reduction [Refer to GROUP 13A Water Pump Installation (Refer to GROUP 14 Water
On-vehicle Service, Fuel Pump Connector Disconnection Pump P.14-21).
(How to Reduce Pressurized Fuel Lines) P.13A-932]. EGR Valve and EGR Valve Stay Installation (Refer to
Engine Coolant Draining (Refer to GROUP 14 On-vehi- GROUP 17 EGR Valve P.17-85).
cle Service, Engine Coolant Replacement P.14-13). Throttle Body Assembly Installation (Refer to GROUP
Air Cleaner Assembly Removal (Refer to GROUP 15 Air 13A Throttle Body Assembly P.13A-950).
Cleaner P.15-4). Exhaust Manifold Installation (Refer to GROUP 15
Ignition Coil Removal (Refer to GROUP 16 Ignition Sys- Exhaust Manifold P.15-9).
tem, Ignition Coil P.16-39). Strut Tower Bar Installation (Refer to GROUP 42A Strut
Strut Tower Bar Removal (Refer to GROUP 42A Strut Tower Bar P.42A-11).
Tower Bar P.42A-11). Ignition Coil Installation (Refer to GROUP 16 Ignition
Exhaust Manifold Removal (Refer to GROUP 15 System, Ignition Coil P.16-39).
Exhaust Manifold P.15-9). Air Cleaner Assembly Installation (Refer to GROUP 15
Throttle Body Assembly Removal (Refer to GROUP 13A Air Cleaner P.15-4).
Throttle Body Assembly P.13A-950). Engine Coolant Refilling (Refer to GROUP 14 On-vehi-
EGR Valve and EGR Valve Stay Removal (Refer to cle Service, Engine Coolant Replacement P.14-13).
GROUP 17 EGR Valve P.17-85). Fuel Leak Check
Water Pump Removal (Refer to GROUP 14 Water Pump
P.14-21).
TSB Revision
8 13
9
4
N 7
24 3 Nm
18 2 ft-lb 2
5
N 6
3
10
11
20 2 Nm
12 15 1 ft-lb
AC506764 AC

1. Control wiring harness connection 9. Brake booster vacuum hose
2. Radiator upper hose connection connection
3. Radiator lower hose connection 10. Engine oil level gauge
4. Heater hose connection 11. Intake manifold stay
5. Water pump inlet pipe 12. Cylinder head cover PCV hose
6. Cooling water line gasket connection
7. O-ring <<A>> >>F<< 13. Fuel high-pressure hose
8. Emission vacuum hose connection connection
TSB Revision
ENGINE MECHANICAL
11A-55
18 12 1 Nm
12 1 Nm Apply engine oil to all
17 3 Nm 30 2 Nm
106 9 in-lb
20 106 9 in-lb
to 19 moving parts before
13 2 ft-lb 22 1ft-lb
installation.
17 24 N
10 2 Nm <Cold engine>
89 17 in-lb 35 2 Nm
26 1 ft-lb to +180 2
14
15
(Engine oil)
16
21
<Cold engine>
35 2 Nm
to +180 2
26 1 ft-lb 22
N 23
(Engine oil)
25
N 26
AC608197AB

Valve timing chain (Refer to <<C>> >>D<< 19. Camshaft bearing cap
P.11A-63). <<C>> >>D<< 20. Thrust camshaft bearing cap
14. Timing chain upper guide >>C<< 21. Camshaft and camshaft sprocket
<> >>E<< 15. Front camshaft bearing cap assembly
assembly 22. Camshaft bearing
16. Camshaft bearing <<D>> >>B<< 23. Cylinder head bolt
<<C>> >>D<< 17. Oil feeding camshaft bearing cap <<D>> >>B<< 24. Cylinder head bolt assembly
<<C>> >>D<< 18. Camshaft bearing cap >>A<< 25. Cylinder head assembly
>>A<< 26. Cylinder head gasket
MB991454: Engine Hanger Balancer MB991928: Engine Hanger
MB991527: Hanger MB991956: Engine Hanger Plate
MB991895: Engine Hanger
TSB Revision

.
<<A>> FUEL HIGH-PRESSURE HOSE REMOVAL

1. Remove the stopper of the fuel high-pressure hose.
Stopper
AC301860 AC
2. Raise the retainer of the fuel high-pressure hose and pull out
the fuel high-pressure hose in the direction shown in the
Retainer
figure.
NOTE: If the retainer is released, install it securely after
removing the fuel high-pressure hose.
AC301861AC
<> FRONT CAMSHAFT BEARING CAP

ASSEMBLY REMOVAL
CAUTION
bearing cap 4
assembly
2
3
TSB Revision
ENGINE MECHANICAL
11A-57
<<C>> OIL FEEDING CAMSHAFT BEARING
CAUTION
Engine front
2 6 8 4
1 5 7 3
1 5 7 3
2 6 8 4
AC506746 AC
<<D>> CYLINDER HEAD BOLT/CYLINDER HEAD

BOLT ASSEMBLY REMOVAL
1. Temporarily install the engine oil pan which was removed at
the valve timing chain removal (Refer to P.11A-45).
2. Place a garage jack against the engine oil pan with a piece
of wood in between to support the engine and transaxle
assembly.
TSB Revision
3. Remove special tool MB991928 or MB991895 which was

MB991928 installed for supporting the engine and transaxle assembly
when the valve timing chain was removed.
MB991454
AC611558AB
MB991895
MB991454
AC611557AB
Engine front 4. Loosen and remove the bolts in two or three steps in the
order of number shown in the figure.
3 5 10 8 2
1 7 9 6 4
AC506767AD
TSB Revision
ENGINE MECHANICAL
11A-59
.
>>A<< CYLINDER HEAD GASKET/CYLINDER

HEAD ASSEMBLY INSTALLATION
CAUTION
Do not allow any foreign materials get into the coolant pas-
sages, oil passages and cylinder.
1. Wipe off the sealant and grease on the top surface of
Degrease cylinder head block and the bottom surface of the cylinder
head, and degrease the surface where the sealant is
applied.
Bottom view of cylinder head
Degrease
Top view of cylinder block

AC607682AB
2 mm or 3 mm ( 0.08 in or 0.12 in) 2. Apply the sealant to the top surface of cylinder block as
shown in the figure.
3. Install the cylinder head gasket to the cylinder block.
NOTE: When the cylinder gasket is installed to the cylinder
Cylinder head block, check that the sealant is securely applied to the bead
gasket
line of the cylinder head gasket.
4. Apply the sealant to the top surface of cylinder head gasket
as shown in the figure.
Cylinder head 5. Install the cylinder head assembly.
gasket
2 mm or 3 mm
( 0.08 in or 0.12 in)
Cylinder
block AC511063 AD
TSB Revision
>>B<< CYLINDER HEAD BOLT

ASSEMBLY/CYLINDER HEAD BOLT
INSTALLATION
1. Replace cylinder head bolts with a new ones.
2. For two bolts of the timing chain side, the washer can be
removed from the bolt. Install the washer, with its sag facing
upward, to the bolts.
3. Apply a small amount of engine oil to the cylinder head bolt
threads and the washers.
Engine front 4. Tighten the bolts by the following procedure (plastic region
angular tightening method).
(1) Tighten the bolts to 35 2 N m (26 1 ft-lb) in the order
8 6 1 3 9 of number shown in the figure.
CAUTION
The bolt is not tightened sufficiently if the tightening
angle is less than a 180 degrees angle.
10 4 2 5 7
If the tightening angle exceeds the standard specifica-
tion, remove the bolt and repeat the installation steps
AC506767AE
from Step 1.
(2) Put a paint mark on the cylinder head bolt head and
cylinder head, tighten to 180 2 degrees in the order
180 shown in the figure, and check that the paint mark on the
cylinder head bolt head aligns with the paint mark on the
cylinder head.
Paint marks Paint marks
AC506768 AC
5. Install special tool MB991928 or MB991895 which was

MB991928 installed for supporting the engine and transmission
assembly when the valve timing chain was removed (Refer
to P.11A-63).
6. Remove the garage jack which supports the engine and
transaxle assembly.
7. Remove the engine oil pan installed temporarily.
MB991454
AC611558AB
MB991895
MB991454
AC611557AB
TSB Revision
ENGINE MECHANICAL
11A-61
>>C<< CAMSHAFT AND CAMSHAFT SPROCKET
CAUTION
from its position.
.

CAMSHAFT BEARING CAP INSTALLATION
Engine front
Identification of intake side shaft bearing cap are the same in shape, check the bearing
and exhaust side cap number and additionally its symbol to identify the intake
E 5
and exhaust sides for correct installation.

Bearing cap No.
7 3 1 5
8 4 2 6
8 4 2 6
3 1
7 5
>>E<< FRONT CAMSHAFT BEARING CAP

CAUTION
(2)
(1) and temporarily tighten the front camshaft bearing cap to the
4 camshaft 1
assembly
1 2
AC511062AC
TSB Revision
>>F<< FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
Fuel After connecting the fuel high-pressure hose, slightly pull
high-pressure it in the pull-out direction to check that it is installed firmly.
3 mm
hose
(0.12 in)
In addition, check that there is approximately 3mm (0.12
inch)play. After the check, install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe, and
install the fuel high-pressure hose.
Fuel line pipe

(Engine oil applied)
AC301864 AD
Stopper
AC301863AC
TSB Revision
ENGINE MECHANICAL
TIMING CHAIN
11A-63
TIMING CHAIN
M1112007200153

Engine Room Under Cover Front Removal (Refer to Engine Oil Pan Installation (Refer to P.11A-45).
GROUP 51 Under Cover P.51-16). Cylinder Head Cover Assembly Installation (Refer to
Engine Room Side Cover (RH) Removal (Refer to P.11A-22).
GROUP 51Under Cover P.51-16). Engine Oil Refilling (Refer to GROUP 12 - On-vehicle
Cylinder Head Cover Assembly Removal (Refer to Service, Engine Oil Replacement P.12-4).
P.11A-22). Engine Room Side Cover (RH) Installation (Refer to
Engine Oil Pan Removal (Refer to P.11A-45). GROUP 51 Under Cover P.51-16).
Engine Room Under Cover Front Installation (Refer to
Apply engine oil to all 10 2 Nm

moving parts before 89 17 in-lb
installation.
8
11
10
10 2 Nm
89 17 in-lb
7
24 4 Nm
18 3 ft-lb
9
10 2 Nm
89 17 in-lb
12
45 5 Nm
34 3 ft-lb
5 13 2 Nm
10 2 Nm
1 111 2 in-lb
10 2 Nm 89 17 in-lb
9.0 1.0 Nm 89 17 in-lb
80 9 in-lb 4
23 2 Nm 6 N
48 7 Nm 17 1 ft-lb
36 5 ft-lb 10 2 Nm
89 17 in-lb
2 3 25 4 Nm
18 3 ft-lb
48 7 Nm
22 4 Nm
36 5 ft-lb
16 3 ft-lb
AC611622AB

<<A>> Crankshaft pulley (Refer to 5. Cylinder block engine front
P.11A-19). mounting bracket
>>D<< 1. Water pump pulley 6. Gasket
2. Idler pulley <<D>> >>C<< 7. Timing chain case assembly
3. Alternator drive belt auto-tensioner 8. Timing chain upper guide
<> 4. Power steering oil pump assembly <<E>> >>B<< 9. Timing chain tensioner
<<C>> Engine and transaxle assembly 10. Timing chain tension side guide
holding >>A<< 11. Timing chain
Engine mounting insulator (Refer to 12. Timing chain loose side guide
GROUP 32 Engine Mounting
P.32-3).

TSB Revision
TIMING CHAIN
MB991928: Engine Hanger

.
<<A>> CRANKSHAFT PULLEY REMOVAL

When removing the crankshaft pulley, slightly loosen the water
pump pulley mounting bolts before removal of the drive belt.
.
<> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
1. Remove the power steering oil pump assembly with hose on
it.
2. Tie the removed power steering oil pump with a string at a
position where it will not interfere with the removal and
installation of timing chain.
.
<<C>> ENGINE AND TRANSAXLE ASSEMBLY

HOLDING
Install a special tool for holding the engine and transaxle
assembly.
1. <Engine hanger MB991928 is used>
(1) Assemble the engine hanger (special tool MB991928).
Set the following parts on the base hanger.
Slide bracket (HI)
Foot x 4 (standard) (MB991932)
Joint x 2 (90) (MB991930)
(2) Set the foot of the special tool as shown in the figure.
NOTE: Slide the slide bracket (HI) to adjust the engine
hanger balance.
MB991932
MB991930
MB991932 AC611565AB
(3) Mount special tool MB991454 to the power steering oil

MB991928 pump bracket and the engine hanger, and set it to special
tool MB991928 to support the engine and transaxle
assembly.
MB991454
AC611558AB
2. <Engine hanger MB991895 is used>
TSB Revision
ENGINE MECHANICAL
TIMING CHAIN
11A-65
(1) Set the foot of special tool MB991895 as shown in the
figure.
NOTE: Slide the foot to adjust the engine hanger bal-
ance.
MB991895
AC611564AB
(2) Mount special tool MB991454 to the power steering oil

MB991895 pump bracket and the engine hanger, and set it to special
tool MB991895 to support the engine and transaxle
assembly.
MB991454
AC611557AB
<<D>> TIMING CHAIN CASE ASSEMBLY

REMOVAL
CAUTION
If the adhesive strength of sealant on the timing chain case
assembly is so strong that the boss may be damaged by
peeling off, do not peel it off forcibly.
1. After removing the timing chain case assembly mounting
bolts, slightly pry the boss of the timing chain case assembly
shown in the figure using a flat-tipped screwdriver (), and
remove the timing chain case assembly from the cylinder
head and cylinder block.
Boss
Timing chain
case assembly AC506770 AC
2. If the sealant cannot be peeled off easily, insert a wooden

Hammer
hammer shank into the timing chain case assembly inside
as shown in the figure, pry slightly, and remove the timing
chain case assembly from the cylinder head and cylinder
block.
Timing chain
case assembly AC506771AC
TSB Revision
TIMING CHAIN
<<E>> TIMING CHAIN TENSIONER REMOVAL

1. Temporarily install the crankshaft pulley to the crankshaft.
CAUTION
Turn the crankshaft clockwise.
Camshaft sprocket 2. Turn the crankshaft clockwise to align the sprocket timing
timing marks marks as shown in the figure and set the cylinder No. 1 to
the top dead center of compression stroke.
NOTE: At this time, it is not necessary that the link plate
(orange) of the timing chain always aligns with each
sprocket timing mark.
3. Remove the crankshaft pulley installed temporarily.
Crankshaft sprocket
timing mark
AC506772AG
4. Using a flat-tipped precision screwdriver (), release the

Hard wire or Ratchet release hole
L-shaped ratchet of timing chain tensioner.
hexagon 5. Compress the plunger of timing chain tensioner and insert
wrench hard wire (such as piano wire) or the L-shaped hexagon
wrench (1.5 mm[0.05 inch]) to fix the plunger of the timing
chain tensioner.
6. Remove the timing chain tensioner.
Timing chain
tensioner
AC506773 AD
TSB Revision
ENGINE MECHANICAL
TIMING CHAIN
11A-67
.
>>A<< TIMING CHAIN INSTALLATION

1. Set the timing marks of the camshaft sprockets and the
Camshaft sprocket
timing marks crankshaft sprocket as shown in the figure.
Crankshaft sprocket
timing mark AC506774AC
2. Align each sprocket timing chain mating mark with the link
Link plates (orange) plate (orange) of timing chain to avoid slack of the timing
chain tension side, and install the timing chain to the
sprockets.
Mating
mark Mating
mark
Tension side
Mating mark Link plate (orange)
AC506772 AB
TSB Revision
TIMING CHAIN
>>B<< TIMING CHAIN TENSIONER

INSTALLATION
1. Check that the sprocket timing chain mating marks align
Link plates (orange) with the link plates (orange) of the timing chain, and install
the timing chain tensioner to the cylinder block.
Mating
mark Mating
mark
Mating mark Link plate (orange)
AC506772 AI
2. Remove the hard wire or L-shaped hexagon wrench fixing

Hard wire or the plunger of the timing chain tensioner to apply tension to
L-shaped
hexagon
the timing chain.
wrench
Timing chain
tensioner AC506773 AE
>>C<< TIMING CHAIN CASE ASSEMBLY

INSTALLATION
1. Remove sealant from the timing chain case assembly and
the timing chain case assembly mounting surface of the
cylinder block and the cylinder head.
TSB Revision
ENGINE MECHANICAL
TIMING CHAIN
11A-69
2. Apply a bead of sealant to the timing chain case assembly
4 mm or 5 mm
( 0.16 in or 0.20 in) mounting surface. The bead diameter shall be 4 or 5 mm
(0.18 or 0.20 inch) for the areas shown by "A" in the figure
and 2 or 3 mm (0.08 or 0.12 inch) for the other area.
NOTE: Install the timing chain case assembly within 15 min-
utes after the application of sealant.
A CAUTION
A
If the sealant contacts any other part during installation of
the timing chain case assembly, apply sealant again before
installing the timing chain case assembly.
2 mm or 3. Install the timing chain case assembly to the cylinder block
3 mm and cylinder head so that the sealant does not contact other
( 0.08 in or
0.12 in)
parts.
AC607643AB
4. Insert the bolts to the timing chain case assembly as shown,

B and tighten them to the specified torque.
B
Name Symbol Quantity BOLT DIAMETER
(D) LENGTH (L)
mm (in)
B B Flange A 6 6 25 (0.2 1.0)
bolt
B 6 8 28 (0.3 1.1)
A Bolt C 1 6 25 (0.2 1.0)

A
C NOTE: D: Nominal diameter, L: Nominal length

A
A
Tightening torque:
A, C: 10 2 N m (89 17 in-lb)
B: 24 4 N m (13 3 ft-lb)
A A
B
B
AC506776 AC
>>D<< WATER PUMP PULLEY INSTALLATION

Temporarily tighten the water pump pulley mounting bolts.
Then, tighten them to the specified torque after the installation
of drive belt.
Tightening torque: 9.0 1.0 N m (80 9 in-lb)
TSB Revision
OIL PUMP CHAIN
OIL PUMP CHAIN

M1112009100011
Pre-removal and post-installation operation

Timing Chain Removal and Installation (Refer to
P.11A-63).
8
2
10 2 Nm 26 2 Nm
89 17 in-lb 20 1 ft-lb
10 2 Nm
89 17 in-lb 7
5
23 2 Nm
17 1 ft-lb
3
4 26 2 Nm
6 20 1 ft-lb AC608269 AB

>>B<< 1. Oil pump chain guide >>B<< 5. Oil pump chain
>>B<< 2. Oil pump tensioner lever >>B<< 6. Oil pump sprocket
<<A>> 3. Oil pump sprocket center bolt 7. Oil pump case
<<A>> 4. Oil pump chain and oil pump >>A<< 8. Crankshaft sprocket
sprocket

MB991346: Top Cover Wrench
TSB Revision
ENGINE MECHANICAL
OIL PUMP CHAIN
11A-71
.
<<A>> OIL PUMP SPROCKET CENTER BOLT/OIL

PUMP CHAIN AND OIL PUMP SPROCKET
REMOVAL
1. Hold the oil pump sprocket with special tool MB991346.
2. Loosen the oil pump sprocket center bolt and remove the oil
pump chain and oil pump sprocket.
MB991346
AC611491AB

.
>>A<< CRANKSHAFT SPROCKET INSTALLATION

: Wipe clean with a rag. 1. Wipe the dirt off of the crankshaft sprocket and the
: Wipe clean with a rag and degrease. crankshaft using a rag, and then remove the grease from the
portion shown in the illustration.
Crankshaft
NOTE: Remove grease to prevent a drop in the coefficient
of friction of the pressing portion caused by adhesion of oil.
Engine 2. Set the No. 1 piston at top dead center of the compression
front stroke.
3. Install the crankshaft sprocket to the crankshaft.
Crankshaft sprocket AC609811AB
>>B<< OIL PUMP SPROCKET/OIL PUMP

CHAIN/OIL PUMP TENSIONER LEVER/OIL PUMP
CHAIN GUIDE INSTALLATION
1. Set the No. 1 piston at top dead center of the compression
stroke.
2. Install the oil pump sprocket to the oil pump case.
3. Install the oil pump chain to the crankshaft sprocket.
4. Install the oil pump chain to the oil pump sprocket.
TSB Revision
OIL PUMP
OIL PUMP
M1112009300015

Oil Pan Removal and Installation (Refer to P.11A-45).
23 2 Nm
17 1 ft-lb
1
26 2 Nm
20 1 ft-lb
26 2 Nm
20 1 ft-lb
AC611705AB
Removal steps
<<A>> 1. Oil pump sprocket center bolt
2. Oil pump case

MB991346: Top Cover Wrench
TSB Revision
ENGINE MECHANICAL
OIL PUMP
11A-73
.
<<A>> OIL PUMP SPROCKET CENTER BOLT

REMOVAL
1. Secure the oil pump sprocket and the oil pump chain with
tie-wrap to prevent slippage between the oil pump sprocket
and the oil pump chain.
2. Hold the oil pump sprocket with special tool MB991346.
3. Remove the oil pump sprocket with the oil pump chain
attached.
Tie-wrap
MB991346
AC611704AB
TSB Revision
ENGINE ASSEMBLY
ENGINE ASSEMBLY
M1112001003268
CAUTION
When the engine assembly replacement is performed, use scan tool MB991958 to initialize the learn-
ing value (Refer to GROUP 00, Initialization Procedure for Learning Value in MFI Engine P.00-30).
Fuel Line Pressure Reduction [Refer to GROUP 13A Strut Tower Bar Installation (Refer to GROUP 42A Strut
On-vehicle Service, Fuel Pump Connector Disconnection Tower Bar P.42A-11).
(How to Reduce Pressurized Fuel Lines) P.13A-932]. Drive Shaft Installation (Refer to GROUP 26 Drive Shaft
Engine Room Under Cover Front Removal (Refer to Assembly P.26-17).
GROUP 51 Under Cover P.51-16). Radiator Installation (Refer to GROUP 14 Radiator
Engine Room Side Cover (RH) Removal (Refer to P.14-26).
GROUP 51Under Cover P.51-16). Engine-ECU Installation (Refer to GROUP 13A
Engine Coolant Draining (Refer to GROUP 14 On-vehi- Engine-ECU P.13A-952).
cle Service, Engine Coolant Replacement P.14-13). Battery and Battery Tray Installation
Engine Oil Draining (Refer to GROUP 12 On-vehicle Air Cleaner Assembly Installation (Refer to GROUP 15
Service, Engine Oil Replacement P.12-4). Air Cleaner P.15-4).
Transmission Fluid Draining (Refer to GROUP 22A Transmission Fluid Draining (Refer to GROUP 22A
On-vehicle Service, Transmission Fluid Replacement On-vehicle Service, Transmission Fluid Replacement
P.22A-8) <M/T>, (Refer to GROUP 23A On-vehicle Ser- P.22A-8) <M/T>, (Refer to GROUP 23A On-vehicle Ser-
vice, CVT Fluid Replacement P.23A-133) <CVT>. vice, CVT Fluid Replacement P.23A-133) <CVT>.
Engine Upper Cover Removal (Refer to GROUP 11A Engine Oil Refilling (Refer to GROUP 12 On-vehicle Ser-
Camshaft P.11A-22). vice, Engine Oil Replacement P.12-4).
Air Cleaner Assembly Removal (Refer to GROUP 15 Air Engine Coolant Refilling (Refer to GROUP 14 On-vehi-
Cleaner P.15-4). cle Service, Engine Coolant Replacement P.14-13).
Battery and Battery Tray Removal Drive Belt Tension Check (Refer to P.11A-9).
Engine-ECU Removal (Refer to GROUP 13A Engine Room Side Cover (RH) Installation (Refer to
Engine-ECU P.13A-952). GROUP 51 Under Cover P.51-16).
Radiator Removal (Refer to GROUP 14 Radiator Engine Room Under Cover Front Installation (Refer to
P.14-26). GROUP 51 Under Cover P.51-16).
Drive Shaft Removal (Refer to GROUP 26 Drive Shaft Engine Upper Cover Installation (Refer to GROUP 11A
Assembly P.26-17). Camshaft P.11A-22).
Strut Tower Bar Removal (Refer to GROUP 42A Strut Fuel Leak Check
Tower Bar P.42A-11).
TSB Revision
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-75
6
7 9
8.5 1.5 Nm
76 13 in-lb 12 2 Nm
102 22 in-lb
AC506785AC

1. Control wiring harness connection 7. Brake booster vacuum hose
2. Battery cable connection connection
3. Radiator upper hose connection 8. Cooling water line hose connection
4. Radiator lower hose connection <<A>> >>C<< 9. Fuel high-pressure hose
5. Heater hose connection connection
6. Emission vacuum hose connection Drive belt (Refer to P.11A-19).
TSB Revision
ENGINE ASSEMBLY
14
66 7 Nm
49 5 ft-lb
50 5 Nm 13 2 Nm
37 4 ft-lb 111 2 in-lb
10
9.0 2.0 Nm
80 17 in-lb
13
25 4 Nm
11 18 3 ft-lb
12 23 6 Nm
17 4 ft-lb
AC609240AB

<> 10. Power steering oil pump assembly <<D>> CVT assembly
<<C>> 11. A/C compressor and clutch 12. Grounding cable connection
assembly <<E>> >>B<< 13. Engine mounting insulator
<<D>> Manual transaxle assembly <<F>> >>A<< 14. Engine assembly

MB991895: Engine Hanger MB992201: Engine Hanger Plate

.
<<A>> FUEL HIGH-PRESSURE HOSE REMOVAL

1. Remove the stopper of the fuel high-pressure hose.
Stopper
AC301860 AC
TSB Revision
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-77
2. Raise the retainer of the fuel high-pressure hose and pull out
the fuel high-pressure hose in the direction shown in the
Retainer
figure.
NOTE: If the retainer is released, install it securely after
removing the fuel high-pressure hose.
AC301861AC
<> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
1. Remove the power steering oil pump assembly with hose on
it.
2. Tie the removed power steering oil pump with a string at a
position where it will not interfere with the removal and
installation of engine assembly.
.
<<C>> A/C COMPRESSOR AND CLUTCH

ASSEMBLY REMOVAL
1. Remove the A/C compressor and clutch assembly together
with the hose from the bracket.
2. Tie the removed A/C compressor and clutch assembly with
a string at a position where it will not interfere with the
removal and installation of engine assembly.
.
<<D>> MANUAL TRANSAXLE ASSEMBLY/CVT

ASSEMBLY REMOVAL
1. Install the front end upper bar bolt to the position as shown
in the figure.
2. Remove the transaxle assembly. (Refer to GROUP 22A,
Transaxle Assembly P.22A-12) <M/T>, (Refer to GROUP
23A, Transaxle Assembly P.23A-149) <CVT>.
AC609445AB
<<E>> ENGINE MOUNTING INSULATOR

REMOVAL
of wood in between to support the engine assembly.
TSB Revision
ENGINE ASSEMBLY
MB991928AC609295 2. When the transaxle assembly is removed, remove special

tool MB991928 or MB991895 which supports the engine
assembly.
MB991454
AC611555AB
MB991895AC609296
MB991454
AC611554AC
3. Remove special tool MB992201.

4. Operate a garage jack so that the engine weight is not
applied to the engine mounting insulator, and remove the
engine mounting insulator.
MB992201
AC611567AB
<<F>> ENGINE ASSEMBLY REMOVAL

AC609297 1. Mount the special tool MB991454 to the power steering oil
pump bracket and the engine hanger, and set the chain
block.
2. After checking that all cables, hoses and wiring harness
connectors and so on are disconnected from the engine, lift
the engine assembly slowly with the chain block to remove
the engine assembly upward from the engine compartment.
MB991454
AC611556AB
TSB Revision
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-79
.
>>A<< ENGINE ASSEMBLY INSTALLATION

AC609297 Install the engine assembly, being careful not to pinch the
cables, hoses, or wiring harness connectors.
MB991454
AC611556AB
>>B<< ENGINE MOUNTING INSULATOR

INSTALLATION
of wood in between, and install the engine mounting
insulator while adjusting the position of the engine.
2. Install special tool MB991454.
MB991928AC609295 3. Install special tool MB991928 or MB991895 which is used
during installation of transaxle assembly to hold the engine
assembly (Refer to GROUP 22A Transaxle Assembly
P.22A-12) <M/T>, (Refer to GROUP 23A Transaxle
Assembly P.23A-149) <CVT>.
MB991454
AC611555AB
MB991895AC609296
MB991454
AC611554AC
TSB Revision
ENGINE ASSEMBLY
>>C<< FUEL HIGH-PRESSURE HOSE

INSTALLATION
CAUTION
Fuel After connecting the fuel high-pressure hose, slightly pull
high-pressure it in the pull-out direction to check that it is installed firmly.
3 mm
hose
(0.12 in)
In addition, check that there is approximately 3 mm (0.12
inch) play. After the check, install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe, and
install the fuel high-pressure hose.
Fuel line pipe

(Engine oil applied)
AC301864 AD
Stopper
AC301863AC
TSB Revision
11A-1
GROUP 11A
ENGINE
MECHANICAL
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 11A-2 BASE ENGINE . . . . . . . . . . . . . . . . . . 11A-3

GENERAL DESCRIPTION
GENERAL DESCRIPTION
M2112000101162
This model is equipped with a newly developed 4B11 MIVEC (MITSUBISHI INNOVATIVE VALVE TIM-
engine. It is a 4-cylinder, double overhead camshaft ING ELECTRONIC CONTROL SYSTEM) for
(DOHC) engine with a 2.0-L cylinder displacement. both the intake and exhaust valves
This engine has adopted the following features: Cylinder block made of an aluminum alloy
Valve train with direct-acting valve tappets
Silent timing chain
MAIN SPECIFICATIONS
Descriptions Specifications
Engine type 4B11
Bore stroke mm (in) 86 (3.4) 86 (3.4)
Total displacement cm3 (cu in) 1,998 (121.9)
Combustion chamber Pent-roof type
Valve mechanism Type DOHC
Intake valve 8
Exhaust valve 8
Valve timing Intake valve Opens (BTDC) 3 28 <California>
0 25 <except California>
Closes (ABDC) 45 20 <California>
Exhaust valve Opens (BBDC) 41 21 <California>
Closes (ATDC) 3 23 <California>
Maximum output kW/r/min (HP/r/min) 107/6,000 (143/6,000) <California>
113/6,000 (152/6,000) <except California>
Maximum torque N m/r/min (lbs-ft/r/min) 194/4,250 (143/4,250) <California>
198/4,250 (146/4,250) <except California>
Fuel injection system type Electronic control MPI
Ignition system type Electronic spark-advance control type (4-coil
type)
Generator type Alternating current system (with built-in IC
regulator)
Starter motor type Reduction drive type
ENGINE MECHANICAL
BASE ENGINE
11A-3
BASE ENGINE
M2112001001050
CYLINDER HEAD
Exhaust side Intake side
Valve guide
AK502483 AD
A cylinder head made of an aluminum alloy, which is Cross-flow type intake and exhaust ports have been
lightweight and offers a high level of cooling effi- adopted. Two intake ports and two exhaust ports are
ciency, has been adopted. A pentroof combustion provided independently on the right and left sides.
chamber with a center spark plug has been adopted. Five camshaft bearings are provided at the intake
It has a small valve compound angle to realize a and exhaust sides, respectively. The No. 4 bearing
compact chamber. sustains the thrust load of the camshaft. Only the No.
1 bearing uses a bearing cap that integrates both the
intake and exhaust sides.
VALVE SEATS
Sintered alloy valve seats have been adopted. The oversized (0.3 mm) service parts are available.
VALVE GUIDES
Valve guides that are common to both the intake and The oversized (0.25 mm) service parts are available.
exhaust have been adopted.
BASE ENGINE
Oil hole
Water hole Water hole

AK604543 AB
A dual-layer, metal type cylinder head gasket that

excels in heat resistance and sealing performance
has been adopted.
CYLINDER HEAD COVER
AK502485
A Plastic cylinder head cover has been adopted.

ENGINE MECHANICAL
BASE ENGINE
11A-5
CYLINDER BLOCK
Cylinder block
Bearing cap
Oil jet
Ladderframe
AK502486 AE
A cylinder block made of an aluminum alloy has ITEM SPECIFICATIONS

been adopted for weight reduction.
5 bearings are used for the crankshaft journals and Distance between top and 230.1 (9.06)
the No. 3 bearing sustains the thrust load of the crankshaft center mm (in)
crankshaft. Bore mm (in) 86 (3.4)
The water jacket is the full Siamese type. Bore pitch mm (in) 96 (3.8)
An oil jet is used in front of the cylinder block to sup-
ply engine oil to the timing chain. Stroke mm (in) 86 (3.4)
BASE ENGINE
PISTONS
The pistons are made of a special aluminum alloy.
Their weight has been reduced by lowering their
overall height and increasing the depression at each
20
end of the piston pin.
A
The piston pin hole center is offset 0.8 mm (0.031 in)
towards the thrust side of the piston center.
The skirt portion along the perimeter of the piston is
finished with streaks that excel in oil retention and
Front mark seizure resistance.
Piston offset ITEM SPECIFICATIONS
Basic diameter mm (in) 86 (3.4)
Pin hole diameter mm (in) 21 (0.8)
Overall height mm (in) 50.5 (1.99)
AK603610AB
PISTON PINS
The piston pins are the semi-floating type. Each pin
is press-fit and secured in the small end of the con-
necting rod, while it floats in the piston.
ITEM SPECIFICATIONS
d2 d1 D Outer diameter (D) mm 21 (0.8)
(in)
h Inner diameter (d1) mm 12 (0.5)
(in)
AK502996AE Inner diameter (d2) mm 10.5 (0.41)
(in)
Overall length (h) mm (in) 58 (2.3)
ENGINE MECHANICAL
BASE ENGINE
11A-7
PISTON RINGS
Piston ring No. 1 Piston ring No. 2
Piston ring No. 1
Maker mark
Piston ring No. 2
Oil ring
Oil ring
Rail
Spacer
AK604544 AB
The piston rings consist of No. 1 and No. 2 rings and

an oil ring.
Item Piston ring No. 1 Piston ring No. 2 Oil ring
Shape Inside bevel, Barrel Taper undercut 3-piece, Barrel
Surface treatment (cylinder Chrome plating Parkerizing Hard plated Parkerizing
contact surface)
Supplier mark 1T 2T None
BASE ENGINE
CONNECTING RODS
The connecting rods are made of highly rigid, forged
carbon steel. The cross section of the rod portion is
d D
shaped like the letter H.
A fracture-split process has been adopted for split-
ting the big end of the connecting rod.
The fracture split connecting rod has the high inser-
tion force between the rod and the cap as well as the
high installation location accuracy.
The oil holes that feed oil from the main journals of
the crankshaft to the crankshaft pins lubricate the
bearings at the big ends of the connecting rods.
Item Specifications
Small end hole diameter 21 (0.87)
(d) mm (in)
Big end hole diameter (D) 51 (2.01)
2204
mm (in)
L Center-to-center distance 149.25 (5.876)
(L) mm (in)
AK502491AD
CONNECTING ROD BEARINGS

The upper and lower connecting rod bearings are the
same. Each connecting rod bearing is provided with
a backing plate. Its bearing portion is made of an alu-
A
minum alloy and its backing plate is made of ordinary
sheet steel.
Identification The width of the connecting rod bearing has been
color
made as narrow as possible in proportion to the
bearing cap in order to reduce friction loss.
H
Item Specifications
AK502492AD Width (H) mm (in) 17 (0.7)
Thickness (A) mm (in) 1.5 (0.06)
ENGINE MECHANICAL
BASE ENGINE
11A-9
CRANKSHAFT
Balance weight Oil hole
Balance weight Oil hole Balance weight

AK502493AD
A forged crankshaft has been adopted. Item Specifications

It has 5 main bearings and 8 balance weights.
The crankshaft pins are located at equal 180 inter- Pin outer diameter mm 48 (1.9)
vals. (in)
The oil holes feed engine oil from the journals to the Journal outer diameter 52 (2.0)
pins. mm (in)
A crankshaft sprocket and an oil pump drive shaft are
press-fit to the front of the crankshaft.
CRANKSHAFT BEARINGS, THRUST BEARINGS

Front
Lower bearing
Oil groove
Thrust bearing
Oil hole
Groove Identification
color
Upper bearing
Identification
color
AK602940AC
The upper crankshaft bearings have oil grooves and Item Specifications
the lower crankshaft bearings do not.
Each crankshaft bearing is provided with a backing Crankshaft bearing Width mm 18 (0.71)
plate. Its bearing portion is made of an aluminum (in)
alloy and its backing plate is made of ordinary sheet Thickness 2.0 (0.08)
steel. A thrust bearing, which sustains the load in the mm (in)
thrust direction, is provided at each end of the No. 3 Crankshaft thrust Thickness 2.0 (0.08)
bearing. bearing mm (in)
BASE ENGINE
CRANKSHAFT PULLEY
Rubber
Timing mark
AK604551 AB
The pulley is made of cast iron. A torsion damper has been adopted to reduce the
The pulley portion has grooves for the V-ribbed belt torsional vibration of the crankshaft, as well as to
(with 6 crests). dramatically reduce noise and vibration in the
The flange portion of the pulley has a timing mark high-speed range.
notch for checking the ignition timing.
DRIVE PLATE
Drive plate
Ring gear
AK502496AD
The drive plate is made of sheet metal. The drive plate is mounted with 7 bolts.
ENGINE MECHANICAL
BASE ENGINE
11A-11
FLYWHEEL
A cast iron ring gear is a shrink fit in the iron casting
of the flywheel.
The flywheel is mounted with 7 bolts.
Ring gear
AK603618AB
TIMING CHAIN TRAIN

Timing mark Timing mark
link plate (orange) Timing mark
link plate (orange)
Exhaust V.V.T. sprocket

Intake V.V.T. sprocket
Chain guide
Tensioner lever
Crankshaft spocket
Timing chain
tensioner
Cranshaft spocket
timing mark
Timing mark
link plate (orange)
AK502497AD
The two camshafts are driven by the timing chain via Three (orange) mark link plates are installed on the
the camshaft sprockets. timing chain to locate the sprockets.
The timing chain is a silent, endless type, consisting Item Number of teeth
of 180 links. It is installed around the V.V.T. sprockets
and the crankshaft sprocket. V.V.T. sprockets 54
Crankshaft sprocket 27
BASE ENGINE
TIMING CHAIN TENSIONER

The tensioner maintains the tension of the timing
Rack and chain. It contains a piston with a built-in spring.
washer With the tensioner installed, its piston directly pushes
assembly
on the tension lever in order to automatically adjust
the tension of the timing chain.
Piston
Spring
AK502997AE
VALVE TRAIN
Intake
camshaft
Exhaust
camshaft Valve tappet
Intake valve
Exhaust valve
AK502499 AD
The valve train is the 4-valve, double overhead cam- A valve tappet is interposed between the camshaft
shaft (DOHC) type in which the camshafts are and each valve, which allows the valve to open and
located above the valves. close.
Two intake and exhaust valves for each cylinder are
arranged in a V shape.
ENGINE MECHANICAL
BASE ENGINE
11A-13
VALVES
Intake Exhaust
D d D d
L L
AK502500 AD
The valves are made of heat-resistant steel and are Item Intake valve Exhaust valve
nitrided on their entire surface.
Head diameter 35 (1.4) 29 (1.1)
(D) mm (in)
Stem diameter 5.5 (0.22) 5.5 (0.22)
(d) mm (in)
Overall length (L) 113.180 105.887
mm (in) (4.4559) (4.1688)
VALVE STEM SEALS

The valve stem seals are integrated with the valve
Spring spring seats.
The valve stem seal portion excels in sealing perfor-
mance and is equipped with a spring to prevent oil
from descending.
AK502501AD
VALVE SPRINGS
To prevent the engine from surging at high speeds,
unequal-pitch springs are used.
Item Specifications
Free height (h) mm (in) 47.44 (1.867)
Total number of windings 8.67
h
AK502502 AD
BASE ENGINE
VALVE TAPPETS
To adjust the valve lift, 47 sizes of valve tappets are
available in 0.015 mm (0.0006 in) increments, from
Thickness 3.000 mm (0.1181 inch) to 3.690 mm (0.1453 in).
Identification
mark
AK502503 AD
MIVEC (MITSUBISHI INNOVATIVE VALVE TIMING ELECTRONIC CONTROL SYSTEM)
A Exhaust V.V.T. sprocket Intake V.V.T. sprocket B
Section A-A Section B-B
Engine oil Engine oil

control valve control valve
A
Cylinder head
Engine oil control

valve filter
Cylinder head
Cylinder block
Cylinder block B
AK503014 AE
The MIVEC consists of the parts shown in the illus- This system continuously varies and optimally con-
tration. trols the opening and closing timing of the individual
intake and exhaust valves, in order to improve torque
and power output in all speed ranges.
ENGINE MECHANICAL
BASE ENGINE
11A-15
V.V.T. SPROCKET (VARIABLE VALVE TIMING SPROCKET)
Intake V.V.T. sprocket
Timing mark Vane housing Stopper pin
Vane roter
Advance oil Vane
chamber bushing
V.V.T. sprocket
bolt
Sprocket Retard oil chamber
Exhaust V.V.T. sprocket

Timing mark Vane housing Stopper pin
Vane bushing
Vane roter
Advance oil
chamber
Spring
V.V.T. sprocket
bolt
Retard oil chamber
Sprocket
AK503061AD
The engine oil control valve controls the hydraulic

pressure in order to move the vane rotor in the V.V.T.
sprocket to optimally control valve timing.
CAMSHAFT
Cam positon
sensing cam
Intake camshaft
Advance
Retard oil channel
oil channel
Dowel pin
Hollow section Sealing cap
Exhaust camshaft
Advance
Retard oil channel
oil channel AK502506 AD
The camshaft are hollow for weight reduction. A cam position sensing cam for detecting the cam
Each camshaft is provided with an oil passage to position (used by the cam position sensor) is inte-
guide the hydraulic pressure from the engine oil con- grated at the back of each camshaft.
trol valve to the V.V.T. sprocket.
BASE ENGINE
Item Specifications
Overall length mm (in) Intake 435.00 (17.126)
Exhaust 438.27 (17.255)
Journal outer diameter mm (in) Intake No.1 30 (1.2)
No.2 5 24 (0.9)
Exhaust No.1 36 (1.4)
No.2 5 24 (0.9)
Camshaft lift mm (in) Intake 8.45 (0.333)
Exhaust 8.20 (0.323)
ENGINE OIL CONTROL VALVE

Insulation
coilar Enameled
copper wire
Bobbin Terminal
Default
Spool Pressure pressure
chamber chamber Tape
Plunger spring
Spring guide Shaft
Plunger
Valve sleeve Seal cap
Drain Drain Yoke

Pump O-ring
Bracket
Stator Guide cap
AK302997AE
The engine oil control valve consists of a solenoid

valve, which switches the hydraulic pressure that
acts on the vane rotor in the V.V.T. sprocket assem-
bly. This valve is actuated by a signal from the
engine ECU.
ENGINE MECHANICAL
BASE ENGINE
11A-17
TIMING CHAIN CASE
Timing chain case
Oil seal
AK502507AD
The timing chain case is made of an aluminum alloy.

A front crankshaft oil seal is press-fit into the case.
NOTES
11B-1
GROUP 11B
ENGINE OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS . . . . . . 11B-2 OIL PAN AND TIMING CHAIN CASE 11B-26
REMOVAL AND INSTALLATION . . . . . . . . 11B-26
SERVICE SPECIFICATIONS. . . . . . . 11B-2
TIMING CHAIN . . . . . . . . . . . . . . . . . . 11B-32
FASTENER TIGHTENING REMOVAL AND INSTALLATION . . . . . . . . 11B-32
SPECIFICATIONS . . . . . . . . . . . . . . . 11B-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-37
SEALANTS AND ADHESIVES . . . . . 11B-7 CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11B-39

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-42
GENERATOR AND IGNITION CYLINDER HEAD AND VALVES. . . . 11B-45

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B-10 REMOVAL AND INSTALLATION . . . . . . . . 11B-45
REMOVAL AND INSTALLATION . . . . . . . . 11B-10 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-49
THROTTLE BODY AND EGR OIL PUMP CHAIN. . . . . . . . . . . . . . . . 11B-53

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B-14 REMOVAL AND INSTALLATION . . . . . . . . 11B-53
PISTON AND CONNECTING ROD . . 11B-59
INTAKE MANIFOLD AND FUEL REMOVAL AND INSTALLATION . . . . . . . . 11B-59
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B-17
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-66
CRANKSHAFT AND CYLINDER
EXHAUST MANIFOLD. . . . . . . . . . . . 11B-21 BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11B-68
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-73
WATER HOSE AND PIPE . . . . . . . . . 11B-24
11B-2 ENGINE OVERHAUL
M1113000201501
Descriptions Specifications
Engine type 4B11
Bore stroke mm (in) 86 (3.39) 86 (3.39)
Total displacement cm3 (cu in) 1,998 (121.9)
Combustion chamber Pent-roof type
Valve mechanism Type DOHC
Intake valve 8
Exhaust valve 8
Valve timing Intake valve Opens (BTDC) 25 0 <CALIFORNIA>,
28 3 <Except CALIFORNIA>
Closes (ABDC) 48 23 <CALIFORNIA>,
Exhaust valve Opens (BBDC) 24 44 <CALIFORNIA>,
Closes (ATDC) 0 20 <CALIFORNIA>,
Fuel injection system type Electronic control MPI
Ignition system type Electronic spark-advance control type (4-coil
type)
Generator type Alternating current system (with built-in IC
regulator)
Starter motor type Reduction drive type
M1113000301627

Timing chain
Valve clearance mm (in) Intake 0.20 (0.008)
Exhaust 0.30 (0.012)
Camshaft
Cam height of camshaft mm Intake 43.25 (1.703) 42.75 (1.683)
(in) Exhaust 45.00 (1.772) 44.50 (1.752)
Camshaft oil clearance mm (in) 0.035 0.072
(0.0014 0.0028)
Cylinder head and valves
Distortion of cylinder head bottom mm (in) Within 0.05 (0.002) 0.02 (0.0008)
Grinding limit of cylinder head bottom mm (in) 0.2 (0.008)
Overall height of cylinder head mm (in) 128.5 (5.06)
TSB Revision
ENGINE OVERHAUL
11B-3
Overall length of valve mm (in) Intake 113.18 (4.456) 112.68 (4.436)
Exhaust 105.89 (4.169) 105.39 (4.149)
Valve margin mm (in) Intake 1.022 (0.0402) 0.522 (0.0206)
Exhaust 1.094 (0.0431) 0.594 (0.0234)
Free height of valve spring mm (in) 47.44 (1.868) 46.44 (1.828)
Squareness of valve spring 2 or less 4
Clearance between valve guide Intake 0.020 0.047 0.10 (0.004)
and valve stem mm (in) (0.0008 0.0019)
Exhaust 0.030 0.054 0.15 (0.006)
(0.0012 0.0021)
Valve seat contact width mm Intake 1.16 1.46 (0.046 0.058)
(in) Exhaust 1.35 1.65 (0.053 0.065)
Oversize rework dimensions of 0.25 oversize 11.23 11.25
valve guide hole mm (in) diameter (0.442 0.443)
Intake oversize rework 0.3 oversize 36.22 36.24
dimensions of valve seat hole diameter (1.426 1.427)
mm (in)
Exhaust oversize rework 0.3 oversize 30.22 30.24
dimensions of valve seat hole diameter (1.190 1.191)
mm (in)
Piston and connecting rod
Piston pin press-fit load N (pound) 7,500 17,500
(1,686 3,934)
Clearance between piston ring No.1 0.03 0.07 (0.001 0.003) 0.1 (0.004)
and ring groove mm (in) No.2 0.03 0.07 (0.001 0.003) 0.1 (0.004)
Piston ring end gap mm (in) No.1 0.15 0.28 (0.006 0.011) 0.8 (0.03)
No.2 0.30 0.45 (0.012 0.018) 0.8 (0.03)
Oil 0.10 0.35 (0.004 0.014) 1.0 (0.004)
Clearance of connecting rod big end thrust mm (in) 0.10 0.25 (0.004 0.010) 0.4 (0.016)
Outside diameter of connecting rod bolt mm (in) 0.1 (0.004)
Connecting rod bearing oil clearance mm (in) 0.018 0.045 0.1 (0.004)
(0.0007 0.0018)
Crankshaft and cylinder block
Underhead length of bearing cap bolt mm (in) 75.3 (2.96)
Crankshaft end play mm (in) 0.05 0.25 (0.002 0.010) 0.4 (0.016)
Crankshaft journal oil clearance mm (in) 0.012 0.030 0.1 (0.004)
(0.0005 0.0012)
Distortion of cylinder block top surface mm (in) 0.05 (0.002) 0.02 (0.0008)
Grinding limit of cylinder block top surface mm (in) 0.2 (0.008)
Cylinder block cylinder bore mm (in) 86 (3.4)
Cylindricity of cylinder block mm (in) 0.15 (0.006)
TSB Revision
FASTENER TIGHTENING SPECIFICATIONS

M1113023402071
Item Specification
Generator and ignition system
Idler pulley bolt 48 7 N m (36 4 ft-lb)
Auto tensioner 22 4 N m (17 2 ft-lb)
Crankshaft bolt 210 N m (155 ft-lb)
Generator nut 44 10 N m (32 7 ft-lb)
Generator bolt 44 10 N m (32 7 ft-lb)
Ignition coil bolt 10 2 N m (89 17 in-lb)
Spark plug 25 5 N m (19 3 ft-lb)
Power steering pump bracket bolt (M8) 23 2 N m (17 1 ft-lb)
Power steering pump bracket bolt (M10) 44 8 N m (33 5 ft-lb)
Throttle body and EGR system
Vacuum pump assembly bolt (M6) 11 1 N m (98 8 in-lb)
Vacuum pump assembly bolt (M8) 24 3 N m (18 1 ft-lb)
Throttle body bolt 9.5 2.5 N m (84 22 in-lb)
Throttle body stay bolt 20 2 N m (15 1 ft-lb)
Exhaust gas recirculation valve support bolt 20 2 N m (15 1 ft-lb)
Exhaust gas recirculation pipe bolt 20 2 N m (15 1 ft-lb)
Exhaust gas recirculation support stay A bolt 20 2 N m (15 1 ft-lb)
Exhaust gas recirculation support stay B bolt 20 2 N m (15 1 ft-lb)
Exhaust gas recirculation valve bolt 24 3 N m (18 1 ft-lb)
Manifold absolute pressure (MAP) sensor screw 4.0 1.0 N m (36 8 in-lb)
Solenoid valve screw 4.0 1.0 N m (36 8 in-lb)
Intake manifold and fuel system
Oil dipstick guide bolt 10 2 N m (89 17 in-lb)
Injector protector rear bolt 20 2 N m (15 1 ft-lb)
Fuel rail bolt 20 2 N m (15 1 ft-lb)
Intake manifold nut 20 2 N m (15 1 ft-lb)
Intake manifold assembly bolt washer 20 2 N m (15 1 ft-lb)
Intake manifold stay bolt 20 2 N m (15 1 ft-lb)
Injector protector front bolt 20 2 N m (15 1 ft-lb)
Generator bracket bolt 44 8 N m (33 5 ft-lb)
Knock sensor bolt 20 2 N m (15 1 ft-lb)
Engine oil pressure switch 10 2 N m (89 17 in-lb)
Exhaust manifold
Exhaust manifold upper cover bolt 14 1 N m (124 8 in-lb)
Exhaust manifold lower cover bolt 14 1 N m (124 8 in-lb)
Exhaust manifold nut 49 5 N m (36 3 ft-lb)
Exhaust manifold bracket D bolt 20 5 N m (15 3 ft-lb)
TSB Revision
ENGINE OVERHAUL
11B-5
Item Specification
Exhaust manifold bracket bolt 41 10 N m (30 7 ft-lb)
Exhaust manifold bracket A, B bolt 41 10 N m (30 7 ft-lb)
Crankshaft position sensor bolt 11 1 N m (98 8 in-lb)
Crankshaft position sensor cover bolt (M6) 11 1 N m (98 8 in-lb)
Crankshaft position sensor cover bolt (M10) 49 6 N m (36 4 ft-lb)
Water hose and pipe
Water inlet fitting bolt 24 3 N m (18 1 ft-lb)
Water outlet fitting bolt 24 3 N m (18 1 ft-lb)
Thermostat housing bolt 24 3 N m (18 1 ft-lb)
Engine hanger bolt 28 8 N m (21 5 ft-lb)
Engine coolant temperature sensor 30 9 N m (22 6 ft-lb)
Water pump bolt 24 3 N m (18 1 ft-lb)
Water pipe nut 24 3 N m (18 1 ft-lb)
Camshaft position sensor 11 1 N m (98 8 in-lb)
Oil pan and timing chain case
Cylinder head cover bolt 3.0 1.0 N m (27 8 in-lb)
5.5 0.5 N m (49 8 in-lb)
Timing chain case bolt (M6) 10 2 N m (89 17 in-lb)
Timing chain case bolt (M8 10) 13 1 N m (115 8 in-lb)
Timing chain case bolt (M8 28) 24 4 N m (18 2 ft-lb)
Oil pan bolt (M6) 10 2 N m (89 17 in-lb)
Oil pan bolt (M8) 29 2 N m (21 1 ft-lb)
Air compressor bracket bolt 23 6 N m (17 4 ft-lb)
Oil drain plug 39 5 N m (29 3 ft-lb)
Oil filter 14 2 N m (124 17 in-lb)
PCV valve 2.5 0.4 N m (22 3 in-lb)
Engine support bracket assembly washer bolt 45 5 N m (33 3 ft-lb)
Timing chain
Chain upper guide bolt 10 2 N m (89 17 in-lb)
Oil jet bolt 10 2 N m (89 17 in-lb)
V.V.T. intake sprocket bolt 59 5 N m (44 3 ft-lb)
V.V.T. exhaust sprocket bolt 59 5 N m (44 3 ft-lb)
Timing chain tensioner bolt 10 2 N m (89 17 in-lb)
Tensioner lever bolt 10 2 N m (89 17 in-lb)
Timing chain guide bolt 10 2 N m (89 17 in-lb)
Camshaft
Engine oil control valve (OCV) bolt 10 2 N m (89 17 in-lb)
Camshaft bearing cap bolt (M6) 12 1 N m (107 8 in-lb)
Front camshaft bearing cap bolt (M8) 17 3 N m (14 2 ft-lb)
30 2 N m (22 1 ft-lb)
TSB Revision
Item Specification
Cylinder head and valves
Cylinder head bolt 35 2 N m (26 1 ft-lb) +180
Oil pump chain
Drive plate bolt 40 2 N m (29 1 ft-lb) +30
Flywheel bolt 40 N m (30 ft-lb) 130 N m (96 ft-lb)
Oil pump case bolt 26 2 N m (19 1 ft-lb)
Oil pump sprocket bolt 23 2 N m (17 1 ft-lb)
Oil pump tensioner lever bolt 10 2 N m (89 17 in-lb)
Oil pump chain guide bolt 10 2 N m (89 17 in-lb)
Ladder frame bolt 26 1 N m (19 1 ft-lb)
Piston and connecting rod
Connecting rod cap bolt 5.0 N m (44 in-lb) 20 N m (15 ft-lb) +90
Crankshaft and cylinder block
Crankshaft sensing ring bolt 11 1 N m (98 8 in-lb)
Bearing cap bolt 26.5 2.0 N m (20 1 ft-lb) +45
NEW TIGHTENING METHOD BY USING PLASTIC REGION TIGHTENING BOLT
2. Bearing cap bolt
.
Plastic region tightening bolts are used in some parts

of the engine. Install these bolts according to the 3. Connecting rod cap bolt
method described in the body of the manual because Tightening method
the tightening method of these bolts are different After tightening to the specified torque, further
from the conventional method. The service limit is tighten 45 and 90 , or 180 (90 + 90 ). Follow
determined for these bolts. Be sure to strictly follow the tightening method described in the body of
the service limit described in the body of the manual. the manual because the tightening method differs
Parts to be used from part to part.
1. Cylinder head bolt
SIZE OF TORQUE WRENCH USED

Tool size Main parts to be used
T25 Solenoid valve
T25 Manifold absolute pressure (MAP) sensor
T30 Crankshaft sensing ring
T55 Cylinder head bolt
TSB Revision
ENGINE OVERHAUL
SEALANTS AND ADHESIVES
11B-7
M1113000501494
Item Specified sealant

Flywheel bolt LOCTITE 262 or equivalent
Ladder frame Three bond 1217G, LOCTITE 5900, 5970, 5971 or equivalent
Cylinder block
Cylinder head
Cylinder head gasket
Oil pan
Timing chain case
Cylinder head cover Three bond 1217G or equivalent
Engine coolant temperature sensor LOCTITE 262 or equivalent
Engine oil pressure switch LOCTITE 565 or equivalent
SPECIAL TOOLS
M1113000601899
Tool Tool number and Supersession Application

name
MB991883 Securing of drive plate and
Flywheel stopper flywheel
MB991883
MB992106 Installation of O-ring on injector

O-ring installer injection nozzle side
MB991396 Removal and installation of oil

Oil filter wrench filter
B991396
MD998727 MD998727-01 Removal of oil pan

Oil pan FIPG cutter
D998727
MB991448 MB991448-01 Press fit of front oil seal

Bushing remover and
installer base
TSB Revision
SPECIAL TOOLS

name
MD998735 MD998735-01 Compression of valve spring
Valve spring
compressor
MB992089 MB992089-01
Retainer holder C
MB992085 Extraction of valve stem seal

Valve stem seal pliers
MD998737 MD998737-01 Installation of valve stem seal

Valve stem seal
installer
MD998780 MIT216941 Extraction and press fit of piston

Piston pin setting tool pin
MB991659
Guide D
MB991614 General service tool Installation of crankshaft bearing

Angle gauge cap bolt and installation of
balancer shaft module bolt
MB991614
MD998718 MD998718-01 Press fit of rear oil seal

Rear oil seal installer
TSB Revision
ENGINE OVERHAUL
SPECIAL TOOLS
11B-9
name
MB991367 Removal and installation of oil
Special spanner pump sprocket
B991367
MB991385
Pin
B991385
MB991398 Removal and installation of spark

Spark plug wrench plug
TSB Revision
GENERATOR AND IGNITION SYSTEM

M1113001001403
10 2 Nm
89 17 in-lb
9
25 5 Nm
19 3 ft-lb
10
23 2 Nm
17 1 ft-lb
44 8 Nm
33 5 ft-lb
5
8 4
2
48 7 Nm
36 4 ft-lb
22 4 Nm
17 2 ft-lb
7 1
44 10 Nm
6 48 7 Nm 32 7 ft-lb
36 4 ft-lb 44 10 Nm
210 Nm 32 7 ft-lb
155 ft-lb
AK600613AD

1. Idler pulley <<A>> >>B<< 6. Crankshaft pulley bolt
2. Idler pulley >>B<< 7. Washer
3. Generator >>B<< 8. Crankshaft pulley
4. Power steering pump bracket 9. Ignition coil
>>C<< 5. Auto tensioner <> >>A<< 10. Spark plug

MB991398: Spark Plug Wrench MB991883: Flywheel Stopper
TSB Revision
ENGINE OVERHAUL
11B-11
.
<<A>> CRANKSHAFT PULLEY BOLT REMOVAL

1. Use special tool MB991883 to secure the drive plate or
flywheel.
MB991883 2. Remove the crankshaft pulley bolt.
AK502869 AD
<> SPARK PLUG REMOVAL

Using special tool MB991398, removal the spark plug.
MB991398
Spark plug
AK600875AC

.
>>A<< SPARK PLUGS INSTALLATION

Using special tool MB991398, tighten the spark plug to the
specified torque.
MB991398 Specified torque: 18 2 N m (13 1 ft-lb)
Spark plug
AK600875AC
TSB Revision
>>B<< CRANKSHAFT PULLEY / WASHER /

CRANKSHAFT PULLEY BOLT INSTALLATION
flywheel.
MB991883
AK503335 AD
: Wipe clean with a rag. 2. Wipe off the dirt on the washer and on the thread hole of the
: Wipe clean with a rag and degrease. crankshaft using a rag.
: Wipe clean with a rag, degrease and 3. Wipe off the dirt on the crankshaft pulley and the crankshaft
apply a small amount of engine oil.
sprocket using a rag, and then remove the grease from the
NOTE: Remove grease to prevent the coefficient of friction
of the pressing portion from declining due to adhesion of oil.
Washer Crankshaft 4. Install the crankshaft pulley.
sprocket
5. Apply an appropriate and minimum amount of engine oil to
the threaded portion of the crankshaft and lower part of the
flange.
6. With off the chamfered side on the inside of the washer
facing the bolt top, install the washer to the crankshaft pulley
bolt.
Crankshaft Crankshaft 7. Tighten the crankshaft pulley bolt to the specified torque.
pulley bolt
Specified torque: 210 N m (155 ft-lb)
Crankshaft pulley
Engine front
AK602911AD
TSB Revision
ENGINE OVERHAUL
11B-13
>>C<< GENERATOR / POWER STEERING PUMP
BRACKET INSTALLATION
Power steering 1. Temporarily tighten power steering pump bracket bolts.
pump bracket 2. Temporarily tighten generator bolts.
1 3. Tighten them to the specified torque according to the order
as illustrated.
Specified torque
Power steering pump bracket:
M8 23 2 N m (17 1 ft-lb)
M10 44 8 N m (33 5 ft-lb)
Generator: 44 10 N m (32 7 ft-lb)
Generator
5 75 mm
2 (2.95 in)
80 mm
3 (3.15 in)
4
AK503383AD
TSB Revision
THROTTLE BODY AND EGR SYSTEM

M1113032700063
2
3
11 1 Nm
4 98 8 in-lb
1
24 3 Nm
18 1 ft-lb
9.5 2.5 Nm
84 22 in-lb
6 20 2 Nm
15 1 ft-lb
7 12
11 20 2 Nm
8 15 1 ft-lb
13
16 20 2 Nm 24 3 Nm
14 15 1 ft-lb 18 1 ft-lb
18
9
10
17
20 2 Nm 15
15 1 ft-lb
20 20 2 Nm
19 15 1 ft-lb
5
4.0 1.0 Nm
36 8 in-lb
22 21 4.0 1.0 Nm
36 8 in-lb AK603509AB

1. Vacuum pipe assembly >>B<< 11. Exhaust gas recirculation pipe <for
2. Purge hose California>
3. Chamber >>B<< 12.Gasket <for California>
4. Purge hose >>B<< 13.Gasket <for California>
5. Water hose >>B<< 14.Exhaust gas recirculation support stay
6. Throttle body stay A <for California>
>>D<< 7. Throttle body >>B<< 15.Exhaust gas recirculation support stay
>>D<< 8. Throttle body gasket B <for California>
>>C<< 9. Exhaust gas recirculation valve <for >>B<< 16.Exhaust gas recirculation valve
California> support <for California>
>>C<< 10.Exhaust gas recirculation valve gasket >>B<< 17.Gasket <for California>
<for California> >>B<< 18.Exhaust gas recirculation inlet pipe
<for California>
TSB Revision
ENGINE OVERHAUL
11B-15
19.Solenoid valve
20.O-ring
>>A<< 21.Manifold absolute pressure (MAP)
sensor
22.O-ring

.
>>A<< MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR INSTALLATION
CAUTION
Install the manifold absolute pressure (MAP) sensor,
taking care not to give a shock to it.
Do not use a manifold absolute pressure (MAP) sensor
that has been dropped.
.
>>B<< EXHAUST GAS RECIRCULATION INLET

PIPE / EXHAUST GAS RECIRCULATION VALVE
SUPPORT / EXHAUST GAS RECIRCULATION
SUPPORT STAY A / EXHAUST GAS
RECIRCULATION SUPPORT STAY B / EXHAUST
GAS RECIRCULATION PIPE / GASKET
INSTALLATION
1. Temporarily tighten each part so that the protrusion of each
Exhaust gas
recirculation gasket is positioned as illustrated.
Protrusion
inlet pipe
Exhaust gas
recirculation valve AK503321AD
Exhaust gas Protrusion

recirculation pipe
Protrusion AK503320AD
TSB Revision
2. Tighten mounting bolts to the specified torque of 20 2 N m

(15 1 ft-lb) in the order shown in the illustration.
8
6 3
4 5
7
1
10 2
9 AK503289AD
>>C<< EXHAUST GAS RECIRCULATION VALVE

GASKET INSTALLATION
Exhaust gas Install the exhaust gas recirculation valve gasket with the diag-
recirculation valve onally shaded area used as the illustrated position so as not to
confuse the front with the back.
Shaded position
AK503319AE
>>D<< THROTTLE BODY GASKET / THROTTLE

BODY INSTALLATION
1. Make sure that the throttle body gasket is placed before
installing the throttle body.
B B 2. Temporarily tighten throttle body and throttle body stay
mounting bolts at A and B in the illustration.
B 3. Tighten the throttle body mounting bolt at illustrated position
B A to the specified torque of 20 2 N m (15 1 ft-lb).
A 4. Tighten the throttle body mounting bolts at illustrated
position B to the specified torque of 9.5 2.5 N m (84 22
in-lb).
AK503290AD
TSB Revision
ENGINE OVERHAUL
INTAKE MANIFOLD AND FUEL SYSTEM
11B-17
M1113032500144
6
20 2 Nm
11 15 1 ft-lb
8 3
9
10 20 2 Nm
7 15 1 ft-lb
5
4 20 2 Nm
15 1 ft-lb
17
20 2 Nm
15 1 ft-lb
20 2 Nm
21 15 1 ft-lb
16
15
20 2 Nm
22 15 1 ft-lb 14
10 2 Nm 20 2 Nm
89 17 in-lb 15 1 ft-lb
13 20 2 Nm
1 15 1 ft-lb
20 12 20 2 Nm
2 15 1 ft-lb
44 8 Nm
33 5 ft-lb
18
10 2 Nm
89 17 in-lb
19 AK603507 AB

1. Oil dipstick rod 13.Intake manifold stay B <except for
2. O-ring California>
>>G<< 3. Injector protector rear 14.Intake manifold stay C <except for
>>G<< 4. Bracket California>
>>G<< 5. Bracket 15.Injector protector front
>>G<< 6. Fuel rail assembly >>C<< 16.Intake manifold
>>F<< 7. Injection support 17.Intake manifold gasket
8. O-ring 18.Oil dipstick guide
>>F<< 9. Injector 19.O-ring
>>E<< 10.O-ring >>B<< 20.Generator bracket
11. Fuel rail 21.Knock sensor
>>D<< 12.Intake manifold stay >>A<< 22.Engine oil pressure switch

MB992106: O-ring Installer
TSB Revision

.
>>A<< ENGINE OIL PRESSURE SWITCH INSTAL-

LATION
CAUTION
Do not allow sealant to squeeze out to the screw tip.
Do not exceed the specified torque.
1. Completely remove sealant adhering to the engine oil
pressure switch and cylinder block threaded holes.
2. Apply sealant (LOCTITE 565 or equivalent) of 5 mm to the
threaded portion of the engine oil pressure switch shown in
the illustration.
3. Tighten the engine oil pressure switch to the cylinder block
to the specified torque.
AK502866AD
Specified torque: 10 2 N m (89 17 in-lb)
.
>>B<< GENERATOR BRACKET INSTALLATION

B A
Tighten the Generator bracket to the specified torque.
Specified torque: 44 8 N m (33 5 ft-lb)
NOTE: Be careful when install mounting bolts as they are dif-
A B
ferent in length. See illustration for bolt locations.
A:
M10 40 mm (1.6 in)
B:
M10 35 mm (1.4 in)
B
A A AK503595AC
>>C<< INTAKE MANIFOLD INSTALLATION

CAUTION
Temporarily tighten the intake manifold because there is a
bolt tightening procedure for the intake manifold, fuel rail
and injector protector.
Install the intake manifold and temporarily tighten bolts.
.
>>D<< INTAKE MANIFOLD STAY INSTALLATION

Make sure that the intake manifold stay is in intimate contact
with the intake manifold and cylinder block boss before tighten-
ing it to the specified torque.
AK502727AD
TSB Revision
ENGINE OVERHAUL
11B-19
>>E<< O-RING INSTALLATION
CAUTION
Do not allow engine oil to enter the fuel rail.
When inserting an O-ring into the injector on the injection noz-
zle side, use special tool MB992106 to gradually expand the
O-ring, and fit it in place.
MB992106
AK502784AD
>>F<< INJECTOR AND INJECTOR SUPPORT

INSTALLATION
1. Apply spindle oil or gasoline to the O-ring of the injector.
2. Insert the injector into the fuel rail while rotating the injector
from side to side, taking care not to damage the O-ring.
3. Check that the injector rotates smoothly. If it does not rotate
smoothly, the O-ring may be caught. Remove the injector
and check the O-ring for damage. Then, insert it again into
the fuel rail and check.
4. Make sure that the protrusion of the injector is at the center
as shown in the illustration.
AK502744
5. Securely assemble the injector to the injector groove and

fuel rail collar.
AK502745
TSB Revision
>>G<< FUEL RAIL ASSEMBLY / BRACKET /

INJECTOR PROTECTOR REAR INSTALLATION
1. Install the fuel rail assembly, bracket and injector protector
on the cylinder head.
2. Tighten mounting bolts to the specified torque together with
temporarily tightened intake manifold mounting bolts in the
6 7
order shown in the illustration.
8 4 5 Specified torque: 20 2 N m (15 1 ft-lb)
2 3
9 1 10
AK603524 AB
TSB Revision
ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-21
EXHAUST MANIFOLD
M1113004901320
<For except CALIFORNIA>

14 1 Nm 7
124 8 in-lb
41 10 Nm
30 7 ft-lb
49 5 Nm 3
36 3 ft-lb
11 1 Nm
98 8 in-lb
49 6 Nm 11 1 Nm
36 4 ft-lb 98 8 in-lb
20 5 Nm 4 5
15 3 ft-lb 9
6
8
41 10 Nm
30 7 ft-lb 14 1 Nm
10
124 8 in-lb
2
AK603508 AB

1. Exhaust manifold bracket D 6. O-ring
>>B<< 2. Exhaust manifold bracket A 7. Exhaust manifold upper cover
>>B<< 3. Exhaust manifold bracket B 8. Exhaust manifold lower cover
4. Crankshaft position sensor cover 9. Exhaust manifold
>>A<< 5. Crankshaft position sensor 10. Exhaust manifold gasket
TSB Revision
EXHAUST MANIFOLD
<For CALIFORNIA>
14 1 Nm
124 8 in-lb 5
49 5 Nm
36 3 ft-lb 7 11 1 Nm
98 8 in-lb
49 6 Nm 11 1 Nm
36 4 ft-lb 98 8 in-lb
2 3
1
4
41 10 Nm
30 7 ft-lb
6 8
14 1 Nm
124 8 in-lb
AK603581 AB

1. Exhaust manifold bracket 5. Exhaust manifold upper cover
2. Crankshaft position sensor cover 6. Exhaust manifold lower cover
>>A<< 3. Crankshaft position sensor 7. Exhaust manifold
4. O-ring 8. Exhaust manifold gasket
TSB Revision
ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-23
.
>>A<< CRANKSHAFT POSITION SENSOR

INSTALLATION
CAUTION
Do not apply a force such as torsion or twist to the
O-ring during assembly of the sensor.
Assemble the sensor, taking care not to give a shock to
it.
Do not use a sensor that has been dropped.
Tighten the crankshaft position sensor to the specified torque.
.
>>B<< EXHAUST MANIFOLD BRACKET A /

EXHAUST MANIFOLD BRACKET B
INSTALLATION
CAUTION
The exhaust manifold gasket, washers and nuts must not
be reused.
Make sure that exhaust manifold bracket B is in direct contact
with the exhaust manifold and exhaust manifold bracket A, and
then tighten it to the specified torque.
Exhaust manifold
bracket A AK502376 AD
TSB Revision
WATER HOSE AND PIPE
WATER HOSE AND PIPE

M1113032900078
24 3 Nm
10 18 1 ft-lb
30 9 Nm
11 12 22 6 ft-lb 4
24 3 Nm
5 18 1 ft-lb
3
28 8 Nm 24 3 Nm 1
21 5 ft-lb 15 18 1 ft-lb
16 6
17 7
24 3 Nm
18 1 ft-lb
11 1 Nm 2
98 8 in-lb 8
9
18
19
11 1 Nm
98 8 in-lb
13
14
AK502857AD

1. Water hose 11. Water pipe gasket
2. Water hose <for California> 12. O-ring
>>C<< 3. Engine coolant temperature sensor 13. Water pump assembly
4. Water outlet fitting 14. Water pump gasket
5. Outlet fitting gasket 15. Engine hanger
6. Water inlet fitting 16. Intake camshaft position sensor
>>B<< 7. Thermostat 17. O-ring
>>A<< 8. Thermostat housing 18. Exhaust camshaft position sensor
9. Thermostat housing gasket 19. O-ring
>>A<< 10. Water pipe assembly
TSB Revision
ENGINE OVERHAUL
WATER HOSE AND PIPE
11B-25
.
>>A<< THERMOSTAT HOUSING / WATER PIPE

Assemble the thermostat housing and water pipe, and tempo-
rarily tighten them to the cylinder head and water pump. Then
tighten them to the specified torque.
.
>>B<< THERMOSTAT INSTALLATION

Install the thermostat with the jiggle-valve facing almost straight
upwards.
Jiggle valve
AK304916 AC
>>C<< ENGINE COOLANT TEMPERATURE

SENSOR INSTALLATION
CAUTION
Be careful not to give a shock, twist and the like to the
resin mold with a tool during installation.
1. Apply an appropriate and minimum amount of sealant
(LOCTITE 262 or equivalent) to the engine coolant
temperature sensor, taking care not to allow sealant to
squeeze out.
2. Tighten the engine coolant temperature sensor to the
cylinder block to the specified torque.
AK502544 AD
TSB Revision
OIL PAN AND TIMING CHAIN CASE

M1113026300312
3.0 1.0 Nm 5.5 0.5 Nm

6
27 8 in-lb 49 4 in-lb
1
11
10
4
2.5 0.4 Nm
3 22 3 in-lb
16
10 2 Nm 2
89 17 in-lb
13 1 Nm
115 8 in-lb
45 5 Nm 10 2 Nm
33 3 ft-lb 89 17 in-lb 14 2 Nm
9 124 17 in-lb
8
14 15 13
24 4 Nm
18 2 ft-lb 10 2 Nm
7 89 17 in-lb
39 5 Nm 29 2 Nm
29 3 ft-lb 21 1 ft-lb
12 23 6 Nm
17 4 ft-lb
AK603510AB
1. Breather hose <<A>> >>E<< 9. Oil filter
2. PCV hose >>D<< 10. Cylinder head cover
3. PCV valve 11. Cylinder head cover gasket
4. O-ring 12. Air compressor bracket
5. Oil filler cap <> >>C<< 13. Oil pan
6. O-ring 14. Engine support bracket
7. Oil drain plug >>B<< 15. Front oil seal
8. Oil drain plug gasket <<C>> >>A<< 16. Timing chain case

MB991396: Oil Filter Wrench MB991448: crankshaft front oil seal installer
MD998727: Oil Pan FIPG Cutter
TSB Revision
ENGINE OVERHAUL
11B-27
.
<<A>> OIL FILTER REMOVAL

Use special tool MB991396 to remove the oil filter.
MB991396
AK502733AD
<> OIL PAN REMOVAL

1. Remove oil pan tightening bolts.
CAUTION
Lightly tap the oil pan FIPG cutter to drive in, taking care
not to damage the ladder frame and oil pan sealed area.
2. Lightly tap special tool oil pan FIPG cutter (MD998727) to
Groove drive in the illustrated groove of the oil pan and ladder
frame.
Groove AK502874AD
3. Lightly tap and slide special tool MD998727 to remove the

oil pan.
MD998727
AK502732AD
TSB Revision
<<C>> TIMING CHAIN CASE REMOVAL

If the timing chain case is difficult to remove, insert a hammer
handle as shown in the illustration and lightly pry it.
Hammer
AK502907AD

.
>>A<< TIMING CHAIN CASE INSTALLATION

CAUTION
Be sure to remove liquid gasket that has entered mounting
holes and O-ring grooves.
1. Completely remove liquid gasket adhering to the timing
chain case, cylinder block and cylinder head.
CAUTION
Sufficiently check that there is no residual oil on the place
where degreasing is performed. If fingerprints are left, do
not touch it with bare hands after the degreasing, since the
oils from your fingers will harm the seal ability.
2. Using white gasoline and so on, degrease the surface where
the liquid gasket is applied and the contact surface between
the cylinder block and the cylinder head.
TSB Revision
ENGINE OVERHAUL
11B-29
CAUTION
Install the timing chain case within three minutes after
applying liquid gasket.
4.5 0.5 mm 3. Apply liquid gasket (Three bond 1217G, LOCTITE 5900,
(0.18 0.02 in) 5970, 5971 or equivalent) of 2.5 0.5 mm (0.10 0.02 inch)
in thickness to the timing chain case. For illustrated A
A locations, however, apply liquid gasket of 4.5 0.5 mm (0.18
A A
0.02 inch) in diameter or liquid gasket of 2.5 0.5 mm
A 4.5 0.5 mm (0.10 0.02 inch) by putting one on top of another as shown
(0.18 0.02 in)
in the illustration.
B BA 3 0.5 mm
A
(0.118 0.02 in) 4. Install the timing chain case.
2.5 mm NOTE: Be careful when install mounting bolts as they are
(0.098 in)
different in length.
2.5 0.5 mm
(0.10 0.02 in)
3 0.5 mm 1 0.5 mm
(0.118 0.02 in) (0.04 0.02 in) 2.5 0.5 mm
(0.10 0.02 in)
2.5 0.5 mm
(0.10 0.02 in)
B-B view A-A view

AK603505 AB
5. Tighten timing chain case mounting bolts to the specified

A A torque.
Specified torque
A: 24 4 N m (18 2 ft-lb)
A B: 10 2 N m (89 17 in-lb)
A
C: 10 2 N m (89 17 in-lb)
D: 13 1 N m (115 8 in-lb)
B
B
B
C B
D
B B
A
A
A: M8 28 mm (1.1 in)
B: M6 25 mm (1.0 in)
C: M6 25 mm (1.0 in)
D: M8 10 mm (0.4 in) AK502378 AD
TSB Revision
>>B<< FRONT OIL SEAL INSTALLATION

1. Apply engine oil to the internal circumference of the oil seal.
2. Use special tool MB991448 to install the front oil seal on the
timing chain case.
MB991448
AK502802AD
>>C<< OIL PAN INSTALLATION

1. Completely remove liquid gasket adhering to the cylinder
block and oil pan.
2. Using white gasoline and so on, degrease the cylinder block
and oil pan.
CAUTION
1 mm
Install the oil pan within three minutes after liquid gasket is
(0.04 in) applied.
3. Apply liquid gasket (Three bond 1217G, LOCTITE 5900,
5970, 5971 or equivalent) of 2.5 0.5 mm (0.10 0.02 inch)
of thickness in diameter to the illustrated area of the oil pan.
4. Tighten the oil pan to the specified torque.
Specified torque
2.5 0.5 mm M6: 10 1 N m (89 17 in-lb)
(0.10 0.02 in)
M8: 29 2 N m (21 1 ft-lb)
AK502377AD
>>D<< CYLINDER HEAD COVER INSTALLATION

head cover, timing chain case and cylinder head.
2. Using white gasoline and so on, degrease the cylinder head
cover, timing chain case and cylinder head.
CAUTION
Install the cylinder head cover immediately after liquid gas-
ket is applied.
3. Appropriately use a minimum amount of sealant. Be careful
not to allow sealant to squeeze out from the application
area.
Apply liquid gasket (Three bond 1217G or equivalent) of 4
mm of thickness in diameter.
AK502734AH
TSB Revision
ENGINE OVERHAUL
11B-31
13
4. Tighten the cylinder head cover to the tightening torque of
1 6 7 8 14 3.0 1.0 N m (27 8 in-lb) in the order shown in the
illustration.
5. Then, tighten it to the specified torque in the same order.
18 5 2 9 Specified torque: 5.5 0.5 N m (49 4 in-lb)
12 15
4 3 10 16
17 11
AK502760AF
>>E<< OIL FILTER INSTALLATION

1. Clean the oil filter mounting surface of the ladder frame.
2. Apply engine oil to the O-ring of the oil filter.
AK305422 AD
CAUTION
Use special tool MB991396 to install the oil filter. Tighten-
ing it by hand causes oil leakage due to lack of torque.
3. Screw in the oil filter. When the O-ring contacts the mounting
MB991396 surface, use a filter wrench to tighten it
Specified torque: 3/4 turn (14 2 N m [124 17 in-lb]).
AK502733AD
TSB Revision
TIMING CHAIN
TIMING CHAIN
M1113026600261
Apply engine oil to

all moving parts
before installation.
59 5 Nm 8
44 3 ft-lb
10
7
10 2 Nm
89 17 in-lb
1
10 2 Nm
89 17 in-lb
10 2 Nm
89 17 in-lb 9
59 5 Nm 6
44 3 ft-lb
3 5
10 2 Nm 10 2 Nm
89 17 in-lb 89 17 in-lb
AK502933 AD

1. Chain upper guide 6. Oil jet
<<A>> >>D<< 2. Timing chain tensioner <> >>B<< 7. Exhaust V.V.T. sprocket bolt
3. Tensioner lever 8. Exhaust V.V.T. sprocket assembly
4. Timing chain guide <<C>> >>A<< 9. Intake V.V.T. sprocket bolt
>>C<< 5. Timing chain 10. Intake V.V.T. sprocket assembly
TSB Revision
ENGINE OVERHAUL
TIMING CHAIN
11B-33
.
<<A>> TIMING CHAIN TENSIONER REMOVAL

1. Insert a flatblade screwdriver into the release hole of the
Ratchet release hole
timing chain tensioner to release the latch.
Wire 2. Push the tensioner lever by hand and push in the plunger of
the timing chain tensioner until it hits the bottom. Then,
insert a hard wire (piano wire or the like) of 1.5 or
hexagonal bar wrench (1.5 mm [0.05 inch]) into the fixing
hole of the plunger.
3. Remove the timing chain tensioner.
Plunger fixed
hole
AK502854 AG
<> EXHAUST V.V.T. SPROCKET BOLT

REMOVAL
Hold the hexagonal portion of the exhaust camshaft with a
wrench and loosen the exhaust V.V.T. sprocket bolt.
AK502737
<<C>> INTAKE V.V.T. SPROCKET BOLT REMOVAL

Hold the hexagonal portion of the intake camshaft with a
wrench and loosen the intake V.V.T. sprocket bolt.
AK502736
TSB Revision
TIMING CHAIN

.
>>A<< INTAKE V.V.T. SPROCKET BOLT INSTAL-

LATION
1. Assemble the intake V.V.T. sprocket assembly in the
V.V.T. sprocket
following procedure.
Make sure that the knock pin of the inlet camshaft assembly
is positioned facing straight upward.
Apply an appropriate and minimum amount of engine oil to
the circumference of the tip of the intake V.V.T. sprocket
assembly and the entire circumference of the area into
which the intake V.V.T. sprocket assembly is inserted.
Camshaft Slowly insert the intake V.V.T. sprocket assembly into the
V.V.T. sprocket bolt
normal position of the inlet camshaft assembly with its
AK503070AD
knock pin hole facing straight upward.
2. Install the V.V.T. sprocket.
3. Make sure that the V.V.T. sprocket is securely inserted into
the bottom and that the V.V.T. sprocket does not rotate with
the hexagonal portion of the camshaft secured with a
wrench.
4. Hold the hexagonal portion of the camshaft with a wrench
and tighten the intake V.V.T. sprocket bolt to the specified
torque.
AK502739
>>B<< EXHAUST V.V.T. SPROCKET BOLT

INSTALLATION
1. Assemble the exhaust V.V.T. sprocket assembly in the
following procedure.
Make sure that the knock pin of the exhaust camshaft
assembly is positioned facing straight upward.
Apply an appropriate and minimum amount of engine oil to
the circumference of the tip of the exhaust V.V.T. sprocket
assembly and the entire circumference of the area into
which the exhaust V.V.T. sprocket assembly is inserted.
Slowly insert the exhaust V.V.T. sprocket assembly into the
normal position of the exhaust camshaft assembly with its
knock pin hole facing straight upward.
2. Install the V.V.T. sprocket.
3. Make sure that the V.V.T. sprocket is securely inserted into
the bottom and that the V.V.T. sprocket does not rotate with
the hexagonal portion of the camshaft secured with a
wrench.
TSB Revision
ENGINE OVERHAUL
TIMING CHAIN
11B-35
4. Hold the hexagonal portion of the camshaft with a wrench
and tighten the camshaft sprocket bolt to the specified
torque.
AK502738
>>C<< TIMING CHAIN INSTALLATION

1. Align the timing mark of the V.V.T. sprocket.
Timing mark 2. Align the crankshaft sprocket keys with illustrated positions.
Crankshaft key
AK502924 AD
Link plate (orange)

3. Align the link plate (orange) with the timing mark of the
Timing mark exhaust V.V.T. sprocket and loop the timing chain.
AK502910AD
TSB Revision
TIMING CHAIN
4. Align the link plate (orange) with the timing mark of the
Timing mark Link plate
(orange)
intake V.V.T. sprocket to loop the timing chain.
Rotate the intake V.V.T. sprocket by one or two teeth to
align with the timing mark.
AK502757AD
5. Align the timing mark of the crankshaft sprocket with the link
plate (orange) to loop the timing chain. Because of timing
chain slacks, hold it to prevent the timing mark from coming
off the link plate (orange).
Link plate
(orange)
Timing mark
AK603512AB
6. Make sure that the timing mark of each sprocket is aligned

Timing mark
link plate (orange) with the link plate (orange) of the timing chain at all of three
locations.
7. Install the timing chain guide and tensioner lever.
V.V.T. exhaust V.V.T. intake

sprocket sprocket
timing mark timing mark
Crankshaft sprocket Timing mark

timing mark link plate (orange)
AK502909AD
TSB Revision
ENGINE OVERHAUL
TIMING CHAIN
11B-37
>>D<< TIMING CHAIN TENSIONER
INSTALLATION
1. Install the timing chain tensioner on the cylinder block and
Ratchet release hole
tighten it to the specified torque.
Wire Specified torque: 11 1 N m (98 8 in-lb)
2. Remove the hard wire (piano wire or the like) of 1.5 or
hexagonal bar wrench (1.5 mm [0.05 inch]) from the timing
chain tensioner. This enables the plunger of the timing chain
tensioner to push the tensioner lever to keep the timing
Plunger fixed
chain tight.
hole
AK502854 AG
INSPECTION
M1113026700213
.
VALVE CLEARANCE ADJUSTMENT

Measure valve clearance as described in the following proce-
dure.
Check and adjust the valve clearance with the timing chain
installed.
CAUTION
Always rotate the crankshaft clockwise.
1. Rotate the crankshaft clockwise to align the timing mark of
Timing mark
the V.V.T. sprocket with the top surface of the cylinder head
as illustrated. (Set the No. 1 piston at top dead center on the
compression stroke.)
AK502968AE
Exhaust valve side 2. Valve clearance can be measured at the illustrated location
No.1 No.3 in this condition.
7
5
1
3
9
1 1
6
4
8
8
6
2
4
1 2
1 0
5
1
No.1 No.2
Intake valve side AK502387AG
TSB Revision
TIMING CHAIN
3. Use a thickness gauge to measure clearance between the

camshaft and valve tappet.
Standard value (when engine is cold):
Intake side: 0.20 mm (0.008 inch)
Exhaust side: 0.30 mm (0.012 inch)
4. If measured values are out of the standard value, record
measured values.
AK502758
5. Rotate the crankshaft by one turn clockwise to set the No. 4

Timing mark piston at top dead center on the compression stroke.
NOTE: The timing mark of the V.V.T. exhaust sprocket must
be at the illustrated position.
AK502545AG
Exhaust valve side 6. Valve clearance can be measured at the illustrated location
No.2 No.4 in this condition.
7. If measured values are out of the standard value, record
7
5
1
3
measured values.
9
1 1
8. If the measured value is out of the standard value, replace

2
6
4
8
the valve tappet.

8
6
2
4
NOTE: There are 47 kinds of valve tappets at intervals of

1 2
0.015 mm (0.0006 inch) in the range between 3.000 (0.1181

1 0
5
1
No.3 No.4 inch) and 3.690 mm (0.1453 inch).

Intake valve side AK502388AF
Wall thickness 9. Use the following procedure select a valve tappet.

(1) Measure thickness of a removed valve tappet.
(2) Calculate thickness of a valve tappet so that valve
clearance meets the standard value.
A: Thickness of valve tappet to be selected
B: Thickness of removed valve tappet
C: Measured valve clearance
Formula
Intake side: A = B + (C 0.20 mm [0.008 inch])
AK304938 AE
Exhaust side: A = B + (C 0.30 mm [0.012 inch])
Refer to "Removal and installation of camshaft" for removal,
installation and inspection procedure of valve tappets.
TSB Revision
ENGINE OVERHAUL
CAMSHAFT
11B-39
CAMSHAFT
M1113026900176
7
17 3 Nm 30 2 Nm 8
14 2 ft-lb 22 1 ft-lb 7 12 1 Nm
107 8 in-lb
7
8
6
7
5 6 11
9 10
Apply engine oil to

all moving parts 13
12
10 2 Nm
89 17 in-lb
1
2
4
3
10 2 Nm
89 17 in-lb
AK502934 AD

>>C<< 1. Engine oil control valve (OCV) <<A>> >>B<< 7. Camshaft bearing cap
exhaust <<A>> >>B<< 8. Thrust camshaft bearing cap
>>C<< 2. O-ring >>B<< 9. Bearing
>>C<< 3. Engine oil control valve (OCV) >>B<< 10. Camshaft intake
intake >>B<< 11. Camshaft exhaust
>>C<< 4. O-ring 12. Bearing
<<A>> >>B<< 5. Front camshaft bearing cap <> >>A<< 13. Valve tappet
<<A>> >>B<< 6. Oil feeding camshaft bearing cap
TSB Revision
CAMSHAFT

.
<<A>> FRONT CAMSHAFT BEARING CAP / OIL

FEEDING CAMSHAFT BEARING CAP / CAM-
SHAFT BEARING CAP / THRUST CAMSHAFT
BEARING CAP REMOVAL
CAUTION
Loosing the camshaft bearing cap installation bolts in four
2 to five steps. Do not loosen bolts in one step as this
6 10 12 8 causes the valve spring force to push on the bolts and
4 make them jump out causing damage to the threads.
5 9 11 7 First remove a mounting bolt of the front camshaft bearing cap
and then a mounting bolt of each camshaft bearing cap in the
3 order shown in the illustration.
5 9 11 7
1 12 8
6 10
AK502389AD
<> VALVE TAPPET REMOVAL

Pick out valve tappets with fingers and store removed valve
tappets with tags describing the installed position attached for
reassembly.

.
>>A<< VALVE TAPPET INSTALLATION

Install valve tappets at the same position based on tags
describing the installed position for reassembly.
.
>>B<< CAMSHAFT / BEARING / THRUST

CAMSHAFT BEARING CAP / CAMSHAFT
BEARING CAP / OIL FEEDING CAMSHAFT
BEARING CAP / FRONT CAMSHAFT BEARING
CAP INSTALLATION
1. When replacing a camshaft bearing, select a bearing with
the size corresponding to the identification mark in the table
below.
2. Install camshaft bearings on the cylinder head.
Front camshaft bearing cap Camshaft bearing
Identification identification color
mark Identification Inner diameter
mark mm (in)
1 40.000 - 40.008 Black
AK502969AD (1.5748 - 1.5751)
2 40.008 - 40.016 None
(1.5751 - 1.5754)
3 40.016 - 40.024 Green
(1.5754 - 1.5757)
TSB Revision
ENGINE OVERHAUL
CAMSHAFT
11B-41
3. The identification color of the camshaft bearing is painted at
the illustrated position.
Identification
color
AK502970 AD
4. Set the dowel pins of the camshaft at the illustrated

Dowel pin
positions.
AK502390 AD
5. Install them upon checking the identification mark so as not

to misidentify cap No. and to confuse the intake side with the
exhaust side.
Identification mark Identification mark
E 2
Cap No. I: Intake side

E: Exhaust side
7 3 1 5
8 4 2 6
8 4 2 6
7 3 1 5
AK503813 AD
TSB Revision
CAMSHAFT
Timing chain side 7. Tighten each front camshaft bearing cap mounting bolt to
(1) (2) the temporarily torque of 17 3 N m (14 2 ft-lb) in the
order shown (1).
4 1
8. Tighten each front camshaft bearing cap mounting bolt to
3 3 the specified torque in the order shown (2).
2 4
1 2
AK503814AD
>>C<< O-RING / ENGINE OIL CONTROL VALVE

INSTALLATION
CAUTION
The O-ring must not be reused.
Wind non-adhesive tape (seal tape, etc.) around the
notch of the oil passage of the engine oil control valve
before installing the O-ring to prevent damage. Damage
to the O-ring causes oil leakage.
1. Apply a small amount of engine oil to the O-ring of the
engine oil control valve.
2. Install the engine oil control valve on the cylinder head.
Tape
3. Tighten the engine oil control valve to the specified torque.
AK303651AF
INSPECTION
M1113027000154
.
CAMSHAFT
Measure camshaft height (camshaft major axis). If the height is
less than the limit, replace the camshaft.
Standard value:
Intake: 43.25 mm (1.703 inches)
Exhaust: 45.00 mm (1.772 inches)
Limit:
Intake: 42.75 mm (1.683 inches)
Exhaust: 44.50 mm (1.752 inches)
AK503020AD
TSB Revision
ENGINE OVERHAUL
CAMSHAFT
11B-43
CAMSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD)
1. Thoroughly wipe oil on the outside diameter of the camshaft
and the inside diameter of the bearing.
2. Install the bearing to the camshaft.
3. Put straightly the plastigage having the length of the bearing
width on the journal axis, centering the axis.
Plastigage 4. Carefully install the bearing cap.Tighten the bolt as
instructed in >>B<< Bolt Installation Point.
5. Remove the bolt and the bearing cap carefully.
AK503390 AD
6. Measure the plastigage whose width is most compressed

using the scale printed on the plastigage bag. When the
Plastigage measured value deviates from the standard one, replace the
bearing.
Standard value: 0.035 0.072 mm (0.0014 0.0028 inch)
CAUTION
When the bearing is used again, be careful not to reverse
the cylinder head side and the camshaft side during instal-
lation.
AK503391AD
VALVE TAPPET
Wall thickness 1. Measure the valve tappet at the illustrated position. If the
measured value is not in agreement with the value in the
table corresponding to the identification mark, replace the
valve tappet.
AK304938 AE
2. The valve tappet has an identification mark and stamping of

Top view Under view thickness at illustrated positions.
Thickness stamp There are 47 kinds of valve tappets at intervals of 0.015 mm
3.
0 0
0
(0.0006 inch) in the range between 3.000 mm (0.1181 inch)
and 3.690 mm (0.1453 inch).
0 1
Identification mark
AK502867AD
TSB Revision
CAMSHAFT
Thickness mm Identification Thickness mm Identification Thickness mm Identification

(in) mark (in) mark (in) mark
3.000 (0.1181) 01 3.240 (0.1276) 17 3.480 (0.1370) 33
3.015 (0.1187) 02 3.255 (0.1281) 18 3.495 (0.1376) 34
3.030 (0.1193) 03 3.270 (0.1287) 19 3.510 (0.1382) 35
3.045 (0.1199) 04 3.285 (0.1293) 20 3.525 (0.1388) 36
3.060 (0.1205) 05 3.300 (0.1299) 21 3.540 (0.1394) 37
3.075 (0.1211) 06 3.315 (0.1305) 22 3.555 (0.1400) 38
3.090 (0.1217) 07 3.330 (0.1311) 23 3.570 (0.1406) 39
3.105 (0.1222) 08 3.345 (0.1317) 24 3.585 (0.1411) 40
3.120 (0.1228) 09 3.360 (0.1323) 25 3.600 (0.1417) 41
3.135 (0.1234) 10 3.375 (0.1329) 26 3.615 (0.1423) 42
3.150 (0.1240) 11 3.390 (0.1335) 27 3.630 (0.1429) 43
3.165 (0.1246) 12 3.405 (0.1341) 28 3.645 (0.1435) 44
3.180 (0.1252) 13 3.420 (0.1346) 29 3.660 (0.1441) 45
3.195 (0.1258) 14 3.435 (0.1352) 30 3.675 (0.1447) 46
3.210 (0.1264) 15 3.450 (0.1358) 31 3.690 (0.1453) 47
3.225 (0.1270) 16 3.465 (0.1364) 32
TSB Revision
ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-45
M1113006901597
35 2 Nm
26 1 ft-lb +180
3
35 2 Nm
26 1 ft-lb +180
1 4
2
8 7
11 12
21
13 15 9
16
18 17
19
10
20
14
Apply engine oil to

all moving parts
before installation. 6
AK604561 AB

>>D<< 1. Cylinder head bolt 9. Valve spring
>>D<< 2. Cylinder head bolt washer 10. Intake valve
>>D<< 3. Cylinder head bolt & washer <<A>> >>B<< 11. Retainer lock
assembly 12. Valve spring retainer
>>C<< 4. Cylinder head assembly 13. Valve spring
>>C<< 5. Cylinder head gasket 14. Exhaust valve
6. Oil feeder control valve (OCV) filter <> >>A<< 15. Valve stem seal
<<A>> >>B<< 7. Retainer lock <> >>A<< 16. Valve stem seal
8. Valve spring retainer 17. Intake valve guide
TSB Revision

18. Exhaust valve guide
19. Intake valve seat
20. Exhaust valve seat
21. Cylinder head
MD998735: Valve Spring Compressor MB992085: Valve Stem Seal Pliers
MB992089: Retainer Holder MD998737: Valve Stem Seal Installer

.
<<A>> RETAINER LOCK REMOVAL

CAUTION
Be careful not to allow retainer holder C to interfere with
MB992089 the wall of the tappet hole and to damage it.
Use a special tool MD998735 and MB992089 to compress the
valve spring and to remove the retainer lock.
NOTE: Store removed parts such as valves and springs with
tags describing cylinder No. and installed position attached for
reassembly.
MD998735
AK502741AD
<> VALVE STEM SEAL REMOVAL

Use special tool MB992085 to firmly pinch the base (larger
external shape) of the stem seal and twist it right and left for
MB992085
pulling out.
Valve stem seal AK502782AD
TSB Revision
ENGINE OVERHAUL
11B-47
.
>>A<< VALVE STEM SEAL INSTALLATION

CAUTION
The valve stem seal must not be reused.
Do not damage the tappet wall during assembly.
Be sure to use a special tool to install the valve stem
seal. Poor installation causes oil loss via valve guides.
If oil is not applied, the valve stem seal may rise to the
surface after it is press fitted.
1. Apply a thin coat of engine oil to a new valve stem seal.
AK503378AE
2. Use special tool MD998737 to press fit the valve stem seal
into the valve guide with the valve stem used as a guide.
MD998737
AK502742AD
>>B<< RETAINER LOCK INSTALLATION

Use a special tool MD998735 and MB992089 to compress the
MB992089 valve spring and to install the retainer lock.
MD998735
AK502741AD
TSB Revision
>>C<< CYLINDER HEAD GASKET / CYLINDER

HEAD ASSEMBLY INSTALLATION
1. Completely remove the liquid gasket on the upper plane of
Degreasing the cylinder block and the lower plane of the cylinder head.
CAUTION
2. Using white gasoline and so on, degrease the place
specified in the illustration.
Bottom face of cylinder head
Degreasing
Top face of cylinder block

AK602902AD
3. As shown in the illustration, apply a 2 to 3 mm (0.079 to

0.118 inch) of sealant (Three bond 1217G, LOCTITE 5900,
5970, 5971 or equivalent) to the top face of cylinder block.
4. Install the cylinder head gasket.
NOTE: Check that the center of the liquid gasket is located
toward the cylinder gasket in the position specified in the
illustration.
5. As shown in the illustration, apply a 2 to 3 mm (0.079 to
0.118 inch) of sealant (Three bond 1217G, LOCTITE 5900,
5970, 5971 or equivalent) to the top face of cylinder head
2 to 3 mm gasket.
(0.079 to 0.118 in)
6. Install the cylinder head assembly.
Timing chain side
AK602942AD
TSB Revision
ENGINE OVERHAUL
11B-49
>>D<< CYLINDER HEAD BOLT INSTALLATION
1. Install new cylinder head bolts and washers in the following
procedure.
NOTE: Cylinder head bolts and washers must not be
reused.
2. Apply an appropriate amount of engine oil to top and bottom
surfaces of washers and threaded portion of bolts.
3. Install cylinder head bolts to the cylinder head.
NOTE: Bolts and washers are different parts for bolts on the
timing chain side.
4. Tighten cylinder head bolts in several steps to the specified
Timing chain side
torque according to the assembly order shown.
8 6 1 3 9
10 4 2 5 7
AK502392 AD
5. Put a paint mark on all of cylinder head bolt heads and

Paint mark Paint mark cylinder head.
90 90 CAUTION
If the tightening angle is 180 or less, tightening perfor-
mance may not be secured. Use caution to the tighten-
ing angle during tightening.
If the tightening angle becomes more than 180 , com-
Paint mark Paint mark pletely loosen bolts and start tightening over again
according to the procedure.
AK502523AD 6. Tighten the cylinder head 90 according to the tightening
order.
Tighten it further 90 and make sure that the paint mark on
the cylinder head bolt is in a straight line with that on the
cylinder head.
INSPECTION
M1113007001371
.
CYLINDER HEAD
1. Check the cylinder head for water leakage, gas leakage,
damage or cracks before cleaning.
2. Completely remove oil, scale, sealant, carbon, etc. After
cleaning oil passages, blow air to make sure that they are
not clogged.
TSB Revision
CAUTION
The grinding limit shall be within 0.2 mm (0.008 inch) in
combination with the cylinder block to be assembled.
3. For the flatness on the cylinder head bottom, measure
distortion using a straight edge and thickness gauge. If the
distortion exceeds the limit, grind and repair it.
Distortion on bottom
Standard value: Within 0.05 mm (0.002 inch)
Limit: 0.02 mm (0.0008 inch)
Grinding limit: 0.2 mm (0.008 inch)
AK502740 Cylinder head height: 128.5 mm (5.06 inches)
.
VALVE
1. Repair the valve seat if contact with the valve seat is poor,
uneven or broken.
2. Measure the margin.
If the limit is exceeded, replace the valve.
The bottom of valve
seat contact facet Standard value:
Intake 1.022 mm (0.0402 inch)
Exhaust 1.094 mm (0.0431 inch)
Margin
Limit:
AK305408AD
Exhaust 0.594 mm (0.0234 inch)
3. Measure overall length of the valve.
If the limit is exceeded, replace the valve.
Standard value:
Intake 113.18 mm (4.456 inches)
Exhaust 105.89 mm (4.169 inches)
Limit:
Length Intake 112.68 mm (4.436 inches)
Exhaust 105.39 mm (4.149 inches)
AK305409AD
VALVE SPRING
1. Measure free height of the spring.
Squareness
If the limit is exceeded, replace the spring.
Standard value: 47.44 mm (1.868 inch)
Limit: 46.44 mm (1.828 inch)
2. Measure squareness of the spring.
Free height If the inclination exceeds the limit, replace the spring.
Standard value: 2 or less
Limit: 4
AK305410AD
TSB Revision
ENGINE OVERHAUL
11B-51
VALVE GUIDE
Measure clearance between the valve guide and valve stem. If
the clearance exceeds the limit, replace the valve guide or
valve, or both.
Standard value:
Intake 0.020 0.047 mm (0.0008 0.0019 inch)
Valve
guide Exhaust 0.030 0.054 mm (0.0012 0.0021 inch)
Limit:
Stem diameter Exhaust 0.15 mm (0.006 inch)
Guide inside diameter AK300168 AF
VALVE SEAT
Assemble the valve, then measure the contact width. If the
measurement exceeds the specified limit, replace the valve
seat.
Valve seat
Standard value
Contact width Intake: 1.16 1.46 mm (0.046 0.058 inch)
Exhaust: 1.35 1.65 mm (0.053 0.065 inch)
CAUTION
If the variation in the width exceeds 0.2 mm (0.008 inch)
even if the contact width is within the standard value,
AK601281AD
replace or correct the valve seat.
REPAIR PROCEDURE OF VALVE SEAT

1. Check clearance between valve guide and valve and
replace the valve guide if necessary before repairing the
valve seat.
2. Repair the valve seat so that seat width and seat angle are
1.16 1.46 mm
1.35 1.65 mm (0.053 0.065 in) to the specified shape.
(0.046 0.058 in) 3. Lap valve and valve seat with lapping compound after
30 repairing valve seat.
30
45 45
60
AK503333AD
TSB Revision
REPLACEMENT PROCEDURE OF VALVE SEAT

0.5 1 mm
1. Scrape the valve seat to be replaced from inside to make its
(0.02 0.04 in) wall thickness thin before pulling out.
Cut
0.5 1 mm
(0.02 0.04 in)
AK300719AE
2. Repair the valve seat hole of the cylinder head to match it

with the diameter of the oversize valve seat to be press
fitted.
Intake valve seat bore diameter:
Valve seat 0.3 O.S.: 36.22 36.24 mm (1.426 1.427 inches)
height
Exhaust valve seat bore diameter:
0.3 O.S.: 30.22 30.24 mm (1.190 1.191 inches)
Oversize hole 3. Press fit the valve seat, taking care not to score the cylinder
diameter
AK300720AE head bore at room temperature.
4. Ream the valve seat.
Refer to "Repair procedure of valve seat."
REPLACEMENT PROCEDURE OF VALVE GUIDE

1. Pull out the valve guide with a press toward the cylinder
block side.
2. Ream the valve guide hole of the cylinder head to match it
with the diameter of the oversize valve guide to be press
fitted.
CAUTION
Do not use a valve guide with the same size as that of the
pulled out valve guide because it cannot be press fitted.
Valve guide bore diameter
0.25 O.S.: 11.23 11.25 mm (0.442 0.443 inch)
3. Press fit the valve guide to the illustrated dimension.
NOTE: Press fit the valve guide from the cylinder head top
surface.
4. After pressing fit the valve guide, insert a new valve to check
for sliding.
14.6 15.2 mm
(0.57 0.60 in)
AK603511AB
TSB Revision
ENGINE OVERHAUL
OIL PUMP CHAIN
11B-53
OIL PUMP CHAIN
M1113033700011
3 2
40 2 Nm
29 1 ft-lb +30
6 40 Nm 130 Nm
30 ft-lb 96 ft-lb
12
13
7
10 2 Nm 26 1 Nm
89 17 in-lb 10 2 Nm
89 17 in-lb 19 1 ft-lb
11
Apply engine oil to
all moving parts
23 2 Nm
10 26 2 Nm
19 1 ft-lb
17 1 ft-lb
AK603506 AB
<<A>> >>F<< 1. Drive plate bolt <CVT> >>C<< 8. Oil pump tensioner lever
2. Adapter plate <CVT> >>C<< 9. Oil pump chain
3. Drive plate <CVT> <> >>C<< 10. Oil pump sprocket
<<A>> >>E<< 4. Flywheel bolt <M/T> 11. Oil pump case
5. Flywheel <M/T> >>B<< 12. Crankshaft sprocket
>>D<< 6. Rear oil seal <<C>> >>A<< 13. Ladder frame
>>C<< 7. Oil pump chain guide

MB991367: Special Spanner MB991883: Flywheel Stopper
MB991385: Pin MD998718: Rear Oil Seal Installer
MB991614: Angle Gauge
TSB Revision
OIL PUMP CHAIN

.
<<A>> DRIVE PLATE BOLT / FLYWHEEL BOLT

REMOVAL
flywheel.
MB991883 2. Remove the drive plate bolts or flywheel bolts.
AK502869 AD
<> OIL PUMP SPROCKET REMOVAL

Fix the oil pump sprocket with a special tools MB991367 and
MB991367 MB991385 MB991385, loosen a center bolt, and remove the oil pump
sprocket.
Oil pump sprocket
AK604583AB
<<C>> LADDER FRAME REMOVAL

1. Pry the illustrated position with a screwdriver or tap the boss
Boss with a hammer.
AK502755AD
2. If the ladder frame does not come off, insert a flatblade

screwdriver into the gap between the ladder frame and
bearing cap as shown in the illustration and lightly pry it to
remove the ladder frame.
AK502756
TSB Revision
ENGINE OVERHAUL
OIL PUMP CHAIN
11B-55
.
>>A<< LADDER FRAME INSTALLATION

CAUTION
Be sure to remove liquid gasket that has entered mounting
holes.
block and ladder frame.
CAUTION
2. Using white gasoline and so on, degrease the surface where
the liquid gasket is applied and the contact surface between
the cylinder block and ladder frame.
3. Squeeze liquid gasket (Three bond 1217G, LOCTITE 5900,
8.5 mm 5970, 5971 or equivalent) of 2 to 3 mm (0.08 to 0.12 inch)
1 mm (0.04 in) (0.33 in) in thickness and apply it to the illustrated position of the
ladder frame.
3 mm (0.12 in)
1.75 mm (0.07 in)
8.5 mm
3 mm (0.33 in)
(0.12 in)
AK502868AD
4. Tighten the ladder frame to the specified torque in the order

6 8 shown in the illustration.
11
2 3
1 4
12
10 9 5 7
AK603522AB
TSB Revision
OIL PUMP CHAIN
>>B<< CRANKSHAFT SPROCKET INSTALLATION

: Wipe clean with a rag. 1. Wipe off the dirt on the crankshaft sprocket and the
: Wipe clean with a rag and degrease. crankshaft using a rag, and then remove the grease from the
Crankshaft
NOTE: Remove grease to prevent a drop in the coefficient
of friction of the pressing portion caused by adhesion of oil.
Engine
2. Set the No. 1 piston at top dead center on the compression
front stroke.
3. Install the crankshaft sprocket to the crankshaft.
Crankshaft sprocket AK603521AB
>>C<< OIL PUMP SPROCKET / OIL PUMP CHAIN /

OIL PUMP CHAIN GUIDE / OIL PUMP TENSIONER
LEVER INSTALLATION
1. Set the No. 1 piston at top dead center on the compression
stroke.
2. Using the special tools MB991367 and MB991385, install
MB991367 MB991385 the oil pump sprocket to the oil pump case.
3. Install the oil pump chain to the crankshaft sprocket.
4. Install the oil pump chain to the oil pump sprocket.
Oil pump sprocket
AK604583AB
>>D<< REAR OIL SEAL INSTALLATION

CAUTION
Do not apply oil to the circumference of the oil seal and oil
seal pressing hole on the cylinder block side to prevent
teeth from pulling out.
After applying a small amount of engine oil to the oil seal lip,
use special tool MD998718 to press fit the oil seal.
MD998718
AK502871AD
TSB Revision
ENGINE OVERHAUL
OIL PUMP CHAIN
11B-57
>>E<< FLYWHEEL BOLT INSTALLATION
1. Clean off sealant and oil of thread of crankshaft and flywheel
bolt.
2. Use special tool MB991883 to secure the flywheel.
MB991883
AK603577 AB
3. Apply engine oil to thread of crankshaft and bolt seat area of

flywheel.
4. Apply the sealant (LOCTITE 262 or equivalent) to the thread
of flywheel bolt.
AK600847AC
5. Tighten flywheel bolts to temporary torque 40 N m (30 ft-lb)

4 7 in the order shown to illustration.
6. Tighten flywheel bolts to specified torque in the order shown
1 2 in the illustration.
Specified torque: 130 N m (96 ft-lb)
6 5
3 AK603576 AB
TSB Revision
OIL PUMP CHAIN
>>F<< DRIVE PLATE BOLT INSTALLATION

1. Use special tool MB991883 to secure the drive plate.
2. Clean off sealant and oil of thread of crankshaft and drive
MB991883 plate bolt.
3. Tighten drive plate bolts to specified torque.
AK503335 AD
CAUTION
If the tightening angle is less than 30 , tightening per-
formance may not be secured. Use caution to the tight-
ening angle during tightening.
MB991614
pletely loosen bolts and start tightening over again
4. Use special tool MB991614 to tighten bolts 30 according to
30 the tightening order.
AK603584AB
TSB Revision
ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-59
M1113008401811
6 7
5
10
11
9
Apply engine oil to 3

all moving parts
5.0 Nm 20 Nm +90
44 in-lb 14 ft-lb
1
AK603501AB

>>G<< 1. Connecting rod cap bolt >>C<< 7. Piston ring No. 2
<<A>> >>F<< 2. Connecting rod cap >>B<< 8. Oil ring
>>E<< 3. Connecting rod bearing <> >>A<< 9. Piston pin
>>E<< 4. Connecting rod bearing 10. Piston
>>D<< 5. Piston connecting rod assembly 11. Connecting rod
>>C<< 6. Piston ring No. 1

MD998780: Piston Setting Tool MB991659: Guide D
TSB Revision

.
<<A>> CONNECTING ROD REMOVAL

Mark the connecting rod on the big end with the cylinder num-
ber it is being removed from.
Cylinder No.
AK502531AE
<> PISTON PIN REMOVAL

Guide A: 17.9 mm Special tool MD998780 consists of parts shown in the illustra-
(0.70 in) tion. Also use special tool MB991659 to remove the piston pin.
Push rod Guide B
Guide A: 18.9 mm
(0.74 in)
Guide C
Guide A: 20.9 mm
(0.82 in)
Guide D
Base (MB991659)
Guide A: 21.9 mm
(0.86 in)
AK305415AE
TSB Revision
ENGINE OVERHAUL
11B-61
1. Insert the push rod into the piston pin from the front mark
Front mark side of the piston top surface, and attach special tool
MB991659.
2. Set the piston and connecting rod assembly on the base so
A
20
that the front mark of the piston faces upward.
Push rod 3. Use a press to push the push rod and pull out the piston pin.
NOTE: After pulling out the piston pin, organize pistons, pis-
Pinston pin ton pins and connecting rods by cylinder No.
Front mark
Guide D
Base
AK603502 AB

.
>>A<< PISTON PIN INSTALLATION

1. When replacing a piston, check the cylinder bore size mark
stamped on the illustrated position of the cylinder block and
No.1 select a corresponding piston from the table below.
No.2 Cylinder bore size mark Piston size mark

A A
No.3
No.4 B B
C C
J 1
J 2
J 3
J 4
J 5
AK503237AD
TSB Revision
NOTE: The piston size mark is indicated on the piston top

Piston mark size face.
2. Insert the push rod into the piston pin and attach guide A.
20
A
3. Align the front mark of the piston with that of the connecting
rod to assemble.
4. Apply engine oil to the circumference of the piston pin.
5. Insert the guide A side of the piston pin assembled in
section 1 into the pin hole from the front mark side of the
piston.
AK603503 AB
6. Screw guide B into guide A and open clearance between

guide A and guide B by 3 mm (0.12 inch) (make the base in
L line with flushed surface) to assemble.
7. Set the piston on special tool piston setting base so that its
front mark faces upward.
8. Use a press to press fit the piston pin. If the press fit load is
Guide B Guide A:
20.9 mm below the standard value, replace the piston pin (piston
(0.82 in) assembly) or connecting rod, or both.
Standard value: 7,500 17,500 N (1,686 3,934 pound)
AK502517AD
>>B<< OIL RING INSTALLATION

1. Assemble the spacer of the oil ring into the piston ring
groove. Then, assemble the upper side rail, and after this
assemble the lower side rail.
Upper Lower NOTE: Install the side rail and end gap of the spacer so that
side side
rail gap rail gap they are at the position as shown in the illustration.
Spacer gap AK400536 AC

CAUTION
The side rail may be broken if its end gap is widened by a
ring expander as in other piston rings.
2. When assembling the side rail, push it by fingers, after fitting
one end of the side rail into the piston groove, for easy
assembly.
3. After assembling the oil ring into the piston, make sure that
the side rail turns smoothly to either direction.
AK304891
TSB Revision
ENGINE OVERHAUL
11B-63
>>C<< PISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION
Use a piston ring expander to assemble piston rings with their
identification marks facing upward. Piston rings can be assem-
bled by hand without using the piston ring expander.
Piston ring
expander
AK304892AD
Identification mark
Identification mark
No. 1 ring: 1T
No. 2 ring: 2T
No.1
No.2
AK502529 AE
>>D<< PISTON CONNECTING ROD ASSEMBLY

INSTALLATION
1. Apply a sufficient amount of engine oil to the circumference
of the piston, piston rings and oil ring.
2. Arrange end gap positions of piston rings and oil ring (side
Side rail No.1 rail and spacer) as shown in the illustration.
3. Insert the piston and connecting rod assembly from the top
surface of the cylinder block with the front mark of the piston
Piston pin top face facing toward the timing chain side.
No.2 Side rail

AK400403 AC
CAUTION
Driving it in hard causes breakage of piston rings and
damage to the crank pin.
4. Firmly tighten the piston ring with a ring band and insert the
piston and connecting rod assembly.
AK502730
TSB Revision
>>E<< CONNECTING ROD BEARING

INSTALLATION
Pin identification mark position 1. When replacing a connecting rod bearing, select the bearing
corresponding to the crankshaft pin outside diameter
according to the crankshaft pin identification in the table
below.
No.1
No.2
No.3
No.4
AK502527AD
Crankshaft pin Connecting rod bearing

Identification mark Journal diameter mm (in) Identification color Identification mark
1 47.966 47.972 (1.8884 1.8887) Black 1
2 47.960 47.966 (1.8882 1.8884) None 2
3 47.954 47.960 (1.8880 1.8882) Green 3
2. An identification mark of a crankshaft is stamped at the
illustrated position by No.
3. A connecting rod bearings an identification color or
identification mark at the illustrated position.
Identification
Identification mark
color
AK502521 AD
>>F<< CONNECTING ROD CAP INSTALLATION

NOTE: The connecting rod resulting from the breaking process
has the high insertion force. The new connecting rod assembly
may possibly be difficult to remove the connecting rod.
If difficult to remove it, alternately strike the two bolt heads with
a plastic hammer while the connecting rod bolt is slightly loos-
ened, or strike the center of the cap shafts inside diameter
slightly and outward.
TSB Revision
ENGINE OVERHAUL
11B-65
If the outside of the cap is directly struck, the lateral force is
added to the broken-out section. Thus, pay attention to the bro-
ken-out section that might be difficult to be separated or might
fall.
Clean the broken-out section before the installation to the
engine, using compression air.
1. Assemble the bearing cap on the connecting rod by aligning
it with the mark put during removal. If a new connecting rod
without a mating mark is used, assemble so that the detent
notch of the bearing is on the same side as illustrated.
Cylinder No.
Notch 2
Front mark
AK503157AE
2. Make sure that clearance of the thrust of the connecting rod

big end is appropriate.
Limit: 0.4 mm (0.016 inch)
AK502752
>>G<< CONNECTING ROD CAP BOLT

INSTALLATION
1. Check in the following procedure before reusing the
connecting rod bolt.
(1) Measure the outside diameter "A."
(2) Measure the smallest outside diameter "B" within the
20.5 mm (0.81 in) range "X" shown in the illustration.
X (3) If the difference of outside diameter of thread exceeds
the limit, replace the connecting rod bolt.
B A
Limit: 0.1 mm
35 mm (1.38 in) 2. Apply engine oil to the threaded portion and seat surface of
the bolt before installing it.
3. After installing each bolt and tightening it by fingers, tighten
AK604589AD
bolts alternately to properly assemble the cap.
4. Tighten the bolt in several steps until the torque reaches 5.0
N m (44 in-lb).
5. Tighten the bolt in several steps until the torque reaches 20
N m (15 ft-lb).
TSB Revision
6. Put a paint mark on the bolt head as illustrated.

7. Put a paint mark on the connecting rod at 90 position in the
90 tightening direction of the bolt with reference to the paint
mark position of the bolt.
CAUTION
formance may not be secured. Use caution to the tight-
Paint mark Paint mark ening angle during tightening.
AK502749AD
pletely loosen the bolt and start tightening over again
8. Tighten the bolt 90 , and make sure that the paint mark of
the connecting rod is aligned with that of the bolt.
INSPECTION
M1113008501368
.
PISTON RINGS
1. Check clearance between piston rings and ring grooves. If
the limit is exceeded, replace piston rings or piston, or both.
Standard value:
No. 1 ring: 0.03 0.07 mm (0.001 0.003 inch)
No. 2 ring: 0.03 0.07 mm (0.001 0.003 inch)
AK502751
2. Put piston rings into the cylinder bore, press them against
Please down ring the piston top face, and push them in. After achieving
with piston
squareness, measure the end gap with a thickness gauge. If
the end gap is excessive, replace piston rings.
Standard value:
No. 1 ring: 0.15 0.28 mm (0.006 0.011 inch)
No. 2 ring: 0.30 0.45 mm (0.012 0.018 inch)
Oil ring: 0.10 0.35 mm (0.004 0.014 inch)
Piston ring
End cap Limit:
AK603466 AB
No. 1 ring: 0.8 mm (0.03 inch)
No. 2 ring: 0.8 mm (0.03 inch)
Oil ring: 1.0 mm (0.04 inch)
.
CRANKSHAFT PIN OIL CLEARANCE

(PLASTIGAGE METHOD)
1. Wipe oil off the crankshaft pin and connecting rod bearing.
2. Place a plastigage in length equal to the bearing width on
the pin shaft straight in alignment with the shaft center.
TSB Revision
ENGINE OVERHAUL
11B-67
3. Carefully install the connecting rod cap and tighten bolts to
the specified torque of 5.0 N m (44 in-lb) 20 N m (15
ft-lb) +90 .
4. Remove bolts and gently remove the connecting rod cap.
Plastigage
AK503373 AD
5. Measure the crushed plastigage width (area most widely

crushed) using a scale printed on the plastigage bag.
Plastigage
AK503374AD
TSB Revision
CRANKSHAFT AND CYLINDER BLOCK

M1113008702105
6 5
11 1 Nm
98 8 in-lb
4 3
26.5 2.0 Nm
Apply engine oil to 20 1 ft-lb +45
all moving parts
1
AK604556AB

>>E<< 1. Crankshaft bearing cap bolt >>C<< 5. Crankshaft bearing upper
>>E<< 2. Crankshaft bearing cap >>B<< 6. Thrust bearing
>>D<< 3. Crankshaft bearing lower >>A<< 7. Crankshaft sensing ring
<<A>> 4. Crankshaft 8. Cylinder block

MB991614: Angle Gauge

.
<<A>> CRANKSHAFT REMOVAL

After removing the crankshaft with the crankshaft sensing ring
attached, temporarily place it on a V-block to prevent teeth of
the sensing ring from deforming.
TSB Revision
ENGINE OVERHAUL
11B-69
NOTE: If a tooth bends, be sure to replace the crankshaft sens-
ing ring with a new one.

.
>>A<< CRANKSHAFT SENSING RING INSTALLA-

TION
Tighten crankshaft sensing ring bolts to the torque of 11 1
N m in the tightening order shown in the illustration.
1
4 3
2
Crankshaft sensing ring AK502865AD
>>B<< THRUST BEARING INSTALLATION

1. Install the thrust bearing on the No. 3 bearing on the cylinder
block side. Application of engine oil makes the installation
easier.
2. Install the thrust bearing so that the grooved side is on the
crankshaft weight side.
Groove
AK502394 AE
TSB Revision
>>C<< CRANKSHAFT BEARING UPPER

INSTALLATION
1. When replacing the crankshaft bearing upper, select a
bearing with the size corresponding to the crankshaft journal
No.1
diameter in the table below.
No.2
No.3
No.4
No.5
J 1
J 2
J 3
J 4
J 5
AK502530 AD
2. The crankshaft bearing upper has an identification color or

Groove
Identification
Identification mark
color
AK502396 AD
Cylinder block Crankshaft bearing

1 56.000 56.006 (2.2047 2.2050) Black 1
2 56.006 56.012 (2.2050 2.2052) None 2
3 56.012 56.018 (2.2052 2.2054) Green 3
3. Install the selected crankshaft bearing upper.
.
TSB Revision
ENGINE OVERHAUL
11B-71
>>D<< CRANKSHAFT BEARING LOWER
INSTALLATION
1. When replacing the crankshaft bearing lower, select a
Journal identification mark position
bearing with the size corresponding to the crankshaft journal
diameter in the table below.
No.1
No.2
No.3
No.4
No.5
AK502528AD
2. The crankshaft bearing lower has an identification color or

Identification
Identification mark
color
AK502418 AD
Crankshaft Crankshaft bearing

0 51.985 51.988 (2.0467 2.0468) Pink or red 0
1 51.982 51.985 (2.0465 2.0467) Black 1
2 51.979 51.982 (2.0464 2.0465) None 2
3 51.976 51.979 (2.0463 2.0464) Green 3
4 51.973 51.976 (2.0462 2.0463) Blue 4
3. Install the selected crankshaft bearing lower.

.
TSB Revision
>>E<< CRANKSHAFT BEARING CAP /

CRANKSHAFT BEARING CAP BOLT
INSTALLATION
1. Install the crankshaft bearing cap with reference to the
identification mark as illustrated.
10 6 2 3 7
9 5 1 4 8
AK502395 AD
2. Make sure that the underhead length of the bolt is at or

below the limit before installing the crankshaft bearing cap
bolt. If the length exceeds the limit, replace the bolt with a
new one.
3. Apply engine oil to the threaded portion and seat surface of
Shank length the bolt.
4. Tighten crankshaft bearing cap bolts to the torque of 26.5
2.0 N m (20 1 ft-lb) according to the tightening order.
AK402401AD
CAUTION
MB991614 formance may not be secured. Use caution to the tight-
ening angle during tightening.
45
pletely loosen bolts and start tightening over again
5. Use special tool MB991614 to tighten bolts 45 according to
the tightening order.
AK502750AD
6. Check end play of the crankshaft after installing the

crankshaft bearing cap. If the end play exceeds the limit,
replace the thrust bearing.
AK503375
TSB Revision
ENGINE OVERHAUL
11B-73
INSPECTION
M1113008801381
.
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE

METHOD)
Oil clearance can be easily measured by using a "plastigage."
When using a "plastigage," perform measurement in the follow-
ing procedure.
1. Fully wipe oil off the outside diameter of the crankshaft and
inside diameter of the bearing.
2. Assemble the crankshaft.
3. Place a plastigage in length equal to the bearing width on
the journal shaft straight in alignment with the shaft center.
4. Carefully install the bearing cap and tighten the bolt
according to the main point of installation >>B<<.
5. Remove the bolt, and then carefully remove the crankshaft
bearing cap.
AK502747
6. Measure the crushed plastigage width (area most widely

crushed) using a scale printed on the plastigage bag.
AK502748
CYLINDER BLOCK
1. Visually check the cylinder block for scratch, rust and
corrosion. Use a flaw detecting agent to check for cracks. If
it is found faulty, repair or replace it.
2. Measure distortion on the top surface of the cylinder block
using a straight edge and thickness gauge.
If distortion exceeds the limit, grind and repair it.
A gasket or the like must not be adhered to the top surface
of the cylinder block during measurement.
Distortion on bottom
Standard value: Within 0.05 mm (0.0020 inch)
Limit: 0.02 mm (0.0008 inch)
Grinding limit: 0.2 mm (0.008 inch)
AK502746
3. Check the cylinder wall for scratch or seizure. If there is any
defect, replace the cylinder block.
TSB Revision
4. Measure the bore and cylindricity of the cylinder using a

cylinder gauge.
If the cylinder is excessively worn, repair the cylinder and
replace the piston and piston rings.
12 mm (0.47 in)
Measuring points are as shown in the illustration.
Standard value
Cylinder bore: 86 mm (3.4 inches)
Cylindricity: 0.15 mm (0.006 inch)
AK503371AD
TSB Revision
12-1
GROUP 12
ENGINE
LUBRICATION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 12-2 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 12-3
OIL PASSAGE . . . . . . . . . . . . . . . . . . 12-2 OIL DIPSTICK, OIL FILLER CAP,

OIL DRAIN PLUG . . . . . . . . . . . . . . . . 12-4
OIL FILTER . . . . . . . . . . . . . . . . . . . . 12-3
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . 12-4
12-2 ENGINE LUBRICATION
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M2120000100249
The lubrication system is a full-flow, filter pumping After the oil is pumped to the individual crankshaft
system. journals, it passes through a passage in the crank-
The engine oil that accumulates in the oil pan is shaft and is fed to the pins. After the oil is pumped to
drawn and discharged by the oil pump. After its pres- the cylinder head, it flows to the camshaft journals
sure is regulated by the relief valve, the oil passes and the engine oil control valves.
through the oil filter. Then, it flows from the oil pas-
sage in the cylinder block to the individual crankshaft
journals and the cylinder head.
OIL PASSAGE
M2120000200194
Oil screen
Relief valve Oil pump
Cylinder block oil passage
Oil filter bracket
Oil filter
Cylinder block oil passage

Engine oil pressure swich (main gallery)
Engine oil control valve Cylinder head oil passage Crankshaft journal
V.V.T. sprocket Camshaft journal Crankshaft pin
Oil pan
AK603615AB
ENGINE LUBRICATION
OIL FILTER
12-3
OIL FILTER
M2120005000195
The oil filter is installed on the left side of the cylinder
block.
Item Specifications Element
Filtering system Full-flow filtering, filter

paper type
Filtering area m2 0.11
Rated flow volume L/min 30 Oil filter
AK502549 AD
OIL PAN
M2120006000187
The oil pan is made of sheet metal and contains an oil sump in
Oil pan the forward area of the engine.
FIPG (Formed-In-Place Gasket) is used to seal between the oil
Gasket
pan and the ladder frame.
Drain plug
Engine front
AK603617 AB
12-4 ENGINE LUBRICATION
OIL DIPSTICK, OIL FILLER CAP, OIL DRAIN PLUG
OIL DIPSTICK, OIL FILLER CAP, OIL DRAIN PLUG

M2120007000124
The oil dipstick, oil filler cap, and oil drain plug are
located with serviceability in mind.
Oil filler cap
Oil dipstick
Engine front
Oil drain plug
AK503035AD
OIL PUMP
M2120002000077
The oil screen is integrated into the oil pump case to The oil pump case, which is installed to the bottom of
be compact and lightweight. the ladder flame, is driven by the oil pump chain
through the oil pump sprocket installed to the front of
the oil pump case.
13-1
GROUP 13
FUEL
CONTENTS
MULTIPORT FUEL SYSTEM (MFI) . . . . . . . . . . . . . . . . . . . . . . 13A
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B

NOTES
13-1
GROUP 13
FUEL
CONTENTS
MULTIPORT FUEL INJECTION (MFI) . . . . . . . . . . . . . . . . . . . . 13A
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B

NOTES
13A-1
GROUP 13A
MULTIPORT FUEL
SYSTEM (MFI)
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 13A-2 HEATED OXYGEN SENSOR HEATER

CONTROL. . . . . . . . . . . . . . . . . . . . . . 13A-49
CONTROL UNIT. . . . . . . . . . . . . . . . . 13A-6
A/C COMPRESSOR RELAY
SENSOR. . . . . . . . . . . . . . . . . . . . . . . 13A-8 CONTROL. . . . . . . . . . . . . . . . . . . . . . 13A-50
ACTUATOR . . . . . . . . . . . . . . . . . . . . 13A-23 GENERATOR CONTROL. . . . . . . . . . 13A-51
FUEL INJECTION CONTROL . . . . . . 13A-29 EVAPORATIVE EMISSION CONTROL

SYSTEM INCORRECT PURGE FLOW
IGNITION TIMING AND CONTROL FOR MONITOR . . . . . . . . . . . . . . . . . . . . . . 13A-52
CURRENT CARRYING TIME . . . . . . 13A-35
EXHAUST GAS RECIRCULATION
THROTTLE VALVE OPENING ANGLE CONTROL. . . . . . . . . . . . . . . . . . . . . . 13A-53
CONTROL AND IDLE SPEED
CONTROL . . . . . . . . . . . . . . . . . . . . . 13A-38 CONTROLLER AREA NETWORK
(CAN) . . . . . . . . . . . . . . . . . . . . . . . . . 13A-53
MIVEC (Mitsubishi Innovative Valve
Timing Electronic Control System). 13A-40 EVAPORATIVE EMISSION PURGE
CONTROL. . . . . . . . . . . . . . . . . . . . . . 13A-53
MULTIPORT FUEL INJECTION (MFI)
RELAY CONTROL. . . . . . . . . . . . . . . 13A-45 HC TRAP CATALYTIC CONVERTER
DETERIORATION MONITOR. . . . . . . 13A-53
FUEL PUMP RELAY CONTROL . . . . 13A-46
ON-BOARD DIAGNOSTICS. . . . . . . . 13A-53
STARTER RELAY CONTROL. . . . . . 13A-47
13A-2 MULTIPORT FUEL SYSTEM (MFI)
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M2132000101283
Although the control systems are basically the same as those of 2.4L engine used in the GALANT, the follow-
ing improvements have been added.
Improvement / Additions Remark

MIVEC, continuously and variably control the intake System optimally control the timing of the intake
valve timing and exhaust valve timing, is used. valve and exhaust valve in accordance with the
engine speed and load.
Addition of heated oxygen sensor (3rd) Detection of the HC trap catalyst malfunction.
<California>
MULTIPORT FUEL SYSTEM (MFI)
GENERAL DESCRIPTION
13A-3
System Block Diagram
Sensor, switch Engine control module (ECM) Actuator
Mass airflow sensor Barometric pressure sensor No. 1 injector
Intake air temperature sensor No. 2 injector

Manifold absolute pressure Engine control unit
sensor No. 3 injector
Engine coolant temperature No. 4 injector

sensor
[1] Fuel injection control
Throttle position sensor (main) No. 1 ignition coil
Throttle position sensor (sub) [2] Ignition timing control No. 2 ignition coi
Accelerator pedal position No. 3 ignition coi

sensor (main) [3] Throttle valve opening angle
control and idle speed control
Accelerator pedal position No. 4 ignition coi
sensor (sub)
Throttle actuator control
Intake camshaft position [4] MIVEC (Mitsubishi Innovative motor
sensor Valve timing Electronic Control
system)
Exhaust camshaft position Heated oxygen sensor (front)
sensor heater
[5] Power supply control
Crankshaft position sensor (Power supply to sensor, Heated oxygen sensor (rear)
actuator) heater
Heated oxygen sensor (front)
Heated oxygen sensor (3rd)
Heated oxygen sensor (rear) heater*
[6] Fuel pump relay control
Heated oxygen sensor Intake engine oil control
(3rd)* valve
[7] Starter relay control
Knock sensor
Exhaust engine oil control
valve
Generator FR terminal
[8] Heated oxygen sensor heater
Generator L terminal control Multiport fuel injection (MFI)
relay
Engine oil pressure switch
[9] A/C compressor relay control Throttle actuator control
Power steering pressure motor relay
switch
[10] Generator control A/C compressor relay
Fuel tank differential pressure
sensor
Fuel pump relay
Fuel tank temperature sensor [11] Evaporative emission purge
control Starter relay
Vehicle speed sensor <M/T>
Ignition switch-IG Generator G terminal

[12] EGR control
Ignition switch-ST Evaporative emission purge
solenoid
Power supply [13] Diagnosis output
Evaporative emission ventilation
CAN communication solenoid
(input signal)
A/C switch [14] RAM data transmission
Vehicle speed <CVT> EGR valve (stepper motor)*
Fuel level sensor
Transmission range switch CAN communication
<CVT> (output signal)
NOTE
*1: California AK604116 AB
GENERAL DESCRIPTION
Control System Diagram
<Except for California>

Sense Decide Act
1 Mass airflow sensor ECM 1 Intake engine oil control valve
2 Intake air temperature sensor (with barometric
pressure sensor) 2 Exhaust engine oil control valve
3 Throttle position sensor (main/sub)
3 Throttle actuator control motor
4 Manifold absolute pressure sensor
5 Engine coolant temperature sensor 4 Injector
6 Intake camshaft position sensor 5 Evaporative emission purge solenoid
7 Exhaust camshaft position sensor 6 Evaporative emission ventilation
8 Crankshaft position sensor solenoid
9 Knock sensor
10 Heated oxygen sensor (front) Ignition coil, ignition power transistor
11 Heated oxygen sensor (rear) Multiport fuel injection (MFI) relay
12 Fuel tank differential pressure sensor Fuel pump relay
13 Fuel tank temperature sensor Starter relay
Throttle actuator control motor relay
Accelerator pedal position sensor (main/sub) Generator G terminal
Engine oil pressure switch Heated oxygen sensor heater
Power steering pressure switch A/C compressor relay
Generator FR terminal Diagnostic output
Generator L terminal CAN communication (output signal)
Ignition switch-IG
Ignition switch-ST
Power supply
CAN communication (input signal)
3 Throttle position
sensor (main/sub)
2 Exhaust engine
oil control valve 2 Intake air
5 Evaporative emission temperature sensor
purge solenoid
1 Intake engine 3 Throttle actuator 1 Mass airflow sensor
oil control valve control motor
Air
6 Intake inlet
camshaft
position
sensor
4 Injector
7 Exhaust
camshaft
position
sensor
Evaporative
emission
5 Engine coolant canister
temperature sensor
6 Evaporative
9 Knock sensor emission Fuel pressure
ventilation Fuel tank
regulator
solenoid Fuel level
Fuel pump sensor
8 Crankshaft position sensor
12 Fuel tank differential
pressure sensor
10 Heated oxygen sensor (front) 13 Fuel tank
temperature
sensor
11 Heated oxygen
sensor (rear)
AK604117 AB
GENERAL DESCRIPTION
13A-5
<California>
Sense Decide Act
1 Mass airflow sensor ECM 1 Intake engine oil control valve
2 Intake air temperature sensor (with barometric
pressure sensor) 2 Exhaust engine oil control valve
3 Throttle position sensor (main/sub)
3 Throttle actuator control motor
5 Engine coolant temperature sensor 4 Injector
6 Intake camshaft position sensor 5 Evaporative emission purge solenoid
7 Exhaust camshaft position sensor 6 Evaporative emission ventilation
8 Crankshaft position sensor solenoid
9 Knock sensor 7 EGR valve (stepper motor)
10 Heated oxygen sensor (front)
11 Heated oxygen sensor (rear) Ignition coil, ignition power transistor
12 Heated oxygen sensor (3rd) Multiport fuel injection (MFI) relay
13 Fuel tank differential pressure sensor Fuel pump relay
14 Fuel tank temperature sensor Starter relay
Throttle actuator control motor relay
Accelerator pedal position sensor (main/sub) Generator G terminal
Engine oil pressure switch Heated oxygen sensor heater
Power steering pressure switch A/C compressor relay
Generator FR terminal Diagnostic output
Generator L terminal CAN communication (output signal)
Ignition switch-IG
Ignition switch-ST
Power supply
CAN communication (input signal)

3 Throttle position
sensor (main/sub)
2 Exhaust engine
oil control valve 2 Intake air
5 Evaporative emission temperature sensor
purge solenoid
1 Intake engine 3 Throttle actuator 1 Mass airflow sensor
oil control valve control motor
Air
6 Intake inlet
camshaft
position
sensor
4 Injector
7 Exhaust
camshaft 7 EGR valve
position (stepper motor)
sensor
Evaporative
10 Heated emission
oxygen canister
sensor 5 Engine
(front) coolant 6 Evaporative
temperature emission Fuel pressure
sensor ventilation Fuel tank
regulator
9 Knock sensor solenoid Fuel level
Fuel pump sensor
8 Crankshaft position sensor
12 Fuel tank differential
pressure sensor
11 Heated oxygen sensor (rear) 13 Fuel tank
temperature
sensor
12 Heated oxygen sensor (3rd)
AK604118 AB
CONTROL UNIT
CONTROL UNIT
M2132021500153
ENGINE CONTROL MODULE (ECM)
ECM
Microprocessor
Input Input Output Output

sensor interface interface actuator
RAM ROM
AK604119 AB
ECM is installed in the engine room. ECM judges uses flash-memory ROM that allows re-writing of
(calculates) the optimum control to deal with the con- data so that change and correction of control data is
stant minute changes in driving conditions based on possible using special tools. It also uses Electrically
information input from the sensors and drives the Erasable Programmable Read Only Memory
actuator. ECM is composed of 32-bit microprocessor (EEPROM) so that studied compensation data is not
and Random Access Memory (RAM), Read Only deleted even if battery terminals are disconnected.
Memory (ROM) and Input /Output interface. ECM
ECM CONNECTOR INPUT/OUTPUT PIN ARRANGEMENT

71
72
73
74
75
76
77
78
79
80
81
82
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
83
84
85
86
87
88
89
90
91
92
93
94
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
100
101
102
103
104
105
106
95
96
97
98
99
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
107
108
109
110
111
112
113
114
115
116
117
118
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
AK602565 AC
NOTE: *: California
1 Intake engine oil control valve 2 No.1 injector
3 No.2 injector 4 Ignition coil No.1 (ignition power transistor)
5 Ignition coil No.2 (ignition power transistor) 6 Starter active signal
7 Exhaust camshaft position sensor 8 Crankshaft position sensor
9 Sensor supplied voltage 10 Throttle position sensor (main)
11 Throttle position sensor (sub) 12 Power supply voltage applied to throttle
position sensor
13 Throttle position sensor ground 14 Intake camshaft position sensor
CONTROL UNIT
13A-7
15 Throttle actuator control motor (+) 16 Throttle actuator control motor (-)
17 Exhaust engine oil control valve 18 No.3 injector
19 No.4 injector 20 Ignition coil No.3 (ignition power transistor)
21 Ignition coil No.4 (ignition power transistor) 23 Exhaust camshaft position sensor ground
24 Crankshaft position sensor ground 25 Knock sensor
26 Engine coolant temperature sensor 27 Engine coolant temperature sensor ground
30 Intake camshaft position sensor ground 31* EGR valve (stepper motor coil <A>)
32* EGR valve (stepper motor coil ) 33* Heated oxygen sensor (3rd) heater
34 Heated oxygen sensor (front) heater 35 Heated oxygen sensor (rear) heater
36 Engine oil pressure switch 37 Evaporative emission purge solenoid
38 Heated oxygen sensor (front) 39 Heated oxygen sensor (front) offset voltage
40 Heated oxygen sensor (rear) 41 Heated oxygen sensor (rear) offset voltage
42 Knock sensor ground 44 Power supply voltage applied to manifold
absolute pressure sensor
45 Manifold absolute pressure sensor 46 Manifold absolute pressure sensor ground
47* EGR valve (stepper motor coil <C>) 48* EGR valve (stepper motor coil <D>)
54* Heated oxygen sensor (3rd) 55* Heated oxygen sensor (3rd) offset voltage
58 Power steering pressure switch 60 Generator G terminal
61 Generator FR terminal 62 Generator L terminal
71 Throttle actuator control motor ground 72 Throttle actuator control motor power
supply
73 MFI relay (power supply) 74 Accelerator pedal position sensor (main)
75 Power supply voltage applied to accelerator 76 Accelerator pedal position sensor (main)
pedal position sensor (main) ground
77 Accelerator pedal position sensor (sub) 78 Power supply voltage applied to accelerator
pedal position sensor (sub)
79 Accelerator pedal position sensor (sub) 81 ECM ground
ground
82 Power supply 83 Throttle actuator control motor ground
84 Throttle actuator control motor relay 87 Mass airflow sensor
88 Mass airflow sensor ground 89 Intake air temperature sensor
90 CAN interface (high) 91 CAN interface (low)
92 Ignition switch-IG 93 ECM ground
96 Fuel pump relay 102 A/C compressor relay
103 Flash EP-ROM power supply 104 Backup power supply
105 Ignition switch-ST 106 Starter relay
112 Fuel tank differential pressure sensor 113 Fuel tank differential pressure sensor
ground
114 Power supply voltage applied to fuel tank 115 Fuel tank temperature sensor
differential pressure sensor
117 Evaporative emission ventilation solenoid
SENSOR
SENSOR
M2132001000565
.
MASS AIRFLOW SENSOR

Mass airflow sensor is installed in the air intake hose. Mass air-
Silicon substrate
flow sensor is composed of an extremely small heatsensing
resistor. The mass airflow sensor controls the amount of elec-
tric current flowing into the heat sensing resistor to keep the
Heat sensing
resistor heat sensing resistor at a constant temperature to the intake air
temperature. The faster the air flow speed, the higher the mass
Intake air
flow rate.Because the amount of heat transfer from the heat
sensing resistor to the air increases, the mass airflow sensor
Sensing area
Diaphragm
increases the amount of electric current to the heat sensing
AK602252AC resistor. Thus, the amount of electric current increases in
accordance with the air mass flow rate. The mass airflow sen-
sor measures the air mass flow rate by detecting the amount of
electric current. The mass airflow sensor amplifies the detected
electric current amount and outputs it into the ECM. ECM uses
this output current and engine speed to calculate and decide
basic fuel injection time. Sensor properties are as shown in the
figure.
From MFI relay
Output current mA
Mass flow g/s
Mass airflow sensor ECM

AK602221AG
INTAKE AIR TEMPERATURE SENSOR

Intake air temperature sensor is built in to the mass airflow sen-
sor. Intake air temperature sensor detects intake air tempera-
ture through thermistor's resistance change and outputs the
voltage according to intake air temperature to ECM. ECM uses
this output voltage to compensate fuel injection control and
Sensory part ignition timing control. Sensor properties are as shown in the
(thermistor) figure.
AK602253AC
SENSOR
13A-9
ECM Output voltage V

Intake air temperature 5V
sensor (thermistor)
Resistance k
Intake air Intake air

temperature C (F) temperature C (F)
AK602207AG
MANIFOLD ABSOLUTE PRESSURE SENSOR

The manifold absolute pressure sensor is installed in the intake
Manifold absolute
pressure sensor manifold. Manifold absolute pressure sensor uses a piezo
resistive semiconductor to output the voltage according to man-
ifold absolute pressure to ECM. ECM uses this output voltage
to compensate fuel injection volume according to manifold
absolute pressure. Sensor properties are as shown in the fig-
ure.
Pressure AK602254AC
Output voltage V
Manifold absolute ECM

pressure sensor
Power supply 5V
5V
Output signal
Ground
0 101
Pressure kPa (in.Hg)
AK602206AH
.
SENSOR
ENGINE COOLANT TEMPERATURE SENSOR

The engine coolant temperature sensor is installed in the ther-
mostat housing. Engine coolant temperature sensor uses ther-
mistor's resistance change to detect coolant temperature and
output the voltage according to coolant temperature to ECM.
ECM uses this output voltage to appropriately control fuel injec-
tion volume, idle speed and ignition timing. Sensor properties
are as shown in the figure.
Sensory part
(thermistor)
AK602255AC

Engine coolant
temperature sensor 5V
(thermistor)
Resistance k
Engine coolant Engine coolant

AK602208 AG
THROTTLE POSITION SENSOR

The throttle position sensor is installed in the throttle body.
Throttle body Throttle position sensor outputs voltage to ECM based on the
throttle shaft rotation angle. ECM uses this signal to detect the
throttle valve opening angle to perform throttle actuator control
motor feedback control. This throttle position sensor uses Hall
IC and is a non-contact type.
Throttle
position
sensor
AK604120AB
.
SENSOR
13A-11
STRUCTURE AND SYSTEM
Throttle shaft Throttle position sensor is composed of a permanent magnet
Magnet Stator
fixed on the throttle shaft, Hall IC that outputs voltage according
Hall IC to magnetic flux density and a stator that efficiently introduces
magnetic flux from the permanent magnet to Hall IC.
To ECM
Yoke Fixed to the motor cover

AK602566AC
Magnetic flux density at Hall IC is proportional to the output

Hall IC
voltage.
Throttle position sensor has 2 output systems throttle position
sensor (main) and throttle position sensor (sub), and the output
voltage is output to ECM. When throttle valve turns, output volt-
age of throttle position sensor (main) and throttle position sen-
Fully closed sor (sub) changes. This allows ECM to detect actual throttle
opening angle. ECM uses this output voltage for throttle actua-
tor control motor feedback control. Also, ECM compares output
voltage of the throttle position sensor (main) and throttle posi-
tion sensor (sub) to check for abnormality in the throttle position
sensor. The relationship between throttle opening angle and
Half opened output voltage of the throttle position sensor (main) and throttle
Hall IC position sensor (sub) is as shown in the figure below.
Fully opened
Magnet flux
AK604555AB
SENSOR
Throttle position sensor

Throttle position Throttle position
sensor (main) sensor (sub)
Hall IC Hall IC
Output voltage V
5
Throttle position
4.5 sensor (main)
2.5
Throttle position
sensor (sub)
0.5
5V 5V 0
Throttle valve opening angle
Fully Fully
ECM closed opened
AK602222AE
ACCELERATOR PEDAL POSITION SENSOR

Accelerator pedal position sensor is integrated with accelerator
pedal, and detects accelerator opening angle. ECM uses the
output voltage of this sensor to control appropriate throttle
valve opening angle and fuel injection volume. This accelerator
Accelerator pedal position
sensor connector pedal position sensor uses Hall IC and is a non-contact type.
Accelerator pedal arm
AK602569AC
.
SENSOR
13A-13
STRUCTURE AND SYSTEM
Accelerator pedal position sensor is composed of a permanent
Magnet magnet fixed on the magnet carrier of the pedal shaft, Hall IC
outputs voltage according to magnetic flux density and a stator
Hall IC
that efficiently introduces magnetic flux from the permanent
magnet to Hall IC.
Pedal shaft
AK602570AC
Magnetic flux density at Hall IC is proportional to the output

Magnetic flux density Hall IC voltage.
: minimum The accelerator pedal position sensor has 2 output systems
accelerator pedal position sensor (main) and accelerator pedal
N S position sensor (sub), and the output voltage is output to ECM.
According to depression of the accelerator pedal, output volt-
age of the accelerator pedal position sensor (main) and accel-
erator pedal position sensor (sub) changes. This allows ECM to
S N detect the actual accelerator pedal depression amount. ECM
uses accelerator pedal position sensor (main) output voltage
for appropriate throttle valve opening angle control and fuel
Magnetic flux density
: maximum injection volume control. Also, ECM compares output voltage of
the accelerator pedal position sensor (main) and accelerator
pedal position sensor (sub) to check for abnormality in sensor.
N S
The relationship between accelerator opening angle and output
voltage of the accelerator pedal position sensor (main) and
accelerator pedal position sensor (sub) is as shown in the fig-
ure below.
S N
Magnetic flux Hall IC

AK602571 AC
SENSOR
Accelerator pedal position sensor
Accelerator pedal Accelerator pedal

position sensor (main) position sensor (sub)
Hall IC Hall IC
Output voltage V
Accelerator pedal
5 position sensor (main)
2
Accelerator pedal
1 position sensor (sub)
5V 5V
0
ECM Accelerator Fully
pedal stroke opened
AK602211AE
HEATED OXYGEN SENSOR (except centor

exhaust pipe heated oxygen sensor <California>)
Heated oxygen sensors are installed in 2 positions (front, rear)
on the catalytic converter. Heated oxygen sensor has a built-in
heater to help early activation of the sensor. This allows feed-
back control of air-fuel ratio soon after engine start.
.
Sensing area
AK602572 AC
Electro motive This sensor uses the oxygen concentration cell principle of
force (V) Theoretical air fuel ratio solid electrolyte (zirconia) and displays the property of sudden
0.8 change in output voltage near theoretical air-fuel ratio. This
property is used to detect oxygen density in exhaust gas. Feed-
back to ECM allows it to judge whether air-fuel ratio is rich or
Rich Lean lean compared to theoretical air-fuel ratio.
14 15 16
Air fuel ratio AK602262AC
SENSOR
13A-15
This allows ECM precise feedback control to get theoretical
Purge ratio
air-fuel ratio with best cleaning efficiency of 3-way catalytic con-
100
verter.
HC
50
NOx
CO
0
Theoretical air fuel ratio
AK602263AC
From MFI relay
Heated xygen sensor
Heater
ECM
Zirconia element
0.5V
AK602576AC
CRANKSHAFT POSITION SENSOR

Crankshaft sensing ring A crankshaft position sensor is installed on the right side of the
(36 teeth including 3 missing teeth) cylinder block. The crankshaft position sensor monitors rotation
of crankshaft sensing ring (36 teeth including 3 missing teeth)
installed on the crankshaft and converts to voltage (pulse sig-
nal) that is output to ECM. ECM uses crankshaft position sen-
sor's output pulse to detect crankshaft position.
Crankshaft
position .
sensor
AK602737AC
SENSOR
The crankshaft position sensor uses a magnetic resistance ele-

Crank shaft sensing ring ment. When the vane of the crankshaft-sensing blade passes
the front surface of the magnetic resistance element, the flux
Magnet flux from the magnet passes the magnetic resistance element.
Thus, resistance of the magnetic resistance element increases.
When the vane of the crankshaft-sensing blade does not pass
the front surface of the magnetic resistance element, the flux
Vane
from the magnet does not pass the magnetic resistance ele-
ment and the resistance decreases. The crankshaft position
Magnetic resistance element
sensor converts this change in resistance of the magnetic
Crank shaft sensing ring resistance element to a 5 V pulse signal and outputs it to ECM.
Magnet flux
Vane

AK602265AC
ECM
Crankshaft position sensor
5V
5V
Output signal
AK602285AC
INTAKE CAMSHAFT POSITION SENSOR

Camshaft position sensor
The intake camshaft position sensor is installed on the left side
of the cylinder head. The intake camshaft position sensor mon-
Sensing portion itors shape of the half-moon sensing portion and converts to
voltage (pulse signal) that is output to ECM. Upon receiving this
output voltage, the ECM effects feedback control to optimize
the phase of the intake camshaft. Also, ECM uses a combina-
tion of the intake camshaft position sensor output pulse signal
Camshaft and crankshaft position sensor output pulse signal to identify
cylinders in the compression process.
AK602738AC
SENSOR
13A-17
The intake camshaft position sensor uses a magnetic resis-
Camshaft position sensing portion tance element. When the camshaft position sensing portion
passes the front surface of the magnetic resistance element,
Magnet flux
the flux from the magnet passes the magnetic resistance ele-
ment. Thus, resistance of the magnetic resistance element
increases. When the camshaft position sensing portion does
not pass the front surface of the magnetic resistance element,
the flux from the magnet does not pass the magnetic resistance
Magnetic resistance element element and the resistance decreases. The intake camshaft
position sensor converts this change in resistance of the mag-
Camshaft position sensing portion
netic resistance element to a 5 V pulse signal and outputs it to
Magnet flux
ECM
.
EXHAUST CAMSHAFT POSITION SENSOR

The exhaust camshaft position sensor is installed on the right
side of the cylinder head. The exhaust camshaft position sen-
sor monitors shape of the half-moon sensing portion and con-
verts to voltage (pulse signal) that is output to ECM. Upon
receiving this output voltage, the ECM effects feedback control
Magnetic resistance element to optimize the phase of the exhaust camshaft. The structure
AK602574AC and system of this sensor are basically the same as intake
camshaft position sensor.
.
ECM
Camshaft position sensor
5V
5V
Output signal
AK602287AC
KNOCK SENSOR
A knock sensor is installed on the left side of the cylinder block.
Knock sensor uses the piezoelectric element to convert the
vibration of the cylinder block generated when engine is in
operation to minute voltage that is output to ECM. ECM uses
the minute output voltage from the knock sensor filtered
through the cylinder block's natural frequency to detect knock-
ing, and compensates the ignition timing lag according to the
strength of the knocking.
Piezoelectric element
AK602739 AC
SENSOR
ECM
5V
Knock sensor
Piezoelectric element
AK602226AD
BAROMETRIC PRESSURE SENSOR

A barometric pressure sensor is built into ECM. The barometric
Barometric pressure sensor pressure sensor is a semiconductor diffused pressure element
(built in ECM)
which outputs voltage to ECM according to atmospheric pres-
sure. ECM uses this output voltage to sense the altitude of the
vehicle and compensates fuel injection volume to achieve the
appropriate air-fuel ratio for that altitude.
AK602575AC
ENGINE OIL PRESSURE SWITCH

The engine oil pressure switch is installed on the left side of the
cylinder block. The engine oil pressure switch detects whether
the oil pressure is high or low using the contact switch. When
the oil pressure becomes higher than the specified value after
the engine starts, the contact point of the engine oil pressure
Oil switch opens. This allows the ECM to detect the oil pressure is
pressure
higher than the specified value. The ECM outputs the OFF sig-
nal to the combination meter through the CAN and then turns
Contact switch off the oil pressure warning lamp.
AK602587AC
SENSOR
13A-19
ECM
Operating pressure
ECM terminal voltage V
Oil pressure: high
OFF
12
Oil pressure:low
ON
0
Engine oil Oil pressure kPa (in.Hg)

ON pressure switch
OFF
AK602228 AD
POWER STEERING PRESSURE SWITCH

A power steering pressure switch is installed on the power
Power steering steering oil pump. The power steering pressure switch uses a
pressure switch contact switch to detect the power steering oil pressure. When
power steering oil pressure rises due to operation of the steer-
ing wheel, the power steering load switch outputs an ON signal
to ECM. ECM performs idle-up according to the voltage and
Oil prevents reduction in engine speed due to power steering load
pressure and so maintains stable idle speed.
AK601174AF
ECM
ECM Operating pressure

terminal voltage V
Oil pressure:low
OFF
12
Oil pressure: high
ON
0
Power steering Oil pressure kPa (in.Hg)

ON pressure switch
OFF
AK602213 AE
.
SENSOR
FUEL TANK DIFFERENTIAL PRESSURE SENSOR

The fuel tank differential pressure sensor is installed to the fuel
Fuel tank differential pump module. The fuel tank differential pressure sensor out-
pressure sensor puts the voltage to the ECM using the piezo resistive semicon-
ductor in accordance with the difference between pressure in
the fuel tank and the pressure of the atmosphere. When moni-
toring the evaporative leak, the ECM detects malfunctions of
the evaporative emission control system by monitoring the
amount of output voltage changes from this sensor. The sensor
characteristics are as shown in the diagram.
Pressure
AK604121AB

Fuel tank differential pressure sensor
Power supply 5V
Output signal
Ground
0 Pressure kPa (in. Hg)

AK604122 AB
FUEL TANK TEMPERATURE SENSOR

The fuel tank temperature sensor is installed to the fuel pump
module. The fuel tank temperature sensor detects the tempera-
Fuel tank ture inside the fuel tank using the resistance change in the ther-
temperature mistor and outputs the voltage to the ECM in accordance with
sensor the temperature inside the fuel tank. The ECM monitors the
evaporative leak in accordance with the fuel tank temperature.
The sensor characteristics are as shown in the diagram.
Sensory part
(thermistor)
AK604123 AB

Fuel tank temperature 5V
sensor (thermistor) Resistance k
Fuel tank Fuel tank

AK604124 AB
SENSOR
13A-21
.
GENERATOR FR TERMINAL
Generator turns ON/OFF the power transistor in the voltage
regulator to adjust current flow in the field coil according to
alternator output current. In this way generator's output voltage
is kept adjusted (to about 14.7 V). The ratio of power transistor
ON time (ON duty) is output from generator FR terminal to
ECM. ECM uses this signal to detect generator's output current
and drives throttle actuator control motor according to output
current (electric load). This prevents change in idle speed due
to electric load and helps maintain stable idle speed.
Ignition switch-IG
Battery
B S
ECM
FR
Field coil
IC regulator
Generator
AK602229AD
.
SENSOR
GENERATOR L TERMINAL
After turning on the ignition switch, the current is input by the
ECM to the generator L terminal. This allows the IC regulator to
be on and the field coil to be excited. When the generator
rotates in this situation, the voltage is excited in the stator coil
and the current is output from B-terminal through the commuta-
tion diode. Also the generated voltage is input to the voltage
regulator through the commutation diode. After the electric gen-
eration begins, the current is supplied to the field coil from this
circuit. In addition, the generated voltage is output from the
generator L terminal to the ECM. This allows the ECM to detect
that the electric generation begins. The ECM outputs the ON
signal to the combination meter through the CAN and then
turns off the generator malfunction light.
Ignition switch-IG
Battery
B S ECM
CAN
communication
Field coil Generator

malfunction
light
Combination meter
IC regulator
Generator
AK602577 AC
ACTUATOR
13A-23
ACTUATOR
M2132002000353
INJECTOR
An injector is an injection nozzle with the electromagnetic valve
Fuel
that injects fuel based on the injection signal sent by ECM. 1
injector is installed in the intake manifold of each cylinder and
fixed to the fuel rail. When electricity flows through the solenoid
Connector coil, the plunger gets sucked in. The ball valve is integrated
with the plunger, and gets pulled together with the plunger till
the fully open position so that the injection hole is fully open
and the fuel gets injected.
Filter
Solenoid coil
Plunger
Ball valve
Plate AK602272AC
From ETACS-ECU From MFI relay
Injector relay
ON
OFF
No. 1 No. 2 No. 3 No. 4
Injectors
ECM
AK602578 AC
Voltage from the battery gets applied from the injector relay to
the injector and up to the ECM. ECM turns ON its power tran-
sistor and prepares the injector's ground circuit. Thus, current
flows through the injector while power transistor is ON and the
injector injects fuel.
ACTUATOR
THROTTLE ACTUATOR CONTROL MOTOR

A throttle actuator control motor is installed in throttle body. The
Throttle body throttle actuator control motor performs the Open/Close of the
throttle valve through the reduction gear. ECM changes current
direction according to the Open/Close direction and also
changes current to the motor coil to control the throttle actuator
control motor.
Throttle actuator control motor is composed of a good
response, low energy, and small DC motor with brush and can
generate rotation force corresponding to the current applied on
the coil. When there is no current passing through the throttle
Throttle actuator
control motor actuator control motor, the throttle valve remains at a pre-
AK604125AB
scribed opening angle. So, even if current stops because of a
fault in the system, a minimum level of running remains possi-
ble.
From battery
Throttle actuator MFI relay

control motor ON
OFF
To ECM
Throttle actuator
control motor relay
ON
OFF
Power supply ECM
AK602231 AE
ACTUATOR
13A-25
IGNITION COIL
Refer to GROUP 16 Ignition Coil P.16-2.
EXHAUST GAS RECIRCULATION (EGR) VALVE

Refer to GROUP 17 Emission Control Exhaust Gas Recircu-
lation (EGR) System P.17-12.
EVAPORATIVE EMISSION PURGE SOLENOID

Refer to GROUP 17 Emission Control Evaporative Emission
Control System P.17-11.
INTAKE ENGINE OIL CONTROL VALVE

The intake engine oil control valve is installed on the left side of
Spool valve movement the cylinder head. Receiving the duty signal from the ECM, the
intake engine oil control valve moves the spool valve position
Advance Retard
and divides the oil pressure from the cylinder block into the
chamber chamber advanced chamber and the retarded chamber of the V.V.T.
Spring sprocket as well as continually changes the intake camshaft
phase. The spring makes spool valve stop at the position
where the intake camshaft is at the most retarded angle when
the engine is stopped. The ECM moves the spool valve posi-
tion by increasing and decreasing ON duty ratio of the intake
Coil Plunger engine oil control valve and allows the intake camshaft to be at
Drain Drain the target phase angle. When the duty ratio increases, the
Oil pressure AK604740AD spool valve moves. The sprocket rotates toward the advanced
angle side. When the duty ratio decreases, the sprocket rotates
toward the retarded angle side. When the medium duty ratio, at
which the spool valve is at the medium position, is achieved, all
the oil passages are closed. This allows the phase angle to be
kept constant. The ECM changes and controls the duty ratio in
accordance with the engine operation to get the optimum
phase angle.
From MFI relay

ECM
50ms
OFF
12V
Intake engine oil ON
control valve 0V
T
The longer the ON position, the more

advanced the intake camshaft angle
AK602579 AD
ACTUATOR
EXHAUST ENGINE OIL CONTROL VALVE

The exhaust engine oil control valve is installed on the right
Spool valve movement side of the cylinder head. Receiving the duty signal from the
ECM, the exhaust engine oil control valve moves the spool
Retard Advance valve position and divides the oil pressure from the cylinder
chamber chamber block into the advanced chamber and the retarded chamber of
Spring the V.V.T. sprocket as well as continually changes the exhaust
camshaft phase. The spring makes spool valve stop at the
position where the exhaust camshaft is at the most advanced
angle when the engine is stopped. The ECM moves the spool
valve position by increasing and decreasing ON duty ratio of
Coil Plunger the exhaust engine oil control valve and allows the exhaust
Drain Drain camshaft to be at the target phase angle. When the duty ratio
Oil pressure AK604747 AC increases, the spool valve moves. The sprocket rotates toward
the retarded angle side. When the duty ratio decreases, the
sprocket rotates toward the advanced angle side. When the
medium duty ratio, at which the spool valve is at the medium
position, is achieved, all the oil passages are closed. This
allows the phase angle to be kept constant. The ECM changes
and controls the duty ratio in accordance with the engine oper-
ation to get the optimum phase angle.
From MFI relay

ECM
50ms
OFF
12V
Exhaust engine oil ON
control valve 0V
T
The longer the ON position, the more

retarded the exhaust camshaft angle
AK602579 AG
ACTUATOR
13A-27
EVAPORATIVE EMISSION VENTILATION
SOLENOID
The evaporative emission ventilation solenoid, an ON/OFF
Evaporative Connector
emission type solenoid valve, is integrated in the evaporative canis-
ventilation ter.The evaporative emission ventilation solenoid is installed
solenoid
between the evaporative canister and the air-releasing end,
where the evaporative emission ventilation solenoid takes or
To filter shuts off air.When the current is not flowing through the coil, the
air flows between the nipples, "A" and "B", and through the
evaporative canister.When the current is flowing through the
coil, the air is sealed in the nipple "A" and the air through the
To canister AK604127 AB
evaporative canister is shut off.When monitoring the evapora-
tive leak, the ECM turns the evaporative emission ventilation
solenoid on to create the slight vacuum condition in the evapo-
rative emission control system. The ECM shuts off the air flow-
ing through the evaporative canister to maintain the vacuum
condition necessary for monitoring.
From MFI relay Engine speed to switch

ECM terminal voltage V evaporative emission
ventilation solenoid
ECM
OFF
12
ON
0
Evaporative emission
Engine speed r/min
AK604554 AB
ACTUATOR
GENERATOR G TERMINAL
ECM uses ON/OFF of generator G terminal to control genera-
tor output voltage. When the power transistor in the ECM turns
ON, output voltage gets adjusted to about 12.8 V. When gener-
ator output voltage drops to 12.8 V it becomes lower than volt-
age of the charged battery and almost no current is output from
the generator. When the power transistor in the ECM turns
OFF, output voltage gets adjusted to about 14.7 V. When gen-
erator output voltage is about 14.7 V, generator outputs current
to produce electricity. In case electric load is generated sud-
denly, ECM controls generator G terminal's On-duty to limit the
sudden increase in generator load due to generation and thus
prevents change in idle speed.
Ignition switch-IG
Battery
B S
ECM
Field coil
IC regulator
Generator
AK602233AD
FUEL INJECTION CONTROL
13A-29
M2132003001036
Fuel injection volume is regulated to obtain the opti- intake air volume. ECM adds prescribed compensa-
mum air-fuel ratio in accordance with the constant tions to this basic drive time according to conditions
minute changes in engine driving conditions. Fuel such as the intake air temperature and engine cool-
injection volume is controlled by injector drive time ant temperature to decide injection time. Fuel injec-
(injection time). There is a prescribed basic drive tion is done separately for each cylinder and is done
time that varies according to the engine speed and once in two engine rotations.
System Configuration Diagram
Mass airflow sensor
Intake air temperature sensor
Manifold absolute
pressure sensor
Engine coolant
temperature sensor
Injector
ECM Accelerator pedal position sensor
Knock sensor
Intake camshaft position sensor
Ignition switch-ST
Heated oxygen sensor (front, rear)
AK604128AB
1. INJECTOR ACTUATION (FUEL INJECTION)

TIMING
Injector drive time in case of multiport fuel injection (MFI) is
controlled as follows according to driving conditions.
Fuel Injection During Cranking and Normal Operation
<No. 2 TDC> <No.1 TDC> <No. 3 TDC> <No. 4 TDC> <No. 2 TDC>
Crankshaft H
position L
sensor signal
Intake camshaft H
position sensor
signal L
Exhaust camshaft H
position sensor
signal L
Cylinder stroke : Fuel injection
No. 1 Cylinder Compression Combustion Exhaust Intake

No. 3 Cylinder Intake Compression Combustion Exhaust
No. 4 Cylinder Exhaust Intake Compression Combustion
No. 2 Cylinder Combustion Exhaust Intake Compression
AK604622AB
Fuel injection to each cylinder is done by driving the injector at

optimum timing while it is in exhaust process based on the
crankshaft position sensor signal. ECM compares the crank-
shaft position sensor output pulse signal and intake camshaft
position sensor output pulse signal to identify the cylinder.
Using this as a base, it performs sequential injection in the
sequence of cylinders 1, 3, 4, 2.
13A-31
Additional Fuel Injection During Acceleration
Crankshaft H
position sensor
signal L
Increase injection for acceleration
Cylinder stroke

AK604623 AB
In addition to the synchronizing fuel injection with crankshaft

position sensor signal during acceleration, the volume of fuel is
injected according to the extent of the acceleration.
2. Fuel injection volume (injector drive time)

control
The figure shows the flow for injector drive time calculation.
Basic drive time is decided based on the mass airflow sensor
signal (intake air volume signal) and crankshaft position sensor
signal (engine rotation signal). This basic drive time is compen-
sated according to signals from various sensors and optimum
injector drive time (fuel injection volume) is calculated accord-
ing to driving conditions.
Fuel Injection Volume Control Block Diagram
Air fuel ratio

compensation
(Predetermined
Mass airflow sensor compensation)
Basic fuel
injection time
determination
Crankshaft
position sensor
Heated oxygen
sensor feedback
compensation
Heated oxygen
sensor
Engine coolant
Engine coolant
temperature
temperature sensor compensation
Acceleration-
deceleration
compensation
Barometric pressure
sensor
Fuel pressure
compensation
Manifold absolute
pressure sensor
Battery voltage Battery voltage

compensation
Injector
AK602278AD
.
13A-33
[Injector basic drive time]
Fuel injection is performed once per cycle for each cylinder.
Basic drive time refers to fuel injection volume (injector drive
time) to achieve theoretical air-fuel ratio for the intake air vol-
ume of 1 cycle of 1 cylinder. Fuel injection volume changes
according to the pressure difference (injected fuel pressure)
between manifold absolute pressure and fuel pressure (con-
stant). So, injected fuel pressure compensation is made to
injector drive time for theoretical air-fuel ratio to arrive at basic
drive time.
Basic fuel Intake air amount per cycle per cylinder

Fuel injection pressure compensation
injection time Theoretical air-fuel ratio
AK602279AC
Intake air volume of each cycle of 1 cylinder is calculated by
ECM based on the mass airflow sensor signal and crankshaft
position sensor signal. Also, during engine start, the map value
prescribed by the engine coolant temperature sensor signal is
used as basic drive time.
.
[Injector drive time compensation]

After calculating the injector basic drive time, the ECM makes
the following compensations to control the optimum fuel injec-
tion volume according to driving conditions.
List of main compensations for fuel injection control

Compensations Content
Heated oxygen sensor feedback compensation The heated oxygen sensor signal is used for
making the compensation to get air-fuel ratio with
best cleaning efficiency of the 3-way catalytic
converter. This compensation might not be made
sometimes in order to improve drivability,
depending on driving conditions. (Air-fuel ratio
compensation is made.)
Air-fuel ratio compensation Under driving conditions where heated oxygen
sensor feedback compensation is not performed,
compensation is made based on pre-set map
values that vary according to engine speed and
intake air volume.
Engine coolant temperature compensation Compensation is made according to the engine
coolant temperature. The lower the engine coolant
temperature, the greater the fuel injection volume.
Acceleration/ Deceleration compensation Compensation is made according to change in
intake air volume. During acceleration, fuel injection
volume is increased. Also, during deceleration, fuel
injection volume is decreased.
Fuel injection compensation Compensation is made according to the pressure
difference between atmospheric pressure and
manifold absolute pressure. The greater the
difference in pressure, the shorter the injector drive
time.
Battery voltage compensation Compensation is made depending on battery
voltage. The lower the battery voltage, the greater
the injector drive signal time.
Learning value for fuel compensation Compensation amount is learned to compensate
feedback of heated oxygen sensor. This allows
system to compensate in accordance with engine
characteristics.
.
[Fuel limit control during deceleration]

ECM limits fuel when decelerating downhill to prevent exces-
sive rise of catalytic converter temperature and to improve fuel
efficiency.
.
[Fuel-cut control when over-run]

When engine speed exceeds a prescribed limit (6,600 r/min),
ECM cuts fuel supply to prevent overrunning and thus protect
the engine. Also, if engine speed exceeds 4,000 r/min for 15
seconds while vehicle is stationary (no load), it cuts fuel supply
and controls the throttle valve opening angle to protect the
engine.
IGNITION TIMING AND CONTROL FOR CURRENT CARRYING TIME
13A-35
IGNITION TIMING AND CONTROL FOR CURRENT
CARRYING TIME
M2132027100089
Ignition timing is pre-set according to engine driving
conditions. Compensations are made according to
pre-set values depending on conditions such as
engine coolant temperature, battery voltage etc. to
decide optimum ignition timing. Primary current con-
nect/disconnect signal is sent to the power transistor
to control ignition timing. Ignition is done in sequence
of cylinders 1, 3, 4, 2.

MFI relay Battery
Mass airflow sensor

Manifold absolute
pressure sensor
Engine coolant
temperature sensor
ECM Intake camshaft position sensor
Exhaust camshaft position sensor
Ignition
coils Crankshaft position sensor
Knock sensor
Ignition switch-ST
Spark plugs
Cylinder No. 1 2 3 4
AK502722 AD
1. Ignition distribution control

Based on the crankshaft position sensor signal and camshaft
position sensor signal, ECM decides the ignition cylinder, cal-
culates the ignition timing and sends the ignition coil primary
current connect/disconnect signal to the power transistor of
each cylinder in the ignition sequence.
Crankshaft H
position L
sensor signal
Intake camshaft H
position sensor
signal L
Exhaust camshaft H
position sensor
signal L
Cylinder stroke Ignition

AK604624 AB
13A-37
2. Spark-advance control and current carrying
time control
.
[During start]
ECM initiates ignition at fixed ignition timing (5 BTDC) syn-
chronized with the crankshaft position sensor signal.
.
[During normal operation]

After determining the basic spark-advance based on the intake
air volume and engine speed, ECM makes compensations
based on input from various sensors to control the optimum
spark-advance and current carrying time.
List of main compensations for spark-advance control and current carrying time control
Intake air temperature compensation Compensation is made according to intake air
temperature. The higher the intake air temperature
the greater the delay in ignition timing.
Engine coolant temperature compensation Compensation is made according to engine coolant
temperature. The lower the engine coolant
temperature the greater the advance in ignition
timing.
Knocking compensation Compensation is made according to generation of
knocking. The greater the knocking the greater the
delay in ignition timing.
Stable idle compensation Compensation is made according to change in idle
speed. In case engine speed becomes lower than
target speed, ignition timing is advanced.
Delay compensation when changing shift During change of shift, sparking is delayed
compared to normal ignition timing to reduce
engine output torque and absorb the shock of the
shift change.
Battery voltage compensation Compensation is made depending on battery
voltage. The lower the battery voltage the greater
the current carrying time and when battery voltage
is high current carrying time is shortened.
.
[Control for checking ignition timing]

During basic ignition timing set mode for M.U.T.-III actuator test
function, sparking is done with fixed ignition timing (5 BTDC)
synchronized with crankshaft position sensor signal.
THROTTLE VALVE OPENING ANGLE CONTROL AND IDLE SPEED CONTROL
THROTTLE VALVE OPENING ANGLE CONTROL AND IDLE

SPEED CONTROL
M2132003500328
ECM detects the amount of accelerator pedal
depression (as per operator's intention) through the
accelerator pedal position sensor. Based on pre-set
basic target opening angles it adds various compen-
sations and controls the throttle valve opening angle
according to the target opening angle.
Motor drive power supply
(From throttle actuator
control motor relay)
Throttle actuator Engine coolant

control motor Motor drive circuit temperature sensor
Intake air temperature
sensor
Throttle Main
position Crankshaft position sensor
sensor
Sub A/C switch (CAN)
Power steering pressure
Control unit switch
Accelerator Sub Generator FR terminal

pedal position
sensor Transmission range
Main switch (CAN) <CVT>
Barometric pressure
sensor
ECM
AK602236AE
While starting While driving

ECM adds various compensations to the target Compensations are made to the target opening
opening angle that are set based on the engine cool- angle set according to the accelerator pedal opening
ant temperature, so that the air volume is optimum angle and engine speed to control the throttle valve
for starting. opening angle.
While idling
ECM controls the throttle valve to achieve the target
opening angle that are set based on the engine cool-
ant temperature. In this way best idle operation is
achieved when engine is cold and when it is hot.
Also, the following compensations ensure optimum
control.
THROTTLE VALVE OPENING ANGLE CONTROL AND IDLE SPEED CONTROL
13A-39
List of main compensations for throttle valve opening angle and idle speed control
Stable idle compensation (immediately after start) In order to stabilize idle speed immediately after
start, target opening angle is kept big and then
gradually reduced. Compensation values are set
based on the engine coolant temperature.
Rotation speed feedback compensation (while In case there is a difference between the target idle
idling) speed and actual engine speed, ECM
compensates the throttle valve opening angle
based on that difference.
Atmospheric pressure compensation At high altitudes atmospheric pressure is less and
the intake air density is low. So, the target opening
angle is compensated based on atmospheric
pressure.
Engine coolant temperature compensation Compensation is made according to the engine
coolant temperature. The lower the engine coolant
temperature the greater the throttle valve opening
angle.
Electric load compensation Throttle valve opening angle is compensated
according to electric load. The greater the electric
load, the greater the throttle valve opening angle.
Compensation when shift is in D range <CVT> When transmission is changed from P or N range
to some other range, throttle valve opening angle is
increased to prevent reduction in engine speed.
Compensation when A/C is functioning Throttle valve opening angle is compensated
according to functioning of A/C compressor. While
A/C compressor is being driven, the throttle valve
opening angle is increased.
Power steering fluid pressure compensation Throttle valve opening angle is compensated
according to power steering functioning. When
power steering oil pressure rises and power
steering pressure switch is ON, the throttle valve
opening angle is increased.
Initialize control
After ignition switch turns OFF, ECM drives the throt-
tle valve from fully closed position to fully open posi-
tion and records the fully closed/open studied value
of the throttle position sensor (main and sub) output
signals. The recorded studied values are used as
studied value compensation for compensating basic
target opening angle when the engine is started next.
MIVEC (Mitsubishi Innovative Valve Timing Electronic Control System)
MIVEC (Mitsubishi Innovative Valve Timing Electronic

Control System)
M2132023500212
MIVEC is the system which continuously varies and
controls the opening and closing timings of the intake
valve and the exhaust valve.

Intake engine oil control valve
Crankshaft Retard direction

position sensor
Spool valve movement

Manifold absolute Spool valve
pressure sensor
ECM
Advance direction
To oil pan
Intake camshaft Retard chamber
position sensor Oil pressure
Advance chamber
To oil pan
Spring
Exhaust engine oil control valve
Crankshaft Advance direction

position sensor
Spool valve movement

Manifold absolute Spool valve
pressure sensor
ECM
Retard direction
To oil pan
Exhaust camshaft Advance chamber
position sensor Oil pressure
Retard chamber
To oil pan
Spring
AK604826 AB
MIVEC allows the optimum valve timing to be con- Based on the assessed information, the ECM
trolled in accordance with the engine operation and sends the duty signal to the intake engine oil con-
the idling stability to be improved, as well as the out- trol valve and exhaust engine oil control valve as
put and the torque to be better in all the operation well as controls the spool valve position.
ranges. Changing the spool valve position allows the oil
The ECM assesses the engine operation through pressure to be divided into the retarded chamber
the signals from each sensor. and the advanced chamber, as well as allows the
phases of the intake camshaft and the exhaust
camshaft to be continuously changed.
13A-41
Phase Angle Detection
Crankshaft H
position L
sensor signal
Intake camshaft H
position sensor
signal L
Exhaust camshaft H
position sensor
signal L
: phase angle
AK604625 AB
The detected phase angle is calculated using the cam position sensor signal.
Valve lift amount Valve lift amount
High torque High output
Exhaust valve Intake valve

Intake valve (initial position)
Exhaust valve
Initial position
Crank angle Crank angle
High load range at

High load range at high speed
low and middle speeds
Load
Middle load range
Low load range at

low speed
Engine speed
Valve lift amount Low-fuel consumption Valve lift amount Low-fuel consumption
Exhaust valve
(initial position: most advance) Intake valve
Intake valve Exhaust valve
(initial position: most retard)
Initial position
Overlap: nothing <Except for California> Crank angle Overlap: large Crank angle
small <California>
AK604129AB
13A-43
Operation condition Valve timing Operation Effectiveness
Within range of low <Except for California> Overlap is decreased and Idle speed stable
speed and low load amount of exhaust gas
TDC
at idle flowing back into intake
Overlap:
nothing
Intake valve port is limited.
(initial position)
Exhaust valve
(initial position)
BDC
<California>
TDC
Overlap: Intake valve

small (initial position)
Exhaust valve
(initial position)
BDC
AK604130 AB
Operation condition Valve timing Operation Effectiveness

Within range of low TDC
Advancing closing timing of Low and middle speed
speed and high load intake valve allows amount torques improved
at acceleration of intake air flowing back
Intake valve
into intake port to be limited
Exhaust valve
as well as allows
volumetric efficiency to be
improved, resulting in low
and middle speed torques
Open improved.
Close
BDC AK604131AB
Within range of TDC

Increasing overlap amount Fuel economy
middle speed and Overlap: allows pumping loss to be improved
large
middle load decreased. Retarding
opening timing of exhaust
valve allows burned gas to
work sufficiently and allows
cycle efficiency to be
Exhaust valve
improved, resulting in
Open higher expansion ratio.
Intake valve
BDC AK604132 AB
Within range of high TDC

Retarding closing timing of Output improved
speed and high load intake valve in accordance
with engine speed allows
Intake valve
valve timing to be
Exhaust valve controlled according to
inertia force of intake air
and allows volumetric
efficiency to be improved.
Close
BDC AK604133 AB
MULTIPORT FUEL INJECTION (MFI) RELAY CONTROL
13A-45
MULTIPORT FUEL INJECTION (MFI) RELAY CONTROL
M2132006000173
Battery
LOCK
Ignition switch ST ACC
IG1 IG2
MFI relay OFF

ON
ETACS-ECU
To each sensor and

actuator
Power Battery
supply back up ECM
MFI relay control Ignition switch-IG
AK604134AB
When the ignition switch-IG "ON" signal is input, Throttle valve initializing control
ECM turns ON the power transistor for control of the
MFI relay. As a result, current flows through the MFI
relay's coil, the relay switch turns ON and power is
supplied to each sensor and actuator. Also, when
ignition switch-IG "OFF" signal is input, ECM per-
forms the following controls and then turns OFF the
power transistor for control of MFI relay.
FUEL PUMP RELAY CONTROL
FUEL PUMP RELAY CONTROL

M2132006500208
Battery
LOCK
ST ACC Ignition switch
IG1 IG2
MFI
OFF
relay
ON
To ECM
ETACS Fuel pump

OFF
-ECU relay
ON
Ignition switch-ST
Fuel pump M
ECM
Fuel pump Crankshaft position sensor

relay control
AK604135 AB
When current flows through the fuel pump relay, the a result, power is supplied to the fuel pump. Also, if
relay turns ON and the fuel pump is driven. The fuel engine speed falls below a set value, the fuel pump
pump relay is built into the ETACS-ECU. When the relay is turned OFF. Thus, it deals with sudden stop-
ignition switch-ST signal is input, ECM turns ON the pages such as engine stalling etc. by stopping the
power transistor for control of the fuel pump relay. As pump.
STARTER RELAY CONTROL
13A-47
M2132025500092
<M/T>
Battery
Ignition switch-ST
Clutch
interlock ON
switch OFF
ETACS
-ECU
Starter relay OFF

ON
ON
Engine-ECU OFF
Starter
Starter relay
control M
AK604136 AB
<CVT>
Battery
Ignition switch-ST
P
Transmission R
range switch N
D
ETACS
-ECU
Starter relay OFF

ON
ON
Engine-ECU OFF
Starter
Starter relay
control M
AK604137 AB
When the ignition switch-ST signal is input, ECM

turns ON the power transistor for control of the
starter relay.
HEATED OXYGEN SENSOR HEATER CONTROL
13A-49
HEATED OXYGEN SENSOR HEATER CONTROL
M2132007000206
ECM
Heated oxygen sensor heater
Engine coolant
MFI relay temperature sensor
Battery
AK602241AD
When exhaust gas temperature is low, the heated in cutting the fuel during deceleration. Based on driv-
oxygen sensor response is dull. So, response is ing conditions and the heated oxygen sensor activa-
improved by raising the sensor temperature by pass- tion state, ECM changes the amount of current (duty
ing current through the heater at a low exhaust gas ratio) to the heater to quicken the activation of the
temperature, such as in the immediate aftermath of heated oxygen sensor.
the engine start, or during the warm up operation and
A/C COMPRESSOR RELAY CONTROL
A/C COMPRESSOR RELAY CONTROL

M2132034500120
Battery
A/C compressor relay OFF

ON
A/C
refrigerant
temperature
OFF ON switch
A/C compressor
assembly A/C switch (CAN)
A/C compressor A/C compressor
clutch relay control
ECM AK604138 AB
The ECM turns on the power transistor when the A/C

switch ON signal is input by the A/C-ECU through
the CAN. This allows the A/C compressor relay to be
ON and to be operated. During the high load opera-
tion, such as the acceleration with the fully opened
accelerator, the ECM secures the acceleration capa-
bility by turning off the A/C compressor relay for the
specified period to produce no load on the A/C com-
pressor.
GENERATOR CONTROL
13A-51
GENERATOR CONTROL
M2132025000172
Engine coolant temperature sensor

Generator G terminal
Generator FR terminal
ECM
A/C switch (CAN)
Ignition switch-ST Generator
AK602242AD
During engine idle operation, ECM controls duty of G terminal OFF duty, ECM restricts sudden increase
conduction between generator G terminal and in generator's output current and output current is
ground. (G terminal duty is controlled to be the same increased only gradually. (Battery current is supplied
as ON duty of the power transistor inside the voltage to the headlamp etc. till generator produces sufficient
regulator). If headlights etc. are turned on while current.) Thus, ECM prevents change in idle speed
engine is idling, the consumed current increases due to sudden increase of engine load.
suddenly, but by gradually increasing the generator
EVAPORATIVE EMISSION CONTROL SYSTEM INCORRECT PURGE FLOW MONITOR
EVAPORATIVE EMISSION CONTROL SYSTEM INCORRECT

PURGE FLOW MONITOR
M2132027200019
MFI relay
Battery
purge solenoid
To injector
Mass airflow sensor

Fuel
tank
Barometric pressure sensor Evaporative emission
Intake air temperature sensor Fuel level

sensor
Engine coolant
temperature sensor

Fuel level sensor (CAN)
Fuel tank temperature sensor
ECM
AK604139 AB
The ECM detects whether the fuel vapor leakage The ECM measures the vacuum condition through
exists or not from the evaporative emission control the fuel tank differential pressure sensor signal. By
system. By the specified pattern within the certain comparing the normal (expected) value and the
operation range, the ECM drives the evaporative actual value, the ECM detects whether the fuel vapor
emission purge solenoid and the evaporative emis- leakage exists or not from the evaporative emission
sion ventilation solenoid. This allows slight vacuum control system.
to be produced in the fuel tank.
EXHAUST GAS RECIRCULATION CONTROL
13A-53
EXHAUST GAS RECIRCULATION CONTROL
M2132016000099
Refer to GROUP 17 Emission Control Exhaust
Gas Recirculation System P.17-12.
CONTROLLER AREA NETWORK (CAN)

M2132019000429
CAN communication is established to ensure the reli-
able transmission of information. Refer to GROUP
54C General InformationP.54C-2.
EVAPORATIVE EMISSION PURGE CONTROL

M2132012000138
Refer to GROUP 17 Emission Control Evaporative
Emission Control System P.17-11.
HC TRAP CATALYTIC CONVERTER DETERIORATION

MONITOR
M2132027300016
Refer to GROUP 17 Emission Control Emission
Reduction SystemP.17-14.
ON-BOARD DIAGNOSTICS
M2132009001067
The engine control module (ECM) has been provided
with the following functions for easier system inspec-
tion.
.
Diagnostic Trouble Codes and Malfunction Indicator Lamp (SERVICE ENGINE SOON
or Check Engine Lamp) Function
The diagnostic trouble code and malfunction indica- NOTE: *1: Diagnostic Trouble Code
tor lamp (SERVICE ENGINE SOON or Check NOTE: *2: Malfunction Indicator Lamp
Engine Lamp) items are shown in the following table.
DTC*1 DIAGNOSTIC ITEM MIL*2 ITEM
Engine control module (ECM)
P0011 Intake variable valve timing system target error
P0014 Exhaust variable valve timing system target error
P0016 Crankshaft/camshaft (intake) position sensor phase problem
P0017 Crankshaft/camshaft (exhaust) position sensor phase problem
P0031 Heated oxygen sensor heater (front) circuit low
P0032 Heated oxygen sensor heater (front) circuit high
P0037 Heated oxygen sensor heater (rear) circuit low
P0038 Heated oxygen sensor heater (rear) circuit high
P0043 Heated oxygen sensor heater (3rd) circuit low <California>

P0044 Heated oxygen sensor heater (3rd) circuit high <California>
P0069 Abnormal correlation between manifold absolute pressure sensor and
barometric pressure sensor
P0101 Mass airflow circuit range/performance problem
P0102 Mass airflow circuit low input
P0103 Mass airflow circuit high input
P0106 Manifold absolute pressure circuit range/performance problem
P0107 Manifold absolute pressure circuit low input
P0108 Manifold absolute pressure circuit high input
P0111 Intake air temperature circuit range/performance problem
P0112 Intake air temperature circuit low input
P0113 Intake air temperature circuit high input
P0116 Engine coolant temperature circuit range/performance problem
P0117 Engine coolant temperature circuit low input
P0118 Engine coolant temperature circuit high input
P0122 Throttle position sensor (main) circuit low input
P0123 Throttle position sensor (main) circuit high input
P0125 Insufficient coolant temperature for closed loop fuel control
P0128 Coolant thermostat (Coolant temperature below thermostat regulating
temperature)
P0131 Heated oxygen sensor (front) circuit low voltage
P0132 Heated oxygen sensor (front) circuit high voltage
P0133 Heated oxygen sensor (front) circuit slow response
P0134 Heated oxygen sensor (front) circuit no activity detected
P0137 Heated oxygen sensor (rear) circuit low voltage
P0138 Heated oxygen sensor (rear) circuit high voltage
P0139 Heated oxygen sensor (rear) circuit slow response
P0140 Heated oxygen sensor (rear) circuit no activity detected
P0143 Heated oxygen sensor (3rd) circuit low voltage <California>
P0144 Heated oxygen sensor (3rd) circuit high voltage <California>
P0145 Heated oxygen sensor (3rd) circuit slow response <California>
P0146 Heated oxygen sensor (3rd) circuit no activity detected <California>
P0171 System too lean
P0172 System too rich
P0181 Fuel tank temperature sensor circuit range/performance
P0182 Fuel tank temperature sensor circuit low input
P0183 Fuel tank temperature sensor circuit high input
P0201 Injector circuit-cylinder 1
13A-55

P0222 Throttle position sensor (sub) circuit low input
P0223 Throttle position sensor (sub) circuit high input
P0300 Random/multiple cylinder misfire detected
P0301 Cylinder 1 misfire detected
P0326 Knock sensor circuit performance
P0327 Knock sensor circuit low
P0328 Knock sensor circuit high
P0335 Crankshaft position sensor circuit
P0340 Intake camshaft position sensor circuit
P0365 Exhaust camshaft position sensor circuit
P0401 Exhaust gas recirculation flow insufficient detected <California>
P0420 Warm up catalyst efficiency below threshold <except for California>
P0421 Warm up catalyst efficiency below threshold <California>
P0441 Evaporative emission control system incorrect purge flow
P0442 Evaporative emission control system leak detected (small leak)
P0443 Evaporative emission control system purge control valve circuit
P0446 Evaporative emission control system vent control circuit
P0450 Evaporative emission control system pressure sensor malfunction
P0451 Evaporative emission control system pressure sensor range/performance
P0452 Evaporative emission control system pressure sensor low input
P0453 Evaporative emission control system pressure sensor high input
P0455 Evaporative emission control system leak detected (gross leak)
P0456 Evaporative emission control system leak detected (very small leak)
P0461 Fuel level sensor circuit range/performance
P0462 Fuel level sensor circuit low input
P0463 Fuel level sensor circuit high input
P0489 EGR valve (stepper motor) circuit malfunction (ground short) <California>
P0490 EGR valve (stepper motor) circuit malfunction (battery short) <California>
P0500 Vehicle speed sensor malfunction <M/T>
P0506 Idle control system RPM lower than expected
P0507 Idle control system RPM higher than expected

P0513 Immobilizer malfunction
P0551 Power steering pressure switch circuit range/performance
P0554 Power steering pressure switch circuit intermittent
P0603 EEPROM malfunction
P0606 Engine control module main processor malfunction
P0622 Generator FR terminal circuit malfunction
P0630 Vehicle Identification Number (VIN) malfunction
P0638 Throttle actuator control motor circuit range/performance
P0642 Throttle position sensor power supply
P0657 Throttle actuator control motor relay circuit malfunction
P1021 Intake engine oil control valve circuit
P1025 Exhaust engine oil control valve circuit
P1231 Active stability control plausibility
P1232 Fail safe system
P1233 Throttle position sensor (main) plausibility
P1234 Throttle position sensor (sub) plausibility
P1235 Mass airflow sensor plausibility
P1236 A/D converter
P1237 Accelerator pedal position sensor plausibility
P1238 Mass airflow sensor plausibility (torque monitor)
P1239 Engine RPM plausibility
P1240 Ignition angle
P1241 Torque monitor
P1242 Fail safe control monitor
P1243 Inquiry/response error
P1244 RAM test for all area
P1245 Cycle RAM test (engine)
P1247 CVT plausibility <CVT>
P1320 Ignition Timing Retard Insufficient
P1506 Idle control system RPM lower than expected at low temperature
P1507 Idle control system RPM higher than expected at low temperature
P1590 TCM to ECM communication error in torque reduction request <CVT>
P1603 Battery backup circuit malfunction
P1676 Variant coding
P2100 Throttle actuator control motor circuit (open)
P2101 Throttle actuator control motor magneto malfunction
P2122 Accelerator pedal position sensor (main) circuit low input
13A-57

P2123 Accelerator pedal position sensor (main) circuit high input
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) circuit range/performance problem
P2138 Accelerator pedal position sensor (main and sub) circuit range/performance
problem
P2195 Heated oxygen sensor (front) inactive
P2228 Barometric pressure circuit low input
P2229 Barometric pressure circuit high input
P2252 Heated oxygen sensor offset circuit low voltage
P2253 Heated oxygen sensor offset circuit high voltage
P2423 HC adsorber (HC trap catalyst) efficiency below threshold <California>
U0001 Bus off
U0101 CVT-ECU time-out
U0121 ABS-ECU time-out
U0141 ETACS-ECU time-out
U0167 Immobilizer communication error
U0180 Combination meter time-out
.
Data List Function

The data list items are shown in the following table. NOTE: When M.U.T.-III is used, M.U.T.-III items
NOTE: Data list items consist of M.U.T.-III items and appear alphabetically
GST items. GST items can be accessed through the
use of a general scan tool.
M.U.T.-III Item
M.U.T.-III SCAN TOOL ITEM NO. INSPECTION ITEM UNIT
DISPLAY
A/C compressor relay 93 A/C compressor relay ON/OFF
A/C SW 76 A/C switch ON/OFF
Absolute load value 72 Absolute load value %
Airflow sensor 10 Mass airflow sensor mV
Airflow sensor AA Mass airflow sensor g/s
APP sensor (main) 11 Accelerator pedal position sensor (main) mV
APP sensor (main) BE Accelerator pedal position sensor (main) %
APP sensor (sub) 12 Accelerator pedal position sensor (sub) mV
APP sensor (sub) BF Accelerator pedal position sensor (sub) %
Barometric pressure sensor BB Barometric pressure sensor kPa (in.Hg)
Brake light switch 74 Brake light switch ON/OFF
Calculated load value 73 Calculated load value %
Closed throttle position switch 84 Closed throttle position switch ON/OFF
Cranking signal 79 Cranking signal (ignition switch-ST) ON/OFF
Crankshaft position sensor 2 Crankshaft position sensor r/min
ECT sensor 6 Engine coolant temperature sensor C ( F)
EGR step motor 31 EGR valve (stepper motor) Step
Engine control relay 95 Engine control relay ON/OFF
Engine oil pressure switch 90 Engine oil pressure switch ON/OFF
ETV relay 96 Throttle actuator control motor relay ON/OFF
EVAP. emission purge SOL. 49 Evaporative emission purge solenoid duty %
duty
Exhaust VVT angle (bank1) 39 Exhaust MIVEC phase angle CA
Fan duty 47 Fan motor duty %
Fuel level gauge 51 Fuel level gauge %
Fuel pump relay 97 Fuel pump relay ON/OFF
Fuel system status (bank 1) 105 Fuel control system status Closed loop/
Open circuit
drive
condition
Fuel system status (bank 2)* 106
Fuel tank differential PRS. 52 Fuel tank differential pressure sensor mV
SNSR
Fuel tank temperature sensor 53 Fuel tank temperature sensor C ( F)
Ignition switch 85 Ignition switch (IG1) ON/OFF
13A-59
M.U.T.-III SCAN TOOL ITEM NO. INSPECTION ITEM UNIT
DISPLAY
Injectors 17 Injectors ms
Intake air temperature sensor 5 Intake air temperature sensor C ( F)
Intake VVT angle (bank1) 36 Intake MIVEC phase angle CA
ISC learned value (A/C OFF) 68 Idle speed control learned value (A/C OFF) L/s
ISC learned value (A/C ON) 69 Idle speed control learned value (A/C ON) L/s
Knock retard 32 Knock retard CA
Learned knock retard 33 Knock control learned value %
Long term fuel trim (bank 1) 26 Long-term fuel trim %
MAP sensor 8 Manifold absolute pressure sensor kPa (in.Hg)
Neutral switch 87 Neutral switch ON/OFF
Normally closed brake switch 89 Normally closed brake switch ON/OFF
Oxygen sensor (bank 1 sensor AC Heated oxygen sensor (front) V
1)
Oxygen sensor (bank 1 sensor AD Heated oxygen sensor (rear) V
2)
Power steering switch 83 Power steering pressure switch ON/OFF
Power supply voltage 1 Power supply voltage V
Relative TP sensor BC Relative throttle position sensor %
Short term fuel trim (bank 1) 28 Short-term fuel trim %
Spark advance 16 Ignition timing advance CA
Starter relay 102 Starter relay <M/T> ON/OFF
Target EGR BA Target EGR valve (stepper motor) %
Target ETV value 59 Throttle actuator control motor target value V
Target idle speed 3 Target idle speed r/min
Throttle actuator 58 Throttle actuator control motor %
TP sensor (main) 13 Throttle position sensor (main) mV
TP sensor (main) AB Throttle position sensor (main) %
TP sensor (main) learned 14 Throttle position sensor (main) mid opening mV
value learning value
TP sensor (sub) 15 Throttle position sensor (sub) mV
TP sensor (sub) BD Throttle position sensor (sub) %
Vehicle speed 4 Vehicle speed km/h (mph)
NOTE: *:The item is only displayed, but not applied.
GST Item
PARAMETER DESCRIPTION COMMON EXAMPLE OF GENERAL
IDENTIFICATION SCAN TOOL DISPLAY
(PID)
01 Number of emission-related DTCs and MIL status DTC and MIL status:
Number of DTCs stored in this ECU DTC_CNT: xxxd
Malfunction Indicator Lamp (MIL) status MIL: OFF or ON
Supported tests which are continuous Support status of continuous

monitors:
Misfire monitoring MIS_SUP: YES
Fuel system monitoring FUEL_SUP: YES
Comprehensive component monitoring CCM_SUP: YES
Status of continuous monitoring tests since DTC cleared Completion status of

continuous monitors since DTC
cleared:
Misfire monitoring MIS_RDY: YES or NO
Fuel system monitoring FUEL_RDY: YES or NO
Comprehensive component monitoring CCM_RDY: YES or NO
Supported tests run at least once per trip Supported status of

non-continuous monitors:
Catalyst monitoring CAT_SUP: YES
Heated catalyst monitoring HCAT_SUP: NO
Evaporative system monitoring EVAP_SUP: YES
Secondary air system monitoring AIR_SUP: NO
A/C system refrigerant monitoring ACRF_SUP: NO
Oxygen sensor monitoring O2S_SUP: YES
Oxygen sensor heater monitoring HTR_SUP: YES
EGR system monitoring EGR_SUP: YES
Status of tests run at least once per trip Completion status of

non-continuous monitors since
DTC cleared:
Catalyst monitoring CAT_RDY: YES or NO
Heated catalyst monitoring HCAT_RDY: YES
Evaporative system monitoring EVAP_RDY: YES or NO
Secondary air system monitoring AIR_RDY: YES
A/C system refrigerant monitoring ACRF_RDY: YES
Oxygen sensor monitoring O2S_RDY: YES or NO
Oxygen sensor heater monitoring HTR_RDY: YES or NO
EGR system monitoring EGR_RDY: YES or NO
13A-61
(PID)
03 Fuel system 1 status FUELSYS1:

OL/CL/OL-Drive/OL-Fault/CL-F
ault
Fuel system 2 status FUELSYS2:
OL/CL/OL-Drive/OL-Fault/CL-F
ault
04 Calculated LOAD Value LOAD_PCT: xxx.x%
05 Engine Coolant Temperature ECT: xxx C (xxx F)
06 Short Term Fuel TrimBank 1 SHRTFT1: xxx.x %
07 Long Term Fuel TrimBank 1 LONGFT1: xxx.x %
08 Short Term Fuel TrimBank 2 SHRTFT2: xxx.x %
09 Long Term Fuel TrimBank 2 LONGFT2: xxx.x %
0B Intake Manifold Absolute Pressure MAP: xxx kPa (xx.x inHg)
0C Engine RPM RPM: xxxxx min-1
0D Vehicle Speed Sensor VSS: xxx km/h (xxx mph)
0E Ignition Timing Advance for #1 Cylinder SPARKADV: xx
0F Intake Air Temperature IAT: xxx C (xxx F)
10 Air Flow Rate from Mass Airflow Sensor MAF: xxx.xx g/s (xxxx.x lb/min)
11 Absolute Throttle Position TP: xxx.x%
13 Location of Oxygen Sensor O2SLOC:
O2S11/O2S12/O2S13/O2S21/
O2S22
14 Bank 1Sensor 1 O2S11: x.xxx V
SHRTFT11: xxx.x%
SHRTFT12: xxx.x%
16 Bank 1-Sensor 3 O2S13: x.xxxV
SHRTFT13: xxx.x%
SHRTFT21: xxx.x%
SHRTFT22: xxx.x%
1C OBD requirements to which vehicle is designed OBDSUP: OBD II
1F Time Since Engine Start RUNTM: xxxxx sec.
21 Distance Travelled While MIL is Active MIL DIST: xxxxx km (xxxxx
miles)
2C Commanded EGR EGR_PCT: xxx.x%
2E Commanded Evaporative Purge EVAP_PCT: xxx.x%
2F Fuel Level Input FLI: xxx.x%
30 Number of warm-ups since diagnostic trouble codes cleared WARM_UPS: xxx

(PID)
31 Distance since diagnostic trouble codes cleared CLR_DIST: xxxxx km (xxxxx

miles)
32 Evap System Vapor Pressure EVAP_VP: xxxx.xx Pa (xx.xxx
in H2O)
33 Barometric Pressure BARO: xxx kPa (xx.x inHg)
41 Monitor status this driving cycle
Enable status of continuous monitors this monitoring cycle: Enable status of continuous
NO means disable for rest of this monitoring cycle or not monitors this monitoring cycle:
supported in PID 01, YES means enable for this monitoring
cycle.
Misfire monitoring MIS_ENA: NO or YES
Fuel system monitoring FUEL_ENA: NO or YES
Comprehensive component monitoring CCM_ENA: YES
Completion status of continuous monitors this monitoring Completion status of

cycle: continuous monitors this
monitoring cycle:
Misfire monitoring MIS_COMPL: YES or NO
Fuel system monitoring FUEL_COMP: YES or NO
Comprehensive component monitoring CCM_CMPL: YES or NO
Enable status of non-continuous monitors this monitoring Enable status of

cycle: non-continuous monitors this
monitoring cycle:
Catalyst monitoring CAT_ENA: YES or NO
Heated catalyst monitoring HCAT_ENA: NO
Evaporative system status EVAP_ENA: YES or NO
Secondary air system monitoring AIR_ENA: YES or NO
A/C system refrigerant monitoring ACRF_ENA: YES or NO
Oxygen sensor monitoring O2S_ENA: YES or NO
Oxygen sensor heater monitoring HTR_ENA: YES or NO
EGR system monitoring EGR_ENA: YES or NO
Completion status of non-continuous monitors this Completion status of

monitoring cycle: non-continuous monitors this
monitoring cycle:
Catalyst monitoring CAT_CMPL: YES or NO
Evaporative system status EVAP_CMPL: YES or NO
Oxygen sensor monitoring O2S_CMPL: YES or NO
Oxygen sensor heater monitoring HTR_CMPL: YES or NO
EGR system monitoring EGR_CMPL: YES or NO
13A-63
(PID)
42 Control module voltage VPWR: xx.xxx V

43 Absolute Load Value LOAD_ABS: xxx.x%
44 Commanded Equivalence Ratio EQ_RAT: x.xxx
45 Relative Throttle Position TP_R: xxx.x%
46 Ambient air temperature AAT: xxx C (xxx F)
47 Absolute Throttle Position B TP_B: xxx.x%
49 Accelerator Pedal Position D APP_D: xxx.x%
4A Accelerator Pedal Position E APP_E: xxx.x%
4C Commanded Throttle Actuator Control TAC_PCT: xxx.x%
.
Actuator Test Function

The actuator test items are shown in the following
table.
M.U.T.-III SCAN ITEM INSPECTION ITEM ACTIVATING CONTENT
TOOL DISPLAY NO.
A/C relay 16 A/C compressor clutch relay The relay turns from OFF to ON
EVAP. emission purge 10 Evaporative emission purge The solenoid valve turns from OFF
SOL. solenoid to ON
EVAP. emission 15 Evaporative emission ventilation The solenoid valve turns from OFF
ventilation SOL. solenoid to ON
Fuel pump 9 Fuel pump Fuel pump operates
Ignition timing 5 11 Basic ignition timing Set to ignition timing adjustment
BTDC mode
No. 1 injector 1 Injectors Cut fuel to No. 1 injector
No. 2 injector 2 Cut fuel to No. 2 injector
VVT oil control valve 17 Engine oil control valve Engine oil control valve turns from
OFF to ON
Cooling fan 14 Radiator fan, A/C condenser fan Drives the fan motor
NOTES
13B-1
GROUP 13B
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION . . . . . . . . 13B-2 FUEL TANK . . . . . . . . . . . . . . . . . . . . 13B-3

13B-2 FUEL SUPPLY
GENERAL INFORMATION
GENERAL INFORMATION
M2134000100833
Fuel pipe
.
The fuel system consists of the following compo-

nents: Fuel tank
Fuel injector Fuel pump module
Fuel rail Evaporative emission canister
SPECIFICATIONS
Item Specification
Fuel tank capacity dm3 (gal) 59 (15.5)
Fuel pump type Electric
Fuel filter type Cartridge (incorporates fuel pump module)
Fuel return system Returnless
Fuel pump pressure regulator pressure kPa (psi) 324 (46)
Fuel injector Type Elector-magnetic
Quantity 4
Evaporative emission control system Canister
CONSTRUCTION DIAGRAM
Fuel tank
Fuel rail
Evaporative
emission
Fuel injector Fuel pump module canister
Fuel pipe
AC610224 AB
This fuel system is designed with consideration for The surface of underfloor fuel pipes is coated
global environment protection to ensure safety at a with 1-mm thickness of plastic to improve resis-
collision, reduce weight, and improve reliability and tance to corrosion and chipping.
quality. This system has the following features: A returnless fuel system eliminates returned fuel
A quick-joint connector of a plastic tube is used from the engine. The heat that fuel receives from
for the fuel high-pressure hoses in the engine the engine is reduced, minimizing fuel tempera-
compartment to reduce the permeation of fuel ture in the fuel tank and controlling the amount of
evaporative emission. evaporated gas.
FUEL SUPPLY
FUEL TANK
13B-3
FUEL TANK
M2134001000817
The fuel cut-off valve, fuel tank leveling valve and
.
The fuel tank assembly consists of the fuel pump

module, the fuel tank, and so on, and features the fuel tube have been installed using in-tank con-
following characteristics: struction to reduce the amount of evaporated fuel
The fuel tank is mounted underneath the second from hoses.
seat to improve safety at a collision. The fuel pump module consists of the following com-
The fuel tank itself is made of a pre-coat zinc ponents:
alloy galvanised steel sheet that contains no Fuel pump
lead. Fuel level sensor
Fuel filter
The capacity of the fuel tank is 59 dm3 (15.5 gal)
Fuel pump pressure regulator
to meet long-distance drives.
Fuel tank temperature sensor
Fuel pump module
Fuel tank
AC610225 AB
Fuel cut-off valve
Fuel check valve
Leveling valve
AC610226AC
NOTES
14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . . 14-2 ENGINE COOLANT CHANGE . . . . . . . . . . 14-13

ENGINE COOLANT CONCENTRATION
SERVICE SPECIFICATIONS. . . . . . . 14-2 TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
COOLING FAN RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
COOLANT . . . . . . . . . . . . . . . . . . . . . 14-2
COOLING FAN MOTOR CHECK . . . . . . . . 14-16
SEALANT. . . . . . . . . . . . . . . . . . . . . . 14-3
THERMOSTAT . . . . . . . . . . . . . . . . . . 14-18
ENGINE COOLING DIAGNOSIS . . . . 14-3 REMOVAL AND INSTALLATION . . . . . . . . 14-18
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-20
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 14-3
TROUBLESHOOTING STRATEGY . . . . . . 14-3
WATER PUMP . . . . . . . . . . . . . . . . . . 14-21
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 14-3
REMOVAL AND INSTALLATION . . . . . . . . 14-21
SYMPTOM PROCEDURES . . . . . . . . . . . . 14-4
WATER HOSE AND WATER PIPE . . 14-22

SPECIAL TOOLS. . . . . . . . . . . . . . . . 14-12
ON-VEHICLE SERVICE. . . . . . . . . . . 14-12 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-25
ENGINE COOLANT LEAK CHECK . . . . . . 14-12

RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-26
RADIATOR CAP OPENING PRESSURE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13 REMOVAL AND INSTALLATION . . . . . . . . 14-26
14-2 ENGINE COOLING
GENERAL INFORMATION
GENERAL INFORMATION
M1141000101028
The cooling system is designed to keep every part of ature, the thermostat opens to circulate the coolant
the engine at appropriate temperature in whatever through the radiator as well so that the heat
condition the engine may be operated. The cooling absorbed by the coolant may be radiated into the air.
method is of the water-cooled, pressure forced circu- The water pump is of the centrifugal impeller type
lation type in which the water pump pressurizes cool- and is driven by the drive belt from the crankshaft.
ant and circulates it throughout the engine. If the The radiator is the corrugated fin, cross flow type.
coolant temperature exceeds the prescribed temper-
Radiator upper hose

Radiator assembly assembly
Radiator fan motor
Transmission oil Radiator condenser

cooler line hose tank assembly
and tube assembly
Condenser fan motor
Cooling fan shroud
Radiator lower hose

AC608448AB
M1141000300944

Valve opening pressure of radiator cap kPa (psi) 93 123 (14 18) Minimum 83 (12)
Thermostat Valve opening temperature of thermostat C ( F) 82 1.5 (180 1)
Full-opening temperature of thermostat C ( F) 95 (203)
Valve lift mm (in) 8.5 (0.33) or more
COOLANT
M1141000400877
Item Quantity dm3 (qt)

Long life antifreeze coolant or an equivalent 7.0 (7.4)
TSB Revision
ENGINE COOLING
SEALANT
14-3
SEALANT
M1141000500885

Engine coolant temperature sensor LOCTITE 262, Three bond 1324 or equivalent
ENGINE COOLING DIAGNOSIS

INTRODUCTION
M1141005300400
The system cools the engine so that it does not over-
heat and maintains the engine at an optimum tem-
perature. The system components are the radiator,
water pump, thermostat, condenser fan assembly.
Possible faults include low coolant, contamination,
belt loosening and component damage.
TROUBLESHOOTING STRATEGY
M1141005200395
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure to find customer exists.
most of the engine cooling faults. 3. Find and repair the malfunction by following the
1. Gather information from the customer. SYMPTOM CHART.
4. Verify that the malfunction is eliminated.
SYMPTOM CHART
M1141005600542
Symptom Inspection procedure Reference page

Coolant leak 1 P.14-4
Engine overheating 2 P.14-5
Radiator fan and condenser fan do not operate 3 P.14-6
TSB Revision
14-4 ENGINE COOLING
SYMPTOM PROCEDURES
Inspection Procedure 1: Coolant Leak
DIAGNOSIS
STEP 1. Check for coolant leaks.

WARNING
When pressure testing the cooling system, slowly
release cooling system pressure to avoid getting
burned by hot coolant.
CAUTION
Be sure to completely clean away any moisture from
the places checked.
When the tester is removed, be careful not to spill any
coolant.
When installing and removing the tester and when test-
ing, be careful not to deform the filler neck of the radia-
tor.
Check that the coolant level is up to the filler neck. Install a radi-
ator tester and apply 160 kPa (23 psi) pressure, and then check
Cap adapter
for leakage from the radiator hose or connections.
Q: Is leakage present from the radiator hose or
Adapter connections?
YES : Repair or replace the appropriate part, then go to
Step 2.
NO : There is no action to be taken.
ACX01844 AE
STEP 2. Retest the system.

Q: It there still coolant leakage?
YES : Return to Step 1.
NO : The procedure is complete.
TSB Revision
ENGINE COOLING
14-5
Inspection Procedure 2: Engine Overheating
DIAGNOSIS
STEP 1. Remove the radiator cap and check for coolant

contamination.
Q: Is the coolant contaminated with rust and oil?
YES : Replace it. Refer to P.14-13.
NO : There is no action to be taken. Go to Step 2.
STEP 2. Check the radiator cap valve opening pressure.

NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
(1) Use a cap adapter to attach the cap to the tester.
(2) Increase the pressure until the gauge indicator stops
moving.
Cap adapter
Minimum limit: 83 kPa (12 psi)
Standard value: 93 123 kPa (14 18 psi)
Q: Does the reading remain at or above the minimum limit?
YES : Go to Step 3.
NO : Replace the radiator cap. Then go to Step 5.
ACX01845AE
STEP 3. Check thermostat operation.

Refer to P.14-20.
Q: Does the thermostat operate correctly?
YES : Go to Step 4.
NO : Replace the thermostat, then go to Step 5.
STEP 4. Check the drive belt for slippage or damage.

Refer to GROUP 00 Maintenance Service, Drive Belts (Check
Condition) P.00-59.
Q: Is the drive belt loose or damaged?
YES : Adjust or replace the drive belt, then go to Step 5.

Check the engine coolant temperature.
Q: Is the engine coolant temperature abnormally high?
TSB Revision
14-6 ENGINE COOLING
Inspection Procedure 3: Radiator Fan and Condenser Fan do not Operate
Radiator Fan and Condenser Fan Drive Circuit
FUSIBLE FUSIBLE
LINK 28 LINK 29
CONDENSER FAN RADIATOR

FAN CONTROL FAN
RELAY RELAY RELAY
CONDENSER RADIATOR
FAN MOTOR FAN MOTOR
ETACS-ECU
Connectors: A-23X, A-26X, A-28X Connectors: A-35, A-40
A-26X A-28X
A-40
A-35
A-23X
AC608955AB AC609446AE
TSB Revision
ENGINE COOLING
14-7
Connector: C-312
When the condenser fan relay is turned ON, bat-
tery voltage is applied from the condenser fan
relay (terminal 3) to the condenser fan motor (ter-
minal 1).
.
FUNCTION
When the radiator fan relay is turned ON, the
radiator fan motor and condenser fan motor
ETACS-ECU
rotate at a low speed.
AC608954AB When the radiator fan relay, fan control relay, and
. condenser fan relay are turned ON, the radiator
CIRCUIT OPERATION fan motor and condenser fan motor rotate at a
Battery voltage is applied to the radiator fan relay high speed.
(terminal 3), fan control relay (terminal 1), and .
condenser fan relay (terminal 1). TROUBLESHOOTING HINTS

ETACS-ECU (terminal 2, 8, and 9) turns ON the Malfunction of fusible link
power transistor in the unit to apply current to the Malfunction of radiator fan relay
radiator fan relay, fan control relay, and con- Malfunction of fan control relay
denser fan relay, thus turning ON the relays. Malfunction of condenser fan relay
When the radiator fan relay is turned ON and the Malfunction of radiator fan motor
fan control relay is also turned ON, battery volt- Malfunction of condenser fan motor
age is applied from the radiator fan relay (termi- Malfunction of relay box
nal 2) to the radiator fan motor (terminal 1). Malfunction of ETACS-ECU
Damaged wiring harness or connector
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-III other system diagnosis codes

Confirm whether the diagnosis codes are output from
ETACS-ECU.
Q: Is the diagnosis code output?
YES : Perform the troubleshooting of ETACS-ECU (Refer to
GROUP 54A ETACS, Diagnosis Code Chart
P.54A-482).
NO : Go to Step 2.
STEP 2. Check the cooling fan relay.

Refer to P.14-15.
Q: Is the check result normal?
YES : Go to Step 3.
NO : Replace the relay.
STEP 3. Connectors check: A-23X condenser fan relay

connector, A-26X radiator fan relay connector and A-28X
fan control relay connector.
Check for the contact with terminals.
YES : Go to Step 4.
NO : Repair the defective connector.
TSB Revision
14-8 ENGINE COOLING
STEP 4. Check the cooling fan motor.

Refer to P.14-16.
YES : Go to Step 5.
NO : Replace the fan motor.
STEP 5. Connectors check: A-40 condenser fan motor

connector and A-35 radiator fan motor connector.
Check for the contact with terminals.
YES : Go to Step 6.
STEP 6. Measure the voltage at radiator fan relay

connector A-26X.
(1) Remove the radiator fan relay, and measure at relay box
side.
(2) Measure the voltage between terminal 3 and earth.
Measure the voltage between terminal 4 and earth.
OK: System voltage
YES : Go to Step 8.
NO : Go to Step 7.
STEP 7. Check the harness between radiator fan relay

connector A-26X (terminal 3, 4) and fusible link number 29.
Check the power supply line for short or open circuit.
YES : An intermittent malfunction is suspected (Refer to
GROUP 00 How to use troubleshooting, How to
Cope with Intermittent Malfunction P.00-13).
NO : Repair the wiring harness.
STEP 8. Measure the voltage at fan control relay connector

A-28X.
(1) Remove the fan control relay, and measure at relay box
side.
OK: System voltage
YES : Go to Step 10.
NO : Go to Step 9.
TSB Revision
ENGINE COOLING
14-9
STEP 9. Check the harness between fan control relay

connector A-28X (terminal 1) and fusible link number 28.
NO : Repair the relay box.
STEP 10. Measure the voltage at condenser fan relay

connector A-23X.
(1) Remove the condenser fan relay, and measure at relay box
side.
Measure the voltage between terminal 4 and earth.
OK: System voltage
NO : Go to Step 11.
STEP 11. Check the harness between condenser fan relay

connector A-23X (terminal 1, 4) and fusible link number 28.
NO : Repair the relay box.
STEP 12. Check the harness between radiator fan relay

connector A-26X (terminal 2) and radiator fan motor
connector A-35 (terminal 1).
Check the output line for short or open circuit.

connector A-28X (terminal 5) and radiator fan motor
TSB Revision
14-10 ENGINE COOLING
STEP 14. Measure the resistance at fan control relay

connector A-28X.
(1) Remove the fan control relay, and measure at relay box
side.
(2) Measure the resistance between terminal 4 and body earth.
OK: Continuity (Less than 2 ohms)
NO : Go to Step 15.

connector A-28X (terminal 4) and earth.
Check the earth line for open circuit.

connector A-28X (terminal 2) and condenser fan relay
connector A-23X (terminal 3).
STEP 17. Check the harness between condenser fan relay

connector A-23X (terminal 3) and condenser fan motor
STEP 18. Measure the resistance at condenser fan motor

connector A-40.
(1) Remove the condenser fan motor connector, and measure
at harness side.
(2) Check the continuity between terminal 2 and body earth.
OK: Continuity (Less than 2 ohms)
NO : Go to Step 19.
TSB Revision
ENGINE COOLING
14-11
STEP 19. Check the harness between condenser fan motor

connector A-40 (terminal 2) and earth.
Check the earth line for open circuit.
STEP 20. Check the harness between ETACS-ECU

connector C-312 (terminal 2) and radiator fan relay
Check the ETACS-ECU input line for open circuit.

connector C-312 (terminal 9) and fan control relay

connector C-312 (terminal 8) and condenser fan relay
STEP 23. M.U.T.-III actuator test

Conduct the MPI system actuator test to check that the fan
works (Refer to GROUP 13A Troubleshooting, Actuator Test
Reference Table P.13A-901).
Item 14: Cooling fan
NO : Replace the ETACS-ECU (Refer to GROUP 54A
ETACS-ECU P.54A-564). Then go to Step 24.

Check that the radiator fan and the condenser fan work.
YES : The procedure is complete.
NO : Return to Step 1.
TSB Revision
SPECIAL TOOLS
SPECIAL TOOLS
M1141000600882

MB991871 General service tool Coolant refilling
LLC changer
MB991871
MB992042 MB992042-01 Engine coolant temperature

Water temp sensor sensor removal and
wrench installation
MB992042
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK
M1141001000690
WARNING
When pressure testing the cooling system, slowly
release cooling system pressure to avoid getting
burned by hot coolant.
CAUTION
Be sure to completely clean away any moisture from
the places checked.
When the tester is taken out, be careful not to spill any
coolant.
Be careful when installing and removing the tester and
when testing not to deform the filler neck of the radia-
tor.
1. Check that the coolant level is up to the filler neck. Install a
radiator tester and apply 160 kPa (23 psi) pressure, and
Cap adapter
then check for leakage from the radiator hose or
connections.
Adapter 2. If there is leakage, repair or replace the appropriate part.
ACX01844 AE
TSB Revision
ENGINE COOLING
ON-VEHICLE SERVICE
14-13
RADIATOR CAP OPENING PRESSURE CHECK
M1141001300840
NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops
Cap adapter moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93 123 kPa (14 18 psi)
3. Replace the radiator cap if the reading does not remain at or
above the limit.
ACX01845AD
ENGINE COOLANT CHANGE

M1141001201125
WARNING
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap anti-clockwise a little to
let the pressure escape through the vinyl tube. After
relieving the steam pressure, remove the cap by
slowly turning it anti-clockwise.
1. Drain the water from the radiator, heater core and engine
after unplugging the radiator drain plug and removing the
radiator cap.
2. Disconnect the cooling water line hose and drain the coolant
in the water jacket.
Cooling water 3. Remove the radiator condenser tank and drain the coolant.
line hose
4. Drain the coolant then clean the path of the coolant by
injecting water into the radiator from the radiator cap area.
5. Install the cooling water line hose.
6. Securely tighten the drain plug of the radiator.
Engine front roll
stopper bracket 7. Reinstall the radiator condenser tank.
AC506619 AD
TSB Revision
ON-VEHICLE SERVICE
CAUTION
Do not use alcohol or methanol anti-freeze or any engine
coolants mixed with alcohol or methanol anti-freeze. The
use of an improper anti-freeze can cause corrosion of the
aluminum components.
8. By referring to the section on coolant, select an appropriate
concentration for safe operating temperature within the
range of 30 to 60%. Use special tool MB991871 to refill the
MB991871
engine coolant up to the top of the radiator port. A
convenient mixture is a 50% water and 50% antifreeze
solution [freezing point: 31 C (23.8 F)].
Recommended antifreeze: Long Life Antifreeze
Coolant or an equivalent
Air hose
Quantity: 7.0 dm3 (7.4 quarts)
AC609929AB
NOTE: For how to use special tool (MB991871), refer to its
manufacturers instructions.
9. Tighten the radiator cap securely.
10.Remove the radiator condenser tank cap, and add the
engine coolant up to the "FULL" line.
11.Turn the A/C switch to OFF position to start the engine and
warm up until the cooling fan operates.
NOTE: This step opens the thermostat fully.
12.Rev the engine several times and then stop it. Check that
there are no coolant leaks.
13.Remove the radiator cap with the engine cool, and then refill
the engine coolant up to the top of the radiator port.
14.Tighten the radiator cap securely.
CAUTION
Do not overfill the radiator condenser tank.
15.Remove the radiator condenser tank cap, and add the
engine coolant up to the "FULL" line.
ENGINE COOLANT CONCENTRATION TEST

M1141001100802
Refer to GROUP 00, Recommended Lubricants and Lubricant
Capacities Table P.00-51.
TSB Revision
ENGINE COOLING
ON-VEHICLE SERVICE
14-15
COOLING FAN RELAY CONTINUITY CHECK
M1141006200826
.
FAN CONTROL RELAY CHECK

Fan control relay Battery voltage Terminal No. to Continuity test
be connected results
to tester
Not applied 2 5 Continuity (Less
than 2 ohms)
Not applied 4 5 Open circuit
Connect Continuity (Less
AC605626 terminal No. 1 than 2 ohms)
and battery (+)
terminal.
Connect
5
2 terminal No. 3
1 2 3
4 and battery ()
4
terminal.
5 1 3
AC610080 AB
RADIATOR FAN RELAY CHECK

Radiator fan relay
Battery voltage Terminal No. to Continuity test
to tester
terminal No. 1 than 2 ohms)
and battery ()
terminal.
AC605626
Connect
terminal No. 3
and battery (+)
terminal.
4
2 2
1 3
4 3 1
AC610081 AB
TSB Revision
ON-VEHICLE SERVICE
CONDENSER FAN RELAY CHECK

Condenser fan relay
Battery voltage Terminal No. to Continuity test
to tester
terminal No.1 than 2 ohms)
and battery (+)
terminal.
AC605626
Connect
terminal No.2
and battery ()
terminal.
1 2 4
3 3
4 1 2
AC610082 AB
COOLING FAN MOTOR CHECK

M1141007600065
Radiator fan 1. Disconnect the fan motor connector.
motor
Condenser fan
motor
AC609446AB
TSB Revision
ENGINE COOLING
ON-VEHICLE SERVICE
14-17
Radiator fan motor 2. Check that the fan motor runs when a positive battery
terminal is connected to the fan motor-side connector
terminal No.1, and terminal No.2 is grounded. Also check to
see that there is no abnormal sound emitted from the fan
motor at this time.
3. If the fan motor is defective, replace it (Refer to P.14-26).
AC609446 AC
Condenser fan motor
AC609446AD
TSB Revision
THERMOSTAT
THERMOSTAT
M1141002401274

Engine Coolant Draining (Refer to P.14-13). Air Cleaner Assembly Installation (Refer to GROUP 15
Engine Upper Cover Removal (Refer to GROUP 11A Air Cleaner P.15-4).
Camshaft P.11A-22). Engine Upper Cover Installation (Refer to GROUP 11A
Air Cleaner Assembly Removal (Refer to GROUP 15 Air Camshaft P.11A-22).
Cleaner P.15-4). Engine Coolant Refilling (Refer to P.14-13).
4
3
24 3 Nm
18 2 ft-lb
10 2 Nm
89 17 in-lb
2
1
AC506788 AC

<<A>> >>B<< 1. Radiator lower hose connection 3. Cooling water inlet hose fitting
2. Control wiring harness clamp >>A<< 4. Thermostat
connection <CVT>
TSB Revision
ENGINE COOLING
THERMOSTAT
14-19
.
<<A>> RADIATOR LOWER HOSE DISCONNEC-

TION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.
Mating marks
AC200641AD

.
>>A<< THERMOSTAT INSTALLATION

CAUTION
Make absolutely sure that no oil adheres to the rubber ring
of the thermostat. Also do not fold or scratch the rubber
ring during installation.
Install the thermostat so that the jiggle valve is facing straight
Jiggle valve
up. Be careful not to fold or scratch the rubber ring.
Rubber ring
AC000279 AD
>>B<< RADIATOR LOWER HOSE CONNECTION

1. Insert each hose as far as the projection of the water inlet
Projection fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
Water inlet Mating

fitting marks
AC200642 AX
TSB Revision
THERMOSTAT
INSPECTION
M1141002500814
.
Thermostat Check
1. Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value: Valve opening temperature: 82 1.5 C
(180 3 F)
ACX00400
2. Check that the amount of valve lift is at the standard value

when the water is at the full-opening temperature.
NOTE: Measure the valve height when the thermostat is
fully closed, and use this measurement to compare the
valve height when the thermostat is fully open.
Standard value:
Full-opening temperature:95 C (203 F)
Valve lift
Amount of valve lift: 8.5 mm (0.33 inch) or more
ACX00401AD
TSB Revision
ENGINE COOLING
WATER PUMP
14-21
WATER PUMP
M1141002701338

Engine Coolant Draining (Refer to P.14-13). Drive Belt Installation (Refer to GROUP 11A Crankshaft
Drive Belt Removal (Refer to GROUP 11A Crankshaft Pulley P.11A-19.)
Pulley P.11A-19.) Drive Belt Tension Check (Refer to GROUP 11A Engine
Adjustment, Drive Belt Tension Check and Adjustment
P.11A-9.)
Engine Coolant Refilling (Refer to P.14-13).
24 3 Nm
18 2 ft-lb
N4
5N
24 3 Nm
18 2 ft-lb
24 3 Nm 3
18 2 ft-lb 9.0 1.0 Nm
1 80 9 in-lb
AC509330 AC

1. Water pump pulley 3. Water pump
2. Water pump inlet pipe mounting 4. Cooling water line gasket
nuts 5. Water pump gasket
TSB Revision
WATER HOSE AND WATER PIPE

M1141003301496

Engine Coolant Draining (Refer to P.14-13). Thermostat Installation (Refer to P.14-18.)
Engine Cover Removal (Refer to GROUP 11A Camshaft Air Cleaner Assembly Installation (Refer to GROUP 15
P.11A-22). Air Cleaner P.15-4.)
Air Cleaner Assembly Removal (Refer to GROUP 15 Air Engine Cover Installation (Refer to GROUP 11A Cam-
Cleaner P.15-4.) shaft P.11A-22.)
Thermostat Removal (Refer to P.14-18.) Engine Coolant Refilling (Refer to P.14-13).
21 N
11 1 Nm 24 3 Nm
98 8 in-lb 18 2 ft-lb
17
1 19
18
N 20
7
25 24
11 1 Nm 24 3 Nm
98 8 in-lb 18 2 ft-lb
10 2 Nm
89 17 in-lb
23
22
24 3 Nm
18 2 ft-lb
24 3 Nm
24 3 Nm 18 2 ft-lb
18 2 ft-lb
4
2
5N
3 6
8
30 9 Nm
16 N 22 7 ft-lb
14
24 3 Nm
18 2 ft-lb
9 13
10 2 Nm
15 89 17 in-lb
12 N 11 10 5.0 1.0 Nm
11 N 44 9 in-lb
20 2 Nm 24 3 Nm
15 1 ft-lb 18 2 ft-lb
AC609590AB

1. Vacuum pipe assembly 6. Engine coolant temperature
<<A>> >>C<< 2. Radiator upper hose sensor connector
3. Throttle body water feed hose 7. Control wiring harness
4. Cooling water outlet hose fitting connection
5. Cooling water outlet hose fitting <> >>B<< 8. Engine coolant temperature
gasket sensor
TSB Revision
ENGINE COOLING
14-23
9. Ground cable connection
10. EGR valve pipe <vehicles for
California>
11. EGR pipe gasket <vehicles for
California>
12. Cooling water line hose <vehicles
for California>
13. Wiring harness bracket
14. Heater hose connection
15. Thermostat case
16. Thermostat case gasket
17. Transmission oil cooler line hose
connection <CVT>
18. Cooling water line hose <M/T>
19. Water pump inlet pipe
>>A<< 20. O-ring
21. Cooling water line gasket
22. Cooling water line hose <M/T>
23. Cooling water line pipe <M/T>
24. Throttle body water return hose
<vehicles for Federal M/T>
25. Cooling water line pipe <vehicles
for Federal M/T>

MB992042: Water Temp Sensor Wrench

.
<<A>> RADIATOR UPPER HOSE DISCONNEC-

TION
Mating marks
AC200641AD
TSB Revision
<> ENGINE COOLANT TEMPERATURE

SENSOR REMOVAL
Use special tool MB992042 to remove the engine coolant tem-
perature sensor.
MB992042
AC509216 AC

.
>>A<< O-RING INSTALLATION

CAUTION
Avoid adhesion of engine oil or grease to the O-ring.
Thermostat case
Fit the O-ring in the water pump inlet pipe groove, wet the
O-ring circumference or the pipe mounting area inner wall, and
then insert the O-ring.
O-ring
Water pump
inlet pipe AC103007AF
>>B<< ENGINE COOLANT TEMPERATURE

SENSOR INSTALLATION
1. Apply sealant to the engine coolant temperature sensor
thread.
Specified sealant: LOCTITE 262 or equivalent
AC103399AD
2. Use special tool MB992042 to tighten the engine coolant

temperature sensor to the specified torque.
MB992042
AC509216 AC
TSB Revision
ENGINE COOLING
14-25
.
>>C<< RADIATOR UPPER HOSE CONNECTION

Projection fitting.
Water inlet Mating

fitting marks
AC200642 AX
INSPECTION
M1141003400542
Water Pipe and Hose Check

Check the water pipe and hose for cracks, damage and clogs.
Replace them if necessary.
TSB Revision
RADIATOR
RADIATOR
M1141001501654

Engine Room Under Cover Front A Removal (Refer to Air Cleaner Installation (Refer to GROUP 15 - Air Cleaner
GROUP 51 Under Cover P.51-16). P.15-4).
Engine coolant Draining (Refer to P.14-13). Engine coolant Refilling and Check (Refer to P.14-13).
Air Cleaner Removal (Refer to GROUP 15 - Air Cleaner Engine Room Under Cover Front A Installation (Refer to
P.15-4). GROUP 51 Under Cover P.51-16).
9.0 2.0 Nm
9.0 2.0 Nm 80 17 in-lb
80 17 in-lb 15 12 2 Nm
102 22 in-lb
5
5.0 1.0 Nm
44 9 in-lb
3
4
21
7 20
12 2 Nm 6
8 102 22 in-lb 18
18
1
2N
9.5 3.5 Nm 19 3.4 0.5 Nm

84 31 in-lb 31 4 in-lb
25 16
17
19 4.4 0.5 Nm
39 4 in-lb 26
10
12
11
4.0 2.0 Nm
9 36 17 in-lb 23
12 2 Nm
102 22 in-lb 3.4 0.5 Nm 4.4 0.5 Nm
31 4 in-lb 39 4 in-lb
12 2 Nm
102 22 in-lb
14
13
24
22
AC608449 AB
Radiator removal steps Radiator removal steps

1. Radiator drain plug 5. Radiator condenser tank hose
2. O-ring <<A>> >>A<< 6. Radiator upper hose
3. Radiator cap 7. Radiator cap assembly
4. Transmission fluid cooler line <<A>> >>A<< 8. Radiator upper hose
hose assembly <CVT> 9. Radiator hose clamp
TSB Revision
ENGINE COOLING
RADIATOR
14-27
Radiator removal steps
<<A>> >>A<< 10. Radiator lower hose
11. Radiator hose bracket <M/T>
12. Radiator hose support <CVT>
13. Radiator fan motor connector
14. Condenser fan motor connector
Headlamp support panel cover
(Refer to GROUP 51 Front
Bumper Assembly and Radiator
Grille P.51-3).
Hood lock release cable, hood
switch (Refer to GROUP 42
Hood P.42A-7).
Front impact sensor (Refer to
GROUP 52B Front Impact
Sensors P.52B-361).
15. Front end upper bar assembly
16. Fan, fan motor and fan shroud
assembly
17. Radiator assembly
18. Support upper insulator
19. Support lower insulator
20. Radiator condenser tank
21. Radiator condenser tank bracket
Fan shroud removal steps
5. Radiator condenser tank hose
7. Radiator cap assembly
13. Radiator fan motor connector
14. Condenser fan motor connector
(Refer to GROUP 51 Front
Bumper Assembly and Radiator
Grille P.51-3).
Hood lock release cable, hood
switch (Refer to GROUP 42
Hood P.42A-7).
15. Front end upper bar assembly
16. Fan, fan motor and fan shroud
assembly
22. Radiator fan motor
23. Fan
24. Condenser fan motor
25. Fan
26. Fan shroud
TSB Revision
RADIATOR

.
<<A>> RADIATOR UPPER HOSE/RADIATOR

LOWER HOSE REMOVAL
Mating marks
AC200641AD

.
>>A<< RADIATOR LOWER HOSE/RADIATOR

UPPER HOSE INSTALLATION
Projection fitting, water outlet fitting or radiator.
Radiator, water inlet Mating

fitting or water outlet marks
fitting AC200642 AY
TSB Revision
14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . . 14-2 WATER PUMP . . . . . . . . . . . . . . . . . . 14-3
WATER PASSAGE . . . . . . . . . . . . . . 14-3

14-2 ENGINE COOLING
GENERAL INFORMATION
GENERAL INFORMATION
M2140000100780
The cooling system is a water-cooled pressurized, To improve engine cooling performance and save
forced circulation type which offers the following fea- weight, a plastic tank and aluminum radiator fins
tures. are used.
To stabilize engine coolant temperature, the ther-
mostat is located at the coolant inlet port from the
radiator.
SPECIFICATIONS
Item Specification
Cooling method Water-cooled pressurized, forced
circulation with electrical fan
Radiator Type Pressurized corrugate type
Performance kJ/h (kcal/h) 222,480 (53,148)
Water pump Type Centrifugal impeller
Drive method Drive belt
Thermostat Type Wax pellet with jiggle valve
Valve open temperature C ( F) 82 (180)
Radiator upper hose

Radiator assembly assembly
Radiator fan motor
Transmission oil Radiator condenser

cooler line hose tank assembly
and tube assembly
Condenser fan motor
Cooling fan shroud
Radiator lower hose

AC608448AB
ENGINE COOLING
WATER PASSAGE
14-3
WATER PASSAGE
M2140004000172
<Hot> <Cold>
Thermostat Thermostat
Water pump Water pump
Heater Heater
EGR EGR
Throttle body Throttle body

CVT oil CVT oil
cooler cooler
Radiator Radiator
AK603624 AB
NOTE: EGR: Exhaust Gas Recirculation <California only>

CVT: Continuously Variable Transmission
WATER PUMP
M2140003000168
The water pump is the centrifugal, impeller type that
is installed in front of the cylinder block. It is driven by
the drive belt.
Item Specifications
Discharge volume L/min 185
Impeller
Impeller diameter mm (in) 62 (2.4)
Pulley outer diameter mm 137 (5.4)
(in)
AK503034 AD
NOTES
15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 15-2 INTAKE MANIFOLD . . . . . . . . . . . . . . 15-5

SERVICE SPECIFICATION . . . . . . . . 15-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-8
INTAKE AND EXHAUST DIAGNOSIS 15-2 EXHAUST MANIFOLD . . . . . . . . . . . . 15-9

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 15-2 REMOVAL AND INSTALLATION . . . . . . . . 15-9
TROUBLESHOOTING STRATEGY . . . . . . 15-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-11
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 15-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 15-3 EXHAUST PIPE AND MAIN
MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-12
SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-4 REMOVAL AND INSTALLATION . . . . . . . . 15-12
AIR CLEANER . . . . . . . . . . . . . . . . . . 15-4

15-2 INTAKE AND EXHAUST
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1151000100899
The exhaust pipe is divided into three parts.
SERVICE SPECIFICATION
M1151000300989
Item Limit
Exhaust manifold distortion of the installation surface mm (in) 0.70 (0.028)
INTAKE AND EXHAUST DIAGNOSIS

INTRODUCTION
M1151006900365
Intake leaks usually create driveability issues that
are not obviously related to the intake system.
Exhaust leaks or abnormal noise is caused by
cracks, gaskets and fittings, or by exhaust pipe or
muffler damage due to impacts during travel. The
exhaust leaks from these sections and causes the
exhaust noise to increase. There may be cases
when the system contacts the body and vibration
noise is generated.
M1151007000365
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find an 3. Find the malfunction by following the Symptom
intake or exhaust system fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1151007100362

Exhaust Leakage 1 P.15-3
Abnormal Noise 2 P.15-3
TSB Revision
INTAKE AND EXHAUST
INTAKE AND EXHAUST DIAGNOSIS
15-3
SYMPTOM PROCEDURES
Inspection Procedure 1: Exhaust Leakage
DIAGNOSIS STEP 2. Check the gasket for cracks, damage.

Q: Is the gasket damaged?
STEP 1. Start the engine. Have an assistant stay YES : Replace the gasket, then go to Step 1.
in the drivers seat. Raise the vehicle on a hoist. NO : Go to Step 3.
Have the assistant rev the engine while
searching for exhaust leaks.
STEP 3. Check for loosening in each coupling
Q: Is the exhaust leaking? section.
YES : Go to Step 2.
Q: Is there any loosening in any section?
YES : Tighten, then go to Step 1.
Inspection Procedure 2: Abnormal Noise
DIAGNOSIS STEP 4. Check for interference of the pipes and

muffler with the body.
STEP 1. Start the engine. Have an assistant stay Q: Are the pipes and muffler interfering with the
in the drivers seat. Raise the vehicle on a hoist. body?
Have the assistant rev the engine while YES : Repair, then go to Step 1.
searching for exhaust leaks. NO : Go to Step 5.
Q: Is any abnormal noise generated?
YES : Go to Step 2. STEP 5. Check the heat protectors.
Q: Are any heat protectors loose or damaged?
YES : Tighten or replace, then go to Step 1.
STEP 2. Check for missing parts in the muffler. NO : Go to Step 6.
Tap the muffler lightly to check for loose baffles,
etc. STEP 6. Check the pipes and muffler for damage.
Q: Are there any missing parts in the muffler?
Q: Are the pipes and muffler damaged?
YES : Replace, then go to Step 1.
NO : Go to Step 3.
STEP 3. Check the hanger for cracks.

Q: Is the hanger cracked?
NO : Go to Step 4.
TSB Revision
SPECIAL TOOL
SPECIAL TOOL
M1151000600827

MB991953 MB991953-01 Removal and installation
Oxygen sensor wrench of heated oxygen sensor
B991953
AIR CLEANER
M1151002101489
1.5 0.3 Nm 6
14 2 in-lb
5
7 8
3
4
9
4.0 1.0 Nm
36 8 in-lb
9.5 3.5 Nm
84 31 in-lb
4.0 1.0 Nm
36 8 in-lb
10
7.0 3.0 Nm
62 27 in-lb
2
9.5 3.5 Nm
84 31 in-lb 9.5 3.5 Nm
84 31 in-lb
AC608341AB

1. Air cleaner element 8. Air cleaner cover
2. Air cleaner intake duct 9. Air cleaner body
3. Breather hose connection Engine control module (Refer to
4. Air cleaner intake hose GROUP 13A Engine Control
5. Vacuum hose connection Module (ECM) P.13A-952).
6. Mass airflow sensor connector Battery and battery tray
7. Mass airflow sensor 10. Air cleaner bracket
TSB Revision
INTAKE AND EXHAUST
INTAKE MANIFOLD
15-5
INTAKE MANIFOLD
M1151003002035

Engine Coolant Draining (Refer to GROUP 14 On-vehi- EGR Valve and EGR Valve Stay Installation (Refer to
cle Service, Engine Coolant Replacement P.14-13). GROUP 17 EGR Valve P.17-85). <Vehicles for Califor-
Engine Upper Cover Removal (Refer to GROUP 11A nia>
Camshaft P.11A-22). Fuel Injector Installation (Refer to GROUP 13A Injector
Drive Belt Removal (Refer to GROUP 11A Crankshaft P.13A-945).
Pulley P.11A-19). Throttle Body Installation (Refer to GROUP 13A Throttle
Air Cleaner Assembly and Air Cleaner Intake Hose Body P.13A-950).
Removal (Refer to P.15-4). Air Cleaner Assembly and Air Cleaner Intake Hose Instal-
Throttle Body Removal (Refer to GROUP 13A Throttle lation (Refer to P.15-4).
Body P.13A-950). Drive Belt Installation (Refer to GROUP 11A Crankshaft
Fuel Injector Removal (Refer to GROUP 13A Injector Pulley P.11A-19).
P.13A-945). Engine Upper Cover Installation (Refer to GROUP 11A
EGR Valve and EGR Valve Stay Removal (Refer to Camshaft P.11A-22).
GROUP 17 EGR Valve P.17-85). <Vehicles for Califor- Engine Coolant Refilling (Refer to GROUP 14 On-vehi-
nia> cle Service, Engine Coolant Replacement P.14-13).
TSB Revision
INTAKE MANIFOLD
22
21
3.5 1.5 Nm 20 2 Nm
21 31 13 in-lb
to
15 1 ft-lb
22 N 14 20 2 Nm
15 1 ft-lb
21 13
N 14 20 2 Nm
11 15 1 ft-lb
2
10
5
20 2 Nm
15 1 ft-lb
7 18
6 3
15 4.0 1.0 Nm
16 4 20 N 36 8 in-lb
25 4 Nm 12 9
18 3 ft-lb 17 N 19
20 2 Nm 4.0 1.0 Nm
3.5 1.5 Nm 20 2 Nm 36 8 in-lb
to 15 1 ft-lb
31 13 in-lb 15 1 ft-lb
AC611344AB

1. Control wiring harness connection >>C<< 12. Injector protector front
2. Emission vacuum hose >>C<< 13. Intake manifold
3. Emission vacuum control chamber 14. Intake manifold gasket
4. Emission vacuum hose >>A<< 15. Screw
5. Brake booster vacuum hose >>B<< 16. Manifold absolute pressure sensor
<<A>> 6. Power steering oil pump assembly 17. O-ring
7. Rocker cover PCV hose >>A<< 18. Screw
8. Engine oil level gauge 19. Purge control solenoid valve
9. Intake manifold stay 20. O-ring
10. Intake manifold stay B <except for 21. Intake manifold harness bracket
California> 22. Engine cover bracket
11. Intake manifold stay C <except for
California>
TSB Revision
INTAKE AND EXHAUST
INTAKE MANIFOLD
15-7
.
<<A>> POWER STEERING OIL PUMP ASSEMBLY

REMOVAL
1. With the hose installed, remove the power steering oil pump
assembly from the bracket.
2. Tie the removed power steering oil pump assembly with a
string at a position where it will not interfere with the removal
and installation of the intake manifold.

.
>>A<< SCREW INSTALLATION

CAUTION
Do not over-tighten. As the self-forming-type screw is
used, the excessive torque can damage the intake mani-
fold threads.
.
>>B<< MANIFOLD ABSOLUTE PRESSURE

SENSOR INSTALLATION
CAUTION
Install the manifold absolute pressure sensor, taking
care that no shock is applied to it.
Do not use a manifold absolute pressure sensor that
has been dropped.
.
TSB Revision
INTAKE MANIFOLD
>>C<< INTAKE MANIFOLD/INJECTOR

PROTECTOR FRONT INSTALLATION
Install the intake manifold and the injector protector front, and
tighten mounting bolts and nuts temporarily.
NOTE: The tightening of the fuel rail assembly, the intake man-
ifold and the injector protector front has the specified order.
Temporarily tighten the intake manifold and injector protector
front mounting bolts and nuts (Refer to GROUP 13A Injector
P.13A-945).
INSPECTION
M1151003101028
.
INTAKE MANIFOLD CHECK

1. Check the intake manifold for damage and cracks, and
replace it if necessary.
2. Check the vacuum outlet port for clogging, and clean it if
necessary.
TSB Revision
INTAKE AND EXHAUST
EXHAUST MANIFOLD
15-9
EXHAUST MANIFOLD
M1151003301594

Front Exhaust Pipe Removal (Refer to P.15-12). Strut Tower Bar Installation (Refer to GROUP 42A Strut
Strut Tower Bar Removal (Refer to GROUP 42A Strut Tower Bar P.42A-11).
Tower Bar P.42A-11). Front Exhaust Pipe Installation (Refer to P.15-12).
<Except for CALIFORNIA>
14 1 Nm
120 13 in-lb
49 5 Nm 8
36 4 ft-lb
28 8 Nm
21 6 ft-lb
N 6 41 10 Nm
30 8 ft-lb
2
N 7
3
10 N
5
41 10 Nm
30 8 ft-lb 4
20 5 Nm
15 3 ft-lb
14 1 Nm
120 13 in-lb
14 1 Nm 14 1 Nm
120 13 in-lb 120 13 in-lb
AC608496 AB

1. Exhaust manifold cover (upper) <<A>> >>A<< 6. Exhaust manifold nut
2. Engine hanger <<A>> >>A<< 7. Exhaust manifold washer
3. Exhaust manifold bracket D <<A>> >>A<< 8. Exhaust manifold
4. Exhaust manifold bracket B <<A>> >>A<< 9. Exhaust manifold cover (lower)
5. Exhaust manifold bracket A 10. Exhaust manifold gasket
TSB Revision
EXHAUST MANIFOLD
<Vehicles for CALIFORNIA>
8.0 2.0 Nm
71 8 in-lb
1
3
2
28 8 Nm
21 6 ft-lb
49 5 Nm 8 4
36 4 ft-lb
N 6
N 7
8.0 2.0 Nm
71 8 in-lb
9 N 10
8.0 2.0 Nm
71 8 in-lb
41 10 Nm
30 8 ft-lb
AC608497AB

1. Heated oxygen sensor (front) <<A>> >>A<< 6. Exhaust manifold nut
connector <<A>> >>A<< 7. Exhaust manifold washer
2. Heated oxygen sensor (front) <<A>> >>A<< 8. Exhaust manifold
3. Exhaust manifold cover (upper) <<A>> >>A<< 9. Exhaust manifold cover (lower)
4. Engine hanger 10. Exhaust manifold gasket
5. Exhaust manifold bracket
TSB Revision
INTAKE AND EXHAUST
EXHAUST MANIFOLD
15-11
.
<<A>> EXHAUST MANIFOLD NUT/EXHAUST

MANIFOLD WASHER/EXHAUST MANI-
FOLD/EXHAUST MANIFOLD COVER REMOVAL
1. Remove the mounting bolts of the exhaust manifold cover
(upper) and move them to the position where they will not
interfere with the loosening of the exhaust manifold nut.
2. Loosen the exhaust manifold nut, and remove the exhaust
manifold nut and the exhaust manifold washer.
3. Remove the exhaust manifold and the exhaust manifold
cover (lower) as a set.

.
>>A<< EXHAUST MANIFOLD COVER/EXHAUST

MANIFOLD/EXHAUST MANIFOLD
WASHER/EXHAUST MANIFOLD NUT INSTALLA-
TION
1. Install the exhaust manifold cover (lower) to the exhaust
manifold (with mounting bolts removed), install the exhaust
manifold and the exhaust manifold cover (upper) to the
engine as a set.
2. Install the new exhaust manifold nut and exhaust manifold
washer, and tighten the exhaust manifold nut to the
specified torque.
3. Install the exhaust manifold cover (upper) to the exhaust
manifold, and tighten the exhaust manifold cover (upper) to
the specified torque.
Tightening torque:
14 1 N m (120 13 in-lb) <except for California>
8.0 2.0 N m (71 18 in-lb) <vehicles for Califor-
nia>
INSPECTION
M1151003400930
.
EXHAUST MANIFOLD CHECK

1. Check the exhaust manifold for damage and cracks, and
replace it if necessary.
2. Using a straight edge and a thickness gauge, check for
distortion of the cylinder head installation surface. If it
exceeds the limit value, replace it.
TSB Revision
EXHAUST PIPE AND MAIN MUFFLER

M1151008701489
AC608351
18 AC608489
24
26 5.0 2.0 Nm
22 45 17 in-lb
7.0 3.0 Nm 9.5 3.5 Nm

84 31 in-lb 17
62 27 in-lb 16
16
<Except for California> 25 N 21 N 21 N
41 10 Nm 44 5 Nm 5.0 2.0 Nm
5.0 2.0 Nm
30 8 ft-lb 33 3 ft-lb 45 17 in-lb
N 23 45 17 in-lb
3 9.5 3.5 Nm
4
84 31 in-lb 12
20 16
1
N 15
14 7
41 10 Nm 9.5 3.5 Nm
N 19 59 10 Nm 30 8 ft-lb 84 31 in-lb
44 78 ft-lb
44 5 Nm
<Vehicles for California> 33 3 ft-lb
8
41 10 Nm 44 5 Nm
N 23 30 8 ft-lb 33 3 ft-lb 9.5 3.5 Nm 12
84 31 in-lb
3
4 20
13 15 N
44 5 Nm 9
33 3 ft-lb
41 10 Nm
14 N 19 30 8 ft-lb
44 5 Nm
59 10 Nm 33 3 ft-lb
44 78 ft-lb 11
2
10
47 11 Nm
35 8 ft-lb 20 5 Nm
20 5 Nm 15 3 ft-lb
15 3 ft-lb AC608678AB
Exhaust main muffler and rear Center exhaust pipe and front
floor panel heat protector floor panel rear heat protector
removal steps removal steps (Continued)
1. Exhaust main muffler Lower side cover (Refer to
15. Exhaust pipe gasket GROUP 52A Front Floor
16. Exhaust muffler hanger Console Assembly P.52A-8).
17. Exhaust tail pipe diffuser Turn up the passenger side floor
18. Rear floor panel heat protector carpet.
Center exhaust pipe and front 3. Heated oxygen sensor (front)
floor panel rear heat protector connector <except for California>
removal steps <<A>> >>B<< 4. Heated oxygen sensor (front)
2. Backbone brace <except for California>
Footrest
TSB Revision
INTAKE AND EXHAUST
15-13
Center exhaust pipe and front
floor panel rear heat protector
removal steps (Continued)
5. Heated oxygen sensor (rear)
connector <vehicles for
California>
<<A>> >>B<< 6. Heated oxygen sensor (rear)
<vehicles for California>
7. Heated oxygen sensor (rear)
connector <except for California>
<<A>> >>B<< 8. Heated oxygen sensor (rear)
<except for California>
9. Heated oxygen sensor (3rd)
connector <vehicles for
California>
10. Harness cover <vehicles for
California>
<<A>> >>B<< 11. Heated oxygen sensor (3rd)
12. Center exhaust pipe
19. Exhaust pipe gasket
20. Exhaust muffler hanger
<> >>A<< 21. Rivet
<> >>A<< 22. Front floor rear panel heat
protector
Front exhaust pipe and front
floor panel front heat protector
removal steps
<<A>> >>B<< 13. Heated oxygen sensor (front)
14. Front exhaust pipe
19. Exhaust pipe gasket
23. Seal ring
24. Dash panel heat protector
<> >>A<< 25. Rivet
<> >>A<< 26. Front floor front panel heat
protector

MB991953: Oxygen Sensor Wrench

.
<<A>> OXYGEN SENSOR REMOVAL

Remove the connection and clamp of oxygen sensor connec-
tor, and then use special tool MB991953 to remove the oxygen
Heated oxygen sensor.
sensor
MB991953
AC301966AG
TSB Revision
<> RIVET/FRONT FLOOR REAR PANEL HEAT

PROTECTOR/FRONT FLOOR FRONT PANEL
HEAT PROTECTOR REMOVAL
CAUTION
Be careful not to score the heat protector by drill.
1. Use a 6.0 / diameter / mm drill to make a hole in the flange
of rivet as shown.
Heat Rivet
protector 2. Break the rivet, and remove the rivet and heat protector.
Drill
AC301909AD

.
>>A<< FRONT FLOOR FRONT PANEL HEAT PRO-

TECTOR/FRONT FLOOR REAR PANEL HEAT
PROTECTOR/RIVET INSTALLATION
Use a riveter to tighten the rivet by the following procedure.
1. Insert part A of rivet into the riveter, and insert the rivet into
Heat protector the assembling area.
2. Operate the tool's handle while pushing the flange surface of
rivet by riveter. Part A of rivet is cut and the rivet is tightened.
Rivet Rivet
Part A
Part A
Riveter AC301910 AD
>>B<< OXYGEN SENSOR INSTALLATION

1. Tighten the oxygen sensor to the specified torque by using
special tool MB991953.
Heated oxygen
sensor Tightening torque: 44 5 N m (33 3 ft-lb)
2. Connect the oxygen sensor connector and install the
MB991953 connector bracket.
AC301966AG
TSB Revision
15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
AIR DUCT AND AIR CLEANER . . . . 15-2 EXHAUST MANIFOLD . . . . . . . . . . . . 15-4
INTAKE MANIFOLD . . . . . . . . . . . . . 15-3 EXHAUST PIPE AND MUFFLER . . . . 15-4

AIR DUCT AND AIR CLEANER
AIR DUCT AND AIR CLEANER

M2150004000656
A front air intake system that actively sucks cooling
air from the front through the top of the radiator has
been adopted in order to improve engine perfor-
mance and reduce air intake noise.
Mass airflow sensor
Air cleaner intake hose Air cleaner assembly
Air cleaner intake duct
AC608342AB
INTAKE AND EXHAUST
INTAKE MANIFOLD
15-3
INTAKE MANIFOLD
M2150005000239
The intake manifold is made of plastic for weight
reduction, and the surface roughness of the inner
walls of the ports has been improved to reduce
intake resistance.
Intake manifold
Air intake plenum

tank resonator
AK502555 AD
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M2150006000566
<California> <Except California>
A clamshell type exhaust manifold is used. A SUS pipe type exhaust manifold is used.
<CALIFORNIA> <Except CALIFORNIA>
AK603623 AB
EXHAUST PIPE AND MUFFLER

M2150003000783
The exhaust system is composed of the front Fewer, more environmentally-friendly rubber
exhaust pipe, center exhaust pipe, and main muffler, hangers to reduce vibration from exhaust system.
and it has the following characteristics. Straighter exhaust pipe to reduce noise.
Main muffler
Center exhaust pipe

Heated oxygen sensor (front)
Heated oxygen sensor (rear)

Front exhaust pipe
AC608352AB
<Vehicles for California>
Main muffler
Heated oxygen Heated oxygen Center exhaust pipe

sensor (front) sensor (rear)

Front exhaust pipe
AC608488 AB
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
STARTER MOTOR . . . . . . . . . . . . . . 16-2 IGNITION COIL . . . . . . . . . . . . . . . . . . 16-2
ALTERNATOR . . . . . . . . . . . . . . . . . . 16-2 SPARK PLUG . . . . . . . . . . . . . . . . . . . 16-3

16-2 ENGINE ELECTRICAL
STARTER MOTOR
STARTER MOTOR
M2161002000160
The starter motor is a reduction drive planetary gear type.
AK603841
ALTERNATOR
M2162001000126
The alternator is a battery detection type.
It uses a pulley with a one-way clutch.
AK603842
IGNITION COIL
M2163001000174
The ignition coil is a plug-top type.
Coil
Plug boots
Rain cover
AK602597AC
ENGINE ELECTRICAL
SPARK PLUG
16-3
SPARK PLUG
M2163005000068
Iridium-tipped spark plugs are used.
Iridium
AK604562AB
NOTES
17-1
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL . . . . . . . . . . . . . . 17-2 EMISSION CONTROL . . . . . . . . . . . . 17-8

GENERAL INFORMATION. . . . . . . . . . . . . 17-2 GENERAL DESCRIPTION . . . . . . . . . . . . . 17-8
CRANKCASE VENTILATION SYSTEM . . . 17-10
AUTO-CRUISE CONTROL SYSTEM 17-2 EVAPORATIVE EMISSION CONTROL
GENERAL INFORMATION. . . . . . . . . . . . . 17-2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-11
CONSTRUCTION AND OPERATION . . . . 17-5 EXHAUST GAS RECIRCULATION (EGR)
SYSTEM <California> . . . . . . . . . . . . . . . . . 17-12
EMISSION REDUCTION SYSTEMS. . . . . . 17-14
17-2 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
ENGINE CONTROL
GENERAL INFORMATION
M2170001000659
For the accelerator system, an electronic throttle
valve control system has been adopted, disposing of
an accelerator cable. This system detects the accel-
erator pedal travel by using a accelerator pedal posi-
tion sensor (APP sensor) in the accelerator pedal
assembly for electronic control of the throttle valve
angle.
Accelerator pedal assembly

[Built-in accelerator pedal position
sensor (APP sensor)]
AC505671AB
AUTO-CRUISE CONTROL SYSTEM

GENERAL INFORMATION
M2170001000682
By using the auto-cruise control system, the driver For this auto-cruise control system, in conjunction
can drive at preferred speeds in a range of approxi- with the electronic throttle valve control system, the
mately 40 to 200 km/h (25 to 125 mph) without engine control module (ECM) electronically controls
depressing the accelerator pedal. the throttle valve.
ENGINE AND EMISSION CONTROL
17-3
"CRUISE" indicator light
Throttle body
[Built-in throttle position sensor
(TP sensor) and
throttle actuator control motor Clutch switch <M/T> AC611099
(TAC motor)]
Auto-cruise
control switch
Vehicle speed
sensor <M/T>
AC611100
Brake pedal
assembly
Transmission
range switch
<CVT> AC611098 Transaxle control
Engine control module (TCM) <CVT> AC606956
module (ECM)
Stoplight switch
Accelerator pedal Data link connector
[Built-in accelerator
pedal position sensor
(APP sensor)]
Hood
lock
release
handle AC611101
AC611102 AD
COMPONENTS AND FUNCTIONS

Component Function
Accelerator pedal position sensor (APP sensor) Informs the ECM of the accelerator pedal
depression.
Auto-cruise control switch "ON/OFF" switch Power switch for auto-cruise control system.
"ACC/RES" switch Vehicle speed is set with the "ACC/RES" switch and
"COAST/SET" switch "COAST/SET" switch.
"CANCEL" switch Cancels the cruise speed setting.
Cancel system Clutch switch <M/T> Because the constant speed driving is cancelled by
the clutch operation, the clutch pedal status is
detected.
Stoplight switch Because the constant speed driving is canceled
by the brake operation, it detects the brake pedal
status.
As for the stoplight switch, two built-in switches,
the stoplight switch which is also used for the
stoplight illumination and the brake switch which
is used exclusively for the auto-cruise control, are
integrated, and thus the reliability is enhanced.
Transmission range Because the constant speed driving is cancelled by
switch <CVT> the selector lever operation, it detects the "N"
position.
"CRUISE" indicator light The light is included in the combination meter and
illuminates when the "ON/OFF" switch is pressed
(auto-cruise control system: ON).
Data link connector If the M.U.T.-III scan tool is connected, the input
check code from the ECM can be read.
Engine control module (ECM) Based on the input signal from each sensor and
switch, it outputs the throttle opening instruction
signal to the TAC motor.
Based on the input signal from each sensor and
switch, it outputs the transaxle control signal to
the TCM <CVT>.
Based on the vehicle speed signal from the
vehicle speed sensor, it calculates the vehicle
speed <M/T>.
Based on the secondary pulley speed sensor
signal from the TCM, it calculates the vehicle
speed <CVT>.
Based on the selector lever "N" position signal of
the transmission range switch from the ECM, it
cancels constant speed driving. <CVT>.
Outputs the ON/OFF signals of "CRUISE"
indicator light and auto-cruise control system.
The diagnostic trouble code signal is sent to the
"CRUISE" indicator light.
The input check code is sent to the data link
connector.
Throttle actuator control motor (TAC motor) The throttle valve opens and closes in response to
the throttle angle signal from the ECM.
17-5
Component Function
Throttle position sensor (TP sensor) Informs the ECM of the throttle valve opening angle.
Transaxle control module (TCM) <CVT> Based on the transaxle control signal from the
ECM, it controls the transaxle.
Outputs the signal from the secondary pulley
speed sensor to the ECM.
Transmits the selector lever "N" position signal
from the transmission range switch to the ECM.
Vehicle speed sensor <M/T> Transmits the vehicle speed signal proportional to
the vehicle speed to the ECM.
CONSTRUCTION AND OPERATION

M2170002000232
SYSTEM OUTLINE The engine control section sends the target acceler-
The ECM calculates the auto-cruise control system ator pedal opening angle value for auto-cruise con-
operation status when the ECM receives input sig- trol system, the TCM issues a command to transaxle
nals from the auto-cruise control switch, vehicle control <CVT>, and the gauge issues an ON/OFF
speed and cancel system [stoplight switch and clutch command for the "CRUISE" indicator light.
switch <M/T> or transmission range switch <CVT>]. In the engine control section, the target throttle valve
opening angle value is calculated from the target
accelerator pedal opening angle value for
auto-cruise control system and the actual accelerator
angle value.The vehicle speed is then controlled by
applying the TAC motor.
BLOCK DIAGRAM
Auto-cruise control switch Stoplight switch, clutch switch <M/T> APP sensor
ECM
ON/OFF ON/OFF Actual accelerator

signal signal pedal opening
Target accelerator angle signal
pedal opening
angle signal
Cruise control section Engine control section
Target throttle
Vehicle Secondary valve opening
speed pulley speed Transmission
Shift control angle signal
signal sensor signal range switch
<M/T> signal <CVT>
<CVT> signal <CVT>
Vehicle speed TCM <CVT>

sensor <M/T>
Secondary Transmission
"CRUISE" Shift control
pulley speed range switch signal <CVT>
indicator light
sensor signal signal <CVT>
ON/OFF signal
<CVT>
"CRUISE" indicator light Transaxle TAC motor
AC611103
SYSTEM FUNCTIONS
.
.
ACCEL FUNCTION
SET FUNCTION 1. When the "ACC/RES" switch is continuously
1. During driving with the vehicle speed range from pressed for 0.5 second or more during constant
approximately 40 to 200 km/h (25 to 125 mph), driving, it accelerates the vehicle with specified
press and release the "COAST/SET" switch. acceleration while the switch is pressed.
2. The vehicle speed when the "COAST/SET" switch 2. Then, when the "ACC/RES" switch is released,
is released is memorized. Thereafter, the constant the vehicle speed at that time is now memorized.
speed driving is performed at that vehicle speed. Thereafter, the constant speed driving is
performed at that vehicle speed.
3. When the "COAST/SET" switch is operated
during the driving with the vehicle speed of 3. Also, when the "ACC/RES" switch is pressed for
approximately 200 km/h (125 mph) or more, the less than 0.5 second, the vehicle is accelerated
constant speed driving will not be performed. 1.6 km/h (1 mph) from the vehicle speed of
constant speed driving, and the accelerated
.
vehicle speed is now memorized. Thereafter, the

COAST FUNCTION constant speed driving is performed at that
1. When the "COAST/SET" switch is continuously vehicle speed.
pressed for 0.5 seconds or longer during constant 4. It is possible to keep pressing the "ACC/RES"
speed driving, the throttle valve becomes fully switch until the vehicle speed is accelerated to
closed while the switch is pressed, and the approximately 200 km/h (125 mph) or above.
vehicle is decelerated. However, after the "ACC/RES" switch is released,
2. When the "COAST/SET" switch is released, the the vehicle speed of approximately 200 km/h (125
vehicle speed at that time is now memorized. mph) becomes the newly memorized vehicle
Thereafter, the constant speed driving is speed. Thereafter, the constant speed driving is
performed at that vehicle speed. performed at that speed.
3. Also when the "COAST/SET" switch is pressed .
for less than 0.5 second, the vehicle is CANCEL FUNCTION

decelerated 1.6 km/h (1 mph) from the vehicle When any of the following conditions are satisfied,
speed of constant speed driving, and the the constant speed driving will be cancelled.
decelerated vehicle speed is now memorized. The auto-cruise control system is stopped by the
Thereafter, the constant speed driving is pressing the "ON OFF" switch.
performed at that vehicle speed. The "CANCEL" switch is pressed.
4. When the "COAST/SET" switch is continuously The brake pedal is depressed.
pressed and the vehicle speed is decelerated to The clutch pedal is depressed <M/T>.
approximately 40 km/h (25 mph) or less, the set The selector lever is shifted to the "N" position
function and coast function are cancelled, and the <CVT>.
constant speed driving is cancelled. The vehicle speed becomes approximately 40
.
km/h (25 mph) or less.
RESUME FUNCTION The vehicle speed is reduced 15 km/h (9 mph) or
1. When the "CANCEL" switch is pressed or the more from the speed at which the constant speed
brake pedal is depressed during the constant driving was started.
speed driving, it cancels the constant speed An abnormality occurs in the vehicle speed sig-
driving. nal.
The engine coolant temperature becomes abnor-
2. Subsequently, when the "ACC/RES" switch is
mally high.
pressed during driving with the vehicle speed of
An abnormality occurs to the ECM.
approximately 40 km/h (25 mph) or more, the
An abnormality occurs to the TCM <CVT>.
constant speed driving is performed with the
An abnormality occurs to the CAN communica-
vehicle speed memorized at the last cancellation
tion.
of constant speed driving.
.
17-7
FAIL-SAFE FUNCTION ECM abnormality
When any of the following conditions are satisfied, TP sensor abnormality
the auto-cruise control system function is stopped APP sensor abnormality
until the system returns to normal. Also, when any of .
the conditions are satisfied during the constant DIAGNOSIS FUNCTION

speed driving, the constant speed driving is can- The diagnostic trouble code check is possible
celled immediately. with the "CRUISE" indicator light.
An abnormality occurs to the auto-cruise control To facilitate the system check, check the service
switch. data output with the M.U.T.-III.
An abnormality occurs to the stoplight switch. NOTE: For diagnostic items, service data output
When any of the following conditions are satisfied, items, and check method, refer to the Service Man-
stop the vehicle once and turn the ignition switch to ual.
"LOCK" (OFF). Otherwise, even when the system
returns to normal, the auto-cruise control system
function will continue to be stopped. Also, when any
of the conditions are satisfied during the constant
speed driving, the constant speed driving is can-
celled immediately.
EMISSION CONTROL
EMISSION CONTROL
GENERAL DESCRIPTION
M2171000101024
The following changes have been made to the con-
trols of the 2.4L engine provided on the GALANT.
Improvement / Additions Remark
Addition of HC trap catalytic converter <California> HC decrease
SYSTEM CONFIGURATION DIAGRAM
purge solenoid
Positive crankcase
ventilation valve
ventilation valve
Evaporative
emission
canister
Heated oxygen Fuel pressure Fuel tank

sensor (front) regulator
Fuel pump Fuel level
sensor
Fuel tank differential

Three-way catalytic converter pressure sensor
Heated oxygen Fuel tank
sensor (rear) temperature
sensor
AK604140 AB
EMISSION CONTROL
17-9
<California>
purge solenoid
Positive crankcase
ventilation valve
ventilation valve
Heated
oxygen Evaporative
sensor emission
(front) canister Fuel
Heated tank
oxygen
sensor EGR valve Fuel pressure
(rear) (stepper motor) regulator
Fuel pump Fuel level
sensor
Fuel tank differential

HC trap Three-way catalytic converter pressure sensor
catalytic
converter Heated oxygen sensor (3rd) Fuel tank
temperature
sensor
AK604141 AB
Exhaust gas cleaning devices list

System Objective / Function Composition parts
Crankcase ventilation HC decrease Positive crankcase ventilation
system Re-combustion of blow-by gas. (PCV) valve
Evaporative emission HC decrease Canister
control system Re-combustion of fuel vapor gas. Evaporative emission purge
solenoid
Exhaust gas recirculation NOx decrease EGR valve
(EGR) system Reduce NOx generation by controlling EGR
<California> volume according to engine warm-up condition
and driving conditions.
EMISSION CONTROL
System Objective / Function Composition parts

Emission Air-fuel ratio Decrease of CO, HC and NOx ECM
reduction feedback Controls air-fuel ratio of air-fuel mixture to Mass airflow sensor
systems control become theoretical air-fuel ratio (about 14.7), Injectors
which is when the 3-way catalytic converter's Heated oxygen sensor
cleaning performance is best. It also controls Crankshaft position sensor
optimum fuel supply based on coolant etc.
temperature, driving conditions etc.
Catalytic Decrease of CO, HC and NOx Monolith catalyst
converter It facilitates oxidation of CO and HC and
reduction of NOx so that all 3 component gases
are cleaned simultaneously.
HC trap HC decrease Monolith catalyst
catalytic During cold operation of engine, exhaust HC is
converter temporarily absorbed. And then Exhaust HC is
<California> released when temperature reaches to level at
which catalyst is activated. This allows HC to be
reduced.
CRANKCASE VENTILATION SYSTEM
M2171000400129
Ventilation hose
Air cleaner
PCV valve
Breather hose
Flow of blow-by gas and clean air (low load area)
Flow of blow-by gas (high load area)
AK604142 AB
A blow-by gas reduction device prevents blow-by case. The blow-by gas in the crankcase is induced to
gas from being expelled into the atmosphere and is the intake manifold through the rocker cover and
of closed type. A positive crankcase ventilation PCV valve. During high load driving, blow-by gas in
(PCV) valve is provided in the ventilation hose from the crankcase is induced to the intake manifold
the rocker cover to the intake manifold. During low through the rocker cover and PCV valve and at the
load driving, clean air is supplied to the crankcase by same time also via the air intake hose and throttle
the air intake hose via the breather hose and rocker body due to negative pressure in the air cleaner.
cover, and it mixes with the blow-by gas in the crank-
EMISSION CONTROL
17-11
POSITIVE CRANKCASE VENTILATION (PCV)
VALVE
PCV valve lifts the plunger according to negative pressure in
the intake manifold to create appropriate ventilation for the
From crankcase.
rocker To intake
cover manifold
Spring Plunger
AK602324 AC
EVAPORATIVE EMISSION CONTROL SYSTEM

M2171000200147
MFI relay
Battery Evaporative emission
purge solenoid
Mass airflow sensor

Manifold absolute pressure canister
sensor
Engine coolant temperature

sensor
Crankshaft position sensor ECM
AK604143 AB
HC (hydrocarbon) generated in the fuel tank are ditions and so performs duty control on the
adsorbed by the active carbon in the canister and evaporative emission purge solenoid. Also, the evap-
stored. HC stored in the canister is introduced to the orative emission purge solenoid is closed during
intake manifold when engine is in operation where it deceleration or immediately after engine start to
is mixed with intake air and combusted. ECM intro- restrict change in air-fuel ratio and prevent engine
duces optimum HC amount according to driving con- from stalling.
EMISSION CONTROL
EVAPORATIVE EMISSION PURGE SOLENOID

To canister An evaporative emission purge solenoid is installed in the
B intake manifold.The evaporative emission purge solenoid con-
trols the intake volume of fuel vapor gas from the canister. The
evaporative emission purge solenoid is a duty control type
solenoid valve. When current is not passing through the coil,
nipple A is kept airtight and fuel vapor gas cannot be sucked in.
When current passes through the coil, air can pass between
nipple A and B and fuel vapor gas is sucked in. ECM changes
A
the ON duty ratio according to engine's operating condition to
To intake manifold AK604745 AC
control the intake volume of fuel vapor gas.
From MFI relay
100 ms
OFF
12V
Evaporative
emission ON
purge solenoid 0V
ECM
AK602245AD
EXHAUST GAS RECIRCULATION (EGR) SYSTEM <California>

M2171000300122
Mass airflow sensor
Manifold absolute
pressure sensor
EGR valve Engine coolant

(stepper motor) temperature sensor
Battery Throttle position sensor
ECM
AK502987AE
When the combustion gas temperature becomes lower the combustion temperature and reduce the
high, generation of the environment polluting NOx volume of NOx generated. ECM calculates the EGR
(nitrogen oxides) increases rapidly. EGR system is introduction volume according to engine operating
used to decrease the volume of NOx generated. conditions and controls the EGR valve opening angle
EGR system re-circulates exhaust gas inside the at optimum. Also, immediately after the ignition
intake manifold. It increases specific heat of the com- switch ON signal is input, it drives fully closed step-
bustion gases and reduces combustion speed to per motor and performs initialization.
EMISSION CONTROL
17-13
EXHAUST GAS RECIRCULATION (EGR) VALVE
An EGR valve is installed in the EGR valve support.The EGR
valve controls EGR flow volume using the stepper motor
Magnet method and reduces exhaust gas (NOx) and fuel consumption.
Coil
The EGR valve drives the stepper motor based on the signal
from ECM. When stepper motor rotor turns in clockwise or
Rotor
anti-clockwise direction, the shaft fitted with a rotor and a screw
expands and contracts and the movement of the shaft causes
the valve to go up and down. Thus, EGR path gap is controlled
minutely. The stepper motor turns 15 per step. The stepper
motor turns forward or back only up to the angle dictated by the
number of pulse signals (number of steps) from the ECM. In
other words, increase and decrease of the EGR flow volume
depends on the number of signals (number of steps) from
Outlet Shaft ECM. ECM changes current flow to the 4 coils (A, B, C, D) in
the stepper motor in sequence according to the phase pattern
in the following chart in order to turn the stepper motor rotor.
Valve
Inlet Open valve changes phase in order of 0 1 2 3 0. Close
valve changes phase in order of 3 2 1 0 3.
Phase Stepper motor coil
number
AK604144 AB Coil A Coil B Coil C Coil D
0 ON OFF OFF ON
1 ON OFF ON OFF
2 OFF ON ON OFF
3 OFF ON OFF ON
From MFI relay
EGR valve
(stepper motor)
Coil Coil Coil Coil Flow rate

A B C D
Step
ECM
AK604145 AB
EMISSION CONTROL
EMISSION REDUCTION SYSTEMS

M2171000800064
These decrease CO, HC and NOx in the exhaust
gases and consist of air-fuel ratio feedback control
and catalytic converter.
1. AIR-FUEL RATIO FEEDBACK CONTROL
Refer to GROUP 13A Fuel Injection Control P.13A-29.
2. CATALYTIC CONVERTER
Catalytic converter is installed in the center of exhaust pipe
<Except for California> below the floor and in the front of exhaust pipe <California>.
Based on appropriate air-fuel ratio feedback from oxygen sen-
sor, CO and HC are oxidized and NOx is reduced. Catalytic
Catalytic converter converter is a monolith with beehive design with catalysts on
the unit surface. It is protected by a thermally insulating mat
and enclosed in a shell.
<California>
Catalytic converter
AK604146 AB
3. HC TRAP CATALYTIC CONVERTER

<California>
The HC trap catalytic converter is installed in the center of
HC trap catalyst exhaust pipe below the floor. The HC trap catalytic converter
Three-way catalyst consists of the HC trap catalyst and the three-way catalysts,
which are the monolith type; the catalyst element is attached to
Exhaust
gas the honeycomb catalyst surface. The HC trap catalyst and the
three-way catalysts are held by the heat-insulating mat and
installed in the shell. The HC trap catalyst temporarily absorbs
the exhaust HC from the engine within the temperature range
in which the three-way catalyst is not activated, and prevents
AK604147 AB the exhaust HC from releasing outside the vehicle. After that,
the HC trap catalyst temperature rises and releases the
absorbed HC. The released HC is burnt out in the downstream
three-way catalyst.
EMISSION CONTROL
17-15
HEATED OXYGEN SENSOR (3RD)
The heated oxygen sensor (3rd) is installed to the HC trap cat-
Heated oxygen sensor (3rd) alytic converter. The heated oxygen sensor (3rd) detects the
oxygen density of the exhaust gas and outputs the voltage to
the ECM in accordance with the oxygen density.
The ECM uses this output voltage to detect the deterioration of
the HC trap catalytic converter. The structure of the heated oxy-
gen sensor (3rd) is the same as that of the heated oxygen sen-
sor (rear) installed in the exhaust pipe.
HC trap catalytic converter
AK604553 AB
HC TRAP CATALYTIC CONVERTER

DETERIORATION MONITOR
Heated oxygen sensor (3rd) Engine coolant

temperature sensor
ECM Accelerator pedal
Heated oxygen sensor (rear) position sensor
AK604148 AB
The ECM detects the deterioration of the HC trap catalytic con-

verter.
When reaching the certain operating range, the ECM begins
monitoring the difference in the feedback time between the
heated oxygen sensor (rear) on the upstream of the HC trap
catalyst and the heated oxygen sensor (3rd) on the down-
stream of the HC trap catalyst. This monitoring allows the ECM
to detect the deterioration of the HC trap catalytic converter.
NOTES
21-1
GROUP 21
CLUTCH
CONTENTS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A
CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B

NOTES
21-1
GROUP 21
CLUTCH
CONTENTS
GENERAL INFORMATION. . . . . . . . 21-2 CONCENTRIC SLAVE CYLINDER . . 21-3

21-2 CLUTCH
GENERAL INFORMATION
GENERAL INFORMATION
M2210000100483
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control. The
clutch shares a brake fluid reservoir with the brake
system.
SPECIFICATIONS
Item Specification
Clutch disc type Dry single plate type
Clutch disc facing diameter OD x ID mm 225 155
Clutch cover type Diaphragm spring type
Clutch cover setting load N (lb) 4,320 350 (971 78)
Control system Hydraulic type
Master cylinder ID mm 15.87
Clutch fluid Brake fluid DOT 3 or DOT 4 (commonly used as brake fluid)
To brake fluid
reservoir
Clutch tube assembly Clutch pedal

Clutch master assembly
cylinder
Transaxle assembly
Concentric slave
cylinder
AC609976AB
CLUTCH
CONCENTRIC SLAVE CYLINDER
21-3
CONCENTRIC SLAVE CYLINDER
M2210005000049
To reduce the clutch pedal force, the clutch control
method is by hydraulic pressure only.
AC405941
Concentric slave cylinder adapter
Concentric slave cylinder
AC503210AB
NOTES
21B-1
GROUP 21B
CLUTCH
OVERHAUL
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 21B-2 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 21B-3

FASTENER TIGHTENING REMOVAL AND INSTALLATION . . . . . . . . 21B-3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 21B-2 CLUTCH INSPECTION . . . . . . . . . . . . . . . . 21B-5
GENERAL SPECIFICATIONS . . . . . . . . . . 21B-2
SERVICE SPECIFICATIONS . . . . . . . . . . . 21B-2
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 21B-2
21B-2 CLUTCH OVERHAUL
SPECIFICATIONS
SPECIFICATIONS
M1212001800604
Item Specification
Clutch cover mounting bolt 18 3 N m (13 2 ft-lb)
Concentric slave cylinder mounting bolt 10 2 N m (89 17 in-lb)
M1212000200762
Item Specification
Clutch operating method Hydraulic type
Clutch disc type Single dry disc type
Clutch disc size OD x ID mm (in) 255 x 155 (10.03 6.10)
Clutch cover type Diaphragm spring type
Clutch cover setting load N (lb) 4320 350 (971 78)
M1212000300457
Item Limit
Diaphragm spring end height difference mm (in) 0.5 (0.019)
Clutch disc facing rivet sink mm (in) Minimum 0.3 (0.012)
LUBRICANTS
M1212000400506
Item Specified lubricant

Clutch fluid Brake Fluid DOT 3 or DOT 4
Clutch disc splines Mitsubishi Part No. 0101011 or equivalent
TSB Revision
CLUTCH OVERHAUL
CLUTCH
21B-3
CLUTCH
M1212001000749
1
10 2 Nm
89 17 in-lb
3 2 4
18 3 Nm
13 2 ft-lb
AK603587AB

>>B<< 1. Clutch set >>A<< 4. Concentric slave cylinder adapter
2. Clutch cover >>A<< 5. Concentric slave cylinder
3. Clutch disc
TSB Revision
21B-4 CLUTCH OVERHAUL
CLUTCH

.
>>A<< CONCENTRIC SLAVE CYLINDER/CON-

CENTRIC SLAVE CYLINDER ADAPTER INSTAL-
LATION
1. After setting the concentric slave cylinder to the transaxle
case, tighten the flange bolt temporally.
AK603605AB
2. Assemble the concentric slave cylinder adapter with the

concentric slave cylinder.
Groove
NOTE: Fit into the groove of the transaxle case.
3. Tighten the flange bolt to the specified torque.
Tightening torque: 10 2 N m (89 17 in-lb)
AK603606AB
>>B<< CLUTCH SET INSTALLATION

1. Apply Mitsubishi grease to the clutch disc splines and rub it
into the splines with a brush.
Clutch disc Specified grease:
Mitsubishi Part No. 0101011 or equivalent
2. Use the general service tool to position the clutch disc on
Flywheel the flywheel.
3. Install the clutch cover onto the flywheel.
General
service
tool
Clutch
cover
AK603620AB
AK603620
TSB Revision
CLUTCH OVERHAUL
CLUTCH
21B-5
CLUTCH INSPECTION
M1212001100456
.
CLUTCH COVER
1. Check the diaphragm spring end for wear and uneven
height. Replace if wear is evident or height difference
Diaphragm spring exceeds the limit.
2. Check the pressure plate surface for wear, cracks and
discoloration.
3. Check the rivets of the strap plate for looseness. If loose,
replace the clutch set.
AK603621AC .
CLUTCH DISC
CAUTION
Don't clean the clutch disc in a cleaning solvent.
1. Check the facing for loose rivets, uneven contact, evidence
of seizure, or deposited oils and greases. If defective,
replace the clutch set.
NOTE: If contaminated with grease or oil, determine the
source of the contaminant and repair it.
2. Measure the rivet sink. Replace the clutch disc if it is below
the limit.
Minimum limit: 0.3 mm (0.012 inch)
Rivet sink
3. Place the clutch disc on the input shaft and check for sliding
condition and play in the rotating direction. If poor sliding
condition is evident, clean, reassemble, and recheck.
If excessive play is evident, replace the clutch disc and/or
input shaft.
AK400613 AD .
CONCENTRIC SLAVE CYLINDER ADAPTER

1. Check the O-ring for damage and deformation. If the O-ring
is damage or deformed, replace the concentric slave
cylinder adapter.
2. Check the surface that touches the concentric slave cylinder
for contamination. If contaminated, clean the surface the
specified clutch fluid.
Specified fluid: Brake Fluid DOT 3 or DOT 4
3. Make sure there are no deformed and/or missing clips.
O-ring
AK603651AB
TSB Revision
NOTES
22-1
GROUP 22
MANUAL
TRANSAXLE
CONTENTS
MANUAL TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A
MANUAL TRANSAXLE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 22B

NOTES
22-1
GROUP 22
MANUAL
TRANSAXLE
CONTENTS
MANUAL TRANSAXLE . . . . . . . . . . . 22-2 TRANSAXLE CONTROL . . . . . . . . . . 22-4

GENERAL INFORMATION. . . . . . . . . . . . . 22-2 GENERAL INFORMATION . . . . . . . . . . . . . 22-4
SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . 22-3
22-2 MANUAL TRANSAXLE
MANUAL TRANSAXLE
MANUAL TRANSAXLE
GENERAL INFORMATION
M2220000100729
F5MBB type has been adopted.
SPECIFICATIONS
Item Specification
Transmission model F5MBB
Transmission type 5-speed forward, 1-speed reverse constant mesh
Gear ratio 1st 3.538
2nd 1.913
3rd 1.333
4th 1.028
5th 0.820
Reverse 3.583
Final gear ratio 4.235
MANUAL TRANSAXLE
MANUAL TRANSAXLE
22-3
SECTIONAL VIEW
M2220000500136
1 2 3 4 5 6 7 8
14
10
13 12
11
AC611252 AB
1. 5th speed gear 8. Clutch housing

2. 4th speed gear 9. Input shaft
3. 3rd speed gear 10. Output shaft
4. 2nd speed gear 11. Front differential
5. Reverse speed gear 12. 1st 2nd speed synchronizer hub
6. 1st speed gear 13. 3rd 4th speed synchronizer hub
7. Transaxle case 14. 5th speed synchronizer hub
22-4 MANUAL TRANSAXLE
TRANSAXLE CONTROL
TRANSAXLE CONTROL
GENERAL INFORMATION
M2222000100286
For the transaxle control, a cable-type remote control Shift cable
gear shift has been adopted, and each section has A cable end that can be installed by one-touch
the following features. has been adopted to the transaxle side and the
shift lever side to improve assembling workability.
Shift lever assembly
For the transaxle side of the shift cable and the
A spherical rotary shaft fulcrum type has been
select cable, mounting sockets that have elastic
adopted to assure a non-rickety, smooth shift
solid inside have been adopted to minimize the
feeling.
binding touch or tight spots.
A resin base bracket has been adopted to reduce
weight. Shift knob
A mass-filled shift knob has been adopted to min-
imize the binding touch or tight spots at the time
of a shift.
Select cable
Shift knob
Shift cable
Shift lever assembly
Transaxle assembly
AC609226AB
22B-1
GROUP 22B
MANUAL
TRANSAXLE
OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS . . . . . . 22B-2 INPUT SHAFT. . . . . . . . . . . . . . . . . . . 22B-25

DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-25
SERVICE SPECIFICATIONS. . . . . . . 22B-2
OUTPUT SHAFT. . . . . . . . . . . . . . . . . 22B-29
ADJUSTING SNAP RINGS AND DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-29
SPACERS . . . . . . . . . . . . . . . . . . . . . 22B-3
SELECT LEVER . . . . . . . . . . . . . . . . . 22B-35
FASTENER TIGHTENING DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-35
SPECIFICATIONS . . . . . . . . . . . . . . . 22B-4
CLUTCH HOUSING . . . . . . . . . . . . . . 22B-37
SEALANTS AND ADHESIVES . . . . . 22B-4 DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-37
LUBRICANTS . . . . . . . . . . . . . . . . . . 22B-5 TRANSAXLE CASE . . . . . . . . . . . . . . 22B-42

SPECIAL TOOLS. . . . . . . . . . . . . . . . 22B-6
DIFFERENTIAL. . . . . . . . . . . . . . . . . . 22B-46
TRANSAXLE . . . . . . . . . . . . . . . . . . . 22B-11 DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-46
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-24
22B-2 MANUAL TRANSAXLE OVERHAUL
M1222000200774
Item Specification
Model F5MBB-1-BBY
Applicable engine 4B11
Type 5-speed transaxle floor shift
Gear ratio 1st 3.538
2nd 1.913
3rd 1.333
4th 1.028
5th 0.820
Reverse 3.538
Final reduction ratio 4.235
M1222000300533
Item Standard value

Rotational starting torque of differential case N m (in-lb) 0.8 1.6 (7.08 14.16)
Output shaft bearing preload N m (in-lb) 0.8 1.6 (7.08 14.16)
Input shaft synchronizer hub No.3 thrust crevice mm (in.) 0 0.1 (0 0.0039)
Input shaft synchronizer hub No.2 thrust crevice mm (in.) 0 0.1 (0 0.0039)
Input shaft radial ball bearing thrust crevice mm (in.) 0 0.1 (0 0.0039)
TSB Revision
MANUAL TRANSAXLE OVERHAUL
ADJUSTING SNAP RINGS AND SPACERS
22B-3
ADJUSTING SNAP RINGS AND SPACERS
M1222012000614
Adjustment shims (for differential side LH tapered roller bearing preload adjustment)
Thickness mm (in) Thickness mm (in)
1.99 2.01 (0.0783 0.0791) 2.44 2.46 (0.0961 0.0969)
2.04 2.06 (0.0803 0.0811) 2.49 2.51 (0.0980 0.0988)
2.09 2.11 (0.0823 0.0831) 2.54 2.56 (0.1000 0.1008)
2.14 2.16 (0.0843 0.0850) 2.59 2.61 (0.1020 0.1028)
2.19 2.21 (0.0862 0.0870) 2.64 2.66 (0.1039 0.1047)
2.24 2.26 (0.0882 0.0890) 2.69 2.71 (0.1059 0.1067)
2.29 2.31 (0.0902 0.0909) 2.74 2.76 (0.1079 0.1087)
2.34 2.36 (0.0921 0.0929) 2.79 2.81 (0.1098 0.1106)
2.39 2.41 (0.0941 0.0949) 2.84 2.86 (0.1118 0.1126)
Adjustment shims (for output shaft bearing preload adjustment)

1.29 1.31 (0.0508 0.0516) 1.94 1.96 (0.0764 0.0772)
1.34 1.36 (0.0528 0.0535) 1.99 2.01 (0.0783 0.0791)
1.39 1.41 (0.0547 0.0555) 2.04 2.06 (0.0803 0.0811)
1.44 1.46 (0.0567 0.0575) 2.09 2.11 (0.0823 0.0831)
1.49 1.51 (0.0587 0.0594) 2.14 2.16 (0.0843 0.0850)
1.54 1.56 (0.0606 0.0614) 2.19 2.21 (0.0862 0.0870)
1.59 1.61 (0.0626 0.0634) 2.24 2.26 (0.0882 0.0890)
1.64 1.66 (0.0646 0.0654) 2.29 2.31 (0.0902 0.0909)
1.69 1.71 (0.0665 0.0673) 2.34 2.36 (0.0921 0.0929)
1.74 1.76 (0.0685 0.0693) 2.39 2.41 (0.0941 0.0949)
1.79 1.81 (0.0705 0.0713) 2.44 2.46 (0.0961 0.0969)
1.84 1.86 (0.0724 0.0732) 2.49 2.51 (0.0980 0.0988)
1.89 1.91 (0.0744 0.0752)
Shaft snap rings (for input shaft synchronizer hub No.3 bushing end play adjustment)
1.75 1.80 (0.0689 0.0709) 2.00 2.05 (0.0787 0.0807)
1.80 1.85 (0.0709 0.0728) 2.05 2.10 (0.0807 0.0827)
1.85 1.90 (0.0728 0.0748) 2.10 2.15 (0.0827 0.0846)
1.90 1.95 (0.0748 0.0768) 2.15 2.20 (0.0846 0.0866)
1.95 2.00 (0.0768 0.0787)
TSB Revision

M1222012100536
Item Specification
Clutch housing case assembly
Roll stopper bracket 90 10 N m (66 6 ft-lb)
Vehicle speed sensor 10 2 N m (88 17 in-lb)
Wiring harness clamp bracket 17 6.8 N m (13 4 ft-lb)
Transaxle case hanger No.1 17 6.8 N m (13 4 ft-lb)
Reverse shift arm bracket assembly 17 5.1 N m (12 3 ft-lb)
Gear shift fork assembly No.2 24 4.8 N m (18 3 ft-lb)
Gear shift head No.1 24 4.8 N m (18 3 ft-lb)
Transaxle case receiver 7.0 2.8 N m (62 24 in-lb)
Transaxle case assembly
Backup light switch 40 16 N m (29 11 ft-lb)
Lock ball assembly 29 8.7 N m (21 6 ft-lb)
Backup light switch wiring harness clamp 7.5 2.3 N m (66 19 in-lb)
Control cable bracket 17 6.8 N m (13 4 ft-lb)
Lever lock pin mounting nut 11.8 3.5 N m (104 30 in-lb)
Control shift lever connecting nut 6.4 1.9 N m (56 16 in-lb)
Control shaft cover 20 8 N m (14 5 ft-lb)
Clutch tube bracket 50 5 N m (37 3 ft-lb)
Transaxle case cover sub assembly mounting bolt 29 8.7 N m (21 6 ft-lb)
5th drive gear mounting nut 123 36.9 N m (90 26 ft-lb)
Rear bearing retainer 42 8.4 N m (31 6 ft-lb)
Reverse idler shaft mounting bolt 30 9 N m (22 6 ft-lb)
Clutch housing case mounting bolt 29 5.8 N m (21 3 ft-lb)
Oil receiver pipe 17 6.8 N m (12 4 ft-lb)
With head straight screw plug 13 5.2 N m (115 45 in-lb)
Differential case
Ring gear 106 6.4 N m (78 4 ft-lb)

M1222000500515

Mating face for transaxle case and clutch housing Mitsubishi Part No. MD994421 or equivalent
Mating face for transaxle case and transaxle case cover sub
assembly
.
TSB Revision
LUBRICANTS
22B-5
FORM-IN-PLACE GASKET (FIPG)
.
Surface Preparation
This transaxle has several areas where the Thoroughly remove all substances deposited on the
form-in-place gasket (FIPG) is used for sealing. To FIPG application surface, using a gasket scraper.
ensure that the FIPG fully serves its purpose, it is Make sure that the FIPG application surfaces is flat
necessary to observe some precautions when apply- and smooth. Also make sure that the surface is free
ing it. Bead size, continuity and location are of para- from oils, greases and foreign substances. Do not fail
mount importance. to remove old FIPG that may remain in the fastener
Too thin a bead could cause leaks. Too thick a bead, fitting holes.
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 FIPG Application

absolutely necessary to apply the FIPG evenly with- Applied FIPG bead should be of the specified size
out a break, while observing the correct bead size. and free of any break. FIPG can be wiped away
FIPG hardens as it reacts with the moisture in the unless it has completely hardened. Install the mating
atmospheric air, and it is usually used for sealing parts in position while the FIPG is still wet (in less
metallic flange areas. than 10 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during installa-
tion. Avoid operating the transaxle or letting oils or
.
Disassembly
water come in contact with the sealed area before a
Parts sealed with a FIPG can be easily removed time sufficient for FIPG to harden (approximately one
without need for the use of a special method. In hour) has passed.
some cases, however, the FIPG in joints may have to FIPG application method may vary from location to
be broken by tapping parts with a mallet or similar location. Follow the instruction for each particular
tool. case described later in this manual.
LUBRICANTS
M1222000400518

Gear oil DiaQueen NEW MULTI GEAR OIL API classification GL-3, SAE 75W-80
Select lever oil seal Mitsubishi Part No. 0101011 or equivalent
Oil seal
TSB Revision
SPECIAL TOOLS
SPECIAL TOOLS
M1222000600578
Tool Tool number Supersession Application

and name
MB992221 Remove of synchronizer hub
Puler set No.3
MD998802 Remove and installation of 5th

Input shaft drive gear mounting lock nut
holder
MB990801 General service tool Remove of 5th drive gear removal

Rear axle
bearing outer
race puller
MB990801
MB992038 MB992038-01 Measurement of differential

Preload socket side bearing preload
Measurement of output shaft
assembly bearing preload
MB992219 Installation of 5th drive gear

Output shaft
adapter
MB992216 Installation of 5th drive gear

Installer Installation of synchronizer
hub No.3
MB992220 Installation of synchronizer hub

Input shaft No.3
adapter
TSB Revision
SPECIAL TOOLS
22B-7
and name
MB992212 Installation of oil seal
Oil seal installer
MB992075
Handle
MB992000 Installation of plug

Crankshaft
adapter
B992000
MD998917 General service tool Remove of each bearing

Bearing or MD998348-01 Remove of input and output
remover shaft each gear
MD998812 General service tool Use with installer and installer

Installer cap or MIT304180-A adapter
MD998813 General service tool Use with installer and installer

Installer 100 or MIT304180-A adapter
MD998820 MD998820-01 Installation of synchronizer

Installer adapter sleeve No.2 and synchronizer
hub No.2
Installation of 4th gear
sub-assembly and radial ball
bearing
Installation of tapered roller
bearing inner race
TSB Revision
SPECIAL TOOLS

and name
MD998368 Remove of tapered roller bearing
Bearing installer inner race
MD998814 MIT304180-A Use with installer cap and

Installer 200 installer adapter
MD998819 General service tool Install the synchronizer hub

Installer adapter and reverse gear
Installation of 3rd drive gear
Installation of 4th drive gear
Installation of tapered roller
bearing inner race
MB990211 MB990211-01 Use with slide hammer puller
Slide hammer
MB990211
MB992039 MB992039-01 Remove of cylindrical roller

Slide hammer bearing (outer race)
puller Remove of tapered roller
bearing outer race
MD998200 Installation of oil seal

Oil seal installer
MD998550 Install the oil seal

Extension
housing seal
installer
MB991445 MB991445-01 Installation of tapered roller

Bush remover bearing outer race
and installer
base
TSB Revision
SPECIAL TOOLS
22B-9
and name
MB990938 MB990938-01 Installation of tapered roller
Installer bar bearing outer race
MB990699 Installation of tapered roller

Differential oil bearing outer race
seal installer
MD999547 Installation of cylindrical roller

Oil seal installer bearing outer race
MB991015 MB991015-01 Remove of tapered roller bearing

Knuckle oil seal outer race
installer
MB991015

Oil seal installer

Handle

Bearing outer bearing outer race
race installer
MB991395 Remove of tapered roller

Crankshaft front bearing inner race
oil seal installer Remove of speedometr drive
gear
Remove of tapered roller
bearing outer race
TSB Revision
SPECIAL TOOLS

and name
MB990810 General service tool Remove of tapered roller bearing
Side bearing outer race
puller
MB990810
MD999566 Remove of tapered roller bearing

Claw outer race

Oil seal installer bearing outer race
MB990891 MB990891-01 Installation of speedometer drive

Rear gear
suspension
bushing base

Bearing installer bearing outer race
TSB Revision
TRANSAXLE
22B-11
TRANSAXLE
DISASSEMBLY AND ASSEMBLY
M1222016500019
Apply gear oil to

20 8 Nm all moving parts
14 5 ft-lb 40 16 Nm
29 11 ft-lb before installation.
17 6.8 Nm
13 4 ft-lb
16 17 6.8 Nm
13 4 ft-lb
15 9 29 8.7 Nm
17 4 21 6 ft-lb
18 7 8
50 5 Nm 5
37 3 ft-lb 19
17 6.8 Nm
21 13 4 ft-lb
10
6
7.5 2.3 Nm
90 10 Nm
66 19 in-lb 11
66 6 ft-lb
10 2 Nm
2 88 17 in-lb
3
1
20 11.8 3.5 Nm
104 30 in-lb
14 13 12
6.4 1.9 Nm
56 16 in-lb
90 10 Nm
66 6 ft-lb
AK603347AB

1. Roll stopper bracket front <<A>> 11. Selecting bell crank assembly and
2. Roll stopper bracket rear control bell crank dust cover
3. Vehicle speed sensor 12. Lever lock pin
4. Backup light switch assembly 13. Control shift lever
5. Lock ball assembly 14. Dust boot
6. Backup light switch wiring harness 15. Clamp
clamp bracket >>M<< 16. Plug
7. Wiring harness clamp bracket 17. Control shaft cover
8. Wiring harness clamp bracket >>L<< 18. Control shift retainer gasket
9. Transaxle case hanger No.1 19. Shift and select lever shaft
10. Control cable bracket >>K<< 20. Oil seal
21. Clutch tube bracket
TSB Revision
TRANSAXLE
29 5.8 Nm 36 35
Apply gear oil to 21 3 ft-lb 34
all moving parts
41
40
39
42 8.4 Nm
31 6 ft-lb
38
37
30 9 Nm
22 6 ft-lb 29 8.7 Nm
21 6 ft-lb
24 4.8 Nm
18 3 ft-lb
23
29 5.8 Nm
21 3 ft-lb 30
33 123 36.9 Nm
90 26 ft-lb
22
24
25
27 26
28
29
31
32 AK603528AB

>>J<< 22. Transaxle case cover sub assembly 32. Needle roller bearing
23. Gear shift fork assembly No.3 <<D>> >>E<< 33. 5th drive gear
>>I<< 24. Synchronizer sleeve No.3 34. Shaft snap ring
>>H<< 25. Shaft snap ring 35. Shaft snap ring
<> >>G<< 26. Synchronizer hub No.3 36. Shaft snap ring
>>G<< 27. Synchromesh shifting key spring 37. Reverse idler gear shaft mounting
No.3 (A) bolt
>>G<< 28. Synchromesh shifting key spring 38. Gasket
No.3 (B) 39. Rear bearing retainer mounting bolt
>>G<< 29. Synchronizer ring assembly 40. Rear bearing retainer
<<C>> >>F<< 30. 5th drive gear mounting lock nut >>D<< 41. Transaxle case assembly
31. 5th gear
TSB Revision
TRANSAXLE
22B-13
Apply gear oil to

all moving parts
before installation. 24 4.8 Nm 46 45
18 3 ft-lb
24 4.8 Nm
47 18 3 ft-lb
43
53
44 57
58
59 50
48
52
51 49
60
54
55
17 5.1 Nm 56
42 12 3 ft-lb
AK603529AB

>>C<< 42. Reverse shift arm bracket assembly 52. Reverse shift fork
43. Gear shift fork shaft No.2 53. Gear shift fork assembly No.2
44. Gear shift head No.1 >>A<< 54. Reverse idler shaft
45. Shaft snap ring >>A<< 55. Reverse idler thrust washer
>>B<< 46. Gear shift fork shaft No.1 >>A<< 56. Reverse idler gear
>>B<< 47. Gear shift fork assembly No.1 57. Input shaft assembly
48. Roller 58. Output shaft assembly
49. Shaft snap ring 59. Differential assembly
50. Gear shift fork shaft No.3 60. Clutch housing case assembly
51. Shaft snap ring

MB992221: Puller set MB992216: Installer
MD998802: Input shaft Holder MB992220: Input shaft adapter
MB990801: Rear axle bearing outer race puller MB992212: Oil seal installer
MB992038: Preload socket MB992075: Handle
MB992219: Output shaft adapter MB992000: Crankshaft adapter
TSB Revision
TRANSAXLE
DISASSEMBLY SERVICE POINTS

.
<<A>> SELECTING BELL CRANK ASSEMBLY

AND CONTROL BELL CRANK DUST COVER
REMOVAL
Remove the fixing nuts shown, then separate the control shift
lever from the selecting bell crank assembly and control bell
crank dust cover.
AK603400
<> SYNCHRONIZER HUB NO.3 REMOVAL

1. Using special tool MB992221, remove the synchronizer hub
No.3.
MB992221
AK603692AB
AB
<<C>> 5TH DRIVE GEAR MOUNTING LOCK NUT

REMOVAL
MD998802 1. Using special tool MD998802, lock the input shaft.
AK603186AB
2. Remove the 5th drive gear mounting lock nut from output
shaft assembly.
AK603188
TSB Revision
TRANSAXLE
22B-15
.
<<D>> 5TH DRIVE GEAR REMOVAL

Using special tool MB990801, remove the 5th drive gear.
MB990801
AK603164AB
ADJUSTMENT BEFORE ASSEMBLY

.
DIFFERENTIAL SIDE BEARING PRELOAD

ADJUSTMENT
1. Set the differential assembly to the clutch housing case
assembly.
2. Push and fit the tapered roller bearing outer race by hand.
Outer race
3. To fit the tapered roller bearing outer race, rotate the
differential assembly by hand about 10 times.
Clutch housing
case assembly AK603344AB
4. Put the clutch housing case assembly on the surface table

A and use a height gauge to measure the dimension "A" which
is from the mating surface of the clutch housing case
assembly to the end surface of the tapered roller bearing
outer race.
Clutch housing
case assembly AK603344AD
5. Put the straight edge on the mating surface of the transaxle

Transaxle case case assembly and measure the dimension "B" with a
assembly Mating surface of
transaxle case 2 vernier caliper.
6. Select the shim whose dimension is the difference between
"B" and "A."
B 7. Install the differential assembly to the clutch housing case
assembly. Tighten the transaxle case bolts to the specified
torque.
Tightening torque: 29 5.8 N m (21 3 ft-lb)
AK603345 AB
TSB Revision
TRANSAXLE
8. Using special tool MB992038, measure the rotational

MB992038
starting torque of differential case. When it is not within the
standard range, reselect the shim.
Standard value: 0.80 1.60 N m (7.08 14.16 in-lb)
AK603182AB
OUTPUT SHAFT ASSEMBLY BEARING PRELOAD

ADJUSTMENT
1. Set the output shaft assembly to the clutch housing case
assembly.
2. Push and fit the tapered roller bearing outer race by hand.
Outer race 3. To fit the tapered roller bearing outer race, rotate the output
shaft assembly by hand.
AK603387AB
4. Put the clutch housing case assembly on the surface table

and measure the dimension "A" which is from the mating
surface of the clutch housing case assembly to the end
surface of the bearing outer race, with a height gauge.
Mating surface of
clutch housing
case assembly
AK603386AC
TSB Revision
TRANSAXLE
22B-17
5. Put the straight edge on the mating surface of the transaxle
case assembly and measure the dimension "B" with a
vernier caliper.
Transaxle case
assembly Mating surface of 6. Select the shim whose dimension is the difference between
transaxle case "B" and "A"
B assembly
7. Install the output shaft assembly and differential assembly to
the clutch housing case assembly. Tighten the transaxle
case bolts to the specified torque.
AK603388AB
8. Place the selected shim, then install the output shaft
assembly.
9. Install the rear bearing retainer to specified torque.
5th gear mounting lock nut 10.Install the 5th gear mounting lock nut to measure rotational
starting torque.
AK603180AB
11.Measure the rotational starting torque of output shaft. When

it is not within the standard range, reselect the shim.
AK603181
ASSEMBLY SERVICE POINTS

.
>>A<< REVERSE IDLER GEAR, REVERSE IDLER

THRUST WASHER AND REVERSE IDLER SHAFT
INSTALLATION
1. Install the reverse idler gear, reverse idler thrust washer and
Addition mark reverse idler shaft.
2. Before installing the transaxle case assembly, confirm that
the reverse idler gear addition mark is positioned as show in
the illustration.
AK603527AB
TSB Revision
TRANSAXLE
>>B<< GEAR SHIFT FORK ASSEMBLY NO.1 AND

GEAR SHIFT FORK SHAFT NO.1 INSTALLATION
1. Fit the shaft snap ring onto the gear shaft fork shaft No. 1.
2. Bring up the notch in the gear shift fork shaft No. 3 to the
reverse shift fork into neutral position, and move the roller in
the reverse shift fork to the gear shift fork shaft No 3 side.
Notch
Reverse shift fork
AK603694AB
3. Pass the gear shift fork shaft No. 1 through the gear shift
fork assembly No. 1 and reverse shift fork in that order, then
install it to the clutch housing case assembly.
AK603916AB
>>C<< REVERSE SHIFT ARM BRACKET

Fit the arm tip of the reverse shift fork into the mating slot in the
reverse shift arm bracket assembly.
AK603699AB
>>D<< TRANSAXLE CASE ASSEMBLY

INSTALLATION
Apply a 1.2 mm (0.0472 inch) diameter bead of sealant as illus-
trated onto the transaxle case assembly.
Specified sealant:
Mitsubishi Part No. MD994421 or equivalent
AK603193AB
TSB Revision
TRANSAXLE
22B-19
>>E<< 5TH DRIVE GEAR INSTALLATION
1. Install special tool MB992219 until it hits the end face of the
output shaft.
MB992219
AK603917AB
2. Install the 5th drive gear.
5th drive gear
AK603918AB
AB
3. Set special tool MB992216 on top of the 5th drive gear.
MB992216
AK603919AB
4. Install the center bolt that is included in the set of special tool
Center bolt MB992216 as shown.
AK603920AB
TSB Revision
TRANSAXLE
5. Press-fit the 5th drive gear as shown.
5th drive gear
AK603921AB
>>F<< 5TH DRIVE GEAR MOUNTING LOCK NUT

INSTALLATION
MD998802 1. Using special tool MD998802, lock the input shaft.
AK603186AB
2. Install the 5th drive gear mounting lock nut from output shaft
assembly.
3. Tighten the 5th drive gear mounting lock nut to the specified
torque.
4. Stake the 5th gear mounting lock nut.
AK603188
>>G<< SYNCHRONIZER RING ASSEMBLY,

SYNCHROMESH SHIFTING KEY SPRING NO.3
(A), SYNCHROMESH SHIFTING KEY SPRING
NO.3 (B) AND SYNCHRONIZER HUB NO.3
INSTALLATION
1. Install the synchromesh shifting key springs No. 3 onto the
synchronizer ring assembly holding the claws and rotation
stops of the key springs in the illustrated positions.
Rotation
stop
AK603195AB
TSB Revision
TRANSAXLE
22B-21
Synchromesh shifting 2. Make sure that the rotation stops of the synchromesh
key spring shifting key springs No. 3 fit into the mating holes in the
synchronizer ring assembly.
AK603187AB
3. Compress the key springs into place inside the hub as

Synchromesh shifting shown.
Synchronizer hub No.3 key spring No.3 (A)
Synchromesh shifting
key spring No.3 (B) AK603941AB
4. Install special tool MB992220 until it hits the end face of the
MB992220 input shaft.
AK603923AB
5. Set special tool MB992216 on top of the synchronizer hub

MB992216 No. 3.
AK603913 AB
6. Install the center bolt that is a part of the set of special tool
Center bolt MB992216 as shown.
AK603914AB
AB
TSB Revision
TRANSAXLE
7. Press-fit the synchronizer hub No. 3 as shown.
Synchronizer
hub No.3
AB
AK603915AB
>>H<< SHAFT SNAP RING INSTALLATION

Snap ring
Select a shaft snap ring that allows distance of the thrust crev-
ice of synchronizer hub No.3 to fall within the standard value
range.
Standard value: 0 0.1 mm (0 0.0039 in.)
NOTE: Try on snap rings in the decreasing order of thickness,
and install the first one that fits into the hub.
AK603971AB
>>I<< SYNCHRONIZER SLEEVE NO.3

INSTALLATION
Put the synchronizer sleeve No. 3 and gear shaft fork assembly
No. 3 together, then install the synchronizer sleeve No. 3 in the
illustrated direction.
Installation
direction
AK603194AB
>>J<< TRANSAXLE CASE COVER SUB

Apply a 1.2 mm (0.0472 inch) diameter bead of sealant as illus-
trated onto the transaxle case cover sub assembly.
Specified sealant:
Mitsubishi Part No. MD994421 or equivalent
AK603192AB
TSB Revision
TRANSAXLE
22B-23
>>K<< OIL SEAL INSTALLATION
1. Using special tool MB992212 and MB992075, install the oil
seal.
2. Pack grease to the oil seal lip area.
Specified grease:
MB992212 Mitsubishi Part No. 0101011 or equivalent
MB992075
AK603704AB
>>L<< CONTROL SHIFT RETAINER GASKET

INSTALLATION
Projection Install the control shift retainer gasket to the control shaft cover
with the projection of the gasket in the illustrated position.
Gasket
AK603750AB
>>M<< PLUG INSTALLATION

Using special tool MB992000, install the plug.
MB992000
AK603703AB
AB
TSB Revision
TRANSAXLE
INSPECTION
M1222016600016
.
BACKUP LIGHT SWITCH

Check for continuity between terminals.
Switch Condition Continuity
Pressed Open
Released Conductive
AK500642
TSB Revision
INPUT SHAFT
22B-25
INPUT SHAFT
M1222001600537
Apply gear oil to

all moving parts
9 7
10 8
11
12
13
14
1
2
3
4
5
6
AK603728AB

>>D<< 1. Snap ring 9. Synchromesh shifting key No2
<<A>> >>C<< 2. Radial ball bearing 10. Compression spring
3. 4th gear sub-assembly <> >>A<< 11. Synchronizer hub No.2
4. Needle roller bearing 12. Synchronizer ring No.3
5. Spacer <> 13. 3rd gear sub-assembly
>>B<< 6. Snap ring 14. Needle roller bearing
7. Synchronizer ring No.4 15. Input shaft
<> >>A<< 8. Synchronizer sleeve No.2

MD998917: Bearing remover MD998813: Installer-100
MD998812: Installer cap MD998820: Installer adapter
TSB Revision
INPUT SHAFT

.
<<A>> RADIAL BALL BEARING REMOVAL

Using special tool MD998917, support the radial ball bearing
MD998917 and remove the radial ball bearing.
AK603165AB
<> SYNCHRONIZER SLEEVE NO.2,

SYNCHRONIZER HUB NO.2 AND 3RD GEAR
SUB-ASSEMBLYREMOVAL
Using special tool MD998917, support the 3rd gear sub-
assembly and remove the 3rd gear sub- assembly, synchro-
MD998917 nizer sleeve No.2 and synchronizer hub No.2.
AK603166AB

.
>>A<< SYNCHRONIZER HUB NO.2 AND SYN-

CHRONIZER SLEEVE NO.2 INSTALLATION
1. Before assembly, make sure that the hub and sleeve face
the correct direction.
NOTE: .
Apply gear oil to the caulked area between the sleeve
Installation
direction
and the hub.
After installation, confirm the sleeve and the hub slide
smoothly.
Oil groove
AK603201AB
TSB Revision
INPUT SHAFT
22B-27
MD998812
2. Using special tools MD998812, MD998813 and MD998820,
install the synchronizer sleeve No.2 and synchronizer hub
MD998813 No.2.
MD998820
AK603167AB
>>B<< SNAP RING INSTALLATION

Select a snap ring that allows distance of the thrust crevice of
synchronizer hub No.2 to fall within the standard value range.
Standard value: 0 0.1 mm (0 0.0039 inch)
NOTE: Note: Try on snap rings in the decreasing order of thick-
ness, and install the first one that fits into the input shaft.
AK603447
>>C<< RADIAL BALL BEARING INSTALLATION

1. Before assembly, make sure that the radial ball bearing
faces the correct direction.
Installation
direction
AK603200AB

MD998812
install the radial ball bearing.
MD998813
MD998820
AK603168AB
TSB Revision
INPUT SHAFT
>>D<< SNAP RING INSTALLATION

Select a snap ring that allows distance of the thrust crevice of
radial ball bearing to fall within the standard value range.
Standard value: 0 0.1 mm (0 0.0039 inch)
NOTE: Note: Try on snap rings in the decreasing order of thick-
ness, and install the first one that fits into the input shaft.
AK603446
TSB Revision
OUTPUT SHAFT
22B-29
OUTPUT SHAFT
M1222002200480
Apply gear oil to 22

all moving parts
23
25
24
10
11
14 12
15 13
16
18 17
19
20
21
1
2
4 3
5
6
7
8
9
AK603531AB

<<A>> >>G<< 1. Tapered roller bearing inner race <<C>> >>C<< 14. Reverse gear
<<A>> >>F<< 2. 4th drive gear 15. Synchromesh shifting key No1
3. Spacer 16. Compression spring
<> >>E<< 4. 3rd drive gear <<C>> >>C<< 17. Synchronizer hub No.1
<> >>D<< 5. 2nd gear >>B<< 18. Synchronizer ring set No.1
6. Needle roller bearing >>B<< 19. Synchronizer outer ring No.1
7. 2nd gear bush >>B<< 20. Synchronizer middle ring No.1
8. Ball >>B<< 21. Synchronizer inner ring No.1
9. Spacer <<C>> >>B<< 22. 1st gear
>>D<< 10. Synchronizer ring set No.2 23. Needle roller bearing
>>D<< 11. Synchronizer inner ring No.2 <<D>> >>A<< 24. Tapered roller bearing
>>D<< 12. Synchronizer middle ring No.2 25. output shaft
>>D<< 13. Synchronizer outer ring No.2
TSB Revision
OUTPUT SHAFT

MD998917: Bearing remover MD998820: Installer adapter
MD998368: Bearing installer MD998814: Installer 200
MD998812: Installer cap MD998819: Installer adapter
MD998813: Installer-100

.
<<A>> TAPERED ROLLER BEARING INNER

RACE AND 4TH DRIVE GEAR REMOVAL
Using special tool MD998917, support the 4th drive gear and
MD998917
remove the tapered roller bearing Inner race and 4th drive gear.
AK603169AB
<> 3RD DRIVE GEAR AND 2ND GEAR

REMOVAL
Using special tool MD998917, support the 2nd gear and
remove the 3rd drive gear and 2nd gear.
MD998917
AK603170AB
<<C>> REVERSE GEAR, SYNCHRONIZER HUB

NO.1 AND 1ST GEAR REMOVAL
Using special tool MD998917, support the 1st gear and remove
the 1st gear, reverse gear and synchronizer hub No.1.
MD998917
AK603171AB
TSB Revision
OUTPUT SHAFT
22B-31
<<D>> TAPERED ROLLER BEARING INNER
RACE REMOVAL
Using special tool MD998917 and MD998368, support the
MD998368 tapered roller bearing Inner race and remove the tapered roller
bearing Inner race.
NOTE: Since special tool MD998917 holds the tapered roller
bearing at the roller portion, the roller portion is broken when
the inner race is removed.
MD998917
AK603465AB
ASSEMBLY SERVICEPOINTS
.
>>A<< TAPERED ROLLER BEARING INNER

RACE INSTALLATION
Using special tools MD998812, MD998813 and MD998820,
MD998812 install the tapered roller bearing inner race.
MD998813
MD998820
AK603172AB
>>B<< SYNCHRONIZER RING SET NO.1

(SYNCHRONIZER OUTER RING NO.1,
SYNCHRONIZER MIDDLE RING NO.1,
SYNCHRONIZER INNER RING NO.1)
INSTALLATION
CAUTION
The rings of the synchronizer ring set No. 1 and No. 2 are
dedicated to the 1st and 2nd gears. Be sure to install the
right ring set to the right gear.
Synchronizer
1. Make sure that the synchronizer outer ring of the
ring set No.1 synchronizer ring set No. 1 is as shown.
Outer ring
AK603515AB
TSB Revision
OUTPUT SHAFT
2. Install the synchronizer ring set No. 1 aligning the claws of

1st gear Synchronizer
middle ring
the synchronizer middle ring to the positioning holes in the
1st gear.
NOTE: Apply gear oil to the sufficiently on the sliding sur-
face
Claws
Holes AK603938AB
>>C<< REVERSE GEAR AND SYNCHRONIZER

HUB NO.1 INSTALLTION
1. Install the reverse gear onto the synchronizer hub in the
illustrated direction.
face
Installation
direction
AK603518 AB

MD998812
install the synchronizer hub and reverse gear.
3. After installation, confirm the 1st gear slides smoothly.
MD998814
MD998819
AK603173AB
TSB Revision
OUTPUT SHAFT
22B-33
>>D<< SYNCHRONIZER RING SET NO.2
(SYNCHRONIZER OUTER RING NO.2,
SYNCHRONIZER MIDDLE RING NO.2,
SYNCHRONIZER INNER RING NO.2) AND 2ND
GEAR INSTALLATION
CAUTION
The rings of the synchronizer ring set No. 1 and No. 2 are
dedicated to the 1st and 2nd gears. Be sure to install the
right ring set to the right gear.
Synchronizer
1. Make sure that the synchronizer outer ring of the
ring set No.2 synchronizer ring set No. 2 is as shown.
Outer ring
AK603516AB
2. Install the synchronizer ring set No. 2 to the 2nd gear

2nd gear Synchronizer
middle ring
aligning the claws of the synchronizer middle ring to the
positioning holes in the 2nd gear.
face
Claws
Holes AK603939AB
>>E<< 3RD DRIVE GEAR INSTALLATION

MD998812 install the 3rd drive gear.
MD998813
MD998819
AB
AK603709AB
TSB Revision
OUTPUT SHAFT
>>F<< 4TH DRIVE GEAR INSTALLATION

MD998812
install the 4th drive gear.
MD998813
MD998819
AK603710AB
AB
>>G<< TAPERED ROLLER BEARING INNER

RACE INSTALLATION
MD998812
install the tapered roller bearing inner race.
MD998813
MD998819
AB
AK603711AB
TSB Revision
SELECT LEVER
22B-35
SELECT LEVER
M1222012800234
Apply gear oil to

all moving parts
14
1
4 8
2
6 5
7
9
10
11
12
13
AK603532AB

1. Shaft snap ring >>A<< 8. Slotted spring pin
2. Select spring seat 9. Transmission oil baffle
3. Spring 10. Shift inner lever No.2
>>B<< 4. Slotted spring pin 11. Spring
5. Shift inter lock plate 12. Select spring shift No.2
6. Shift inner lever No.1 13. Shaft snap ring
7. Shift inter lock plate cover 14. Shift and select lever shaft
TSB Revision
SELECT LEVER

.
>>A<< SLOTTED SPRING PIN INSTALLATION

Drive in the slotted spring pin to the illustrated dimension.
Slotted spring pin
0 0.5 mm
(0 0.19 in.)
AK603690AB
>>B<< SLOTTED SPRING PIN INSTALLATION

Drive in the slotted spring pin to the illustrated dimension.
Slotted spring pin
6.3 0.5 mm
(0.248 0.19 in.)
AK603691AB
TSB Revision
CLUTCH HOUSING
22B-37
CLUTCH HOUSING
M1222003700444
Apply gear oil to 4

all moving parts 7
5
7.0 2.8 Nm
62 24 in-lb
1
2
9
AK603533AB

1. Transaxle case receiver >>E<< 5. Out put shaft cover
2. Magnet <<C>> >>D<< 6. Tapered roller bearing outer race
<<A>> >>G<< 3. Cylindrical roller bearing (outer >>C<< 7. Extension housing oil baffle
race) >>B<< 8. Oil seal
<> >>F<< 4. Tapered roller bearing outer race >>A<< 9. Oil seal

MB990211: Slide hammer MB991445: Bush remover & installer base
MB992039: Slide hammer puller MB990938: Installer bar
MD998200: Oil seal installer MD999547: Oil seal installer
MD998550: Extension housing seal installer MB990699: Differential oil seal installer
TSB Revision
CLUTCH HOUSING

.
<<A>> CYLINDRICAL ROLLER BEARING (OUTER

RACE) REMOVAL
1. Using special tools MB990211 and MB992039, remove the
MB990211 cylindrical roller bearing (outer race).
MB992039
AK603480AB
<> TAPERED ROLLER BEARING OUTER

RACE REMOVAL
MB990211 tapered roller bearing outer race.
MB992039
AK603499AB
<<C>> TAPERED ROLLER BEARING OUTER

RACE REMOVAL
tapered roller bearing outer race.
MB990211
MB992039
AK603713AB
TSB Revision
CLUTCH HOUSING
22B-39
.
>>A<< OIL SEAL INSTALLATION

Using special tools MD998550, install the oil seal.
MD998550
Specified grease:
AK603189AB
>>B<< OIL SEAL INSTALLATION

Using special tools MD998200, install the oil seal.
MD998200 Specified grease:
AK603190AB
>>C<< EXTENSION HOUSING OIL BAFFLE

INSTALLATION
Install the extension housing oil baffle to the clutch housing
case assembly with its projections fitted in the slots in the clutch
housing case assembly.
Projection Projection
AK603483AB
TSB Revision
CLUTCH HOUSING
>>D<< TAPERED ROLLER BEARING OUTER

RACE INSTALLATION
Using special tools MB991445 and MB990938, install the
MB990938
MB991445
AK603714AB
>>E<< OUTPUT SHAFT COVER INSTALLATION

Install the output shaft cover to the clutch housing case assem-
Projections bly with its projections fitted in the slots in the clutch housing
case assembly. Make sure that the oil hole in the output shaft
cover is up as shown.
Oil hole
AK603482AB
>>F<< TAPERED ROLLER BEARING OUTER

RACE INSTALLATION
Using special tools MB990699 and install the tapered roller
bearing outer race.
MB990699
AK603500AB
TSB Revision
CLUTCH HOUSING
22B-41
>>G<< CYLINDRICAL ROLLER BEARING (OUTER
RACE) INSTALLATION
Using special tools MD999547, install the cylindrical roller bear-
ing (outer race).
MD999547
AK603481AB
TSB Revision
TRANSAXLE CASE
TRANSAXLE CASE
M1222016300015
13 5.2 Nm
115 45 in-lb
Apply gear oil to
all moving parts
4 3
10
9
8
17 6.8 Nm
12 4 ft-lb 1 5
7
6
2
17 6.8 Nm
12 4 ft-lb
AK603534AB

1. Oil receiver pipe A <<A>> >>C<< 6. Tapered roller bearing outer race
2. Oil receiver pipe B 7. Shim
3. With head straight screw plug <> >>B<< 8. Tapered roller bearing outer race
4. Slotted spring pin 9. Shim
5. Reverse restrict pin assembly >>A<< 10. Oil seal

MB991015: Knuckle oil seal installer MB992075: Handle
MB990211: Slide hammer MB991966: Bearing outer race installer
MB992210: Oil seal installer
TSB Revision
TRANSAXLE CASE
22B-43
.
<<A>> TAPERED ROLLER BEARING OUTER

RACE REMOVAL
Using special tools MB991015, remove the tapered roller bear-
ing outer race.
MB991015
AK603184AB
<> TAPERED ROLLER BEARING OUTER

RACE REMOVAL
Using special tools MB990211 and MB992039, remove the
MB990211
MB992039
AK603185AB
TSB Revision
TRANSAXLE CASE

.
>>A<< OIL SEAL INSTALLATION

MB992075 1. Using special tools MB992210 and MB992075, press-fit the
MB992210 oil seal until the difference in height between the transaxle
case and oil seal is obtained as shown.
2. Pack grease to the oil seal lip area.
Specified grease:
AK603773AB
Oil seal
3.0 4.0 mm
(0.118 0.157 in.)
AK603478AB
>>B<< TAPERED ROLLER BEARING OUTER

RACE INSTALLATION
Using special tools MB991966, Install the tapered roller bearing
MB991966 outer race.
AK603479AB
TSB Revision
TRANSAXLE CASE
22B-45
>>C<< TAPERED ROLLER BEARING OUTER
RACE INSTALLATION
1. Set special tools MB991015 and MB990938.
MB990938
MB991015
AK603183AB
3.8 4.4 mm 2. Press-fit the tapered roller bearing outer race to the height
(0.150 0.173 in.) Outer race shown in the illustration.
AK603198AB
TSB Revision
DIFFERENTIAL
DIFFERENTIAL
M1222002500351
Apply gear oil to

all moving parts
4
106 6.4 Nm
78 4 ft-lb
AK603535AB

<<A>> >>C<< 1. Tapered roller bearing inner race 4. Ring gear
<> >>B<< 2. Speedometer drive gear 5. Differential case assembly
<<C>> >>A<< 3. Tapered roller bearing inner race

MD998917: Bearing remover MD998812: Installer cap
MB991395: Crankshaft front oil seal installer MB992150: Oil seal installer
MB990810: Side bearing puller MB990891: Rear suspension bushing base
MD999566: Craw MB992138: Bearing installer
TSB Revision
DIFFERENTIAL
22B-47
.
<<A>> TAPERED ROLLER BEARING INNER

RACE REMOVAL
1. Using special tool MD998917 and MB991395, support the
MB991395
tapered roller bearing inner race, and then set them on the
MD998917 press.
2. Push down on the differential case with the press and
remove the tapered roller bearing inner race.
AK603175AB
<> SPEEDOMETR DRIVE GEAR REMOVAL

1. Using special tool MD998917 and MB991395, support the
MB991395 speedometer drive gear, and then set them on the press.
MD998917
remove the speedometer drive gear.
AK603176AB
<<C>> TAPERED ROLLER BEARING INNER

RACE REMOVAL
1. Using special tool MB990810, MD999566 and MB991395,
MB990810 remove the tapered roller bearing inner race.
remove the tapper roller bearing inner race.
MD999566
MB991395
AK603174AB
TSB Revision
DIFFERENTIAL

.
>>A<< TAPERED ROLLER BEARING INNER

RACE INSTALLATION
Using special tools MD998812 and MB992150, install the
MB992150 MD998812 tapered roller bearing inner race.
AK603179 AB
>>B<< SPEEDOMETR DRIVE GEAR

INSTALLATION
Using special tools MB990891, install the speedometer drive
gear.
MB990891
AK603177AB
>>C<< TAPERED ROLLER BEARING INNER

RACE INSTALLATION
Using special tools MB992138, install the tapered roller bearing
MB992138 inner race.
AK603178AB
TSB Revision
23-1
GROUP 23
CONTINUOUSLY
VARIABLE
TRANSAXLE (CVT)
CONTENTS
CVT. . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2 ELECTRONIC CONTROL SYSTEM . . . . . . 23-25

GENERAL INFORMATION. . . . . . . . . . . . . 23-2 CONTROL DESCRIPTION . . . . . . . . . . . . . 23-25
PRINCIPLE OF IMPROVEMENTS IN FUEL CVT CONTROL . . . . . . . . . . . . . . . . . . . . . . 23-26
ECONOMY AND PERFORMANCE LINE PRESSURE CONTROL . . . . . . . . . . . 23-30
WITH CVT. . . . . . . . . . . . . . . . . . . . . . . . . . 23-4 DIRECT CONTROL (TORQUE CONVERTER
DESCRIPTION OF STRUCTURE AND CLUTCH CONTROL) . . . . . . . . . . . . . . . . . 23-31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 23-6 CONTROL BETWEEN N (P) AND D (R). . . 23-31
SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . 23-6 CONTROLLER AREA NETWORK (CAN)
TORQUE CONVERTER . . . . . . . . . . . . . . . 23-7 COMMUNICATION . . . . . . . . . . . . . . . . . . . 23-32
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 23-7 SELF-DIAGNOSIS FUNCTION . . . . . . . . . . 23-32
FORWARD/REVERSE SWITCHING
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . 23-8 TRANSAXLE CONTROL . . . . . . . . . . 23-34
FINAL DRIVE AND DIFFERENTIAL. . . . . . 23-8 GENERAL INFORMATION . . . . . . . . . . . . . 23-34
PULLEY AND STEEL BELT . . . . . . . . . . . . 23-9 SELECTOR LEVER ASSEMBLY . . . . . . . . 23-35
TRANSMISSION FLUID WARMER CVT ERRONEOUS OPERATION
(TRANSMISSION FLUID COOLER). . . . . . 23-11 PREVENTION MECHANISMS . . . . . . . . . . 23-36
POWER FLOW . . . . . . . . . . . . . . . . . . . . . . 23-12 SHIFT LOCK MECHANISM . . . . . . . . . . . . 23-36
OIL PRESSURE CONTROL SYSTEM . . . . 23-16 KEY LOCK MECHANISM . . . . . . . . . . . . . . 23-38
CONTROL DESCRIPTION . . . . . . . . . . . . . 23-16 PADDLE SHIFT
SHIFT MECHANISM. . . . . . . . . . . . . . . . . . 23-18 <VEHICLES WITH SPORT MODE> . . . . . . 23-38
23-2 CONTINUOUSLY VARIABLE TRANSAXLE (CVT)
CVT
CVT
GENERAL INFORMATION
M2231000100132
The new CVT has been developed to achieve excel- achieve "high driving performance" and "better fuel
lent fuel economy, further easy driving, and fun to economy." Depending on the driving conditions, the
drive. This CVT has achieved a quick and smooth comfortable pulley ratio is automatically and continu-
acceleration feel suitable for LANCER, when the ously selected from low to overdrive, ensuring
vehicle accelerates from any speeds. The CVT com- driver-intended smooth driving without shift shocks
bines "torque converter" and "continuously variable due to acceleration pedal operation.
transaxle mechanism by steel belt and pulley" to .
SPECIFICATIONS
Item Standard value
Transaxle model F1CJA
Torque converter Model 3-element, 1-stage, 2-phase
Stall torque ratio 1.99
Lock-up Present
Transaxle type Forward automatic continuously variable (steel
belt-driven), reverse 1 speed
Pulley ratio Forward 2.349 0.394
Reverse 1.750
Shift position P-R-N-D-L or P-R-N-D+6-speed sport mode (with
paddle shift)
Final reduction gear ratio 6.120
Control type Electronically-controlled
Function Shift control Present
Line pressure control Present
Select control Present
Lock-up control Present
Self-diagnosis function Present
Fail-safe function Present
Speedometer gear (detected by the ABS sensor rotor)
Oil pump Model Vane-type pump
Drive type Driven by the engine, sprocket, and chain
Transmission fluid Brand name DIA QUEEN CVTF-J1
Capacity dm3 (qt) Approximately 7.8 (8.2)
CONTINUOUSLY VARIABLE TRANSAXLE (CVT)
CVT
23-3
SYSTEM CONFIGURATION
<In transaxle>
Forward/
Differential Belt and reverse Torque
Wheel gear
Low gear converter
Engine
pulley switching
mechanism
Sprocket and
chain
Parking
mechanism Oil pressure Oil pump
control system
Electronic control
system
<In control valve>
Secondary Primary
pulley pulley
speed speed
sensor sensor
Crankshaft
position sensor
Transmission
Control device range
switch Accelerator
pedal position
sensor
ECM
TCM
ABS-ECU
Mechanical system
Oil pressure system ETACS-

ECU
Electrical system
CAN communication
AC611123AB
CVT
OVERVIEW
Transmission range switch
Transmission
fluid warmer
(Transmission Secondary pulley
fluid cooler) speed sensor
Primary pulley
speed sensor
AC610077AB
PRINCIPLE OF IMPROVEMENTS IN FUEL ECONOMY AND PERFORMANCE WITH CVT

M2231001000031
The general concept of CVT is described as follows:
PRINCIPLE OF IMPROVEMENTS IN FUEL ECONOMY

CVT can continuously vary the pulley ratio, so the
Engine load vehicle can be driven in the high engine fuel effi-
CVT service area
Optimum ciency range all the time, resulting in excellent fuel
fuel ratio economy.
curve
A/T service area

Engine speed
AC507018 AB
CVT
23-5
PRINCIPLE OF IMPROVEMENTS IN POWER PERFORMANCE
The figure shows the maximum driving force diagram
representing the power performance. The compari-
CVT
Engine speed son with A/T shows that when the throttle is fully
open, A/T causes a step change in driving force due
to a step shift, but CVT changes driving force
smoothly because it can accelerate with the engine
A/T kept in the high output range. Therefore, CVT pro-
vides more smooth and shockless driving without
driving loss as much as the shaded area in the figure
Accelerator fully open
shown.
Vehicle speed
Driving force
: This area can be used effectively
and there is no shift shock.
1st gear CVT

2nd gear
A/T 3rd gear

4th gear
Vehicle speed
AC507017 AB
CVT
DESCRIPTION OF STRUCTURE AND OPERATION

SECTIONAL VIEW
M2231000400014
5 4 3 2
7 6
1
8
23
10 22
11 21
12
20
19
18
17
13 14
16
15
AC505738AB
1. Converter housing 4. Reverse brake

2. Driven sprocket 5. Oil pump
3. Chain 6. Forward clutch
CVT
23-7
7. Planet carrier
8. Primary pulley
9. Sun gear
10. Steel belt
11. Side cover
12. Internal gear
13. Parking gear
14. Secondary pulley
15. Final gear
16. Differential case
17. Idler gear
18. Reduction gear
19. Taper roller bearing
20. Output gear
21. Drive sprocket
22. Input shaft
23. Torque converter
TORQUE CONVERTER
M2231000200010
The torque converter with the "3-element, 1-stage,
2-phase" lock-up mechanism has been adopted.
OIL PUMP
M2231000500011
The vane-type oil pump driven by the engine via the
oil pump drive chain has been adopted to increase
efficiency of the pump discharge amount at low
engine speed and optimise the pump discharge
amount at high engine speed. The oil discharged
from the oil pump flows to the control valve, and is
used as operating fluid for the primary and second-
ary pulleys, operating fluid for the clutch, and lubri-
cant for each part.
CVT
FORWARD/REVERSE SWITCHING MECHANISM

M2231000600018
P, N range D range R range

Reverse brake (release) Reverse brake (engage)
Reverse brake (release)
Planet carrier
Forward Internal gear (normal rotation)
Internal gear
clutch Forward
Forward
(engage) clutch
clutch
(release) (release)
Sun gear Sun gear

(reverse
Sun gear rotation)
Primary pulley Input shaft

Internal gear Internal gear (slip) Internal gear
Planet carrier (revolution) Planet carrier Planet carrier (revolution)
(slip) (slip) (secure)
Sun gear Sun gear

Sun gear (reverse rotation)
(stop) (revolution)
AC504691AB
The planetary gear type forward/reverse switch- The power is input from the torque converter via
ing mechanism has been installed between the the input shaft and hydraulically activates the wet
torque converter and primary pulley. multi-disc device to switch between forward and
reverse gears.
FINAL DRIVE AND DIFFERENTIAL
M2231000700015
Output gear
Primary reduction
Idler gear
Reduction gear
Secondary reduction
Final gear
AC506402 AB
The reduction gear is a 2-stage composition, the helical.

primary reduction (a pair of the output gear and The transmission fluid (Mitsubishi genuine
idler gear) and secondary reduction (a pair of the Dia-Queen CVTF-J1) which lubricates the entire
reduction gear and final gear). All the gears are transaxle is also used as lubricant.
CVT
23-9
PULLEY AND STEEL BELT
M2231000800012
Steel belt
Primary pulley
(input side pulley)
Secondary pulley
(output side pulley)
AC504739AC
This unit is comprised of a pair of pulleys of which cally controlled by the primary and secondary pul-
groove width can be changed freely in the axial leys, varying continuously from the low status (pulley
direction, and a steel belt made of a continuous ratio: 2.349) to the overdrive status (pulley ratio:
series of steel elements guided by multilayer steel 0.394) depending on the winding radius of the steel
rings on the both sides. This groove width is hydrauli- belt on the pulley.
STEEL BELT
Steel element:
This is composed of approximately 400 steel elements and two
Approximately 400 12-layer steel rings. The steel belt has the following features.
pieces Other belts such as a rubber belt transfer driving force by their
pulling effect. On the other hand, the steel belt transfers driving
22 force by compression effect of the steel elements. The steel
elements require a friction force with the pulley slope to transfer
driving force. The mechanism is as follows:
Steel ring [Circumference:
approximately 714 mm (28 in)] The secondary pulley hydraulically activates to pinch the ele-
ments. The elements are pressed outwards to expand.
AC504740 AB The steel rings hold out against the force. Tension is gener-
ated at the steel rings. The elements on the primary pulley
side are pinched between the pulleys. Friction force is gener-
ated between the steel belt and pulley. This means that the
CVT
steel elements which transfer the driving force by compression

and the steel rings which maintain the required friction force
share the roles. Then, the tension of the steel rings is distrib-
uted over the entire unit with little stress variation, resulting in
excellent durability.
PULLEY
11 Secondary pulley
Low status: Pulley ratio = r2/r1 Secure pulley
Adjustable pulley
Pulley groove width
Wide
Pulley groove width

Narrow
r1
r2
Primary pulley
Secondary pulley
Secondary pulley
Secure pulley Adjustable pulley
Overdrive status: Pulley ratio = r2/r1
Pulley groove width

Narrow
Pulley groove width

Wide
r1
r2
Primary pulley
Secondary pulley
AC504741AB
The primary and secondary pulleys are both com- pulley. The groove width of the pulley is controlled by
prised of the fixed pulley with 11-degree slope and changing the operating pressure at the primary and
movable pulley. Each has a hydraulic chamber (the secondary pulleys using the engine load (accelerator
primary or secondary chamber) behind the movable angle), primary pulley speed, and secondary pulley
pulley. The movable pulley can slide along the axis speed (vehicle speed) as input signals.
with a ball spline to change the groove width of the
CVT
23-11
TRANSMISSION FLUID WARMER
(TRANSMISSION FLUID COOLER)
M2231000900019
Tranmission fluid cooler The water-cooled transmission fluid warmer (transmission fluid
(Tranmission fluid warmer) cooler) has been adopted. The transmission fluid warmer
(transmission fluid cooler) has been installed directly to the
front of the transaxle to shorten the fluid passage.
The transmission fluid warmer (transmission fluid cooler)
warms the transmission fluid up to an optimum temperature [70
80 C (158 176 F) ] quickly for transaxle performance right
after engine start. Once the transmission fluid has reached the
optimum temperature, the warmer starts cooling down the fluid
AC611028AB to stabilize the temperature.
TRANSMISSION FLUID FILTER

The transmission fluid filter integrated in the transaxle assem-
bly has been adopted. Any impurity in the transmission fluid
has been removed to increase operational reliability of the tran-
saxle assembly.
CVT
POWER FLOW
M2231001100016
P RANGE
Forward clutch (release)
Parking gear (secure)
AC507023AB
The driving force from the engine is not trans- The torque from the tires is not transferred to the
ferred to the primary pulley because the forward components upstream of the secondary pulley
clutch and reverse brake are released. because the parking gear is fixed.
CVT
23-13
R RANGE
Reverse brake (engage)
AC507026 AB
The driving force from the engine rotates the sun For this reason, the primary pulley rotates in the
gear in the reverse direction because the reverse reverse direction, thus the driving force is output
brake is engaged and the planet carrier is fixed. in the reversed state.
CVT
N RANGE
AC507025AB
The driving force from the engine is not trans- The torque from the tires is not transferred
ferred to the primary pulley because the forward because the forward clutch and reverse brake
clutch and reverse brake are released. are released, thus the planet carrier rotates inde-
pendently.
CVT
23-15
D RANGE
Forward clutch (engage)
AC507024 AB
The driving force from the engine rotates the sun For this reason, the primary pulley rotates in the
gear in the normal direction via the forward clutch normal direction, thus the driving force is output
because the forward clutch is engaged. in the normal state.
CVT
OIL PRESSURE CONTROL SYSTEM

CONTROL DESCRIPTION
M2231005000033
.
HYDRAULIC CONTROL
The hydraulic control mechanism is comprised of the
vane-type oil pump driven by the engine via the oil
pump drive chain, the hydraulic control valve which
controls the line pressure and shift change, and the
input signal system.
Oil pump
Control valve
Input signals
Primary
Ratio control valve Primary pulley
pulley revolution
Secondary Stepper motor Secondary valve Secondary pulley

pulley revolution
Secondary pressure
Engine solenoid valve
speed
Line pressure Pressure
Throttle solenoid valve regulator valve
opening Forward clutch
TCM
Manual valve
Transmission Reverse brake
fluid temperature
Lock-up/select
switching solenoid valve Clutch regulator valve Select control valve
Transmission Torque converter
engage
range switch Lock-up control valve
Lock-up Torque converter
solenoid valve release
Primary Torque converter
pressure regulator valve
Secondary
pressure Select
switch valve
Oil pressure system

Electrical system Lubricating and
Mechanical system cooling systems
AC504662 AB
.
CVT
23-17
GENERAL INFORMATION REGARDING THE MAIN COMPONENTS
Component Function
Manual valve Distributes the clutch operating pressure to each circuit,
depending on each shift position.
Torque converter regulator valve Regulates the supply pressure to the torque converter to
optimal pressure for the driving conditions.
Clutch regulator valve Regulates the clutch operating pressure depending on the
driving conditions.
Pressure regulator valve Regulates the discharge pressure from the oil pump to optimal
pressure (line pressure) for the driving conditions.
Ratio control valve Controls in/out flow of line pressure to/from the primary pulley
depending on the stroke difference between the stepper motor
and primary pulley.
Lock-up/select switching solenoid valve Controls switching of lock-up solenoid valve control pressure
Select switch valve between when lock-up engagement/disengagement is
performed and when forward/reverse clutch (forward clutch and
reverse brake) engagement/disengagement is performed.
Line pressure solenoid valve Controls the pressure regulator valve.
Lock-up solenoid valve Controls the lock-up control valve.
Lock-up/select switching solenoid valve Controls the select switch valve.
Stepper motor Controls the pulley ratio.
Secondary valve Reduces the line pressure to regulate the secondary pressure.
Select control valve Engages when select. Regulates the forward clutch pressure
and reverse brake pressure.
Lock-up control valve Regulates the engagement pressure and disengagement
pressure of the torque converter.
Secondary pressure solenoid valve Controls in/out flow of the line pressure to/from the secondary
pulley depending on the driving conditions.
CVT
SHIFT MECHANISM
M2231001200013
SHIFTING FROM LOW TO HIGH
Stepper motor
Pulley ratio linkage

Ratio control valve
Line pressure
Primary pulley
Secondary valve
Secondary pulley
AC504742 AB
No line pressure is applied to the primary pulley The line pressure is applied to the secondary pul-
because the line pressure circuit is closed by the ley because the secondary valve has moved
ratio control valve. downwards.
CVT
23-19
Stepper motor
Pulley ratio linkage Ratio control valve
Line pressure
Primary pulley
Secondary valve
Secondary pulley
AC504743AB
The pulley ratio linkage moves to the left by the The secondary valve moves upwards to drain the
stepper motor. This moves the ratio control valve fluid in the secondary pulley.
linked to the pulley ratio linkage to open the line
pressure circuit, and then the line pressure is
applied to the primary pulley.
CVT
Stepper motor
Ratio control valve

Line pressure
Primary pulley
Steel belt
Adjustable pulley Secondary valve
Secondary pulley
Adjustable pulley
AC504744 AB
The line pressure applied to the primary pulley The steel belt is pulled toward the primary pulley
moves the movable pulley to the right, pressing side to move the movable pulley of the secondary
the steel belt outwards to expand. pulley to the right.
When the movable pulley of the primary pulley
moves to the right, the ratio control valve starts
moving to the right via the pulley ratio linkage
linked to the movable pulley.
CVT
23-21
Stepper motor
Line pressure
Primary pulley
Steel belt
Secondary valve
Adjustable pulley
Secondary pulley
AC504745 AB
When the movable pulley of the secondary pulley The secondary valve moves downwards to apply
moves to the right, the ratio control valve also the line pressure to the secondary pulley, clamp-
moves to the right to close the line pressure cir- ing the steel belt.
cuit. This completes the shift change process.
CVT
SHIFTING FROM HIGH TO LOW
Stepper motor
Line pressure
Primary pulley
Secondary valve
Secondary pulley
AC504746 AB
The pulley ratio linkage moves to the right by the The line pressure is applied to the secondary pul-
stepper motor. This moves the ratio control valve ley because the secondary valve has moved
linked to the pulley ratio linkage to drain the fluid downwards.
in the primary pulley.
CVT
23-23
Stepper motor
Line pressure
Primary pulley
Steel belt
Adjustable pulley
Secondary valve
Secondary pulley
Adjustable pulley
AC504747AB
The line pressure applied to the secondary pulley When the movable pulley of the primary pulley
moves the movable pulley to the left, pressing the moves to the left, the ratio control valve starts
steel belt outwards to expand. moving to the left via the pulley ratio linkage
The steel belt is pulled toward the secondary pul- linked to the movable pulley.
ley side to move the movable pulley of the pri-
mary pulley to the left.
CVT
Stepper motor
Ratio control valve

Line pressure
Primary pulley
Steel belt
Adjustable pulley
Secondary valve
Secondary pulley
Adjustable pulley
AC504748AB
When the movable pulley of the secondary pulley When the movable pulley of the primary pulley
moves to the left to press the steel belt outwards moves to the left, the ratio control valve also
to expand, the movable pulley of the primary pul- moves to the left to close the drain circuit. This
ley moves further to the left accordingly. completes the shift change process.
CVT
23-25
ELECTRONIC CONTROL SYSTEM
CONTROL DESCRIPTION
M2231005000044
The electronic control mechanism is comprised of Line pressure control
various sensors, actuators, and TCM which controls Control between N (P) and D (R)
them. Direct control
TCM calculates the vehicle status from various sen- Engine and CVT integrated control (CAN commu-
sor information and drives each solenoid valve to nication)
perform the following controls: Self-diagnosis function
Shift control (INVECS-III, sport mode <Vehicles
without sport mode>)
CONTROL SYSTEM DIAGRAM
Line pressure solenoid valve Transaxle body

Secondary pressure solenoid valve
Lock-up solenoid valve
Lock-up/select switching solenoid valve
Secondary pulley speed sensor Secondary

pulley
ETACS-ECU
Belt
TCM Primary pulley speed sensor Primary
pulley
Accelerator pedal Variable link

position sensor
Stepper motor
Transmission fluid
temperature sensor
Crankshaft
position sensor ECM Secondary pressure sensor
Primary pressure sensor
Transmission range
switch
ABS-ECU Shift switch assembly
<Vehicles with sport mode>
Paddle shift switch
CAN communication <Vehicles with sport mode>
AC610161AB
.
CVT
SENSOR LIST
Name Function
Sensor Primary pulley speed sensor Outputs the primary pulley (input shaft) speed as a
pulse signal to TCM.
Secondary pulley speed sensor Outputs the secondary pulley (output shaft) speed
as a pulse signal to TCM. The pulse signal is
converted to the vehicle speed by TCM.
Transmission fluid temperature sensor Detects the transmission fluid temperature.
Primary pressure sensor Detects the pressure applied to the primary pulley.
Secondary pressure sensor Detects the pressure applied to the secondary
pulley.
Transmission range switch Detects the selector lever position by the
contact-type switch.
Shift switch assembly <Vehicles with sport Detects the request in the sport mode by the
mode> contact-type switch at the selector lever.
Paddle shift switch <Vehicles with sport Detects the operation status of the paddle shift
mode> switch.
CVT CONTROL
M2231001400017
INVECS-III
INVECS-III has been newly developed based on
INVECS-II utilizing continuous variable characteris-
tics of CVT.
TCM
Target wave pattern Gear changing mechanism

creation section control section
Input Selects the Determines how the

pulley ratio stepper motor works Stepper motor Primary pulley
signals
and determines to change pulley
the pulley according to the
change method. target wave pattern.
AC504721AB
To select the pulley ratio which can provide the driv- vehicle speed, accelerator angle. Then, it outputs the
ing force corresponding to the driver's intention and command to the stepper motor, controls in/out flow of
vehicle conditions. TCM selects the optimal pulley the line pressure to/from the primary pulley, positions
ratio and determines the shift strategy to obtain it by the movable pulley of the primary pulley, and controls
detecting the vehicle driving conditions such as the the pulley ratio.
Engine brake feature on the descending
.
slope
Pulley ratio is controlled to obtain the engine brake
suitable for the drivers feelings.
.
CVT
23-27
Engine brake learning feature on the descending slope
Often use accelerator
HIGH
Pulley ratio
LOW
Often use brake
100%
Throttle opening
Often use accelerator
0%
Acceleration
Often use brake

AC610382 AB
Learning compensation is made to meet the tastes of

a driver by judging the amount of the engine brake
from the application of the accelerator or the brake.
.
Driving feature on the ascending slope
When driving fast on the ascending

slope
Throttle opening 100%
Target primary 80%
revolution speed
lower limit value 60%
40%
20%
Target primary 0%
revolution speed
Increasing the target primary

revolution speed
When driving in a
normal condition
Vehicle speed
AC610384 AB
If the foot leaves the accelerator pedal during driving

on the ascending slope (called lift foot), driving capa-
bility is secured by preventing excessive upshifting.
.
CVT
Learning feature corresponding to tastes and habits of drivers
Target primary
revolution speed
lower limit value
Driving on the
ascending slope
or driving fast
Target primary
revolution speed
Cruising on
flat road
Secondary revolution speed (vehicle speed)

AC610398 AB
Ratio patterns are continuously switched according

to the driving method of the driver.
RATIO PATTERN
The pulley ratio is controlled based on the ratio pat-
tern for each predetermined range to achieve the
optimal pulley ratio.
<D RANGE>
Engine speed (r/min)

7,000
Throttle opening100%
6,000
Low
5,000
4,000
OD
3,000
2,000
Throttle opening 0%
1,000
0 (0) 50 (31) 100 (62) 150 (93) 200 (124)

Vehicle speed km/h (mph)
AC611605AB
The shift change is performed in the entire shift

range from the lowest to the highest pulley ratio.
CVT
23-29
<L RANGE (VEHICLES WITHOUT SPORT
MODE)>

7,000
Throttle opening100%
6,000
Low
5,000
Throttle opening 0%
4,000
OD
3,000
2,000
1,000
0 (0) 50 (31) 100 (62) 150 (93) 200 (124)

AC611606AB
By limiting the shift range to the area around the low-

est pulley ratio, the powerful driving force and engine
brake is secured.
CVT
<SPORT MODE (VEHICLES WITH SPORT

MODE)>

7,000
6,000
Low 1st 4th

5,000
2nd 3rd 6th
4,000
5th
OD
3,000
2,000
1,000
0 (0) 50 (31) 100 (62) 150 (93) 200 (124)

AC611607AB
When the sport mode is switched ON with the selec-

tor lever or paddle shift, the fixed shifting line is
determined. The upshift/downshift operation enables
to shift in steps according to the predetermined shift-
ing line, providing M/T-like shifting. The 6-speed
transmission which is suitable for sporty driving is
adopted.
LINE PRESSURE CONTROL
M2231001300010
The high-precision line pressure control and second-
ary pressure control have reduced the friction for bet-
ter fuel economy.
Input side
Throttle opening
Engine speed Line pressure control
Primary pulley revolution
Secondary pulley revolution Normal hydraulic
pressure control
Stoplight switch signal (Not at selection) Output side
Transmission range switch Set hydraulic
signal pressure
Lock-up signal Hydraulic pressure
Voltage control at selection
(Select control)
Target pulley ratio
Transmission fluid
temperature
Feedback control
Oil pressure sensor
AC504722 AB
CVT
23-31
NORMAL HYDRAULIC CONTROL
The optimal line pressure and secondary pressure
are determined by the accelerator angle, engine
speed, primary pulley (input) speed, secondary pul-
ley (output) speed, stoplight switch signal, transmis-
sion range switch signal, lock-up signal, voltage,
target pulley ratio, fluid temperature, and oil pres-
sure, depending on driving conditions.
SECONDARY PRESSURE FEEDBACK
CONTROL
In the normal hydraulic control or select hydraulic
control, the more precise secondary pressure has
been set by detecting the secondary pressure with
an oil pressure sensor, and by performing the feed-
back control.
DIRECT CONTROL (TORQUE CONVERTER CLUTCH CONTROL)
M2231007000039
.

7,000
6,000
Low
5,000
Disengaged
4,000
Lock-up
OD
3,000
2,000
1,000
Partial lock-up zone
0 (0) 50 (31) 100 (62) 150 (93) 200 (124)

AC611608AB
By carefully controlling the direct operating pressure

depending on the driving conditions, the shock-free
direct operation from low speed has been achieved.
CONTROL BETWEEN N (P) AND D (R)
M2231001500014
When operation between N (P) and D (R) ranges is
performed, the optimal operating pressure is deter-
mined by the accelerator angle, engine speed, and
secondary pulley (output) speed to reduce the shock
caused by selecting.
CVT
CONTROLLER AREA NETWORK (CAN) COMMUNICATION

M2231017000030
The information transaxle between each control unit TCM transmits information such as the rapid
has been ensured via the CAN communication. For deceleration signal, lock-up in progress signal,
further details on CAN, refer to GROUP 54C, CAN torque down request signal to the ECM. It also
P.54C-2. receives information such as the torque down
permission/prohibition signal, lock-up permis-
ENGINE AND CVT INTEGRATED sion/prohibition signal, accelerator angle.
CONTROL (CAN COMMUNICATION
CONTROL)
To control better shift feeling and preventing the
engine speed from dropping, the ECM and TCM
communicate each other to exchange the engine
output control signal to provide the real-time link-
age control depending on the vehicle driving con-
ditions.
SELF-DIAGNOSIS FUNCTION
M2231001600011
DIAGNOSTIC FUNCTION
TCM is equipped with the diagnostic function to mon-
itor the input signals from each sensor and output
signals from the actuators. If abnormality occurs in
the signal system, the diagnostic function memorises
the abnormal symptoms and outputs a diagnosis
code via M.U.T.-III.
FAIL-SAFE FUNCTION
If abnormality occurs in signals from various sensors,
switches, or solenoids, this function allows control-
ling them with the minimum adverse effect to the
driving performance. The following shows the
fail-safe controls when an abnormal signal is input to
TCM from each sensor.
Item Control content
Secondary pulley speed sensor Performs the shift control depending on the accelerator angle. Also,
prohibits the sport mode and controls as the D range <Vehicles with
sport mode>.
Primary pulley speed sensor Performs the shift control depending on the accelerator angle and
secondary pulley rotation (vehicle speed). Also, prohibits the sport
mode and controls as the D range <Vehicles with sport mode>.
Transmission range switch Controls as the D range.
Transmission fluid temperature Controls using the fixed value for the fail-safe function.
sensor
Secondary pressure sensor Stops the secondary pressure feedback control and controls the line
pressure using the fixed value for the fail-safe function. Also,
suppresses the engine torque.
Primary pressure sensor Stops the primary pressure feedback control and controls the line
pressure using the fixed value for the fail-safe function. Also,
suppresses the engine torque.
Line pressure solenoid valve Switches the line pressure solenoid valve OFF to achieve the
maximum line pressure.
CVT
23-33
Item Control content
Secondary pressure solenoid valve Switches the secondary pressure solenoid valve OFF to achieve the
maximum secondary pressure.
Lock-up solenoid valve Switches the lock-up solenoid valve OFF to release lock-up.
Stepper motor Switches all the coils A to D of the stepper motor OFF to retain the
pulley ratio just before the abnormality occurs.
Lock-up/select switching solenoid Switches the lock-up/select switching solenoid valve OFF to release
valve lock-up.
Back-up power supply If the control memory back-up power supply from the battery is not
supplied to TCM, limits the engine torque to protect the transmission
main body. After the normal power is supplied, turning the key switch
from OFF to ON once resumes the normal status.
Paddle shift switch <Vehicles with Prohibits the paddle shift operation.
sport mode>
Shift switch assembly <Vehicles Prohibits the sport mode operation.
with sport mode>
TRANSAXLE CONTROL
TRANSAXLE CONTROL
GENERAL INFORMATION
M2232000600011
The selector lever with the gate-type has been The shift knob painted in metallic silver with a
adopted. For vehicles with sport mode, in addition to high-grade appearance has been adopted, and
the manual gate of selector lever, the paddle shift for higher level specifications, the genu-
has been equipped around the steering wheel to ine-leather shift knob has been provided.
achieve "Fun to Drive." The selector lever has the The main components have been made of resin
following features: to reduce weight and number of components.
The shift gate configuration and the operating The electrical control-type shift lock mechanism
power at each shift position have been properly with the solenoid to facilitate the tuning work in
tuned, ensuring the firm and smooth operation assembly.
feel. The cable control-type key interlock mechanism
The sport mode (6-speed) has been installed to which is field proven has been adopted.
allow the driver to shift manually according to
his/her intention. <Vehicles with sport mode>
<Vehicles without sport mode> <Vehicles with sport mode>
+E
-
-
L
Transaxle control cable
Key interlock cable
Selector lever
assembly
AC611629AB
TRANSAXLE CONTROL
23-35
SELECTOR LEVER ASSEMBLY
M2232002000189
Shift lock release button
P position
detect switch
Shift indicator valve
Shift lock solenoid
Shift switch assembly

Shift lock control relay
AC610078 AB
The electrical control-type shift lock (the shift lever is

locked in the "P" position if the brake pedal is not
depressed) mechanism has been adopted for the
selector lever assembly. The functions of each
switch are as follows:
Name Function
Shift lock release button If the shift lock system has failed, remove the cover
and press the shift lock release button to release the
shift lock forcibly (mechanically).
Shift indicator bulb Illuminates the present selector lever position in the
shift indicator.
Shift switch assembly <Vehicles with sport mode> Detects the selector lever activation in sport mode.
Shift lock solenoid Switches the shift lock mechanism ON/OFF.
Shift lock control relay Switches the shift lock solenoid power supply circuit
ON/OFF.
P position detection switch Detects the "P" position.
TRANSAXLE CONTROL
CVT ERRONEOUS OPERATION PREVENTION MECHANISMS

SHIFT LOCK MECHANISM
M2232000400017
STRUCTURE OF SHIFT LOCK SYSTEM Shift lock solenoid

This system is comprised of the following compo- Shift lock control relay
nents. P position detection switch
Lock lever
SHIFT LOCK CIRCUIT
When all of the following conditions are true, the shift lock sole-
noid is energised, allowing the selector lever to move from the
To stoplight To ignition
switch switch P position to another position.
Ignition switch: ON
P position detection switch: ON (the selector lever is in the
P position)
Shift lock Stoplight switch: ON (brake pedal is depressed)
control relay
P position Shift lock

detect switch solenoid
AC507425AB
OPERATIONAL DESCRIPTION
.
SHIFT LOCK STATUS

With the shift lock status, the shift lock solenoid is not ener-
gized, so when the select operation of the selector lever is
attempted, no select operation is possible because the lock
Lever sub assembly lever blocks the lever assembly path.
Lock lever inhibits

selecting operation
of the lever
sub-assembly.
Shift lock
solenoid
Lock lever
AC610121 AB
.
TRANSAXLE CONTROL
23-37
SHIFT LOCK RELEASE STATUS
When the ignition switch is ON, the selector lever is in the P
position, and the brake pedal is depressed, the shift lock sole-
Lever sub assembly noid is energized to move the shift lock solenoid toward the
direction A shown in the figure. Then the lock lever linked to the
shift lock solenoid moves as shown in the figure, and no longer
blocks the lever sub assembly path when the select operation
Lock lever moves to
is performed, enabling the operation.
allow selecting operation
of the lever sub assembly.
Shift lock
solenoid
Lock lever
AC610122 AB
RELEASE USING THE SHIFT LOCK RELEASE

BUTTON
If the shift lock no longer operates properly due to a dead bat-
tery or the like, remove the cover and press the shift lock
Cover release button to enable shift operation from the P position.
Pressing the shift lock release button moves the lock lever to
the position shown in the figure, enabling shift operation.
Shift lock release button

operation direction
Lock lever
AC610123 AB
TRANSAXLE CONTROL
KEY LOCK MECHANISM

M2232000500014
This mechanism is basically same as that used for
OUTLANDER.
PADDLE SHIFT <VEHICLES WITH SPORT MODE>
M2232000300021
Down shift lever
AC609992
Up shift lever
Down shift
Up shift
(operate it for 2 seconds or more to return to D range.)
AC611129AB
The paddle-shaped upshift/downshift lever has been NOTE: When the mode is changed to the sport
fitted near the steering wheel to allow the driver to mode using the paddle shift during automatic
operate upshift or downshift with his/her hands kept gear shifting, the sport mode is cancelled under
on the steering wheel. The paddle shift has the fol- the following conditions.
lowing features: .
The lever on the right of the vehicle is for upshift The upshift lever is pulled for 2 seconds or
and that on the left is for downshift. more.
As the paddle shift is fixed on the steering column The vehicle is stopped.
to maintain the certain position regardless of the No operation is carried out for 4 minutes and
steering wheel angle, the proper operation can 25 seconds.
be performed without possibility of improper The main components have been made of mag-
up/down position even when the steering wheel nesium alloy to achieve the considerable weight
is fully turned. reduction and pursue a sporty impression.
The paddle shift can perform the upshift/down-
shift operation whether the selector lever is in the
sport mode or automatic shifting to provide a
rapid shift operation.
23-1
GROUP 23
CVT
CONTENTS
CVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A
CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL. . . . . 23B

NOTES
23B-1
GROUP 23B
CONTINUOUSLY
VARIABLE
TRANSAXLE
OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . . 23B-2 DISASSEMBLY AND ASSEMBLY . . . . . . . 23B-57

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23B-60
SPECIFICATIONS . . . . . . . . . . . . . . . 23B-3
FASTENER TIGHTENING REDUCTION GEAR . . . . . . . . . . . . . . 23B-61
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 23B-3 DISASSEMBLY AND ASSEMBLY . . . . . . . 23B-61
GENERAL SPECIFICATION . . . . . . . . . . . 23B-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23B-64
SERVICE SPECIFICATIONS . . . . . . . . . . . 23B-4
SNAP RING, SPACER AND THRUST WASHER REDUCTION GEAR
FOR ADJUSTMENT . . . . . . . . . . . . . . . . . . 23B-4 SUB-ASSEMBLY . . . . . . . . . . . . . . . . 23B-64
SEALANTS AND ADHESIVES . . . . . . . . . . 23B-6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 23B-64
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 23B-6
DIFFERENTIAL. . . . . . . . . . . . . . . . . . 23B-66
SPECIAL TOOLS. . . . . . . . . . . . . . . . 23B-6 DISASSEMBLY AND ASSEMBLY . . . . . . . 23B-66
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23B-68
TRANSAXLE . . . . . . . . . . . . . . . . . . . 23B-10
DISASSEMBLY AND ASSEMBLY . . . . . . . 23B-10 DIFFERENTIAL SUB-ASSEMBLY. . . 23B-69
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 23B-69
FORWARD CLUTCH . . . . . . . . . . . . . 23B-57
23B-2 CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL
GENERAL INFORMATION
GENERAL INFORMATION
M1233201400014
AUTOMATIC TRANSAXLE MODEL

Transaxle model Applicable engine Vehicle model
F1CJA-2-BBZ 4B11 MIVEC CY4A
SECTIONAL VIEW
AK603120
TSB Revision
CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL
SPECIFICATIONS
23B-3
SPECIFICATIONS
M1233205000115
Item Specifications N m
Detent spring 6.9 (61 in-lb)
Plug 7.5 (66 in-lb)
Clip 6.9 (61 in-lb)
Oil pump 19 (14 ft-lb)
Oil pump 28 (21 ft-lb)
Control valve assembly 7.9 (70 in-lb)
Manual lever 22.1 (16 ft-lb)
Bracket 7.9 (70 in-lb)
Oil strainer 7.9 (70 in-lb)
Oil pan 7.9 (70 in-lb)
Drain plug 34.3 (25 ft-lb)
Baffle plate 5.9 (52 in-lb)
Bracket 26 (19 ft-lb)
Baffle plate 26 (19 ft-lb)
Oil pump cover 26 (19 ft-lb)
Converter housing 45 (33 ft-lb)
Shift lever 17.2 (13 ft-lb)
Inhibitor switch 5.5 (49 in-lb)
Primary pulley speed sensor 5.9 (52 in-lb)
Secondary pulley speed sensor 5.9 (52 in-lb)
CVT fluid cooler 4.2 (37 in-lb)
Plug 7.5 (66 in-lb)
Oil filter tube 11 1 (97 9 in-lb)
Control cable bracket 23 3 (17 2 ft-lb)
Harness bracket 23 3 (17 2 ft-lb)
FR roll stopper bracket 90 10 (66 7 ft-lb)
RR roll stopper bracket 90 10 (66 7 ft-lb)
Reduction gear nut 250 (184 ft-lb)
Final gear 154 (114 ft-lb)
GENERAL SPECIFICATION
M1233201000191
Transaxle model F1CJA

Torque converter type 3-element 1-stage 2-phase
lockup available
Transaxle type forward: continuously variable (with steel belt), reverse: 1 gear
Gear ratio 2.349 0.394
Reverse 1.750
Final reduction ratio 6.120
TSB Revision
SPECIFICATIONS
M1233202000149
Item Standard value mm

Reverse brake clearance 1.2 1.5
Total end play 0.25 0.55
Differential preload 0.17 0.29
Reduction gear preload 0.13 0.19
Oil pump drive sprocket to converter housing clearance 0.10 0.23
Mounting bore diameter of reduction gear converter housing side 61.949 61.979
bearing outer race transaxle case side
Mounting bore diameter of differential side converter housing side 84.941 84.976
bearing outer race transaxle case side 67.949 67.979
Mounting bore diameter of reduction gear converter housing side 30.008 30.029
bearing inner race transaxle case side
Mounting bore diameter of differential side converter housing side 60.032 60.078
bearing inner race transaxle case side 40.026 40.051
SNAP RING, SPACER AND THRUST WASHER FOR ADJUSTMENT

M1233204000145
Snap rings (for adjustment of reverse brake)

Thickness mm Identification Thickness mm Identification
2.2 2.8
2.4 3.0
2.6
Needle bearings (for adjustment of total end play)
3.58 4.26
3.75 4.43
3.92 4.60
4.09 4.77
Adjusting shims (for adjustment of differential preload)
0.40 0.96
0.44 1.00
0.48 1.04
0.52 1.08
0.56 1.12
0.60 1.16
0.64 1.20
TSB Revision
SPECIFICATIONS
23B-5
0.68 1.24
0.72 1.28
0.76 1.32
Adjusting shims (for adjustment of reduction gear preload)
0.64 1.48
0.68 1.52
0.72 1.56
0.76 1.60
0.80 1.64
0.84 1.68
0.88 1.72
0.92 1.76
0.96 1.80
1.00 1.84
1.04 1.88
1.08 1.92
1.12 1.96
1.16 2.00
1.20 2.04
1.24 2.08
1.28 2.12
1.32 2.16
1.36 2.20
1.40 2.24
1.44
Adjusting shims (for adjustment of oil pump drive sprocket / converter housing clearance)
0.64 0.92
0.68 0.96
0.72 1.00
0.76 1.04
0.80 1.08
0.84 1.12
0.88
TSB Revision
SPECIAL TOOLS
SEALANT(S) AND ADHESIVE(S)

M1233206000099
Item Specified sealant and adhesive

Transaxle
Converter housing Loctite 509
LUBRICANT(S)
M1233200400033
Item Specified lubricant

Transaxle
CVT fluid application parts Diaqueen CVTF-J1
Vaseline application parts White vaseline (main ingredient: isoparaffinic
hydrocarbon)
SPECIAL TOOLS
M1233207000155
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
B MB990590 MB990211-01 Removal of outer race of
Real axle shaft oil seal reduction gear bearing
remover and differential side
bearing
A MB990590
MB992039 MB992039-01 Removal of outer race of

Slide hammer puller reduction gear bearing
and differential side
bearing
MB992139 Removal and installation

Spring compressor of reverse brake
MB991168 MB991168-01 Installation of differential

Differential oil seal side bearing outer race
installer (converter housing side)
MB991168
MB991702 Installation of differential

Adapter side bearing outer race
(converter housing side)
TSB Revision
SPECIAL TOOLS
23B-7
NAME
Real axle shaft bushing side bearing outer race
installer (transaxle case side)
MB990932 Reduction gear bearing

Installer adapter outer race
MB990938 Reduction gear bearing

Installer bar outer race

Handle
MB992141 Installation of converter

Oil seal installer housing oil seal
MB992206 Installation of converter

Oil seal installer housing side oil seal
MB992140 Installation of side oil seal

Oil seal installer
TSB Revision
SPECIAL TOOLS

NAME
MB990810 Removal of reduction gear
Side bearing puller bearing inner race
(converter housing side),
removal of differential side
bearing inner race
MB990810
removal of differential side
bearing inner race
(transaxle case side)
MB990947 MB990947-01 Removal of reduction gear
Lower arm push arbor bearing inner race
MB990947
MD999566 Removal of reduction gear

Crow bearing inner race
MB990984 Removal of reduction gear

Mount bushing lower roll bearing inner race
insulator arbor (transaxle case side)
MD998917 Removal of reduction gear

Bearing remover bearing inner race
MD998812 MIT304180-A or Installation of reduction

Installer cap General service tool gear bearing inner race
(converter housing side
and transaxle case side),
installation of differential
side bearing outer race
side bearing inner race
installation of reduction
pinion gear
TSB Revision
SPECIAL TOOLS
23B-9
NAME
MD998813 MIT304180-A or Installation of reduction
Installer-100 General service tool gear bearing inner race
and Transaxle case side),
side bearing outer race
side bearing inner race
pinion gear
MD998819 Installation of reduction
Installer adapter (40) gear bearing inner race
and Transaxle case side),
pinion gear
MB991452 Removal of differential
Oil seal installer side bearing inner race

Bearing Installer side bearing inner race
MD998823 Installation of differential

Installer adapter (48) side bearing inner race
TSB Revision
TRANSAXLE
TRANSAXLE
M1233208000192
CAUTION
Only use CVT fluid of the specified brand. Use of CVT fluid other than specified will impair drive-
ability and CVT endurance, and may lead to breakage of CVT.
Only use the specified vaseline. Use of vaseline other than specified will impair driveability and
CVT endurance, and may lead to breakage of CVT.
Disassembly work should be done in a clean dust-proof room.
Prior to disassembly, clean any sand or dirt adhered to the outer parts of transaxle using steam,
white gasoline or another solvent, outside the clean room, so as not to contaminate inner parts of
transaxle during disassembly or assembly. (Do not allow steam to get inside the transaxle, and do
not clean rubber parts with gasoline).
After cleaning, remove the torque converter, and drain the CVT fluid.
Disassembly and assembly work should be done with bare hands or using plastic gloves.
Do not touch inner parts of the transaxle after touching its outer parts. (Wash hands after touching
the outer parts).
Do not use cotton gloves and rags to prevent from lint; instead, use paper rags.
Prior to assembly or disassembly work, make sure conditions are appropriate.
Do not re-use the drained CVT fluid.
Refer to "HOW TO USE THIS MANUAL" for the symbols in the schematic.
TSB Revision
TRANSAXLE
23B-11
11 1 Nm
97 9 in-lb 4
23 3 Nm
17 2 ft-lb 5
11 1 Nm
7 97 9 in-lb
6 23 3 Nm
17 2 ft-lb
90 10 Nm
66 7 ft-lb
90 10 Nm
66 7 ft-lb
AK603121AB
1. RR roll stopper bracket 5. Oil filler tube

2. FR roll stopper bracket 6. Control cable bracket
3. Harness bracket 7. Breather hose
4. Oil level gage
TSB Revision
TRANSAXLE
4.2 Nm 17.2 Nm
37 in-lb 13 13 ft-lb
12 8
5.5 Nm
11 49 in-lb
9 10
7.5 Nm
5.9 Nm 40
38 39
66 in-lb
52 in-lb
15
5.9 Nm
52 in-lb
14 36
37
18
35 34
16
27
26
17 28
7.5 Nm 29
66 in-lb
19
25
20
24
7.9 Nm 23
70 in-lb 22.1 Nm 33
16 ft-lb
7.9 Nm
22 70 in-lb
21
7.9 Nm 31 30
70 in-lb
32 34.3 Nm
25 ft-lb AK603122AB
8. Washer 25. Bush

9. Shift lever 26. Lip seal
10. Inhibitor switch 27. Snap ring
11. CVT fluid filter 28. Valve body harness
12. O-ring 29. Oil pan gasket
13. CVT fluid cooler 30. Magnet
14. Secondary pulley speed sensor 31. Drain plug gasket
15. O-ring 32. Drain plug
16. O-ring 33. Oil pan
17. Plug 34. Torque converter
18. Transaxle 35. O-ring
19. Control valve 36. Primary pulley speed sensor
20. Bracket 37. O-ring
21. O-ring 38. O-ring
22. Oil strainer 39. Plug
23. Spring washer 40. Stud bolt
24. Manual lever
TSB Revision
TRANSAXLE
23B-13
28 Nm
21 ft-lb 6.9 Nm
88 87 61 in-lb
41
86 85 84
83
82
81 80
79
42 77
71 75
72 74
5.9 Nm
52 in-lb
67
70 73
78
69 68 5.9 Nm 76
52 in-lb
19 Nm 26 Nm
43 14 ft-lb 19 ft-lb
54 63
44 66 45 Nm
45 46 33 ft-lb
51 65 64
47 52
53 61
48 56 57
49 50
55
26 Nm
19 ft-lb 58 59
6.9 Nm 60 62
61 in-lb
AK603123 AB
41. O-ring 65. Drive sprocket

42. Side oil shim 66. Thrust washer
43. Adjusting shim 67. Baffle plate
44. Outer race 68. Driven sprocket
45. Reduction gear assembly 69. Baffle plate
46. Outer race 70. Oil pump
47. Adjusting shim 71. Lip seal
48. Outer race 72. Snap ring
49. Differential assembly 73. Driven plate
50. Outer race 74. Needle bearing
51. Forward clutch assembly 75. Sun gear
52. Needle bearing 76. Needle bearing
53. Seal ring 77. Planet carrier
54. Oil pump cover 78. Needle bearing
55. Baffle plate 79. Snap ring
56. Bracket 80. Retaining plate
57. Adjusting shim 81. Drive plate
58. Clip 82. Dish plate
59. Pipe 83. Snap ring
60. Converter housing 84. Retaining plate
61. Converter housing oil seal 85. Spring retainer assembly
62. Converter housing side oil seal 86. Reverse brake piston
63. Oil pump chain 87. Detent spring
64. Adjusting shim 88. Transaxle
TSB Revision
TRANSAXLE

MB990590: Real axle shaft oil seal remover MB990932: Installer adapter
MB992139: Spring compressor MB992075: Handle
MB991168: Differential oil seal installer MB992141: Oil seal installer
MB991702: Adapter MB992206: Oil seal installer
MB990780: Real axle shaft bushing installer MB992140: Oil seal installer
DISASSEMBLY SERVICE POINT
CAUTION
Do not disassemble parts other than specified in this man-
ual.
1. Remove the RR roll stopper bracket and FR roll stopper
bracket from the transaxle.
2. Remove the harness bracket from the transaxle.
3. Remove the oil filler tube and oil level gage from the
transaxle.
4. Remove the control cable bracket and breather hose from
the transaxle.
5. Remove the torque converter from the transaxle.
AK603124
6. Remove the plug from the transaxle case.
AK502775
7. Remove the O-ring from the plug.
AK502774AD
TSB Revision
TRANSAXLE
23B-15
8. Remove the secondary pulley speed sensor from the
converter housing, and detach the O-ring from the sensor.
AK502193AD
9. Remove the primary pulley speed sensor from the transaxle

case, and detach the O-ring from the sensor.
AK502194AD
10.Remove the shift lever from the manual shaft.
AK502195AD
11.Remove the inhibitor switch from the transaxle.
AK502196
TSB Revision
TRANSAXLE
CAUTION
Be careful not to cause damage to the terminal body.
12.Remove the snap ring from the terminal body, and press the
Snap ring terminal body into the transaxle case.
Terminal body
AK502197AF
13.Remove the CVT fluid cooler from the transaxle case, and
detach the O-ring from the cooler.
AK502198
14.Remove the CVT fluid cooler filter from the transaxle case.
AK502199
15.Remove the fastening bolts of converter housing.

B A A A
B A A Bolt symbol A B
A
A Bolt length mm 30 35
A
A A Quantity 18 5
A
B
A B
A B
A A A A A
AK502200 AD
TSB Revision
TRANSAXLE
23B-17
CAUTION
Be careful because adjusting shim of the drive sprocket
may depart.
16.Remove the converter housing by tapping with a plastic
hammer etc.
AK502201
17.Using the Special Tools MB990590 and MB992039, remove

MB990590
the outer race of reduction gear bearing from the converter
housing.
18.Using cylinder gage etc., measure the mounting bore
diameter of reduction gear bearing outer race at the
MB992039 converter housing side; if the standard value is not satisfied,
then replace the converter housing.
Standard value: 61.949 61.979 mm
AK502819AD

MB990590 the outer race of differential side bearing from the converter
housing.
MB992039 20.Using cylinder gage etc., measure the mounting bore
diameter of differential side bearing outer race at the
converter housing side; if the standard value is not satisfied,
then replace the converter housing.
AK502820AD
CAUTION
When removing the oil seal, be careful not to cause dam-
age to the converter housing.
21.Using a flat blade screwdriver etc., remove the converter
housing oil seal from the housing.
AK502204
TSB Revision
TRANSAXLE
22.Remove the clip.
AK502975AD
CAUTION
When removing the pipe, be careful not to bend it.
23.Remove the pipe from the converter housing.
AK502976
24.Remove the plug from the converter housing.
AK603125AB
25.Remove the O-ring from the plug.
AK502774AD
TSB Revision
TRANSAXLE
23B-19
26.Remove the O-ring from the input shaft.
AK502206AF
27.Remove the adjusting shim from the drive sprocket.
AK502206AG
28.Remove the baffle plate.
AK502207AE
29.Expand the snap ring, and remove the driven sprocket, oil
pump chain, and drive sprocket.
Snap ring
AK502208AD
Drive
sprocket
Oil pump chain
Drive sprocket
AK502209AD
TSB Revision
TRANSAXLE
30.Remove the thrust washer from the oil pump cover.
AK502210AD
31.Remove the snap ring from the oil pump.
AK502211AD
32.Remove the reduction gear assembly from the transaxle

case.
AK502212
33.Remove the differential assembly from the transaxle case.
AK502213
34.Remove the bracket.
AK502214AD
TSB Revision
TRANSAXLE
23B-21
AK502215AE
AK502216AE
37.Remove the oil pump cover from the transaxle case.
AK502217AD
38.Remove the seal rings from the oil pump cover.
AK502218AD
39.Remove the needle bearing from the forward clutch

assembly.
AK502219
TSB Revision
TRANSAXLE
40.Remove the oil pan from the transaxle case.

41.Remove the magnet from the oil pan.
AK502220
42.Remove the oil pan gasket from the transaxle case.
AK502221
43.Remove the oil strainer

Bolt symbol A B C
A
Bolt length mm 12 44 12
Quantity 1 1 1
C
AK502222AD
44.Remove the O-ring from the oil strainer.
AK502780
45.Remove the bracket from the control valve assembly.
AK502223AD
TSB Revision
TRANSAXLE
23B-23
46.Remove the manual lever.
AK502224AD
47.Remove the control valve assembly from the transaxle case

as follows:
(1) Insert pins etc. (3 mm) into linkage stopper holes of the
control valve assembly to fix the pulley ratio linkage.
Pin
AK502225AD
(2) Remove fastening bolts of the control valve assembly.
A B Bolt symbol A B
A
A A Bolt length mm 54 44
A Quantity 10 1
A
A A A
A
AK502226AD
(3) Remove the control valve assembly from the transaxle

case.
NOTE: Tilt the control valve assembly, and after remov-
ing from the manual shaft side, remove the terminal body
from the transaxle case.
AK502227
TSB Revision
TRANSAXLE
48.Remove the bush from the control valve.
AK502228
49.Remove the lip seal from the transaxle case.
AK502229AD
50.Remove the valve body harness from the control valve.
AK502233
51.Remove the oil pump from the transaxle case. (One

fastening bolt is installed at the backside from the transaxle
case side).
AK502235AD
TSB Revision
TRANSAXLE
23B-25
52.Remove the O-ring from the oil pump fastening bolt.
AK502236
53.Remove the lip seal from the transaxle case.
AK502237AD

MB990590 outer race of the differential side bearing from the transaxle
case.
diameter of differential side bearing outer race at the
MB992039
transaxle case side; if the standard value is not satisfied,
then replace the CVT assembly.
AK502821AD
56.Remove the adjusting shim from the transaxle case.
AK502239
57.Using the special tools MB990590 and MB992039, remove

MB990590
outer race of the reduction gear bearing from the transaxle
case.
MB992039 diameter of reduction gear bearing outer race at the
transaxle case side; if the standard value is not satisfied,
then replace the CVT assembly.
AK502822 AD
TSB Revision
TRANSAXLE
59.Remove the adjusting shim from the transaxle case.
AK502241
CAUTION
When removing the side oil seal, be careful not to cause
damage to the transaxle case.
60.Using a flat blade screwdriver etc., remove the side oil seal
AK502242
61.Remove the detent spring from the transaxle case.
AK502243AD
62.Remove the forward clutch assembly from the transaxle

case.
AK502244
TSB Revision
TRANSAXLE
23B-27
63.Remove the needle bearing on forward clutch drum side
from the sun gear.
AK502245
64.Remove the sun gear from the planet carrier.
AK502246
65.Remove the needle bearing on primary pulley side from the

sun gear.
AK502247
66.Remove the planet carrier from the transaxle case.
AK502248
67.Remove the needle bearing from the planet carrier.
AK502249
TSB Revision
TRANSAXLE
CAUTION
Check if there is damage, deformation, burn marks or per-
manent sets of the dish plate, driven plate, snap ring, and
drive plate. Replace any defective part.
68.Using a flat blade screwdriver etc., remove the reverse
brake retaining plate, drive plate, driven plate, and dish plate
AK502250
CAUTION
Set the spring compressor right on top of the spring of
spring retainer assembly.
Do not remove the return spring from the spring
retainer assembly.
69.Using the Special Tool MB992139, compress the return
spring, and remove the snap ring from the transaxle case.
70.Remove the retaining plate and return spring assembly.
MB992139
AK502251AE
TSB Revision
TRANSAXLE
23B-29
CAUTION
Be careful. Do not use to much air pressure as this may
cause the reverse brake piston be stuck.
71.Feed the air in the oil hole shown in the diagram, and
remove the reverse brake piston from the transaxle case.
AK502252AD
AK502253
TSB Revision
TRANSAXLE
IDENTIFICATION OF NEEDLE BEARINGS
A D
B
C
AK502299AD
TSB Revision
TRANSAXLE
23B-31
ASSEMBLY SERVICE POINT
CAUTION
When the outer races of reduction gear bearing and differ-
ential side bearing are removed, measure the mounting
bore diameters of outer race in the converter housing and
transaxle case, and replace the housing case or the CVT
assembly if the standard value is not satisfied. The stan-
dard values are listed in "SERVICE SPECIFICATIONS".
CAUTION
Do not re-use the reverse brake piston.
Apply CVT fluid when installing the reverse brake pis-
ton.
1. Install the reverse brake piston, while turning it, on the
transaxle case.
AK502253
2. Align the spring portion of spring retainer assembly with the

Spring retainer assembly
projections of the reverse brake piston, and install the spring
retainer assembly.
Spring
Protrusion
AK502254AI
TSB Revision
TRANSAXLE
CAUTION
When installing the retaining plate, align the tangs at posi-
tions A, B, C in the diagram.
3. Install the retaining plate on the transaxle case.
AK502255
B
A
C
AK502770AD
CAUTION
Set the spring compressor right on top of the spring of
spring retainer assembly.
Do not re-use the snap ring.
When installing the snap ring, make sure that the joint
falls in the area A in the diagram.
4. Using the Special Tool MB992139, compress the return
spring, and install the snap ring on the transaxle case by
means of a flat blade screwdriver etc.
MB992139
AK502251AE
AK502771AD
TSB Revision
TRANSAXLE
23B-33
Driven plate Snap ring
5. Install the reverse brake retaining plate, drive plate, driven
plate, and dish plate on the transaxle case.
Dish plate
Retaining plate
Reverse brake
piston
Drive plate
AK502256AD
CAUTION
When conducting measurements, measure two or more
places, and find the average value.
When installing the snap ring, make sure that the joint
falls in the area A in the diagram.
6. Using a flat blade screwdriver etc., install the snap-ring on
the transaxle case, and measure clearance between the
snap ring and retaining plate. Select the snap ring so as to
obtain standard value of the clearance. For selection of the
snap ring, refer to "SERVICE SPECIFICATIONS".
AK502257
AK502771AD
TSB Revision
TRANSAXLE
CAUTION
Apply vaseline when installing the needle bearing.
Be careful to attach the needle bearing in right direc-
tion.
7. Install the needle bearing on the reverse brake piston. Refer
to A in the "IDENTIFICATION OF NEEDLE BEARINGS" for
right direction.
AK502258
8. Install the planet carrier on the reverse brake.
AK502248
CAUTION
tion.
9. Install the needle bearing on the primary pulley side of the
sun gear. Refer to B in the "IDENTIFICATION OF NEEDLE
BEARINGS" for right direction.
AK502247
10.Install the sun gear on the planet carrier.
AK502246
TSB Revision
TRANSAXLE
23B-35
CAUTION
tion.
11.Install the needle bearing on the forward clutch drum side of
the sun gear. Refer to C in the "IDENTIFICATION OF
NEEDLE BEARINGS" for right direction.
AK502245
12.Install the forward clutch assembly on the transaxle case.
AK502244
CAUTION
13.Measure the total end play as follows:
Oil pump cover
Forward clutch drum Needle bearing

AK502259AD
(1) Measure the distance M1 from the oil pump cover

mounting surface of the transaxle case to the needle
bearing mounting surface of the forward clutch drum.
M1
AK502260 AD
TSB Revision
TRANSAXLE
(2) Measure the distance M2 from the edge of oil pump cover
to the mounting surface on the transaxle case.
(3) Calculate the total end play by the following expression.
Select the needle bearing so that the total end play meets
its standard value.
M2 Total end play = M1 M2 bearing thickness
AK502261AD
CAUTION
tion.
14.Install the selected needle bearing on the forward clutch
assembly. Refer to D in the "IDENTIFICATION OF NEEDLE
BEARINGS" for right direction.
AK502219
CAUTION
Do not re-use the seal rings.
Apply vaseline when installing the seal rings.
15.Install the seal rings on the oil pump cover.
AK502218AD
CAUTION
Do not re-use the bolt.
16.Install the detent spring on the transaxle case and tighten
the bolt to the specified torque.
Tightening torque: 6.9 N m (61 in-lb)
AK502243AD
TSB Revision
TRANSAXLE
23B-37
CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.
17.Install the O-ring on the plug.
AK502774AD
18.Install the plug on the converter housing and tighten the bolt
AK603125AB
CAUTION
Do not bend the pipe when attaching it.
19.Install the pipe on the converter housing.
AK502976
20.Install the clip and tighten the bolt to the specified torque.
AK502975AD
TSB Revision
TRANSAXLE
CAUTION
Do not re-use the outer race.
Replace the outer race together with the inner race.
21.Using the Special Tools MB991168 and MB991702, Install
the differential bearing outer race.
MB991168
MB991702
AK502847AD
CAUTION
When adjusting the preload, apply CVT fluid to the
bearing to make it roll smoothly.
Converter housing 22.Measure the preload A of the differential assembly as
follows:
A
Transmission case
Differential assembly
AK502263AD
(1) Measure the distance M3 from the edge of transaxle case

to the mounting surface of adjusting shim.
M3
AK502264AD
(2) Install the differential assembly on the converter case,

and measure the distance M4 from the differential case to
the edge of converter housing.
M4
AK502265 AD
TSB Revision
TRANSAXLE
23B-39
(3) Install the outer race on differential side bearing, and
measure the distance M5 from the differential case to the
outer race of differential side bearing.
(4) Using the following expression, calculate the distance M6
from the edge of converter housing to the outer race of
differential side bearing.
M6 = M4 M5
M5
(5) Using the following expression, calculate thickness of the
adjusting shim.
AK502266 AD
Thickness of adjusting shim = M3 M6 + preload
Preload standard value: 0.17 0.29 mm
CAUTION
Do not re-use the adjusting shim.
23.Install the selected shim on the transaxle case. For selection
of the adjusting shim, refer to "SERVICE
SPECIFICATIONS".
AK502239
CAUTION
24.Using the Special Tool MB990780, install the outer race of
differential side bearing on the transaxle case.
MB990780
AK502846AD
CAUTION
25.Using the Special Tools MB990932 and MB990938, install
the outer race of reduction gear bearing on the converter
housing.
MB990938
MB990932
AK604111AC
TSB Revision
TRANSAXLE
CAUTION
When adjusting the preload, apply CVT fluid to the
bearing to make it roll smoothly.
26.Measure the preload A of the reduction gear assembly in
the following way.
Bearing
outer race
Reduction gear
A
Transmission case AK502269AD
(1) Measure the distance M7 from the edge of transaxle case

to the mounting surface of adjusting shim.
M7
AK502270 AD
(2) Install the reduction gear assembly on the converter

housing, and measure the distance M8 from the edge of
reduction gear assembly to the edge of converter
housing.
M8
AK502271AD
(3) Install the outer race of reduction gear side bearing on

the bearing, and measure the distance M9 from the edge
of reduction gear assembly to the outer race of reduction
gear bearing.
(4) Using the following expression, calculate the difference
M10 from the outer race of reduction gear bearing to the
edge of converter housing.
M9 M10 = M8 M9
(5) Using the following expression, calculate the thickness of
AK502272AD
adjusting shim.
Thickness of adjusting shim = M7 M10 +preload
Preload standard value: = 0.13 0.19 mm
TSB Revision
TRANSAXLE
23B-41
CAUTION
Do not re-use the adjusting shim.
27.Install the selected adjusting shim on the transaxle case.
For selection of the adjusting shim, refer to "SERVICE
SPECIFICATIONS".
AK502241
CAUTION
MB990938 the outer race of reduction gear bearing on the transaxle
case.
MB990932
AK502951AD
CAUTION
Do not re-use the lip seal.
Apply CVT fluid when installing the lip seal.
29.Install the lip seal on the transaxle case.
AK502237AD
TSB Revision
TRANSAXLE
CAUTION
Do not re-use the O-rings.
Apply CVT fluid when installing the O-rings.
30.Install the O-rings on the oil pump fastening bolts.
AK502236
31.Install the oil pump on the transaxle case and tighten the
bolt to the specified torque. (One fastening bolt is installed at
the backside from the transaxle case side. Only this bolt
should be tightened to the specified torque of 28 N m [21
ft-lb]).
AK502235AD
CAUTION
32.Install the snap ring on the oil pump.
AK502211AD
TSB Revision
TRANSAXLE
23B-43
CAUTION
Do not re-use the lip seal.
Apply CVT fluid or vaseline when installing the lip seal.
33.Install the lip seal on the transaxle case.
AK502229AD
34.Install the valve body harness on the control valve.
AK502233
35.Install the control valve assembly on the transaxle case as

follows:
(1) Insert pins etc. ( 3 mm) into linkage stopper holes of the
control valve assembly to fix the pulley ratio linkage.
Pin
AK502225AD
TSB Revision
TRANSAXLE
(2) Install the terminal body on the transaxle case, while

aligning the detent of terminal body with the transaxle
case as shown in the diagram.
Stopper
AK502274AD
TSB Revision
TRANSAXLE
23B-45
CAUTION
Align the notch of pulley ratio linkage with the prong of
pulley sensor.
(3) Slide the control valve assembly from the bottom, and
install it on the transaxle case.
CAUTION
Apply CVT fluid when attaching the bush.
AK502227
Notch
Protrusion
AK502275 AD
(4) Install the bush on the control valve assembly.
AK502276
TSB Revision
TRANSAXLE
(5) Install the fastening bolts of control valve assembly and

tighten the bolt to the specified torque.
A B
A Tightening torque: 7.9 N m (70 in-lb)
A A
Bolt symbol A B
A
Bolt length mm 54 44
A
A A
Quantity 10 1
A
A
AK502226AD
36.Install the manual lever and tighten the bolt to the specified
torque.
Tightening torque: 22.1 N m (16 ft-lb)
AK502224AD
37.Install the bracket on the control valve assembly and tighten

the bolt to the specified torque.
AK502223AD
CAUTION
38.Install the O-ring on the oil strainer.
AK502277
TSB Revision
TRANSAXLE
23B-47
39.Install the oil strainer and tighten the bolt to the specified
torque.
A Tightening torque: 7.9 N m (70 in-lb)
Bolt symbol A B C
Bolt length mm 12 44 12
B Quantity 1 1 1
C
AK502222AD
CAUTION
Do not re-use the oil pan gasket.
Remove any moisture, oil, and used gasket from the
mounting surface of oil pan gasket.
When installing the oil pan gasket, align the dowel pins
of transaxle case with dowel pin holes A of the oil pan
gasket.
40.Install the oil pan gasket on the transaxle case.
Oil pan gasket A
41.Install the magnet on the oil pan.
A AK502278AE
CAUTION
When installing the oil pan, align the dowel pins of tran-
saxle case with dowel pin holes A of the oil pan.
42.Install the oil pan on the transaxle case and tighten the bolts
A
AK502220AD
CAUTION
Do not re-use the drain plug gasket.
43.Install the drain plug and drain plug gasket on the transaxle
case and tighten the bolt to the specified torque.
TSB Revision
TRANSAXLE
44.Install the oil pump cover on the transaxle case, and fix the
fastening bolts temporarily.
AK502217AD
45.Install the baffle plate, and fix the fastening bolts

temporarily.
AK502216AE
46.Install the baffle plate and tighten the bolt to the specified
torque.
AK502215AE
47.Install the bracket, and tighten the fastening bolts of the oil
pump cover, baffle plate and tighten the bolts to the
specified torque.
AK502214AD
TSB Revision
TRANSAXLE
23B-49
CAUTION
Make sure the tang of thrust washer is aligned with the
mounting hole of oil pump cover.
Apply vaseline when installing the thrust washer.
48.Install the thrust washer on the oil pump cover.
AK502210AD
CAUTION
Pull the driven sprocket up softly to make sure it is
securely attached.
49.Expand the snap ring, and install the driven sprocket, oil
pump chain, and drive sprocket.
Snap ring
AK502208AD
Drive
sprocket
Oil pump chain
Drive sprocket
AK502209AD
50.Measure the clearance A between the oil pump drive

Drive sprocket Converter housing sprocket and the converter housing as follows:
Adjust shim
Oil pump cover

AK502279AD
TSB Revision
TRANSAXLE
(1) Measure the distance M11 between the edge of transaxle

case and the adjusting shim mounting surface of drive
sprocket.
M11 AK502280AD
(2) Measure the distance M12 between the edge of

converter housing and the surface contacting the
adjusting shim.
(3) Use the following expression, to select the adjusting shim
having the standard value.
M12 Standard value of clearance = M11 + M12 thickness of
adjusting shim
AK502281AD
CAUTION
Apply vaseline when installing the adjusting shim.
(4) Install the selected adjusting shim on the drive sprocket.
For selection of the adjusting shim, refer to "SERVICE
SPECIFICATIONS".
AK502206AG
51.Install the baffle plate, and tighten the fastening nuts to the
specified torque.
AK502207AE
TSB Revision
TRANSAXLE
23B-51
CAUTION
52.Install the O-ring on the input shaft.
AK502206AF
53.Install the differential assembly on the transaxle case.
AK502213
54.Install the reduction gear assembly on the transaxle case.
AK502212
CAUTION
Do not re-use the converter housing oil seal.
Apply CVT fluid when installing the converter housing
oil seal.
MB992075 the converter housing oil seal on the converter housing.
Depth from the case edge: within 1.0 0.5 mm
MB992141 (recessed).
Oil seal
AK603128AB
TSB Revision
TRANSAXLE
CAUTION
Do not re-use the converter housing side oil seal.
Apply CVT fluid when installing the converter housing
side oil seal.
the converter housing side oil seal on the converter housing.
MB992075
MB992206
AK603129AB
CAUTION
Remove any moisture, oil and oil sealant from the appli-
cation surface.
Make sure the starting point and the ending point are
about the middle between the bolts.
L4 57.Apply the sealant on the converter housing mounting
L2 surface of the transaxle case in the following way.
Specified sealant: Loctite 509
L3
L5 L1 9 mm
L1
L2 5 mm
L3 1.5 mm
L4 R 8.5 mm
L6
AK502283AD L5 R 5 8 mm
L6 R 3 5 mm
L7 L7 17 mm
L8 3.5 mm
L8
AK502284AD
58.Install the converter housing on the transaxle case, and

B A A A A A tighten the fastening bolts to the specified torque of 45 N m.
B
A Tightening torque: 45 N m (33 ft-lb)
A
A Bolt symbol A B
A A
A
Bolt length mm 30 35
B
A Quantity 18 5
B
A B
A A A A A
AK502200 AD
TSB Revision
TRANSAXLE
23B-53
CAUTION
59.Install the snap ring on the terminal body.
Snap ring
Terminal body
AK502197AF
CAUTION
Do not re-use the side oil seal.
Apply CVT fluid when installing the side oil seal.
60.Using the Special Tool MB992140 and MB992075, install
the side oil seal on the transaxle case.
Depth from the case edge: within 1.8 0.5 mm
Oil seal (recessed).
MB992140
MB992075
AK502285AE
CAUTION
Do not re-use the inhibitor switch.
61.Install the inhibitor switch on the transaxle case as follows:
(1) Install the inhibitor switch on the transaxle case.
AK502196
(2) Install the shift lever on the manual shaft, and tighten the
fastening nuts to the specified torque.
(3) Set the manual shaft at N position.
AK502195AD
TSB Revision
TRANSAXLE
(4) Insert pins etc. ( 5 mm) in adjusting holes in both

Installing bolt
inhibitor switch and shift lever, and after alignment,
tighten the fastening bolts to the specified torque.
Installing bolt CAUTION

Adjustment hole
AK502773AD
62.Install the oil ring on the primary pulley speed sensor.
AK502287AD
63.Install the primary pulley speed sensor on the transaxle

case, and tighten the fastening bolts to the specified torque.
AK502194AD
CAUTION
64.Install the O-ring on the secondary pulley speed sensor.
AK502288AD
TSB Revision
TRANSAXLE
23B-55
65.Install the secondary pulley speed sensor on the transaxle
case, and tighten the fastening bolts to the specified torque.
AK502193AD
CAUTION
Apply CVT fluid or vaseline when installing the CVT
fluid cooler filter.
Do-not re-use the CVT fluid cooler filter.
66.Install the CVT fluid cooler filter on the transaxle case.
AK502199
CAUTION
When installing O-ring, make sure that projection of the
O-ring is put into the groove on the filter.
67.Install the O-ring on the CVT fluid filter.
AK502289
68.Install the CVT fluid cooler on the transaxle case, and

tighten the fastening bolts to the specified torque.
AK502198
TSB Revision
TRANSAXLE
CAUTION
69.Install the O-ring on the plug.
AK502774AD
70.Fasten the plug on the transaxle case and tighten the bolt to
AK502775
CAUTION
71.Install the converter on the transaxle, and measure the size
A to check if it meets the standard value.
A
Standard value: 15.9 mm.
72.Install the control cable bracket and breather hose on the
transaxle.
73.Install the oil filler tube and oil level gage on the transaxle.
74.Install the harness bracket on the transaxle.
A 75.Install the RR roll stopper bracket and FR roll stopper
AK603131AB bracket on the transaxle.
TSB Revision
FORWARD CLUTCH
23B-57
FORWARD CLUTCH
M1233209000184
CAUTION
8
4
3
AK502291AD
Disassembly steps Disassembly steps (Continued)

<<A>> >>E<< 1. Snap ring <<E>> >>A<< 5. Seal ring (small)
<> >>D<< 2. Internal gear <<E>> >>A<< 6. Seal ring (big)
<<C>> >>C<< 3. Snap ring 7. Input shaft
<<D>> >>B<< 4. Snap ring 8. Forward clutch sub-assembly
TSB Revision
FORWARD CLUTCH

.
<<A>>SNAP RING REMOVAL

Using a flat blade screwdriver etc., remove the snap ring from
the forward clutch drum.
AK502292
<>INTERNAL GEAR REMOVAL

Remove the internal gear from the forward clutch drum.
AK502293
<<C>>SNAP RING REMOVAL

Using a flat blade screwdriver etc., remove the snap ring from
the forward clutch drum.
AK502294
<<D>>SNAP RING REMOVAL

Remove the snap ring using snap ring pliers, and remove the
input shaft from the forward clutch drum.
AK502296
TSB Revision
FORWARD CLUTCH
23B-59
<<E>>SEAL RING REMOVAL
Remove the seal rings (small and big) from the input shaft.
Seal ring (small)
Seal ring (big)

AK502776AD
REASSEMBLY SERVICE POINT

.
>>A<<SEAL RING INSTALLATION

CAUTION
Apply vaseline when installing the seal rings.
Do not re-use the seal rings.
Install the seal rings (small and big) on the input shaft.
Seal ring (small)
Seal ring (big)

AK502776AD
>>B<<SNAP RING INSTALLATION

CAUTION
Be careful not to strain the snap ring by expanding it
excessively.
Install the input shaft on the forward clutch drum, and attach the
snap ring.
AK502296
TSB Revision
FORWARD CLUTCH
>>C<<SNAP RING INSTALLATION

CAUTION
Install the snap ring on the forward clutch drum.
AK502294
>>D<<INTERNAL GEAR INSTALLATION

Install the internal gear on the forward clutch drum.
AK502293
>>E<<SNAP RING INSTALLATION

CAUTION
Install the snap ring on the forward clutch drum.
AK502292
INSPECTION
M1233200200040
FORWARD CLUTCH SUB-ASSEMBLY

Check if there is a damage, deformation, or burn marks, and
replace the forward clutch sub-assembly if any defect is found.
INPUT SHAFT AND INTERNAL GEAR

Check if there is a damage or deformation, and replace if any
defect is found.
TSB Revision
REDUCTION GEAR
23B-61
REDUCTION GEAR
M1233200600059
CAUTION
250 Nm
184 ft-lb
1
2
AK502978AD

<<A>> >>C<< 1. Nut 4. Reduction gear sub-assembly
<> >>B<< 2. Reduction gear bearing 5. Adjusting shim
<<C>> >>A<< 3. Reduction gear bearing

MB990810: Side bearing puller MD998917: Bearing remover
MB990947: Lower arm push arbor MD998812: Installer Cap
MD999566: Crow MD998813: Installer-100
MB990984: Mount bushing lower roll insulator MD998819: Installer adapter (40)
arbor
TSB Revision
REDUCTION GEAR

.
<<A>>NUT REMOVAL
Remove the nut from the reduction gear sub-assembly.
AK502979
<>REDUCTION GEAR BEARING REMOVAL

CAUTION
Align the tang of special tool as shown in the diagram.
Using the Special Tools MB990810, MB990947 and
MD999566, remove the inner race of reduction gear bearing
MB990810 (converter housing side) from the reduction gear sub-assembly.
MD999566
MB990947
AK502839AD
AK502980
<<C>>REDUCTION GEAR BEARING REMOVAL

Using the Special Tools MB990984 and MD998917, remove
MB990984
the outer race of reduction gear bearing (transaxle case side)
from the reduction gear sub-assembly.
MD998917
AK502841AD
TSB Revision
REDUCTION GEAR
23B-63
.
>>A<<REDUCTION GEAR BEARING

INSTALLTION
CAUTION
Do not re-use the inner race.
Replace the inner race together with the outer race.
MD998812
Using the Special Tools MD998812, MD998813 and
MD998813 MD998819, install the inner race of reduction gear bearing
(transaxle case side) on the reduction gear sub-assembly.
MD998819
AK502842AD
>>B<<REDUCTION GEAR BEARING

INSTALLATION
CAUTION
MD998812
MD998813 MD998819, install the inner race of reduction gear bearing
(converter housing side) on the reduction gear sub-assembly.
MD998819
AK502840AD
>>C<<NUT INSTALLATION
Install the nut on the reduction gear sub-assembly to the speci-
fied torque.
AK502982
TSB Revision
REDUCTION GEAR SUB-ASSEMBLY
INSPECTION
M1233200700034
.

Measure the inner race press-fit shaft diameter of reduction
gear sub-assembly, and replace the assembly if the diameter
does not meet the standard value.
Standard values
Converter housing side: 30.008 30.029 mm
transaxle case side: 30.008 30.029 mm

ASSEMBLY
M1233200900038
CAUTION
The reduction gear sub-assembly can only be assembled, not disassembled.
AK503079 AD
Assembly steps
>>A<< 1. Idler gear
>>A<< 2. Reduction pinion gear
MD998812: Installer Cap MD998819: Installer adapter (40)
TSB Revision
23B-65
.
>>A<<REDUCTION PINION GEAR / IDLER GEAR

INSTALLATION
CAUTION
When attaching the idler gear to the reduction pinion gear,
Reduction pinion Idler gear
make sure the center boss portion A faces the reduction
gear pinion gear.
Center boss portion A Long
Center boss portion B Short
A B
AK503080AD

MD998819, attach the idler gear to the reduction pinion gear.
MD998812
MD998813
MD998819
AK503032AD
TSB Revision
DIFFERENTIAL
DIFFERENTIAL
M1233213000176
CAUTION
AK502984 AD

<<A>> >>B<< 1. Differential side bearing 3. Differential sub-assembly
<> >>A<< 2. Differential side bearing 4. Adjusting shim

MB990810: Side bearing puller MD998819: Installer adapter (40)
MB991452: Oil seal installer MB992138: Bearing Installer
MD998812: Installer Cap MD998823: Installer adapter (48)
TSB Revision
DIFFERENTIAL
23B-67
.
<<A>>DIFFERENTIAL SIDE BEARING REMOVAL

Using the Special Tool MB990810, remove the inner race of dif-
ferential side bearing (transaxle case side) from the differential
sub-assembly.
MB990810
AK502848AD
<>DIFFERENTIAL SIDE BEARING REMOVAL

Using the Special Tools MB990810 and MB991452, remove the
inner race of differential side bearing (converter housing side)
MB990810
from the differential sub-assembly.
MB991452
AK502844AD

.
>>A<<DIFFERENTIAL SIDE BEARING INSTALLA-

TION
CAUTION
Using the Special Tool MB992138, install the inner race of
reduction gear bearing (converter housing side) on the reduc-
MB992138 tion gear sub-assembly.
AK502990AD
TSB Revision
DIFFERENTIAL
>>B<<REDUCTION GEAR BEARING

INSTALLATION
CAUTION
MD998812 Replace the inner race together with the outer race.
MD998813 Using the Special Tools MD998812, MD998813 and
MD998823, install the inner race of reduction gear bearing
(transaxle case side) on the reduction gear sub-assembly.
MD998823
AK502845AD
INSPECTION
M1233200800031
.
DIFFERENTIAL SUB-ASSEMBLY
Measure the inner race press-fit shaft diameter of differential
sub-assembly, and replace the assembly if the diameter does
not meet the standard value.
Standard values
Converter housing side: 60.032 60.078 mm
Transaxle case side: 40.026 40.051 mm
TSB Revision
23B-69
ASSEMBLY
M1233201200032
CAUTION
The differential sub-assembly can only be assembled, not disassembled.
2
154 Nm
114 ft-lb
AK503081AD
Assembly steps
>>A<< 1. Differential case
>>A<< 2. Final gear

.
>>A<<DIFFERNTIAL CASE/FINAL GEAR INSTAL-

LATION
CAUTION
B A
When attaching the final gear to the differential case, make
sure the side with the bigger distance from the edge to the
flange A face the differential case.
Differential case
Distance from gear edge to flange A Long
Final gear Distance from gear edge to flange B Short
AK503083 AD
TSB Revision
Install the final gear on the differential case, and tighten the fas-
tening bolts to the specified torque.
AK503082
TSB Revision
26-1
GROUP 26
FRONT AXLE
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 26-2 HUB BOLT REPLACEMENT. . . . . . . . . . . . 26-8
SPECIFICATIONS . . . . . . . . . . . . . . . 26-3 FRONT AXLE HUB ASSEMBLY . . . . 26-9

GENERAL SPECIFICATIONS . . . . . . . . . . 26-3 FRONT AXLE HUB ASSEMBLY REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . . . 26-9
SERVICE SPECIFICATIONS . . . . . . . . . . . 26-3
FRONT AXLE HUB ASSEMBLY
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 26-3
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-12
FRONT AXLE HUB ASSEMBLY DISASSEMBLY
FRONT AXLE DIAGNOSIS . . . . . . . . 26-3 AND REASSEMBLY . . . . . . . . . . . . . . . . . . 26-13
TROUBLESHOOTING STRATEGY . . . . . . 26-3
FRONT AXLE HUB ASSEMBLY INSPECTION
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 26-3 (DISASSEMBLY AND REASSEMBLY) . . . . 26-16
NOISE DURING WHEEL ROTATION . . . . 26-4 DRIVESHAFT ASSEMBLY. . . . . . . . . 26-17
NOISE DUE TO EXCESSIVE PLAY OF WHEEL IN DRIVESHAFT ASSEMBLY REMOVAL AND
TURNING DIRECTION . . . . . . . . . . . . . . . . 26-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 26-17
DRIVESHAFT ASSEMBLY DISASSEMBLY AND
SPECIAL TOOLS. . . . . . . . . . . . . . . . 26-5 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 26-22
DRIVESHAFT ASSEMBLY INSPECTION
ON-VEHICLE SERVICE. . . . . . . . . . . 26-8 (DISASSEMBLY AND REASSEMBLY) . . . . 26-25
WHEEL BEARING PLAY CHECK . . . . . . . 26-8 EBJ BOOT REPLACEMENT . . . . . . . . . . . . 26-25
26-2 FRONT AXLE
GENERAL INFORMATION
GENERAL INFORMATION
M1261000100820
For the front axle, the double-row angular contact The number of parts is reduced by integrating the
ball bearing with an integral oil seal is adopted as a magnetic encoder for ABS wheel speed detection
wheel bearing, and EBJ-ETJ type constant velocity into the wheel bearing. <Vehicles with ABS>
joint as a driveshaft. NOTE: .
It has the following features: ETJ (High Efficiency Compact Tripod Joint): the
The driveshaft incorporates lightweight and com- lighter and smaller constant velocity joint com-
pact EBJ-ETJ type constant velocity joints. pared with the conventional TJ has been
Lead-free grease for the constant velocity joint is installed.
adopted. EBJ (High Efficiency Compact Birfield Joint): the
Hexavalent chromium is eliminated from the dust lighter and smaller constant velocity joint com-
cover material. pared with the conventional BJ has been
achieved by adopting the eight small balls.
Strut assembly
Knuckle ETJ (LH)
Front hub
Driveshaft (LH)
ETJ (RH)
Driveshaft (RH)
Dynamic damper
(LH) <M/T>
EBJ
Dynamic damper
(RH)
Wheel bearing Oil seal
Magnetic
encoder
AC504925 AB
AC606246 AB
TSB Revision
FRONT AXLE
SPECIFICATIONS
26-3
SPECIFICATIONS
M1261000200399
Item Specification
Wheel bearing Type Double-row angular contact ball bearing
Driveshaft Joint type Outer EBJ
Inner ETJ
M1261000300879

Wheel bearing end play mm (in) 0.05 (0.002)
Wheel bearing rotation starting torque N m (in-lb) 1.8 (16)
ETJ boot assembly dimension mm (in) 80 3 (3.15 0.12)
Opening dimension of the special EBJ boot band (small) crimping 2.9 (0.11)
tool (MB991561) mm (in) EBJ boot band (large) crimping 3.2 (0.13)
EBJ boot band crimping size mm (in) 2.4 2.8 (0.10 0.11)
LUBRICANTS
M1261000400939
Item Specifid lubricant Quantity

ETJ boot grease Repair kit grease M/T-LH 120 10 g (4.2 0.3 oz)
M/T-RH 130 10 g (4.6 0.3 oz)
CVT 120 10 g (4.2 0.3 oz)
EBJ boot grease Repair kit grease 110 10 g (3.9 0.3 oz)
FRONT AXLE DIAGNOSIS

M1261005600187
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
front axle fault. Chart.
SYMPTOM CHART
M1261005700300
Symptom Inspection Reference page

procedure
Driveshaft Noise during wheel rotation 1 P.26-4
Noise due to excessive play of wheel in turning 2 P.26-5
direction
TSB Revision
26-4 FRONT AXLE
FRONT AXLE DIAGNOSIS
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Noise during Wheel Rotation
DIAGNOSIS
STEP 1. Check the wheel bearing end play.

(1) Remove the caliper assembly and suspend it with a wire.
(2) Remove the brake disc from the front hub.
(3) Attach a dial gauge as shown in the illustration, and then
measure the end play while moving the hub in the axial
direction.
Q: Is the wheel bearing end play within the limit?
YES : Go to step 2.
NO : Replace the part, then go to Step 5.
AC102438
STEP 2. Check the driveshaft and inner shaft for bending.

Q: Is the driveshaft and inner shaft bent?
YES : Go to step 3.
NO : Replace the part. Then go to Step 5.
STEP 3. Check the center bearing for wear.

Q: Is the center bearing worn?
YES : Replace the bearing. Then go to Step 5.
NO : Go to step 4.
STEP4. Check the driveshaft assembly for wear or

damage.
Q: Is the driveshaft assembly worn or damaged?
YES : Replace the driveshaft assembly. Then go to Step 5.

Q: Is the abnormal noise eliminated?
NO : Repeat from Step 1.
TSB Revision
FRONT AXLE
SPECIAL TOOLS
26-5
INSPECTION PROCEDURE 2: Noise Due to Excessive Play of Wheel in Turning Direction
DIAGNOSIS STEP 2. Retest the system.

Q: Is the abnormal noise eliminated?
STEP 1. Check for play in the inner shaft and side YES : The procedure is complete.
gear serration, the driveshaft and side gear NO : Repeat from Step 1.
serration, or the driveshaft and front hub
serration.
Q: Is the play found?
YES : Replace the part. Then go to Step 2.
SPECIAL TOOLS
M1261000601055

name
MB990767 MB990767-01 Fixing of the hub
Front hub and flange
yoke holder
B990767
MB991618 General service tool Removal of the hub bolt

Hub bolt remover
MB991618
MB991897 or MB991113-01, Knuckle and tie rod end ball joint

MB992011 MB990635-01 or disconnection
Ball joint remover General service tool NOTE: Steering linkage puller
(MB990635 or MB991113)is also
MB991897
used to disconnect knuckle and tie
rod end ball joint.
MB990241 MB990241-01 or Removal of the driveshaft
Axle shaft puller General service tool
B
A: MB990242
A Puller shaft
MB990241AD B: MB990244
Puller bar
MB991354 General service tool
Puller body
MB991354
MB991056 or MB991056-01 Removal of the hub

MB991355 Removal of the wheel bearing
Knuckle arm bridge
TSB Revision
26-6 FRONT AXLE
SPECIAL TOOLS

name
A
A: MB991017 MB990998-01 Removal of the hub
B: MB990998 Provisional holding of the wheel
C: MB991000 bearing
B A, B: Front hub Measurement of hub starting
C
MB991017 remover and torque
installer Measurement of wheel bearing
C: Spacer end play
NOTE: MB991000, which belongs
to MB990998, should be used as a
spacer.
Removal of the wheel bearing
inner race (outside) (Use
MB991000 with MD998801.)
MB991099 Measurement of hub starting torque
Oil seal installer
guide
MB991099
MB990326 General service tool

Preload socket
MB990326
MD998801 Removal of the wheel bearing inner

Remover race (outside)
MB992150 Installation of the wheel bearing inner

Oil seal installer race (outside)
MD998812
Installer cap
MD998813
Installer
MB990925 MB990925-01 or Removal of the wheel bearing

Bearing and oil seal General service tool
installer set
MB990925
TSB Revision
FRONT AXLE
SPECIAL TOOLS
26-7
name
MB991388 Press-fitting of the dust cover
Bush remover base
MB991388
MB991576
Base
MB991576
MB990890 MB990890-01 Installation of the wheel bearing

Rear suspension
bushing base
MB990890
MD999528
Adapter
MB991561 MB991561 EBJ boot (resin boot) band

Boot band crimping installation
tool
MB991561
MB990925 BEARING AND OIL SEAL INSTALLER

SET
TOOL TYPE TOOL NUMBER O D mm (in)
MB990925 A MB990926 39.0 (1.54)
MB990927 45.0 (1.77)
MB990928 49.5 (1.95)
MB990929 51.0 (2.00)
A MB990930 54.0 (2.13)
INSTALLER ADAPTER
MB990931 57.0 (2.24)
C BRASS BAR MB990932 61.0 (2.40)
MB990933 63.5 (2.50)
B MB990934 67.5 (2.66)
BAR (SNAP-IN TYPE)
MB990935 71.5 (2.81)
MB990936 75.5 (2.97)
MB990937 79.0 (3.11)
B MB990938
C MB990939
TOOL BOX
ACX02372 AC
TSB Revision
26-8 FRONT AXLE
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
WHEEL BEARING END PLAY CHECK
M1261001100340
1. Remove the caliper assembly, and retain it with a wire and
the like to prevent from falling.
2. Set a dial gauge as shown in the figure. Move the hub in the
axial direction and measure the end play.
Limit : 0.05 mm (0.002 inch)
3. After checking, install the brake disc and the caliper
assembly, and tighten the caliper mounting bolt to the
specified torque.
AC102438
HUB BOLT REPLACEMENT

M1261001000503

MB990767: Front Hub and Flange Yoke Holder
MB991618: Hub Bolt Remover
1. Remove the caliper assembly and suspend it with wire so
that it does not fall.
2. Remove the brake disc.
3. Use special tool MB991618 to remove the hub bolts.
MB991618
Hub bolt
AC302114 AF
4. Install the plain washer to the new hub bolt, and install the
bolt with a nut while holding the hub with special tool
MB990767 MB990767.
Plain 5. Install the brake disc, caliper assembly and tighten the
washer caliper assembly mounting bolts to the specified torque.
AC102440AC
TSB Revision
FRONT AXLE
26-9
M1261001701129
CAUTION
The magnetic encoder collects metallic particles easily, because it is magnetized. Make sure that
the magnetic encoder should not collect metallic particles. Check that there is not any trouble
prior to reassembling it. <Vehicles with ABS>
When removing and installing the front wheel hub assembly, make sure that the magnetic encoder
for wheel speed detection (integrated with the inner oil seal) does not contact with surrounding
parts to avoid damage. <Vehicles with ABS>
When removing and installing the front wheel speed sensor, make sure that the pole piece at the
end does not contact with surrounding parts to avoid damage. <Vehicles with ABS>
The parts indicated by * are the nuts with friction coefficient stabilizer. In removal, ensure there is
no damage, clean dust and soiling from the bearing and thread surfaces, and tighten them to the
specified torque.
Post-installation operation
Using your fingers, press the Ball Joint Dust Cover to
check for a crack or damage.
39 6 Nm
29 4 ft-lb 6
9
13 2 Nm
111 22 in-lb
110 11 Nm * 5
25 5 Nm
81 8 ft-lb 19 3 ft-lb
13
11 N 8.5 1.5 Nm
76 13 in-lb
12 4
100 10 Nm 8
74 7 ft-lb 14 144 - 176 Nm
107 - 129 ft-lb
2N
7 1N
10 * 3
71 10 Nm
52 7 ft-lb
AC505531 AB

1. Split pin 5. Front wheel speed sensor harness
<<A>> >>A<< 2. Driveshaft nut bracket <Vehicles with ABS>
>>A<< 3. Washer 6. Brake hose bracket
4. Front wheel speed sensor <> 7. Caliper assembly
<Vehicles with ABS> <<C>> 8. Brake disc
9. Stabilizer link connection
TSB Revision
26-10 FRONT AXLE

10. Self-locking nut (lower arm ball
joint connection)
<<D>> 11. Self-locking nut (tie-rod end
connection)
<<E>> 12. Drive shaft
13. Hub knuckle assembly and strut
mounting bolt and nuts
14. Hub knuckle assembly
Required Special Tools: MB990767: Front Hub and Flange Yoke Holder
MB990242: Puller Shaft MB991354: Puller Body
MB990244: Puller Ball MB991897 or MB992011: Ball Joint Remover
.
<<A>> DRIVESHAFT NUT REMOVAL

CAUTION
Do not apply the vehicle weight on the front wheel hub
assembly with the driveshaft nut loosened. Otherwise, the
wheel bearing may be broken.
Use special tool MB990767 to counter the hub as shown in the
figure to remove the driveshaft nut.
MB990767
AC102462 AB
<> CALIPER ASSEMBLY REMOVAL

Secure the removed caliper assembly with wire, etc.
.
<<C>> BRAKE DISC REMOVAL

If the brake disc removal is difficult, install bolts (M8 x 1.25 mm)
shown in the figure, and tighten them evenly and gradually to
remove the brake disc.
Bolts
(M81.25)
AC505409 AB
TSB Revision
FRONT AXLE
26-11
<<D>> SELF-LOCKING NUT (TIE-ROD END
CONNECTION) REMOVAL
CAUTION
Loosen the self-locking nut (tie-rod end connection)
from the ball joint, but do not remove here. Use the spe-
cial tool.
To prevent the special tool from dropping off, suspend
it with a rope.
1. Install special tool MB991897 or MB992011 as shown in the
Cord
figure.
Nut
MB991897
or
MB992011
Bolt
Ball joint AC208247AJ
2. Turn the bolt and knob to make the special tool jaws parallel,
Bolt then hand-tighten the bolt. After tightening, check that the
jaws are still parallel.
Parallel NOTE: To adjust the special tool jaws to be parallel, set the
orientation of the knob as shown in the figure.
Correct
3. Unscrew the bolt to disconnect the ball joint.
Knob
.
<<E>> DRIVESHAFT REMOVAL

Wrong AC104739AB
CAUTION
The magnetic encoder collects metallic particles easily,
because it is magnetized. Make sure that the magnetic
encoder does not collect metallic particles. <Vehicles
Oil seal with ABS>
Magnetic When removing the driveshaft, make sure that it does
encoder not contact with the magnetic encoder (integrated with
Wheel the inner oil seal) to avoid damage. <Vehicles with
bearing ABS>
AC504925 AC
MB990244 If the driveshaft is seized, use special tools MB990242 and

(Three) MB990244, MB991354 and MB990767 to push the driveshaft
out from the hub.
MB990767
MB991354
MB990242
AC303949 AB
TSB Revision
26-12 FRONT AXLE

.
>>A<< WASHER/DRIVESHAFT NUT INSTALLA-

TION
CAUTION
encoder should not collect metallic particles. Check
Oil seal that there is not any trouble prior to reassembling it..
Magnetic <Vehicles with ABS>
encoder When installing the driveshaft, make sure that it does
Wheel not contact with the magnetic encoder (integrated with
bearing the inner oil seal) to avoid damage. <Vehicles with
ABS>
AC504925 AC Do not apply the vehicle weight on the wheel bearing
before fully tightening the driveshaft nut. Otherwise,
the wheel bearing may be broken.
Washer 1. Be sure to install the driveshaft washer in the illustrated
direction.
2. Use special tool MB990767 to tighten the driveshaft nut. At
this time, tighten the nuts within the specified torque range
considering the final tightening.
Tightening torque: 144 - 176 N m (107 - 129 ft-lb)
3. If the pin holes do not align with the pins, tighten the
driveshaft nut [less than 200 N m (147 ft-lb)] and find the
MB990767 nearest hole then bend the split pin to fit it.
AC210244 AD
INSPECTION
M1261001800178
Check the hub for cracks and spline for wear.
Check the knuckle for cracks.
Check for defective bearing.
NOTE: If the meshing of the wheel bearing outer race and
the knuckle, or of the wheel bearing inner race and the hub,
is loose, replace the bearing or damaged parts.
TSB Revision
FRONT AXLE
26-13
M1261001900528
2
N 4
5
N 3
AC505536 AB
Disassembly steps MB990883: Rear Suspension Bushing Arbor

<<A>> 1. Hub MB990890: Rear Suspension Bushing Base
2. Dust shield MB990935: Installer Adapter
3. Snap ring MB990938: Brass Bar
<> 4. Wheel bearing MB991000: Spacer
5. Knuckle MB991017: Front Hub Remover and Installer
Assembly steps MB991056 or MB991355: Knuckle Arm Bridge
5. Knuckle MB991099: Oil Seal Installer Guide
>>A<< 4. Wheel bearing
MB991388: Bush Remover Base
3. Snap ring
>>B<< 2. Dust shield
MB991576: Base
1. Hub MB992150: Oil Seal Installer
>>C<< Hub starting torque check MD999528: Adapter
>>D<< Wheel bearing end play check MD998801: Remover
MD998812: Installer Cap
Required Special Tools: MD998813: Installer
MB990326: Preload Socket
.
<<A>> HUB REMOVAL

CAUTION
In the hub removal operation, make sure to replace the
wheel bearing with new one.
Use special tools MB991017, MB991056 or MB991355,
MB991056 or MB991000 to pull out the hub from the knuckle.
MB991355
MB991017
Tighten the nut

with the bolt
MB991000 secured
AC507656 AC
TSB Revision
26-14 FRONT AXLE
<> WHEEL BEARING REMOVAL

1. Use special tools MD998801 and MB991000 to remove the
wheel bearing inner race (outside) from the hub.
MB991000
Inner race MD998801
Hub AC611145AB
2. Use special tools MB992150, MD998812 and MD998813 to

MD998812 assemble the inner race (outside) removed from the hub to
the wheel bearing.
MD998813
MB992150
AC611146 AB
3. Use special tools MB990935 and MB990938 to remove the

MB990938 wheel bearing.
MB990935
Inner race
(outside)
AC507657AD
TSB Revision
FRONT AXLE
26-15
.
>>A<< WHEEL BEARING INSTALLATION

CAUTION
AC209054 The magnetic encoder for wheel speed sensor is
Knuckle installed in the wheel bearing. Install the wheel bearing
Hub so that the encoder is positioned in the direction shown
in the figure.
Driveshaft When press-fit the wheel bearing, push the outer race.
Oil seal
(light gold Encoder
or silver) (dark brown)
AC505560 AB
Use special tools MB990890 and MD999528 to press-fit the

wheel bearing.
MB990890
MD999528
AC611147 AB
>>B<< DUST SHIELD INSTALLATION

Use special tools MB991388 and MB991576 to press-fit the
MB991576 knuckle into the dust shield.
NOTE: Use the bolts (M12) to align the caliper mounting holes.
Dust shield
Bolt
MB991388
AC602563 AC
TSB Revision
26-16 FRONT AXLE
>>C<< HUB ROTATION STARTING TORQUE

CHECK
144 - 176 Nm AC210315 1. Set special tools MB991000, MB991017 and MB991099 as
AC505562
(107 - 129 ft-lb) shown in the figure, tighten the nut to the specified torque,
Tighten the nut with and press-fit the hub into the knuckle.
the bolt secured
MB991017 2. Rotate the hub to make the bearing well-greased.
MB991099
MB991000
AC611153 AB
3. Use Special tool MB990326 to measure the hub rotation

starting torque.
Limit: 1.8 N m (16 in-lb)
4. Hub rotation starting torque should be within the limit value,
and there should be no roughness and gritty feeling in
rotation.
MB990326
AC102513 AB
>>D<< WHEEL BEARING END PLAY CHECK

1. Use special tools MB991000 and MB991017 to measure to
MB991000 determine whether the wheel bearing end play is within the
144 - 176 Nm specified limit or not.
(107 - 129 ft-lb)
Tighten the nut Limit: 0.05 mm(0.002 inch)
with the bolt
2. If the end play is not within the limit range while the nut is
secured
tightened to the specified torque, the bearing, hub and/or
knuckle have probably not been installed correctly. Replace
the bearing and re-install.
MB991017
AC102514 AI
INSPECTION
M1261002000045
Check the front hub and brake disc mounting surfaces for
galling and contamination.
Check the knuckle inner surface for galling and cracks.
TSB Revision
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-17
DRIVESHAFT ASSEMBLY
M1261003501187
CAUTION
When removing and installing the driveshaft assembly, make sure that the wheel speed detection
magnetic encoder (integrated with the inner oil seal) does not contact with surrounding parts to
avoid damage. <Vehicles with ABS>
When removing and installing the front wheel speed sensor, make sure that the pole piece at the
The parts indicated by * are the nuts with friction coefficient stabilizer. In removal, ensure there is
no damage, clean dust and soiling from the bearing and thread surfaces, and tighten them to the
specified torque.
Transmission fluid draining (Refer to GROUP 22A, Using your fingers, press the Ball Joint Dust Cover to
On-vehicle Service, Transmission oil check for a crack or damage.
changeP.22A-8.)<M/T> Transmission fluid refilling (Refer to GROUP 22A,
CVT fluid draining (Refer to GROUP 23A, On-vehicle Ser- On-vehicle Service, Transmission oil
vice, CVT fluid changeP.23A-134. )<CVT> changeP.22A-8.)<M/T>
CVT fluid refilling (Refer to GROUP 23A, On-vehicle Ser-
vice, CVT fluid changeP.23A-134. )<CVT>
39 6 Nm 6 13 2 Nm
29 4 ft-lb 111 22 in-lb
11 N
7
5
10 9N
25 5 Nm
11 N <M/T-LH> 19 3 ft-lb
11 N
8.5 1.5 Nm
10 76 13 in-lb
<CVT-LH> 4
3 144 - 176 Nm
107 - 129 ft-lb
10
<RH>
1N
N 2
8
71 10 Nm
52 7 ft-lb
AC606363 AB
TSB Revision
26-18 FRONT AXLE
DRIVESHAFT ASSEMBLY

1. Split pin <<C>> >>A<< 10. Driveshaft assembly
<<A>> >>B<< 2. Driveshaft nut 11. Circlip
>>B<< 3. Washer Required Special Tools:
4. Front wheel speed sensor MB990242: Puller Shaft
<Vehicles with ABS>
MB990244: Puller Bar
5. Front wheel speed sensor harness
bracket <Vehicles with ABS>
6. Brake hose bracket MB991000: Spacer
7. Stabilizer link connection MB991017: Front Hub Remover and Installer
8. Self-locking nut (lower arm ball MB991354: Puller Body
joint connection) MB991897 or MB992011: Ball Joint Remover
<> 9. Self-locking nut (tie-rod end
connection)

.
<<A>> DRIVESHAFT NUT REMOVAL

CAUTION
Do not apply the vehicle weight on the wheel bearing with
the driveshaft nut loosened. Otherwise, the wheel bearing
may be broken.
Use special tool MB990767 to counter the hub as shown in the
figure to remove the driveshaft nut.
MB990767
AC102462 AB
TSB Revision
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-19
<> SELF-LOCKING NUT (TIE-ROD END
CONNECTION) REMOVAL
CAUTION
Loosen the self-locking nut (tie-rod end connection)
from the ball joint, but do not remove here. Use the spe-
cial tool.
it with a rope.
1. Install special tool MB991897 or MB992011, as shown in the
Cord figure.
Nut
MB991897
or
MB992011
Bolt
Ball joint AC208247AN
orientation of the knob as shown in the figure.
Correct
3. Unscrew the bolt to disconnect the ball joint.
Knob
Wrong AC104739AB
TSB Revision
26-20 FRONT AXLE
DRIVESHAFT ASSEMBLY
<<C>> DRIVESHAFT ASSEMBLY REMOVAL

CAUTION
encoder does not collect metallic particles. <Vehicles
Oil seal with ABS>
Magnetic When removing the driveshaft, make sure that it does
encoder not contact with the magnetic encoder (integrated with
Wheel the inner oil seal) to avoid damage. <Vehicles with
bearing ABS>
AC504925 AC
1. If the driveshaft is seized with the hub, use special tools

MB990242 and MB990244, MB990767 and MB991354 to
push the driveshaft assembly out from the hub.
MB990767
MB990244
(Three)
MB990242 MB991354
AC102550AD
2. While pulling the lower side of the brake disc toward you,
remove the driveshaft assembly from the hub.
CAUTION
Never pull out the driveshaft assembly from the EBJ
Driveshaft assembly side. Otherwise, the ETJ assembly may be
damaged. Always pull out from the ETJ side with a
lever.
Care must be taken to ensure that the oil seal of the
transmission is not damaged by the spline part of the
AC102551AE driveshaft assembly.
3. Insert a lever between the transmission case or transfer and
Transmission driveshaft assembly, and then pull the driveshaft assembly
out from the transmission.
ETJ assembly
Lever
AC102552 AK
TSB Revision
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-21
CAUTION
AC210315 Do not apply the vehicle weight to the wheel bearing with
the driveshaft assembly removed. If, however, the vehicle
weight shall be applied to the bearing (in order to move the
MB991000 vehicle), tighten the following special tools MB991000 and
MB991017 MB991017 to the specified torque 144 - 176 N m (107 - 129
ft-lb).
AC505562 AC

.
>>A<< DRIVESHAFT ASSEMBLY INSTALLATION

CAUTION
encoder should not collect metallic particles. Check
Oil seal that there is not any trouble prior to reassembling it..
Magnetic <Vehicles with ABS>
encoder When installing the driveshaft, make sure that it does
Wheel not contact with the magnetic encoder (integrated with
bearing the inner oil seal) to avoid damage. <Vehicles with
ABS>
AC504925 AC Care must be taken to ensure that the oil seal of the
transmission is not damaged by the spline part of the
driveshaft assembly.
.
>>B<< WASHER/DRIVESHAFT NUT

INSTALLATION
CAUTION
Do not apply the vehicle weight on the front wheel hub
assembly before fully tightening the driveshaft nut. Other-
wise, the wheel bearing may be broken.
Washer 1. Incorporate the driveshaft assembly washer as shown in the
illustration.
2. Use special tool MB990767 to tighten the driveshaft nut. At
this time, tighten the nuts within the specified torque range
considering the final tightening.
3. If the pin holes do not align with the pins, tighten the
driveshaft nut [less than 200 N m (147 ft-lb)] and find the
MB990767 nearest hole then bend the split pin to fit it.
AC210244 AD
TSB Revision
26-22 FRONT AXLE
DRIVESHAFT ASSEMBLY

M1261003701404
CAUTION
As for the EBJ assembly, only the EBJ boot can be replaceable, and other parts cannot be disassem-
bled.
N1
4
5 6
2 N
7
3N
10
8
9
8 13
14
N 12
N 11
AC606364
1 1 EBJ grease
2 1
5
3
ETJ grease
5
5 4
2
6 12
7 3 2 7 3 13 11
ETJ boots repair kit ETJ repair kit EBJ boots repair kit
AC607140 AB

1. Circlip >>A<< 8. Damper band
>>C<< 2. ETJ boot band (large) >>A<< 9. Dynamic damper (LH)
>>C<< 3. ETJ boot band (small) >>A<< 10. Dynamic damper (RH)
<<A>> >>B<< 4. ETJ case 11. EBJ boot band (large)
5. Snap ring 12. EBJ boot band (small)
<<A>> >>B<< 6. Spider assembly 13. EBJ boot
<> >>A<< 7. ETJ boot 14. EBJ assembly
TSB Revision
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-23
LUBRICATION POINTS
Grease: Repair kit grease

amount used:
120 10 g (4.2 0.3 oz) <Except
M/T - RH>,
130 10 g (4.6 0.3 oz) <M/T - RH>
CAUTION
The drive shaft joint uses special
grease. Do not mix old and new or
different types of grease.
Grease: Repair kit grease

amount used: 110 10 g
(3.9 0.3 oz)
CAUTION
The drive shaft joint uses special
grease. Do not mix old and new or
different types of grease.
AC607164AB

.
<<A>> ETJ CASE/SPIDER ASSEMBLY REMOVAL

CAUTION
Do not disassemble the spider assembly.
1. Wipe off grease from the spider assembly and the inside of
the ETJ case.
2. Always clean the spider assembly when the grease contains
water or foreign material.
.
<> ETJ BOOT REMOVAL

1. Wipe off the grease on the shaft spline.
2. When reusing the ETJ boot, wrap plastic tape around the
shaft spline to avoid damaging the boot.
TSB Revision
26-24 FRONT AXLE
DRIVESHAFT ASSEMBLY

.
>>A<< DYNAMIC DAMPER/DAMPER BAND/ETJ

BOOT INSTALLATION
CAUTION
There should be no grease adhered to the rubber part of
the dynamic damper.
1. Install the dynamic damper in the position (A) shown in the
figure .
A A: 221 3 mm (8.70 0.12 inches) <M/T-LH>
A: 426 3 mm (16.77 0.12 inches) <M/T-RH,
CVT-RH>
2. Secure the damper band.
3. Wrap plastic tape around the shaft spline, and then install
the ETJ boot band (small) and ETJ boot.
AC208295 AE
>>B<< SPIDER ASSEMBLY/ETJ CASE

INSTALLATION
CAUTION
The driveshaft joint use special grease. Do not mix old
and new or different types of grease.
If the spider assembly has been cleaned, take special
care to apply the specified grease.
1. Apply the specified grease furnished in the repair kit to the
spider assembly between the spider axle and the roller.
Specified grease: Repair kit grease
2. Install the spider assembly to the shaft from the direction of
the spline chamfered side.
Chamfered side
AC102654AD
3. After applying the specified grease to the ETJ case, insert

the driveshaft and apply grease one more time.
Amount to use:
120 10 g (4.2 0.3 ounce) <Except M/T-RH>
130 10 g (4.6 0.3 ounce) <M/T-RH>
NOTE: When using the repair kit grease, put half of the
grease into the joint and the other half into the boot as a
guideline, and use the grease completely.
AC102656 AB
TSB Revision
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-25
>>C<< ETJ BOOT BAND (SMALL)/ETJ BOOT
BAND (LARGE) INSTALLATION
Adjust the distance (A shown in the illustration) between the
boot bands to the standard value to adjust the air volume inside
the ETJ boot to the specified value, then be sure to tighten the
ETJ boot band (large) and ETJ boot band (small).
Standard value (A):
80 3 mm (3.15 0.12 inches)
AC102657AB
INSPECTION
M1261003800301
Check the driveshaft for damage, bending or corrosion.
Check the inner shaft for damage, bending or corrosion.
Check the output shaft for damage, bending or corrosion.
Check the driveshaft spline part for wear or damage.
Check the inner shaft spline part for wear or damage.
Check the output shaft spline part for wear or damage.
Check the spider assembly for roller rotation, wear or corro-
sion.
Check the groove inside ETJ case for wear or corrosion.
Check the boots for deterioration, damage or cracking.
Check the center bearing for seizure, discoloration or
roughness of rolling surface.
Check the dust cover for damage or deterioration.
EBJ BOOT REPLACEMENT

M1261007500119

MB991561:Boot Band Crimping Tool
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the EBJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble
the boot band and EBJ boot.
AC102658
TSB Revision
26-26 FRONT AXLE
DRIVESHAFT ASSEMBLY
4. Align the center groove on the EBJ boot small end with the
shaft groove.
AC102659
5. Turn the adjusting bolt on special tool MB991561 so that the

MB991561
size of the opening (W) is at the standard value.
Stopper Standard value (W): 2.9 mm (0.11 inch)
<If it is larger than 2.9 mm (0.11 inch)>
Tighten the adjusting bolt.
W
<If it is smaller than 2.9 mm (0.11 inch)>
Loosen the adjusting bolt.
NOTE: The value of W will change by approximately 0.7 mm
Adjusting bolt (0.03 inch) for each turn of the adjusting bolt.
AC102660 AD
NOTE: The adjusting bolt should not be turned more than
once.
Boot 6. Position the EBJ boot band (small) so that there is even
clearance at either end (A and B).
A
Boot band
(small)
Projection AC102661AD
CAUTION
Secure the driveshaft in an upright position and clamp
part of the boot band to be crimped securely in the jaws
of the special tool MB991561.
Crimp the boot band until special tool MB991561
touches the stopper.
7. Use special tool MB991561 to crimp the boot band (small).
MB991561 AC606919 AD
TSB Revision
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-27
8. Check that the crimping amount (C) of the boot band is at
the standard value.
Standard value (C): 2.4 2.8 mm (0.10 0.11 inch)
C <If the crimping amount is larger than 2.8 mm (0.11
inch)>
Readjust the value of (W) in step 5 according to the
following formula, and then repeat the operation in
step 7.
W = 5.5 mm (0.22 inch) C
AC606920 AD Example: If C = 2.9 mm (0.11 inch), then W = 2.6 mm
(0.10 inch)
<If the crimping amount is smaller than 2.4 mm (0.10
inch)>
Remove the EBJ boot band, readjust the value of
(W) in step 5 according to the following formula,
and then repeat the operations in steps 6 and 7
using a new EBJ boot band.
W = 5.5 mm (0.22 inch) C
Example: If C = 2.3 mm (0.09 inch), then W = 3.2
mm (0.13 inch)
9. Check that the boot band is not sticking out past the place
where it has been installed. If the boot band is sticking out,
remove it and then repeat steps 6 to 8, using a new boot
band.
CAUTION
The driveshaft joint uses special grease. Do not mix old
and new or different types of grease.
10.Fill the inside of the boot with the specified amount of the
specified grease.
Amount to use: 110 10 g (3.9 0.3 ounces)
11.Align the center groove on the EBJ boot big end with the
EBJ case groove.
AC102664 AC
12.Follow the same procedure as in step 5 to adjust the size of

the opening (W) on the special tool so that it is at the
standard value.
Standard value (W): 3.2 mm (0.13 inch)
TSB Revision
26-28 FRONT AXLE
DRIVESHAFT ASSEMBLY
13.Position the EBJ boot band (large) so that there is even

Projection
clearance at either end (D and E).
Boot band
(large)
Boot E
AC102665AD
14.Use special tool MB991561 to crimp the EBJ boot band

(large) in the same way as in step 7.
15.Check that the crimping amount (F) of the boot band is at
the standard value.
Standard value (F): 2.4 2.8 mm (0.10 0.11 inch)
<If the crimping amount is larger than 2.8 mm (0.11
inch)>
Readjust the value of (W) in step 12 according to
the following formula, and then repeat the opera-
tion in step 14.
W = 5.8 mm (0.23 inch) F
F
AC102666 AD Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm
(0.11 inch)
<If the crimping amount is smaller than 2.4 mm (0.10
inch)>
Remove the EBJ boot band, readjust the value of
(W) in step 12 according to the following formula,
and then repeat the operations in steps 13 and 14
using a new BJ boot band.
W = 5.8 mm (0.23 inch) F
Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm
(0.14 inch)
16.Check that the boot band is not sticking out past the place
where it has been installed. If the boot band is sticking out,
remove it and then repeat steps 13 to 15, using a new boot
band.
TSB Revision
27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . 27-2

27-2 REAR AXLE
GENERAL INFORMATION
GENERAL INFORMATION
M2270000100478
The rear axle has the following features: The number of parts has been reduced by inte-
The wheel bearing is a unit ball bearing (dou- grating the magnetic encoder for ABS wheel
ble-row angular contact ball bearing) which incor- speed detection into the wheel bearing. <Vehi-
porates the oil seals and is highly resistant to cles with ABS>
thrust loads.
SPECIFICATIONS
Item Specification
Wheel bearing Type Unit ball bearing (double-row angular contact ball bearing)
Ball bearing
Magnetic
encoder
Rear hub
Oil seal AC606273 AB

27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . 27-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . 27-4
SPECIFICATIONS . . . . . . . . . . . . . . . 27-2 ON-VEHICLE SERVICE . . . . . . . . . . . 27-5

SERVICE SPECIFICATIONS . . . . . . . . . . . 27-2 WHEEL BEARING END PLAY CHECK . . . 27-5
REAR HUB ROTARY-SLIDING RESISTANCE
REAR AXLE DIAGNOSIS . . . . . . . . . 27-2 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-5
INTRODUCTION TO REAR AXLE HUB BOLT REPLACEMENT. . . . . . . . . . . . 27-6
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 27-2
REAR AXLE DIAGNOSTIC TROUBLESHOOTING REAR AXLE HUB ASSEMBLY . . . . . 27-7
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . . 27-2 REMOVAL AND INSTALLATION . . . . . . . . 27-7
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 27-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27-8
27-2 REAR AXLE
GENERAL INFORMATION
GENERAL INFORMATION
M1271000100694
The rear axle has the following features: The number of parts has been reduced by inte-
The wheel bearing is a unit ball bearing (dou- grating the magnetic encoder for ABS wheel
ble-row angular contact ball bearing) which incor- speed detection into the wheel bearing. <Vehi-
porates the oil seals and is highly resistant to a cles with ABS>
thrust load. .
Ball bearing
Magnetic
encoder
Rear hub
Oil seal AC606273 AB
SPECIFICATIONS
M1271000300847
Item Limit
Wheel bearing end play mm (in) 0.05 (0.002)
Rear hub rotary-sliding resistance N (lb) 19.2 (4.32)
REAR AXLE DIAGNOSIS

INTRODUCTION TO REAR AXLE DIAGNOSIS
M1271004100179
Noise from the rear axle may be caused by defects in
the components.
REAR AXLE DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1271004200176
rear axle fault. Chart.
SYMPTOM CHART
M1271004300333

Abnormal noise 1 P.27-3
TSB Revision
REAR AXLE
REAR AXLE DIAGNOSIS
27-3
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Abnormal Noise
DIAGNOSIS
STEP 1. Check the rear hub assembly installation bolts for

looseness.
Q: Are the rear hub assembly installation bolts loosened?
YES : Tighten the rear hub assembly installation bolts to the
specified torque 95 14 N m (70 10 ft-lb). Then go
to Step 3.
NO : Go to Step 2.
STEP 2. Check the wheel bearing end play.

(1) Remove the brake drum. <Vehicles with drum brake>
(2) Remove the caliper assembly, and suspend the caliper
assembly with a wire and remove the brake disc. <Vehicles
with disc brake>
<Vehicles with (3) Check the bearing's end play. Place a dial gauge against
drum brake> the hub surface, then move the hub in the axial direction
and check whether or not there is end play.
Q: Is the wheel bearing end play within the limit?
YES : Go to Step 3.
NO : Replace the rear hub assembly, then go to Step 4.
AC606592 AB
<Vehicles with
disc brake>
AC511300 AD
TSB Revision
27-4 REAR AXLE
SPECIAL TOOLS
STEP 3. Check the rear hub rotary-sliding resistance.

(1) Remove the brake drum. <Vehicles with drum brake>
(2) Remove the caliper assembly, and suspend the caliper
with disc brake>
(3) Turn the hub a few times to seat the bearing.
<Vehicles with (4) Wind a rope around the hub bolt and turn the hub by pulling
drum brake> at a 90 degree angle with a spring balance. Measure to
determine whether or not the rotary-sliding resistance of the
rear hub is at the limit value.
Limit: 19.2 N (4.32 lb)
Q: Is the rear hub rotary-sliding resistance within the limit?
YES : Go to Step 4.
NO : Replace the rear hub assembly if an adjustment
cannot be made to within the limit. Then go to Step 4 .
AC606593 AB
<Vehicles with
disc brake>
AC511305 AC
STEP 4. Retest the systems.

Q: Are abnormal noises generated?
SPECIAL TOOLS
M1271000600804

MB990767 MB990767-01 Hub fixing
Front hub and flange
yoke holder
B990767
MB991618 General service tool Hub bolt removal

Hub bolt remover
MB991618
TSB Revision
REAR AXLE
ON-VEHICLE SERVICE
27-5
ON-VEHICLE SERVICE
WHEEL BEARING END PLAY CHECK
M1271000900805
1. Remove the brake drum. <Vehicles with drum brake>
2. Remove the caliper assembly, and suspend the caliper
with disc brake>
<Vehicles with 3. Check the bearing's end play. Place a dial gauge against the
drum brake> hub surface; then move the hub in the axial direction and
check whether or not there is end play.
4. Replace the rear hub assembly if an adjustment cannot be
made to within the limit.
5. After checking, install the brake disc and the caliper
assembly, and tighten the caliper mounting bolt to the
specified torque.
AC606592 AB
<Vehicles with
disc brake>
AC511300 AD
REAR HUB ROTARY-SLIDING RESISTANCE

CHECK
M1271001100460
with disc brake>
3. Turn the hub a few times to seat the bearing.
TSB Revision
27-6 REAR AXLE
ON-VEHICLE SERVICE
<Vehicles with 4. Wind a rope around the hub bolt and turn the hub by pulling
drum brake> at a 90 degree angle with a spring balance. Measure to
determine whether or not the rotary-sliding resistance of the
rear hub is at the limit value.
Limit: 19.2 N (4.32 lb)
5. Replace the rear hub assembly if the rotary-sliding
resistance cannot be made to within the limit.
6. After having finished the inspection, install the brake disc,
caliper assembly and tighten the caliper assembly mounting
AC606593 AB
bolts to the specified torque 55 5 N m (41 3 ft-lb).
<Vehicles with
disc brake>
AC511305 AC
HUB BOLT REPLACEMENT

M1271001000474

MB991618: Hub Bolt Remover
with disc brake>
3. Use special tool MB991618 to remove the hub bolts.
MB991618
Hub bolt
AC302114 AF
4. Install the plain washer to the new hub bolt, and install the
bolt with a nut while holding the hub with special tool
MB990767.
5. Install the brake disc, caliper assembly and tighten the
Plain
washer caliper assembly mounting bolts to the specified torque.
<Vehicles with disc brake>
MB990767
AC205872 AD
TSB Revision
REAR AXLE
REAR AXLE HUB ASSEMBLY
27-7
M1271002000842
CAUTION
Do not disassemble the rear wheel hub assembly.
When the rear wheel hub assembly is removed/installed, make sure that the magnetic encoder
(integrated with inner oil seal) does not contact with surrounding parts to avoid damage. <Vehi-
cles with ABS>
When removing and installing the rear wheel speed sensor, make sure that its pole piece at the
The part indicated with * is the bolt with friction coefficient stabilizer. In removal, replace it with a
new one.
<Vehicles with drum brake> 8.5 1.5 Nm

1 76 13 in-lb
11 2 Nm
98 17 in-lb
* N
95 14 Nm
70 10 ft-lb
5
AC606594 AB
TSB Revision
27-8 REAR AXLE
<Vehicles with disc brake> 8.5 1.5 Nm

76 13 in-lb
13 2 Nm 55 5 Nm
11 2 Nm
111 22 in-lb 41 3 ft-lb
98 17 in-lb 1
3
* N
2
95 14 Nm
70 10 ft-lb
4
AC606597AB

1. Rear wheel speed sensor <Vehicles <<A>> 4. Brake disc <Vehicles with disc brake>
with ABS> 5. Rear brake drum <Vehicles with drum
2. Brake hose bracket <Vehicles with brake>
disc brake> 6. Rear wheel hub assembly
3. Caliper assembly <Vehicles with disc
brake>

.
<<A>> CALIPER ASSEMBLY REMOVAL

Secure the removed caliper assembly with wire, etc.
INSPECTION
M1271002100344
Check the oil seal of the rear hub wheel bearing for crack or
damage.
Check the rear hub wheel bearing for wear or damage.
TSB Revision
31-1
GROUP 31
WHEEL AND TIRE

CONTENTS
GENERAL INFORMATION . . . . . . . . 31-2 TIRE PRESSURE MONITORING SYSTEM

(TPMS) . . . . . . . . . . . . . . . . . . . . . . . . 31-2
31-2 WHEEL AND TIRE
GENERAL INFORMATION
GENERAL INFORMATION
M2310000100941
The wheels and tires of the following specifica- Warns driver of TPMS probrems by flashing*
tions have been established. the TPMS warning light on the combination
Adopt the Tire Pressure Monitoring System meter.
(TPMS).
NOTE: *: Change to continuous illumination
Warns driver of low tire pressure by illuminat-
after flashing for about 1 minute.
ing the TPMS warning light on the combina-
tion meter.
SPECIFICATIONS
.
ROAD WHEEL AND TIRE

Item DE ES GTS
TPMS warning Warning ON 174 (25.2) or less 174 (25.2) or less 174 (25.2) or less
pressure kPa Warning OFF 189 (27.4) or less 189 (27.4) or less 189 (27.4) or less
(psi)
Wheel Type Steel type or Aluminum type Aluminum type
Aluminium type*
Size 16 6 1/2JJ 16 6 1/2JJ 18 7JJ
Amount of wheel 46 (1.8) 46 (1.8) 46 (1.8)
offset mm (in)
PCD mm (in) 114.3 (4.50) 114.3 (4.50) 114.3 (4.50)
Tire Size P205/60R16 91H P205/60R16 91H P215/45R18 89V
SPARE WHEEL AND TIRE

Item Specification
Wheel Type Steel type
Size 16 4T
Amount of wheel offset mm (in) 40 (1.6)
PCD mm (in) 114.3 (4.50)
Tire Size T125/70D16 96M
NOTE: .
The * mark indicates optional item.
PCD indicates the pitch circle diameter of the wheel installation holes.
TIRE PRESSURE MONITORING SYSTEM (TPMS)

M2310000200067
Refer to GROUP 42B Keyless Operation System
(KOS) P.42B-20 or GROUP 42C Wireless Control
Module (WCM) P.42C-9.
31-1
GROUP 31
WHEEL AND TIRE

CONTENTS
WHEEL AND TIRE DIAGNOSIS . . . . 31-2 INSTALLATION SERVICE POINT . . . . . . . 31-7

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 31-2
WHEEL BALANCE ACCURACY . . . . . . . . 31-3 TIRE PRESSURE MONITORING
SYSTEM (TPMS) . . . . . . . . . . . . . . . . 31-7
ON-VEHICLE SERVICE. . . . . . . . . . . 31-7 REMOVAL AND INSTALLATION . . . . . . . . 31-7
TIRE INFLATION PRESSURE CHECK . . . 31-7
TIRE WEAR CHECK. . . . . . . . . . . . . . . . . . 31-7 SPECIFICATIONS . . . . . . . . . . . . . . . 31-8
WHEEL RUNOUT CHECK . . . . . . . . . . . . . 31-7 FASTENER TIGHTENING
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . 31-8
GENERAL SPECIFICATIONS . . . . . . . . . . 31-8
WHEEL AND TIRE. . . . . . . . . . . . . . . 31-7
SERVICE SPECIFICATIONS . . . . . . . . . . . 31-8
31-2 WHEEL AND TIRE
WHEEL AND TIRE DIAGNOSIS

DIAGNOSIS
M1311000700794
Symptom Probable cause Remedy Reference page

Rapid wear Under-inflation Adjust the tire For tire inflation
at shoulders or lack of pressure. pressure, refer to
rotation the label on the
driver's side center
pillar.
ACX00923AB
ACX00924 AB
Rapid wear Over-inflation

at center or lack of
rotation
ACX00925AB
ACX00926AB
Cracked Under-inflation Adjust the tire For tire inflation

treads pressure. pressure, refer to
the label on the
driver's side center
pillar.
ACX00927AB
TSB Revision
WHEEL AND TIRE
31-3
Symptom Probable cause Remedy Reference page
Wear on one Excessive Check the camber. Refer to GROUP
side camber 33, On-vehicle
service Front
wheel alignment
check and
ACX00928 AB
adjustment P.33-8.
ACX00929 AB
Feathered Incorrect toe-in Adjust the toe-in.

edge
ACX00930AB
ACX00931AB
Bald spots Unbalanced Balance the wheels.

wheel
ACX00932AB
ACX00933 AB
Scalloped Lack of rotation of tires or worn Rotate the tires, and Refer to GROUP
wear or out-of-alignment suspension check the front 33, On-vehicle
suspension service Front
alignment. wheel alignment
check and
ACX00934
adjustment P.33-8.
WHEEL BALANCE ACCURACY

M1311001700656
PURPOSE 2. Off-the-car wheel balancers must be calibrated

This section contains tips and procedures for achiev- periodically to ensure good balancing results. An
ing accurate wheel balance. Steering wheel vibration inaccurately calibrated balancer could cause
and/or body shake can result if any of these proce- unnecessary replacement of tires, shocks,
dures are not carefully observed. suspension components, or steering components.
1. Wheels and tires must be properly mounted on a Check your balancer's calibration approximately
balancer in order to achieve correct balance. every 100 balances. Your wheel balancer's instruc-
Centering the wheel on the shaft of the balancer is tion manual should include calibration procedures. If
essential for proper mounting. the calibration procedures specifically for your bal-
ancer are missing, use the generic steps in this sec-
tion for zero calibration, static balance, and dynamic
balance checks. The wheel balancer calibration
checks are also described in the flowchart. (Refer to
P.31-6.)
TSB Revision
31-4 WHEEL AND TIRE
PROCEDURE <Balancing Tips> 3. Install a wheel mounting cone. The appropriate

1. Confirm that the balancer's cone and the wheel size cone for this vehicle is 67.0 mm (2.64
mounting cone are undamaged and free of dirt inches).
and rust. 4. Before balancing the wheel, remove any wheel
2. On this vehicle, the wheel's center hole on the weights from both sides. Also check both sides for
hub side has a chamfered edge. Use a any damage.
back-mounting cone on your wheel balancer to 5. When installing wheel weights, hammer them at a
center the wheel on the balancer shaft. straight (not diagonal) angle.
Hub/Shaft Clamping cup

assembly
Wing nut
Spring plate
Wheel AC000041AC
mounting Standard passenger
cone car wheel
<Confirming Proper Balance> 2. Turn the wheel again 180 degree angle against
1. After balancing the wheel, loosen the wing nut the balancer's hub. If the wheel becomes
and turn the wheel 180 degree angle against the out-of-balance each time it is turned against the
balancer's hub. Then re-tighten the wing nut and balancer's hub, the wheel balancer may require
check the balance again. Repeat wheel balance if calibration.
necessary.
<Wheel Balancer Calibration Checks> If the imbalance is 5 g (0.18 ounce) or less, the
1. Mount an undamaged original-equipment alloy wheel may not be centered on the balancer, or
rim and tire assembly (wheel) onto your the balancing cones, the cup, and/or wing nut are
off-the-car wheel balancer. Balance the wheel. damaged, dirty, or inappropriate for the wheel.
You may need to refer to the balancer manufac-
2. <<Zero Calibration Check>>
turer's instructions to verify the correct attach-
Loosen the balancer wing nut, rotate the wheel a ments. After making the necessary corrections,
half-turn (180 degree angle), and retighten the recheck the wheel balance. If OK, then go to Step
nut. Recheck the balance. 4.
If the imbalance is 5 g (0.18 ounce) or less, the If the imbalance is more than 5 g (0.18 ounce),
zero calibration is OK. Rebalance the wheel, then the balancer requires calibration. Contact the bal-
go to Step 4 to check static balance. ancer manufacturer for calibration by their repair
If the imbalance is more than 5 g (0.18 ounce), go representative.
to Step 3. 4. <<Static Balance Check>>
3. Loosen the balancer wing nut, rotate the wheel
Attach a 5 g (0.18 ounce) weight to the outer rim.
1/4 turn (90 degree angle), and retighten the nut.
Recheck the balancer. The balancer should
Recheck the wheel balance.
detect 5 2 g (0.18 0.06 ounce) of imbalance
170 to 190 degree angle away from the 5 g (0.18
ounce) weight.
If the imbalance is within specification, the static
balance calibration is correct. Go to Step 5 to
check the dynamic balance.
TSB Revision
WHEEL AND TIRE
31-5
If the imbalance is out of specification, the bal- If the imbalance is within specification, the
ancer requires calibration. Contact the balancer dynamic balance calibration is correct. The bal-
manufacturer for calibration by their repair repre- ancer calibration checks are complete.
sentative. If the imbalance is out of specification, the bal-
5. <<Dynamic Balance Check>> ancer requires calibration. Contact the balancer
manufacturer for calibration by their repair repre-
Attach a 5 g (0.18 ounce) weight to the inner rim
sentative.
at 180 degree angle opposite the 5 g (0.18 ounce)
weight that was added in Step 4. Recheck the
balance. The balancer should detect 5 2 g (0.18
0.06 ounce) of imbalance 170 to 190 degree
angle away from both the inner and outer 5 g
(0.18 ounce) weights.
TSB Revision
31-6 WHEEL AND TIRE
WHEEL BALANCER CALIBRATION CHECKING FLOW CHART
Balance wheel.
ZERO CALIBRATION
Rotate wheel 1/2 turn. CHECK
Imbalance = 5 g (0.18 oz) or less Imbalance = more than 5 g (0.18 oz)
Rebalance wheel.
Rotate wheel 1/4 turn.
Imbalance = 5 g (0.18 oz) or less Imbalance = more than 5 g (0.18 oz)
Verify wheel is properly centered.

Verify cones, cup, and wing nut are clean,
undamaged, and appropriate for wheel.
Make necessary corrections, then recheck
wheel balance.
Attach a 5 g (0.18 oz) weight to the outer rim. STATIC BALANCE

CHECK
Is the imbalance 5 2 g (0.18 0.06 oz) at 170 190
degree angle away from the 5 g (0.18 oz) weight?
YES NO
DYNAMIC BALANCE
Attach a 5 g (0.18 oz) weight to the inner rim at 180 CHECK
degree angle opposite the weight on the outer rim.
Is the imbalance 5 2 g (0.18 0.06 oz) at 170 190
degree angle away from both 5 g (0.18 oz) weights?
YES NO
Balancer does not require Balancer requires calibration.

calibration. Contact balancer manufacturer.
AC403557 AC
TSB Revision
WHEEL AND TIRE
ON-VEHICLE SERVICE
31-7
ON-VEHICLE SERVICE
TIRE INFLATION PRESSURE CHECK
M1311000900668
NOTE: For information on tire inflation pressure, refer to the
label attached to the center pillar on the driver's side.
TIRE WEAR CHECK

M1311001000721
Measure the tread depth of the tires.
Minimum limit: 1.6 mm (0.06 inch)
If the remaining tread depth is less than the minimum limit,
replace the tire.
NOTE: When the tread depth of the tires is reduced to 1.6 mm
(0.06 inch) or less, wear indicators will appear.
WHEEL RUNOUT CHECK

M1311001100740
Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with a
dial indicator.
Radial Limit:
Items Steel wheel Aluminum wheel
Radial runout 1.2 mm (0.05 inch) or 1.0 mm (0.04 inch) or
less less
Lateral ACX00651AD
Lateral runout 1.2 mm (0.05 inch) or 1.0 mm (0.04 inch) or
less less
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TIRE

M1311001300573
Tighten the wheel nuts to the specified torque.

M1311003800109
Refer to GROUP 42B Keyless Operation System
(KOS) P.42B-206 or GROUP 42C Wireless Control
Module (WCM) P.42C-115.
TSB Revision
31-8 WHEEL AND TIRE
SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATION
M1311001600400
Item Specification
Wheel nut 98 10 N m (73 7 ft-lb)
M1311000200506
.
ROAD WHEEL AND TIRE

Item DE ES GTS
Wheel Type Steel type or Aluminum type Aluminum type
Aluminium type*
Size 16 6 1/2JJ 16 6 1/2JJ 18 7JJ
Amount of wheel offset mm (in) 46 (1.8) 46 (1.8) 46 (1.8)
PCD mm (in) 114.3 (4.50) 114.3 (4.50) 114.3 (4.50)
Tire Size P205/60R16 91H P205/60R16 91H P215/45R18 89V
SPARE WHEEL AND TIRE

Item Specification
Wheel Type Steel type
Size 16 4T
Amount of wheel offset mm (in) 40 (1.6)
PCD mm (in) 114.3 (4.50)
Tire Size T125/70D16 96M
NOTE: .
The * mark indicates optional item.
PCD indicates the pitch circle diameter of the wheel installation holes.
M1311000300774
Item Limit
Tread depth of tire mm (in) Minimum 1.6 (0.06)
Wheel runout <Aluminum wheel> Radial runout mm (in) 1.0 (0.04) or less
Lateral runout mm (in) 1.0 (0.04) or less
Wheel runout <Steel wheel> Radial runout mm (in) 1.2 (0.05) or less
Lateral runout mm (in) 1.2 (0.05) or less
TSB Revision
32-1
GROUP 32
POWER PLANT
MOUNT
CONTENTS
GENERAL INFORMATION . . . . . . . . 32-2 ENGINE ROLL STOPPER AND

CENTERMEMBER . . . . . . . . . . . . . . . 32-7
SPECIAL TOOLS. . . . . . . . . . . . . . . . 32-2 REMOVAL AND INSTALLATION . . . . . . . . 32-7
ENGINE MOUNTING . . . . . . . . . . . . . 32-3 CROSSMEMBER* . . . . . . . . . . . . . . . 32-9

REMOVAL AND INSTALLATION . . . . . . . . 32-3 REMOVAL AND INSTALLATION . . . . . . . . 32-9
TRANSAXLE MOUNTING . . . . . . . . . 32-5

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
passenger (from rendering the SRS inoperative).
Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any
SRS-related component.
NOTE
The SRS includes the following components: SRS air bag control unit, SRS warning light, front impact sensors, drivers and
passengers (front) air bag modules, knee air bag module, side-airbag module, curtain air bag module, side impact sensors,
seat belt pre-tensioners, clock spring, and interconnecting wiring. Other SRS-related components (that may have to be
removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).
32-2 POWER PLANT MOUNT
GENERAL INFORMATION
GENERAL INFORMATION
M1321000101075
To support the power plant, the inertial axis four-point For the transaxle mounting bracket, lightweight
mount system has been adopted. The system has and high rigidity sheet metal has been adopted to
the following features: reduce the gear noise.
For the engine and transaxle mounting insulator, For the front and rear roll stopper, insulators
the cylindrical liquid seal mount has been developed for CVT have been adopted. It
adopted. It reduces the idling vibration and accel- reduces the idling vibration and accelera-
eration noise, and improves riding comfort. tion/deceleration shock.
For the engine mounting bracket, lightweight and A front axle crossmember has been adopted to
high rigidity aluminum has been adopted to improve steering ability.
reduce acceleration noise.
Engine mounting
insulator
Engine mounting
bracket Rear roll stopper
Transaxle mounting
insulator
Front roll stopper

Transaxle mounting
bracket
AC507295AD
SPECIAL TOOLS
M1321000600828

name
MB990900 or MB990900-01 Removal and installation of
MB991164 Door transaxle mounting insulator
adjusting wrench
MB990900
MB991897 or MB991113-01, Knuckle and tie rod end ball joint

MB992011 MB990635-01 or disconnection
Ball joint remover General service tool NOTE: Conventional steering
linkage puller, MB991406,
MB990635 or MB991113 can
MB991897
also be used
TSB Revision
POWER PLANT MOUNT
ENGINE MOUNTING
32-3
ENGINE MOUNTING
M1321001101584
CAUTION
The part indicated * mark should be temporarily tightened and then should be fully tightened with the
engine weight applied on the vehicle body.
Pre-removal Operation Post-installation Operation
Radiator Condenser Tank Removal (Refer to GROUP 14 Power Steering Oil Pump Installation (Refer to GROUP
Radiator P.14-26). 11A Engine Assembly P.11A-74).
Power Steering Oil Pump Removal (Refer to GROUP 11A Radiator Condenser Tank Installation (Refer to GROUP
Engine Assembly P.11A-74). 14 Radiator P.14-26).
Raise the Engine and Transaxle Assembly to the Position
Where the Weight is not Applied to the Insulator.
13 2 Nm
111 22 in-lb
66 7 Nm
1 49 5 ft-lb
100 5 Nm*
74 4 ft-lb*
66 7 Nm
49 5 ft-lb
2
3
50 5 Nm
37 4 ft-lb
AC506146AD

1. Power steering pressure hose >>A<< 3. Engine mounting insulator stopper
clamp 4. Engine mounting insulator
2. Engine mounting bracket
TSB Revision
ENGINE MOUNTING

.
>>A<< ENGINE MOUNTING INSULATOR STOP-

PER INSTALLATION
Install the engine mounting insulator stopper as shown in the
Engine mounting insulator Engine side figure.
Engine mounting
insulator stopper
AC505483 AB
TSB Revision
POWER PLANT MOUNT
TRANSAXLE MOUNTING
32-5
TRANSAXLE MOUNTING
M1321001401314
CAUTION
The part indicated * mark should be temporarily tightened and then should be fully tightened with the
engine weight applied on the vehicle body.
Battery and Battery Tray Removal (Refer to GROUP 54A Engine Control Module (ECM) Installation (Refer to
Battery P.54A-8). GROUP 13A Engine Control Module (ECM) P.13A-952).
Air Cleaner Assembly Removal (Refer to GROUP 15 Air Air Cleaner Assembly Installation (Refer to GROUP 15
Cleaner P.15-4 ). Air Cleaner P.15-4 ).
Engine Control Module (ECM) Removal (Refer to GROUP Battery and Battery Tray Installation (Refer to GROUP
13A Engine Control Module (ECM) P.13A-952). 54A Battery P.54A-8).
Raise the Engine and Transmission Assembly to the Posi-
tion Where the Weight is not Applied to the Insulator.
50 5 Nm
2 37 4 ft-lb
3
2
47 7 Nm
35 5 ft-lb
50 5 Nm
37 4 ft-lb
95 10 Nm*
70 7 ft-lb*
1
AC610464 AB
Removal steps Required Special Tool:

1. Transaxle mounting bracket MB990900 or MB991164: Door Adjusting Wrench
>>B<< 2. Transaxle mounting insulator
stopper REMOVAL SERVICE POINT
<<A>> >>A<< 3. Transaxle mounting insulator
.
<<A>> TRANSAXLE MOUNTING INSULATOR

REMOVAL
To remove the mounting bolt on the lower side of the transaxle
mounting insulator, use the special tool MB990900 or
MB991164.
TSB Revision
TRANSAXLE MOUNTING

.
>>A<< TRANSAXLE MOUNTING INSULATOR

INSTALLATION
To install the mounting bolt on the lower side of the transaxle
mounting insulator, use the special tool MB990900 or
MB991164.
.
>>B<< TRANSAXLE MOUNTING INSULATOR

STOPPER INSTALLATION
Transaxle
Install the transaxle mounting insulator stopper as shown in the
mounting
Engine side figure.
insulator
Transaxle
mounting
insulator
stopper
AC505484 AB
TSB Revision
POWER PLANT MOUNT
ENGINE ROLL STOPPER AND CENTERMEMBER
32-7
M1321002300726
CAUTION
The part indicated by the *1 mark should be temporarily tightened, and then fully tightened with
the engine and transaxle assembly weight applied on the vehicle body.
The parts indicated by the *2 are the bolts with friction coefficient stabilizer. In removal, ensure
there is no damage, clean dust and soiling from bearing and thread surfaces, and tighten them to
Engine Room Under Cover Front Removal and Installa-
tion (Refer to GROUP 51 Under Cover P.51-16).
53 8 Nm* 1 50 5 Nm
39 6 ft-lb* 1
7 37 4 ft-lb
1
6
4 53 8 Nm* 1
5 39 6 ft-lb* 1
3
71 10 Nm* 2 71 10 Nm* 2
52 8 ft-lb* 2 50 5 Nm 52 8 ft-lb* 2
2 37 4 ft-lb
AC611208 AB
Front roll stopper and Front roll stopper and

centermember removal steps centermember removal steps
1. Flange nut 5. Centermember
2. Centermember and body >>A<< 6. Front roll stopper
connection Rear roll stopper removal steps
3. Centermember and front axle Backbone Brace (Refer to GROUP
crossmember connection 15 - Exhaust Pipe and Main Muffler
4. Centermember and front roll P.15-12).
stopper assembly 7. Flange nut
8. Rear roll stopper
TSB Revision

.
>>A<< FRONT ROLL STOPPER INSTALLATION

Install the front roll stopper so that the hole faces toward the
vehicle front.
Hole
Front of vehicle
AC611209AB
TSB Revision
POWER PLANT MOUNT
CROSSMEMBER
32-9
CROSSMEMBER
M1321003200982
CAUTION
Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B
Service Precautions and Drivers, Front Passengers Air Bag Module and Clock Spring
(P.52B-367). Also, set the front wheels so that they are facing straight forward, and remove the
ignition key. If you fail to do this, the SRS clock spring will be damaged, causing the SRS air bag to
be inoperative resulting in serious injury.
The part indicated by *1 should be temporarily tightened, and then fully tightened with the vehicle
standing on the earth and the curb weight condition.
The parts indicated by *2 are the bolts/nuts with friction coefficient stabilizer. In removal, ensure
there is no damage, clean dust and soiling from the bearing and thread surfaces, and tighten them
Steering Wheel and Air Bag Module Assembly Removal Centremember Removal (Refer to P.32-7).
(Refer to GROUP 37 Steering Wheel P.37-21). Clock Spring Centring (Refer to GROUP 52B Driver's,
Centremember Removal (Refer to P.32-7). Front Passenger's Air Bag Modules and Clock Spring
Power Steering Fluid Draining (Refer to GROUP 37 P.52B-367).
On-vehicle Service, Power Steering Fluid Replacement Steering Wheel and Air Bag Module Assembly Installation
P.37-17). (Refer to GROUP 37 Steering Wheel P.37-21).
Power Steering Fluid Air Bleeding (Refer to GROUP 37
On-vehicle Service, Power Steering System Air Bleeding
P.37-17).
Using Your Fingers, Press The Ball Joint Dust Cover To
Check for A Crack or Samage.
Steering Wheel Straight-ahead Position Check
Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33 On-vehicle Service Front Wheel Alignment
Check and Adjustment P.33-8).
TSB Revision
CROSSMEMBER
10
5.0 2.0 Nm
45 17 in-lb 13 2 Nm
15 3 Nm
111 22 ft-lb
11 2 ft-lb
11
9
7
17 13 2 Nm
57 7 Nm
111 22 ft-lb
42 5 ft-lb
16 70 10 Nm* 2
52 7 ft-lb* 2 18
50 5 Nm
37 4 ft-lb
22 25 5 Nm* 2
N 8 19 3 ft-lb* 2
53 8 Nm 2
N 21 20 5 Nm*
39 6 ft-lb 13 15 3 ft-lb* 2
31 4 Nm
23 3 ft-lb
12
2N
4
14 19
39 6 Nm
29 4 ft-lb
20 1N
4 71 10 Nm* 2
39 6 Nm
5 52 8 ft-lb* 2
23 29 4 ft-lb
3
110 11 Nm* 2
110 11 Nm* 1, 2 81 8 ft-lb* 2
81 8 ft-lb* 1, 2
6
3 15
110 11 Nm* 2
81 8 ft-lb* 2
15
110 11 Nm* 2
81 8 ft-lb* 2 110 11 Nm* 2
15 81 8 ft-lb* 2 AC611244AB

1. Self-lock nut (Lower arm and 9. Pressure hose connection
knuckle connection) 10. Return hose connection
<<A>> 2. Self-lock nut (Tie-rod end and 11. Return tube assembly
knuckle connection) Footrest joint cover removal
3. Lower arm and crossmember 12. Steering gear and joint connecting
mounting bolts and nuts bolt
4. Stabilizer link mounting nuts 13. Flanged nut
5. Stabilizer link assembly 14. Rear roll stopper centre bolt
6. Lower arm assembly 15. Front axle crossmember and body
7. Eye bolt connection
8. Gasket <> Front axle crossmember assembly
TSB Revision
POWER PLANT MOUNT
CROSSMEMBER
32-11
Removal steps (Continued) Removal steps (Continued)
16. Heat protector 22. Steering gear and linkage
17. Power steering oil line bracket 23. Front axle crossmember
>>A<< 18. Joint cover grommet
19. Rear roll stopper
20. Stabilizer bar
MB991897 or MB992011: Ball Joint Remover
21. Steering gear and linkage mounting
bolt

.
<<A>> TIE-ROD END AND KNUCKLE DISCON-

NECTION
CAUTION
Do not remove the nut from the ball joint, but only
loosen it, and use the special tool.
Cord
it with a cord.
Nut MB991897 1. Install special tool MB991897or MB992011 as shown in the
or figure.
MB992011
Bolt
Ball joint AC606180 AB
knob as shown in the figure so that it functions as a fulcrum
Knob Correct of the jaws.
3. Turn the bolt and disconnect the tie-rod end from the
steering knuckle.
Wrong AC606184 AB
<> FRONT AXLE CROSSMEMBER

ASSEMBLY REMOVAL
1. Jack up and support the font axle crossmember, remove the
Piece of wood front axle crossmember mounting bolt.
2. Check the hoses and harnesses for roughness, and then
remove the front axle crossmember assembly with the rear
roll stopper and the steering gear and linkage installed.
Transmission jack
AC606181AB
TSB Revision
CROSSMEMBER

.
>>A<< JOINT COVER GROMMET INSTALLATION

Steering joint
Install the joint cover grommet to the steering gear and linkage
Steering gear cover assembly by aligning the mating marks as shown in the figure.
Joint cover
grommet
AC606182 AB
TSB Revision
32-1
GROUP 32
POWER PLANT
MOUNT
CONTENTS

GENERAL INFORMATION
GENERAL INFORMATION
M2320000100856
For the power plant support, the inertial axis For the transmission mounting bracket, light
four-point mounting system is adopted, and the sys- weight and high rigidity sheet metal is adopted to
tem has the following features. reduce gear noise.
For the engine and transmission mounting insula- For the front and rear roll stoppers, insulators
tor, the cylindrical liquid seal mountings are developed for CVT. This reduces idling vibration
adopted. This reduces idling vibration and accel- and acceleration/deceleration shock.
eration noise, and improves riding comfort. A front axle crossmember is adopted to improve
For the engine mounting bracket, lightweight and steering ability.
high rigidity aluminum is adopted to reduce accel-
eration noise.
Engine mounting
insulator
Engine mounting
bracket Rear roll stopper
Transaxle mounting
insulator
Front roll stopper

Transaxle mounting
bracket
AC507295AE
33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS

33-2 FRONT SUSPENSION
GENERAL INFORMATION
GENERAL INFORMATION
M2330000100965
The MacPherson strut type suspension is adopted. The fully flattened crossmember improves the
.
left/right direction rigidity of installation points of
MAIN FEATURES the lower arms for high steering ability.
The wheel tread is increased to improve corner- Tuning of the lower arm bushes improves the
ing ability. steering ability and riding comfort.
The roll center height is modified to improve the The stabilizer bar is joined to the strut for high
steering ability. efficiency to secure the optimum rolling rigidity,
Increased suspension stroke improves road hold- and improves the steering ability.
ing quality, and secures good adhesion even on Total tuning of struts, springs, and bump rubbers
bumpy-rough roads to reduce shocks received improves the steering ability and riding comfort.
when the vehicle negotiates bumps.
Coil spring
Stabilizer link
Stabilizer bar
Front suspension strut
Lower arm
AC607283 AB
SPECIFICATIONS
.
SUSPENSION SYSTEM
Item Specification
Suspension type MacPherson strut with coil spring
.
WHEEL ALIGNMENT
Item Specification
Camber 0 05'
FRONT SUSPENSION
GENERAL INFORMATION
33-3
Item Specification
Caster 2 40'
Kingpin inclination 13 30'
Toe-in mm (in) 1 (0.04)
.
COIL SPRING
Item Specification
DE, ES GTS
Wire diameter mm (in) 14 (0.6)
Average outside diameter mm (in) 159 (6.3)
Free length mm (in) 5MT 331 (13.0) 316 (12.4)
CVT 338 (13.3) 322 (12.7)
NOTES
34-1
GROUP 34
REAR SUSPENSION
CONTENTS

34-2 REAR SUSPENSION
GENERAL INFORMATION
GENERAL INFORMATION
M2340000100977
The trailing arm type multi-link suspension is The trailing arm bushings are installed in the
adopted. upper position to improve the movement of the
.
suspension when the vehicle negotiates bumps
MAIN FEATURES and increase riding comfort.
The wheel tread is increased to improve corner- Twin tube type shock absorber is adopted to
ing ability. secure optimum rolling rigidity and improve the
The roll center height is modified to improve the steering ability.
steering ability. A high efficiency ball joint type stabilizer link is
A double crossmember is adopted and the upper adopted to improve steering ability.
arm, lower arm, toe control arm are joined to the The toe control arm is installed in the lower posi-
crossmember to improve suspension alignment tion to increase toe and camber rigidity and
accuracy and maintenance performance. improve steering ability.
Improvement of arms installation accuracy elimi-
nates the camber adjustment to improve mainte-
nance performance.
Shock absorber
Upper arm
Coil spring
Stabilizer bar
<GTS, ES>
Toe control arm

Rear crossmember Stay
Trailing arm
AC606248 AB
SPECIFICATIONS
.
SUSPENSION SYSTEM
Item Specification
Suspension type Trailing arm type multi-link
.
REAR SUSPENSION
GENERAL INFORMATION
34-3
WHEEL ALIGNMENT
Item Specification
Camber 0 55'
Toe-in mm (in) 3 (0.12)
.
COIL SPRING
Item Specification
DE, ES GTS
Wire diameter mm (in) 11 (0.4) 11 (0.4)
Mean diameter of coil mm (in) 91 (3.6) 91 (3.6)
Free length mm (in) 351 (13.8) 334 (13.1)
NOTES
34-1
GROUP 34
REAR SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . . 34-2 CONTROL LINK, UPPER ARM AND LOWER

ARM INSPECTION . . . . . . . . . . . . . . . . . . . 34-9
SPECIFICATIONS . . . . . . . . . . . . . . . 34-2 LOWER ARM BUSHING REPLACEMENT . 34-10
FASTENER TIGHTENING
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 34-2 TRAILING ARM . . . . . . . . . . . . . . . . . 34-12
GENERAL SPECIFICATIONS . . . . . . . . . . 34-3 REMOVAL AND INSTALLATION . . . . . . . . 34-12
SERVICE SPECIFICATIONS . . . . . . . . . . . 34-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-13
TRAILING ARM BUSHING
REAR SUSPENSION DIAGNOSIS . . 34-4 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-13
INTRODUCTION TO REAR SUSPENSION
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 34-4 SHOCK ABSORBER ASSEMBLY . . . 34-16
REAR SUSPENSION DIAGNOSTIC REMOVAL AND INSTALLATION . . . . . . . . 34-16
TROUBLESHOOTING STRATEGY . . . . . . 34-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-17
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 34-4 DISASSEMBLY AND ASSEMBLY . . . . . . . 34-17
STABILIZER BAR <GTS, ES> . . . . . . 34-20
SPECIAL TOOL . . . . . . . . . . . . . . . . . 34-6 REMOVAL AND INSTALLATION . . . . . . . . 34-20
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-21
ON-VEHICLE SERVICE. . . . . . . . . . . 34-7 STABILIZER LINK BALL JOINT ROTATION
REAR WHEEL ALIGNMENT CHECK AND TORQUE CHECK . . . . . . . . . . . . . . . . . . . . 34-21
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 34-7 STABILIZER LINK BALL JOINT DUST COVER
STABILIZER LINK BALL JOINT DUST CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-21
COVER INSPECTION . . . . . . . . . . . . . . . . 34-7
REAR SUSPENSION
CONTROL LINK, UPPER ARM AND CROSSMEMBER . . . . . . . . . . . . . . . . 34-22
LOWER ARM . . . . . . . . . . . . . . . . . . . 34-8 REMOVAL AND INSTALLATION . . . . . . . . 34-22
REMOVAL AND INSTALLATION . . . . . . . . 34-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-23
GENERAL INFORMATION
GENERAL INFORMATION
M1341000101066
The trailing arm type multi-link suspension has been
adopted.
Shock absorber
Upper arm
Coil spring
Stabilizer bar
<GTS, ES>
Toe control arm

Rear crossmember Stay
Trailing arm
AC606248 AB
SPECIFICATIONS
M1341012700415
Item Specification
Control link
Control link to crossmember nut 71 10 N m (52 2 ft-lb)
Control link to rear height sensor nut 9.5 2.5 N m (84 22 in-lb)
Control link to trailing arm nut 71 10 N m (52 2 ft-lb)
Lower arm
Lower arm to crossmember nut 71 10 N m (52 2 ft-lb)
Lower arm to trailing arm nut 71 10 N m (52 2 ft-lb)
Lower arm to shock absorber nut 71 10 N m (52 2 ft-lb)
Lower arm to stabilizer link nut 39 6 N m (29 4 ft-lb)
Rear suspension crossmember
Crossmember bracket mounting bolt 71 10 N m (52 2 ft-lb)
Crossmember stay mounting bolt 11 3 N m (97 26 in-lb)
Rear wheel speed sensor clamp bolt 11 2 N m (98 17 ft-lb)
TSB Revision
REAR SUSPENSION
SPECIFICATIONS
34-3
Item Specification
Shock absorber assembly
Shock absorber assembly to body nut 45 7 N m (33 5 ft-lb)
Shock absorber assembly to lower arm nut 71 10 N m (52 2 ft-lb)
Shock absorber self-locking nut 25 5 N m (19 3 ft-lb)
Stabilizer bar
Stabilizer link nut 39 6 N m (29 4 ft-lb)
Stabilizer bracket bolt 31 4 N m (23 3 ft-lb)
Trailing arm
Trailing arm to rear hub assembly bolt 95 14 N m (70 10 ft-lb)
Trailing arm to brake hose bracket nut 11 2 N m (98 17 in-lb)
Trailing arm to body bolt 110 11 N m (81 8 ft-lb)
Rear wheel speed sensor to trailing arm bolt 11 2 N m (98 17 in-lb)
Upper arm
Upper arm to crossmember bolt 71 10 N m (52 2 ft-lb)
Upper arm to trailing arm 71 10 N m (52 2 ft-lb)
M1341000200424
COIL SPRING
Item Specification
DE, ES GTS
Wire diameter mm (in) 11 (0.4) 11 (0.4)
Average out side diameter mm (in) 91 (3.6) 91 (3.6)
Free length mm (in) 351 (13.8) 334 (13.1)
M1341000300904
Item Standard value

Toe in mm (in) 3 2 (0.12 0.08)
Camber 0 55' 0 30' (left/right difference 30'max)
Control link pillow ball bushing and upper arm pillow ball 2.0 3.5 (17.7 31.0)
bushing rotation torque N m (in-lb)
Stabilizer link ball joint rotation torque N m (in-lb) 0.5 2.9 (4.4 25.7)
TSB Revision
REAR SUSPENSION DIAGNOSIS

INTRODUCTION TO REAR SUSPENSION DIAGNOSIS
M1341013100160
If the rear suspension is faulty, the vehicle will not run
straightforward or noise will occur. Incorrect wheel
alignment, malfunction of shock absorber, stabilizer
bar, coil spring, control arms or worn or out-of-bal-
ance will cause these problems.
REAR SUSPENSION DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1341013200167
rear suspension fault. Chart.
SYMPTOM CHART
M1341013500306

Squeaks or other abnormal noise 1 P.34-4
Poor ride 2 P.34-5
Body tilting 3 P.34-5
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Squeaks or other Abnormal Noise
DIAGNOSIS STEP 3. Check the upper arms and/or lower arms

and/or control links for deformity or damage.
STEP 1. Check for loose rear suspension Q: Are the upper arms and/or lower arms and/or
installation bolts and nuts. control links in good condition?
Q: Are the rear suspension installation bolts and nuts YES : Go to Step 4.
loose? NO : Replace the faulty part, then go to Step 5.
YES : Retighten them, then go to Step 5.
NO : Go to Step 2.
STEP 4. Check the trailing arms for deformity or
damage.
STEP 2. Check the malfunction of shock Q: Are the trailing arms in good condition?
absorbers (worn bushings). YES : Go to Step 5.
Q: Are the shock absorbers (bushings) in good NO : Replace the faulty part, then go to Step 5.
condition?
YES : Go to Step 3.
NO : Replace the faulty part, then go to Step 5.
Q: Is the malfunction eliminated?
TSB Revision
REAR SUSPENSION
34-5
INSPECTION PROCEDURE 2: Poor Ride
DIAGNOSIS STEP 3. Check the stabilizer bar and/or stabilizer

links for deformity or damage.
STEP 1. Check the excessive tire inflation Q: Are the stabilizer bar and/or stabilizer link
pressure. deformed or damaged?
Refer to GROUP 31, On-vehicle Service Tire Infla- YES : Replace the faulty part, then go to Step 4.
tion Pressure Check P.31-7. NO : Go to Step 4.
Q: Is the tire inflation pressure in good condition?
YES : Go to Step 2. STEP 4. Retest the system.
NO : Adjust the pressure, then go to Step 4.
STEP 2. Check for malfunction of shock NO : Return to Step 1.
absorbers (weak or broken springs).
Q: Are the shock absorbers in good condition?
YES : Go to Step 3.
INSPECTION PROCEDURE 3: Body Tilting
DIAGNOSIS STEP 3. Check the upper arms and/or lower arms

and/or control links for deformity or damage.
STEP 1. Check for weak or deteriorated Q: Are the upper arms and/or lower arms and/or
bushings. control links deformed or damaged?
Q: Are the bushings in good condition? YES : Replace the faulty part, then go to Step 5.
YES : Go to Step 2. NO : Go to Step 4.
STEP 4. Check the trailing arms for deformity or
STEP 2. Check for weak or broken springs. damage.
Q: Are the springs in good condition? Q: Are the trailing arms deformed or damaged?
YES : Go to Step 3. YES : Replace the faulty part, then go to Step 5.
NO : Replace the faulty part, then go to Step 5. NO : Go to Step 5.

TSB Revision
SPECIAL TOOL
SPECIAL TOOL
M1341000600767

and name
MB992123 Lower arm bushing removal and press-fit
Arm bushing
remover and
installer
MB991447
MB991448 MB991448-01
Bushing remover
and installer
base
MB991449
Bushing remover
and installer
supporter
MB992121 Trailing arm bushing removal and

Arm bushing press-fit
remover and
installer
B992121
MB992125
Arm bushing
base
MB992125
MB990326 General service Stabilizer link ball joint rotation torque

Preload socket tool measurement
MB990326
A: MB991237 MIT221369 or Coil spring removal and installation

Spring general service
compressor tool
A
body
B: MB991239
B MB991237
Arm set
TSB Revision
REAR SUSPENSION
ON-VEHICLE SERVICE
34-7
ON-VEHICLE SERVICE
REAR WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1341011000899
1. Before the wheel alignment measurement, adjust the rear
suspension, wheel, and tires in good condition.
2. Park the vehicle on a level surface to measure the wheel
alignment.
.
TOE-IN
Standard value: 3 2 mm (0.12 0.08 inch)
If it is out of the standard range, adjust as follows:
Turn the toe adjusting bolt (the mounting bolt inside the body
Toe adjusting bolt on the control link) to adjust.
Left wheels: Clockwise (+) Toe in
Right wheels: Clockwise (-) Toe in
Toe-in varies approximately 2.6 mm (0.10inch) (equivalent to
0 16' of the toe angle for one side) for each scale mark.
AC506806AB
CAMBER
Standard value: 0 55' 0 30' (left/right difference 0 30'
max)
NOTE: .
For vehicles with aluminum wheels, attach the cam-
ber/caster/kingpin gauge by using a compensator.
The camber is pre-adjusted at factory and is not adjustable.
Compensator
AC305848 AC
STABILIZER LINK BALL JOINT DUST COVER

INSPECTION
M1341019100027
1. Using your fingers, press the dust cover to check for a crack
or damage.
2. If the dust cover has a crack or damage, replace the
stabilizer link.
NOTE: If the dust cover has a crack or damage, the ball joint
could be damaged.
TSB Revision
CONTROL LINK, UPPER ARM AND LOWER ARM

M1341004800406
CAUTION
The parts indicated by *1 should be temporarily tightened, and then fully tightened with the vehicle
standing on the ground at the curb weight condition.
Post-installation operation
Wheel alignment check and adjustment (Refer to P.34-7.)
71 10 Nm 1 <DE, ES>
3
52 2 ft-lb 1
2 71 10 Nm 1
52 2 ft-lb 1
<GTS> 3 7 <GTS, ES>
71 10 Nm 1
52 2 ft-lb 1 71 10 Nm 1 4
2
2 52 2 ft-lb 1 6
71 10 Nm 1 2 2
52 2 ft-lb 1
2
2 39 6 Nm
2
29 4 ft-lb 2
71 10 Nm 1, 2
<GTS>
2 52 2 ft-lb 1, 2
1 71 10 Nm 1
<DE, ES> 52 2 ft-lb 1
AC606721AB
Control link and upper arm Lower arm removal steps

removal 4. Stabilizer link connection <GTS,
<<A>> 1. Control link <DE, ES> ES>
<<A>> >>B<< 2. Control link <GTS> 5. Lower arm and trailing arm
>>A<< 3. Upper arm connection
Fuel tank vapor hose connection 6. Shock absorber connection
(Refer to GROUP 13B, Fuel tank Rear suspension crossmember
P.13B-9.) stay (Refer to P.34-22.)
7. Lower arm
TSB Revision
REAR SUSPENSION
34-9
.
<<A>> CONTROL LINK REMOVAL

Make a mating mark on the toe adjusting bolt, and remove the
control link.
Mating mark
AC506821AB

.
>>A<< UPPER ARM INSTALLATION

Install the upper arm so that the hole faces the body side.
AC506825
>>B<< CONTROL LINK <GTS> INSTALLATION

Install the control link so that the identification mark faces the
Identification mark
outside of the body.
AC506844AB

INSPECTION
M1341004900298
Check the bushings for wear and deterioration.
Check the control link, upper arm and lower arm for bending
or breakage.
Check all bolts for condition and straightness.
.
TSB Revision
CONTROL LINK AND UPPER ARM PILLOW BALL

BUSHING ROTATION STARTING TORQUE
CHECK<GTS>
MB990326: Preload socket
1. Insert the bolts to the control link and the upper arm pillow
ball bushing (vehicle body outside bushing) respectively,
and install the nuts with the washers from the opposite side.
Rotate the inner cylinder (including washer) for several
turns, and measure the rotation starting torque of the control
link and the upper arm pillow ball bushing respectively using
the special tool MB990326.
MB990326 Standard value: 2.0 3.5 N m (17.7 31.0 in-lb)
2. When the measured value exceeds the standard range,
AC611003AB replace the control link or the upper arm pillow ball bushing.
3. When the measured value is less than the standard range,
check that the control link and the upper arm ball joint has
no looseness or gritty feeling. If there is no looseness or
gritty feeling, it is judged as usable.
LOWER ARM BUSHING REPLACEMENT

M1341011800312

MB992123: Arm Bushing Remover and Installer
MB991448: Bushing Remover and Installer Base
MB991449: Bushing Remover and Installer Supporter
TSB Revision
REAR SUSPENSION
34-11
CAUTION
As the bushing has different outer diameters at both ends,
be careful not to confuse the removal direction with the
press-fit direction.
Use the special tools MB992123, MB991448 and MB991449 to
Driving Out
remove and press-fit the lower arm bushing.
MB992123
Lower arm
MB991449
MB991448
AC506997AB
Press-Fitting
MB992123
Lower arm
MB991449
MB991448
AC506996AB
TSB Revision
TRAILING ARM
TRAILING ARM
M1341002200851
CAUTION
The part indicated by *3is the bolt/nut with friction coefficient stabilizer. In removal, replace it with
new one.
Brake Fluid Draining (Refer to GROUP 35A, On-vehicle Using your fingers, press the Ball Joint Dust Cover to
ServiceBasic Brake System Bleeding P.35A-25.) check for a crack or damage.
Brake Fluid Refilling and Bleeding (Refer to GROUP 35A,
On-vehicle ServiceBasic Brake System Bleed-
ingP.35A-25).
Wheel Alignment Check and Adjustment (Refer to
P.34-7.)
Parking Brake Pedal Stroke Check and Adjustment (Refer
to GROUP 36, On-vehicle Service Parking Brake Pedal
Stroke Check and Adjustment P.36-10.)
<Vehicles with drum brake>

8
2 71 10 Nm 1
11 2 Nm 52 2 ft-lb 1
98 17 in-lb 8.5 1.5 Nm
2
76 13 in-lb
3
5
N 12 16 3 Nm
95 14 Nm
12 2 ft-lb
70 10 ft-lb
1 7 6
1
3 2
110 11 Nm
81 8 ft-lb 1
9
2
2
71 10 Nm 1
2
52 2 ft-lb 1
71 10 Nm 1 10
52 2 ft-lb 1
39 6 Nm
29 4 ft-lb 4
11
AC606787AB

1. Rear wheel speed sensor 6. Rear brake assembly
<Vehicles with ABS> 7. Spacer
2. Rear brake drum 8. Upper arm connection
3. Rear hub assembly 9. Control link connection
4. Parking brake cable 10. Stabilizer link connection
5. Rear brake tube 11. Lower arm connection
12. Trailing arm assembly
TSB Revision
REAR SUSPENSION
TRAILING ARM
34-13
<Vehicles with disc brake>

10
16 3 Nm
2 12 2 ft-lb
11 2 Nm 71 10 Nm 1
98 17 in-lb 3 2
52 2 ft-lb 1
2
8.5 1.5 Nm
76 13 in-lb
4 14 55 5 Nm
3 41 3 ft-lb
N
95 14 Nm 5
70 10 ft-lb
1
7 6
11
2
2
2
110 11 Nm 1
71 10 Nm 1 71 10 Nm 1 9
81 8 ft-lb 1 52 2 ft-lb 1 52 2 ft-lb 1
12
8
39 6 Nm
29 4 ft-lb
13
AC606788 AB

1. Rear wheel speed sensor 8. Parking brake cable
<Vehicles with ABS> 9. Rear brake assembly
2. Clamp 10. Upper arm connection
3. Brake hose connection 11. Control link connection
4. Brake hose bracket 12. Stabilizer link connection
<<A>> 5. Caliper assembly 13. Lower arm connection
6. Brake disc 14. Trailing arm assembly
7. Rear hub assembly

.
<<A>> CALIPER ASSEMBLY REMOVAL

Retain the removed caliper assembly with a wire and the like to
prevent from falling.
INSPECTION
M1341002300290
Check the trailing arm for bending or damage.
TRAILING ARM BUSHING REPLACEMENT

M1341011300384

MB992121: Arm Bushing Remover and Installer
TSB Revision
TRAILING ARM
MB992125: Arm Bushing Base

1. Use the special tools MB992121 and MB992125 to remove
Driving Out
the trailing arm bushing:
MB992121
Trailing arm
MB992125
AC506661AB
2. Determine the installation direction and the installation

position of the trailing arm bushing.
(1) Install so that the protruding side of the trailing arm
bushing inner pipe faces inside the body.
(2) Position the trailing arm bushing inner space as shown in
the figure.
Parallel
AC506450AB
TSB Revision
REAR SUSPENSION
TRAILING ARM
34-15
3. Use the special tools MB992121 and MB992125 to press-fit
Press-fitting
the trailing arm bushing up to the position shown in the
figure:
MB992121
Trailing arm
MB992125
AC506662 AB
TSB Revision
SHOCK ABSORBER ASSEMBLY

M1341002500603
CAUTION
Trunk Side Trim Removal and Installation (Refer to
GROUP 52A Trim P.52A-10.)
45 7 Nm
33 5 ft-lb
<GTS, ES>
1
5
71 10 Nm 1 39 6 Nm
52 2 ft-lb 1 29 4 ft-lb
71 10 Nm 1
2 52 2 ft-lb 1
4
2
2
AC606837AB

1. Stabilizer link connection <GTS, 3. Shock absorber mounting nut
ES> 4. Shock absorber and lower arm
2. Lower arm and trailing arm connection
connection >>A<< 5. Shock absorber assembly
TSB Revision
REAR SUSPENSION
34-17
.
>>A<< SHOCK ABSORBER ASSEMBLY INSTAL-

LATION
Install the shock absorber assembly so that the coil spring end
faces the rear of the vehicle.
AC508628
INSPECTION
M1341002600246
Check the rubber parts for cracks and wear.
Check the shock absorber for malfunctions, oil leakage, or
abnormal noise.
M1341002700180
25 5 Nm
19 3 ft-lb 1
3 2
7
4
8 5
10
9
6
11
AC506862AB

<<A>> >>B<< 1. Self-locking nut 8. Plate
2. Washer 9. Bump rubber
3. Bushing B >>A<< 10. Coil spring
4. Collar 11. Shock absorber
5. Spring upper bracket assembly Required Special Tools:
6. Spring upper pad MB991237: Spring Compressor Body
7. Bushing A
MB991239: Arm Set
TSB Revision

.
<<A>> SELF-LOCKING NUT REMOVAL

CAUTION
To hold the coil spring securely, install the special tool
MB991239 evenly, and so that the space between both
arms of the special tool will be maximum within the
installation range.
Do not use an impact wrench to tighten the bolt of the
special tool MB991237. It will break the special tool.
1. Use the special tools MB991237 and MB991239 to
compress the coil spring.
MB991237
MB991239
AC001070 AB
CAUTION
The locking nut for the piston rod inside the shock
absorber may be loose. Do not use an impact wrench to
loosen the self-locking nut.
2. While holding the piston rod, remove the self-locking nut.
Piston rod
AC102268AB
TSB Revision
REAR SUSPENSION
34-19
.
>>A<< COIL SPRING INSTALLATION

CAUTION
Do not use an impact wrench to loosen the bolt of the spe-
cial tool MB991237. It will break the special tool.
1. Use the special tools MB991237 and MB991239 to
compress the coil spring, and install it to the lower spring
MB991237 pad.
MB991239
AC001070 AB
2. Align the end of the coil spring with the shock absorber as
Within 10 mm
(0.39 in)
AC508627AB
TSB Revision
STABILIZER BAR <GTS, ES>
>>B<< SELF-LOCKING NUT INSTALLATION

CAUTION
The locking nut for the piston rod inside the shock
absorber may be loose. Do not use an impact wrench to
tighten the self-locking nut.
Counter the piston rod of the shock absorber as shown in the
figure, and tighten the self-locking nut to the specified torque.
Piston rod
AC102268AB

M1341003000496
39 6 Nm
31 4 Nm 29 4 ft-lb
23 3 ft-lb
4 2
3 1
39 6 Nm
29 4 ft-lb
AC611124AB

1. Stabilizer link Rear suspension crossmember
>>A<< 2. Stabilizer bracket (Refer to P.34-22.)
>>A<< 3. Bushing >>A<< 4. Stabilizer bar
TSB Revision
REAR SUSPENSION
34-21
.
>>A<< STABILIZER BAR/BUSHING/STABILIZER

BRACKET INSTALLATION
Outside of the vehicle Position the identification mark of the stabilizer bar at the left
side of the vehicle as shown in the figure, and tighten the stabi-
Approx.10 mm (0.39 in)
lizer bracket mounting bolt.
Stabilzer bracket
Bushing
AC507099AB
INSPECTION
M1341001400540
Check the stabilizer bar for deterioration or damage.
STABILIZER LINK BALL JOINT ROTATION

TORQUE CHECK
M1341019300032

MB990326: Preload socket
1. Move the stabilizer link ball joint stud back and forth for
MB990326 several times, install the stud with nut, and measure the
stabilizer link ball joint rotation torque using the special tool
MB990326.
2. When the measured value exceeds the standard range,
replace the stabilizer link.
3. When the measured value is lower than the standard value,
check the stabilizer link ball joint that there is no looseness
AC404845 AC
or gritty feeling. If there is no looseness or gritty feeling, it is
judged as usable.
STABILIZER LINK BALL JOINT DUST COVER

CHECK
M1341013000107
1. Using your fingers, press the dust cover to check for a crack
or damage.
2. If the dust cover has a crack or damage, replace the
stabilizer link.
NOTE: If the dust cover has a crack or damage, the ball joint
could be damaged.
TSB Revision
REAR SUSPENSION CROSSMEMBER

M1341006800468
CAUTION
The part indicated by *is the bolt with friction coefficient stabilizer. In removal, ensure there is no
damage, clean dust and soiling from the bearing and thread surfaces, and tighten them to the
specified torque.
Control link arm removal (Refer to P.34-8.) Center exhaust pipe and main muffler installation (Refer
Upper arm removal (Refer to P.34-8.) to GROUP 15 Exhaust Pipe and Muffler P.15-11.)
Lower arm removal (Refer toP.34-8.) Rear suspension stabilizer bar installation (Refer
Rear suspension stabilizer bar removal (Refer toP.34-20.) toP.34-20.)
Center exhaust pipe and main muffler removal (Refer to Lower arm installation (Refer toP.34-8.)
GROUP 15 Exhaust Pipe and Muffler P.15-11.) Upper arm installation (Refer to P.34-8.)
Control link installation (Refer to P.34-8.)
Rear wheel alignment check and adjustment (Refer
toP.34-7.)
71 10 Nm
3 52 2 ft-lb
71 10 Nm 71 10 Nm
52 2 ft-lb 52 2 ft-lb
1
2 2
11 2 Nm
98 17 in-lb
11 3 Nm
97 26 in-lb
71 10 Nm
11 3 Nm 52 2 ft-lb
97 26 in-lb
AC606849 AB

1. Rear wheel speed sensor clamp 2. Rear suspension crossmember
<Vehicles with ABS> stay
<<A>> 3. Rear suspension crossmember
TSB Revision
REAR SUSPENSION
34-23
.
<<A>> REAR SUSPENSION CROSSMEMBER

REMOVAL
To avoid the brake hose load, fix the trailing arm assembly with
a rope as shown in the figure.
Rope
AC507199AB
INSPECTION
M1341006900120
Check the crossmember for cracks or deformation.
TSB Revision
NOTES
35-1
GROUP 35
SERVICE BRAKE
CONTENTS
BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A
FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) . . . . . . . 35B

NOTES
35A-1
GROUP 35A
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . 35A-2 BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . 35A-5

BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . 35A-7
CONSTRUCTION DESCRIPTION . . . 35A-5 FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . 35A-8
MASTER CYLINDER . . . . . . . . . . . . . . . . . 35A-5 REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . 35A-9
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . 35A-10
35A-2 BASIC BRAKE SYSTEM
GENERAL
GENERAL
M2350000100956
Brake systems with higher reliability and durability
have achieved distinguished braking performance.
FEATURES A rear wheel early lock-prevention proportioning
. valve has been used. <Vehicles without ABS>
IMPROVEMENT OF BRAKING PERFOR- Electronic control braking force distribution sys-
MANCE tem (EBD) has been adopted to assure the maxi-
A 10-inch single brake booster with the variable mum braking force independently of the
boost ratio mechanism has been used to assure passenger's position in the vehicle. <Vehicles
maximum braking force with less pedal pressure with ABS>
in case of emergency. <Vehicles with ABS> X-type piping of brake lines have been adopted
In addition to the 10-inch single brake booster, a for the front and rear wheels.
small and long stroke-type master cylinder has Audible wear indicators are used on the front and
been adopted to achieve downsizing and secure rear brake pads to warn the driver of wear limit.
assist force. .
15-inch or 16-inch ventilated disc brakes have SERVICE QUALITY IMPROVEMENTS

been adopted for the front. Diagnostic function has been adopted to ABS for
8-inch leading trailing-type drum brake, 14-inch easier inspection. <Vehicles with ABS>
or 16-inch solid disc brake has been adopted for Brake fluid reservoir, master cylinder, and brake
the rear. booster have been integrated for downsizing and
.
better serviceability.
IMPROVEMENT IN SAFETY
The 4-wheel anti-lock brake system (4ABS) has
been installed to prevent slippage resulting from
the wheel lock and assure stable vehicle posture
and driveability.<Vehicles with ABS>
BASIC BRAKE SYSTEM
GENERAL
35A-3
<Vehicles without ABS>
Brake booster
Reserve tank
Master cylinder
Rear drum brake
Proportioning valve
Front disc brake
Rear disc brake

AC609311AB
<Vehicles with ABS>
Brake booster
Reserve tank
Master cylinder
Hydraulic unit
Rear drum brake
Front disc brake
Rear disc brake

AC609312AB
GENERAL
SPECIFICATIONS
Item Specifications
Master cylinder Type Tandem type
I.D. mm (in) 20.6 (0.81)
Brake booster Type Vacuum type, single
Effective dia. of power cylinder mm (in) 254 (10.0)
Boost ratio Vehicles without ABS 6.5 (Pedal pressure: 188N)
Vehicles with ABS 6.5 (Pedal pressure: 92N)
8.5 (Pedal pressure: 156N)
Rear wheel hydraulic control type Vehicles without ABS Proportioning valves
Vehicles with ABS Electronic control braking force
distribution system (EBD)
Front disc brake Type Vehicles with 16-inch wheel Floating caliper 1 piston
ventilated disc (V5-S57)
Vehicles with 18-inch wheel Floating caliper 1 piston
ventilated disc (V6-S57)
Disc effective dia Vehicles with 16-inch wheel 222 26 (8.7 1.02)
thickness mm (in) Vehicles with 18-inch wheel 241.6 26 (9.5 1.02)
Cylinder I.D. mm (in) 57.1 (2.25)
Pad thickness mm (in) 10.0 (0.39)
Clearance adjustment Automatic adjustment
Rear drum brake Type Leading trailing drum
Drum I.D. mm (in) 203 (8.0)
Wheel cylinder I.D. mm (in) 19.0 (0.75)
Lining thickness mm (in) 4 (0.157)
Clearance adjustment Automatic
Rear disc brake Type Vehicles with 16-inch wheel Floating caliper 1 piston solid disc
(S4-S35)
Vehicles with 18-inch wheel Floating caliper 1 piston solid disc
(S6-S35)
Disc effective dia Vehicles with 16-inch wheel 226 10 (8.9 0.39)
thickness mm (in) Vehicles with 18-inch wheel 258 10 (10.2 0.39)
Cylinder I.D. mm (in) 34.9 (1.37)
Pad thickness mm (in) 10.0 (0.39)
Clearance adjustment Automatic adjustment
BASIC BRAKE SYSTEM
CONSTRUCTION DESCRIPTION
35A-5
MASTER CYLINDER
M2350001000576
Reserve tank
AC609255
Brake booster Master cylinder

Secondary piston assembly Primary piston assembly
AC505913
AC609469AB
The master cylinder is a tandem type and is inte-

grated with the brake fluid reservoir with the level
switch.
BRAKE BOOSTER
M2350002000698
Diaphragm
Booster return spring

Reaction disc
Operating rod
Push rod
Barometric pressure chamber

AC505931AB
A 10-inch single brake booster has been installed.

The variable boost ratio mechanism which increases
the brake booster gain has been adopted.
VARIABLE BOOST RATIO MECHANISM

The variable boost ratio mechanism changes the input/output
characteristics of the brake booster in two phases by changing
the reaction force applied to the valve plunger during the assist
phase.
.
AT INITIAL ASSISTING
1. When the brake pedal is not depressed (no input load
Reaction
applied), the reaction washer is not deformed.
washer Disc
2. When the brake pedal is depressed, the reaction washer is
deformed to reach the ring piston and disc, then the first
input characteristics begin (Ratio 1).
Ring piston AC507766 AB
AT AN INCREMENT OF ASSIST RATIO

1. The reaction washer is further deformed and pushes down
Spring the ring piston and lock washer, deflecting the spring. All the
Spring force pushing the ring piston and disc is transferred to the
seat brake pedal via spring seat and disc as the reaction force.
Valve
piston
Lock washer AC507768AB
2. The reaction washer is then further deformed, and when the

Reaction
washer
lock washer makes contact with the control housing, the
input characteristics change. All the force applied from the
reaction washer to the ring piston is now transferred to the
control housing via the lock washer, so no force is applied to
Control the brake pedal. The second input characteristics (Ratio 2)
housing begin.
Ring piston Lock washer AC507769AB

BASIC BRAKE SYSTEM
35A-7
BRAKE PEDAL
M2350007000422
<Before collision> <After collision>
Brake pedal and support Brake pedal and support Pedal retreat
member Slope member path in collision
Slope
Collision load
Pedal arm
Pedal arm
Push
rod Push
Brake booster Brake booster rod
Pedal support frame
position before collision
After the breakage
mechanism operates
Pedal support frame position after

collision
AC611958AB
The brake pedal retreat suppression mechanism that When the brake booster is crushed rearward by the
restraints the retraction of the brake pedal surface engine retreat during a frontal collision, the installa-
during a frontal collision has been adopted in order to tion surface of the brake pedal is retreated. In this
reduce the shock to the driver's feet. case, the end of the pedal support is forcibly slid
down and back by the interference with the slope
mounted on the front deck crossmember assembly.
At the same time, the linkage comprised of the pedal
support, pedal arm, and push rod moves the brake
pedal pad surface forward.
FRONT BRAKE
M2350003000602
<15-inch disc brake (V5-S57)>
Normal At wear limit

Pad
<16-inch disc brake (V6-S57)>

Wear indicator Brake disc
AC201769
AC609316 AB
Brakes with the following specifications have been An audible wear indicator that informs the driver
adopted for the front brakes. of application limit has been adopted onto the
The 1-piston ventilate disc brake (V5-S57 <Vehi- front brake LH pads.
cles with 16-inch wheel> or V6-S57 <Vehicles The outer disc type brake disc which can be tight-
with 18-inch wheel>) has been adopted. ened together with the wheel has been intro-
duced for better serviceability.
.
DISC BRAKE DESIGNATION
No. Item Contents

1 Brake disc type V: Ventilated
S: Solid
V 6 - S 57 2 Brake size 4: 14"
(Minimum applicable 5: 15"
1 2 3 4 disc wheel) 6: 16"
3 Number of pistons S: 1 (Floating type)
AC505124
4 Piston size 35: 34.9 mm
(Rounded integral 57: 57.1 mm
value)
BASIC BRAKE SYSTEM
35A-9
REAR BRAKE
M2350004000616
<Vehicles with rear drum brake>
AC609282
8-inch leading trailing-type drum brakes have been

adopted for the rear brakes in order to provide stable
braking force at all times both when moving forward
and reverse.
<Vehicles with rear disc brake>

<14-inch disc brake (S4-S35)>
Normal At wear limit

Pad
<16-inch disc brake (S6-S35)>
Wear indicator Brake disc

AC201769
AC609315AB
Brakes with the following specifications have been The outer disc type brake disc which can be tight-
adopted for the rear. ened together with the wheel has been intro-
The 1-piston solid disc brake (S4-S35 <Vehicles duced for better serviceability.
with 16-inch wheel> or S6-S35 <Vehicles with NOTE: *For the brake disc name, refer to FRONT
18-inch wheel>) has been adopted.* BRAKE P.35A-8.
An audible wear indicator that informs the driver
of application limit has been adopted onto the
brake pads.
BRAKE LINE
M2350005000266
PROPORTIONING VALVE <Vehicles without ABS>
From master cylinder rear brake system
Valve Sleeve
Plate U-packing
Master cylinder
Spring
O-ring
Seal
Guide
To rear brake
Proportioning valve
AC609305AB
A proportioning valve is used to prevent early locking

of the rear wheels, in order to provide improved sta-
bility during braking.
35B-1
GROUP 35B
FOUR-WHEEL
ANTI-LOCK BRAKE
SYSTEM (4ABS)
CONTENTS
GENERAL INFORMATION . . . . . . . . 35B-2 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-6

ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . 35B-6
CONSTRUCTION DESCRIPTION . . . 35B-6 ABS-ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-7
35B-2 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)
GENERAL INFORMATION
GENERAL INFORMATION
M2351000100830
The ABS that ensures directional stability and con- The magnetic encoder for detecting the wheel
trollability during hard braking. ABS is standard speed has been installed instead of the rotor as
equippment on the ES and GTS models but is the wheel speed sensor.
optional. For wiring harness saving and secure data com-
This ABS uses a 4-sensor system that controls all munication, CAN *2 bus has been adopted as a
four wheels independently of each other, and has the tool of communication with other ECUs.
following features:
NOTE: .
EBD *1 (Electronic Brake-force Distribution sys-
*1: EBD (Electronic Brake-force Distribution)
tem) control that can obtain ideal rear wheel
brake force has been employed. *2: For more information about CAN (Controller
Area Network), refer to GROUP 54C P.54C-2.
.
SPECIFICATIONS
Item Specifications
ABS control type 4 sensors
Wheel speed sensor Magnetic encoder Front 86 (N pole: 43, S pole: 43)
Rear 86 (N pole: 43, S pole: 43)
Type Semiconductor
.
5 6 <Vehicles with rear drum brake>
5
SERVICE
REQUIRED
1 2
CHECK
4, 8
3
7
1 2
1 <Vehicles with rear disc brake>
2 AC608518AB
.
FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)
GENERAL INFORMATION
35B-3
MAIN COMPONENTS AND FUNCTIONS
Parts name No. Functional description
Sensor Wheel speed sensor 1 Outputs the frequency signal in proportion to the
rotation speed of each wheel to ABS-ECU.
Magnetic encoder for 2 The wheel speed sensor is a pulse generator. When
wheel speed detection the magnetic encoder for wheel speed detection (a
plate on which north and south pole sides of the
magnets are arranged alternately) rotates, it outputs
frequency pulse signal in proportion to each wheel
speed.
Stop light switch 3 Outputs the signal indicating whether the brake pedal
is depressed or not through ETACS-ECU to ABS-ECU
via the CAN line.
Actuator Hydraulic unit 4 Drives the solenoid valve using the signal from
ABS-ECU, and controls the brake fluid pressure for
each wheel.
ABS warning light 5 Informs the driver of the system status by illuminating,
flashing, or turning off the warning light according to
the signal from ABS-ECU.
Brake warning light 6 Used as the warning light for the parking brake, brake
fluid level, and EBD control. Informs the driver of the
system status by illuminating or turning off the warning
light according to the signal from ABS-ECU, ETACS or
combination meter.
Data link connector 7 Establishes the communication with scan tool.
ABS control unit (ABS-ECU) 8 Controls the actuators (described above) based on the
signals coming from each sensors.
Controls the self-diagnostic functions and fail-safe
functions.
Controls diagnostic function (Compatible with scan
tool).
.
GENERAL INFORMATION
SYSTEM CONFIGURATION
Wheel speed sensor (FL) Control solenoid valve (FR) IN

Wheel speed sensor (RL) Control solenoid valve (FR) OUT
Control solenoid valve (FL) IN
Wheel speed sensor (RR) Control solenoid valve (FL) OUT
Control solenoid valve (RR) IN
Wheel speed sensor (FR)
Control solenoid valve (RR) OUT
Stop light switch Control solenoid valve (RL) IN
ABS-ECU
Control solenoid valve (RL) OUT
ECU power supply
Combination meter
(Brake warning lamp,
ABS warning lamp)
Data link connector
Front-right wheel (FR) Rear right wheel (RR)

ETACS-ECU
Wheel Wheel
speed speed
sensor Stop light switch sensor
(FR) (RR)
Hydraulic unit
Wheel Wheel
speed speed
sensor sensor
(FL) (RL)
Front left wheel (FL) Rear left wheel (RL)
AC608528AB
NOTE: Dashed lines indicate the CAN bus communi-

cation lines.
.
GENERAL INFORMATION
35B-5
ABS ELECTRICAL DIAGRAM
Fusible Fusible Fusible Ignition Fusible

link No.27 link No.26 link No.34 switch (IG1) link No.36
Relay box
(Engine
compartment)
ETACS-ECU
CAN drive CAN drive circuit CAN drive

circuit Analog circuit
Analog
interface interface
Interface circuit circuit Interface
circuit Interface circuit circuit
Stoplight
switch
Data link
connector
Engine
control
module
Stoplight
Hydraulic unit
Solenoid valve
Motor
Solenoid valve
power supply CAN transceiver
circuit
Motor power supply Power supply CPU
Motor power supply
LED drive Interface
circuit circuit
Solenoid valve
power supply Interface circuit
ABS-ECU Combination
meter
(FL) (FR) (RL) (RR)
Wheel speed sensor AC609237AB

SENSOR
M2351001000494
Wheel speed sensor

FRONT REAR
<Vehicles with rear drum brake> <Vehicles with rear disc brake>
Front wheel speed sensor
Rear wheel speed sensor
Encoder for wheel speed detection

Encoder for wheel speed detection
AC608548AB
The wheel speed sensor is a kind of a pulse genera- The front wheel speed sensor consists of the front
tor. It consists of the magnetic encoder for wheel wheel speed sensor mounted on the knuckle and the
speed detection (a plate on which north and south magnetic encoder for wheel speed detection which is
pole sides of the magnets are arranged alternately) press-fitted together with the oil seal to the front
which rotates at the same speed of the wheel and wheel bearing. The rear wheel speed sensor con-
the wheel speed sensor (semiconductor sensor). sists of the rear wheel speed sensor mounted on the
This sensor outputs frequency pulse signals in pro- trailing arm assembly and the magnetic encoder for
portion to the wheel speed. wheel speed detection which is press-fitted together
with the oil seal to the rear wheel bearing.
ACTUATORS
M2351002000356
ABS warning light, Brake warning light

The ABS system informs the driver of the ABS sys- Brake warning light
tem status by illuminating, extinguishing, or flashing Turns ON when an EBD system malfunction
the ABS warning light and brake warning light as fol- occurs.
lows. NOTE: .
ABS warning light Turns ON when the brake fluid level in the
Turns ON when a system malfunction occurs. reservoir tank becomes the specified value or
lower.
Turns ON when the parking brake lever is
pulled and the brake is activated.
ABS warning light and brake warning light illumination or flashing pattern
State ABS warning light Brake warning light
Normal Correct
Faulty ABS failure Illuminates
EBD failure Illuminates Illuminates
When scan tool is Actuator not operated
connected Actuator operated Flash (2Hz)
After actuator operated* Illuminates* Illuminates*
NOTE: *:ABS and brake warning lights remain illumi-
nated until the ignition is switched off.
35B-7
ABS-ECU
M2351003000520
By integrating ABS-ECU into the hydraulic unit, NOTE: *: The brake warning light is used as the
no wiring harness for sending drive signal of the EBD control warning light.
solenoid valve and pump motor is required, ABS-ECU detects vehicle speed from the signals
assuring higher reliability. of the wheel speed sensor and its recognizes the
Self-diagnostic and memory functions are inte- wheel rotation status, estimates the wheel slip
grated into ABS-ECU. If any malfunction is condition based on the preprogrammed algo-
detected by the self-diagnostic function, rithm, and then controls the solenoid valve in the
ABS-ECU activates a fail-safe function and illumi- hydraulic unit so that the wheels do not lock.
nates the ABS warning light and brake warning
light*.
ABS hydraulic pressure control
ABS control cycle
Increase
Hold
Decrease
Wheel speed
Estimated vehicle speed
A C
D
Actual vehicle speed
a
Brake pressure
e
d
b
c
AC506830AB
1. The ABS-ECU calculates the speed and deceler- (Point A), ECU determines that the wheels are
ation of each wheel based on the signals from the about to be locked. At this time, ECU reduces the
four wheel speed sensors, and estimates the brake fluid pressure by outputting the pressure
vehicle speed at that time. decrease signal to the solenoid valves (IN, OUT).
2. When the brake pedal is depressed, the brake (between a and b)
fluid pressure applied to the wheel cylinder 3. When the vehicle deceleration and wheel speed
increases, and the wheel speed decreases. begin recovery, and the vehicle speed reaches
When the difference between the wheel speed the point B, ECU outputs the pressure hold signal
and vehicle speed increases, and the vehicle to maintain the wheel cylinder fluid pressure.
deceleration goes below the specified value (between b and c)
4. When the wheel speed deceleration is further 5. Brake fluid pressure is controlled by repeating the
recovered and overpasses the point C, ECU increase and hold of the pressure. (between d
determines that the wheel lock possibility has and e)
been eliminated and increases the brake fluid 6. When the wheel deceleration goes below the
pressure by outputting the pressure increase sig- threshold again, ABS-ECU controls the brake
nal again. (between c and d) fluid pressure by repeating the cycle (Step 2 to 5).
Four-wheel control
ABS fluid pressure is controlled independently for
four wheels.
EBD fluid pressure control
EBD operating conceptual design
Braking force distribution

by EBD control
Ideal distribution curve when
seated by fixed persons
Rear braking force

Braking Force
Braking force distribution curve Improved
by the existing proportioning valve
Ideal distribution curve when seated by one persons
Front braking force
AC208548AB
EBD control is activated in a range with lower slip NOTE: *: The ABS warning light may stay on after
ratio where ABS is disabled. EBD calculates vehicle the ignition switch is turned ON until the startup vehi-
deceleration and slip amount of the four wheels cle speed reaches approximately 10 km/h (6 mph).
based on the wheel speed sensor signal. If the rear As the ABS-ECU memorizes any diagnostic trouble
wheel speed differs from the vehicle speed by a cer- code related to the wheel speed sensor malfunction
tain level or more, EBD increases, holds, and recorded during the previous ignition ON status,
decreases the pressure at the rear wheel control ABS-ECU continues illuminating the ABS warning
solenoid valve in the hydraulic unit, and then adjusts light until it verifies that the malfunction for that code
rear wheel brake fluid pressure fairly close to an is resolved (startup check).
ideal distribution curve. .
INITIAL CHECK
INITIAL CHECK Performs self-diagnosis in ABS-ECU.
ABS-ECU performs the following initial checks using
the diagnostic functions. ABS-ECU illuminates the
ABS warning light for 3 seconds (including the initial
check) * after the ignition switch is turned ON. If any
malfunction is detected, ABS-ECU continues illumi-
nating the ABS warning light and disables ABS con-
trol.
35B-9
STARTUP CHECK 2. ECU power supply
Checks if ECU power supply voltage stays within
.
When the startup vehicle speed reaches approxi-

mately 10 km/h (6 mph), ABS-ECU performs the fol- the operational range.
lowing checks. 3. Wheel speed sensor
1. Motor, solenoid valve check (Initial startup* only) (1) Monitors the output voltage of the sensor
signal wiring harness and checks for abnormal
Turns ON the motor relay in ECU, and checks the
output voltage (open/short circuit).
pump motor operation. At the same time,
ABS-ECU sequentially energizes each solenoid (2) Checks for any wheels that do not send pulse
valve in a very short period and checks the valve signal while the vehicle is in motion.
operation. (3) Checks if wheel speed which is abnormally
higher or lower than the vehicle speed is input.
NOTE: *: Initial startup indicates a first startup
after the system has started. 4. Pump motor, solenoid valve
2. Wheel speed sensor check Checks that the ABS-ECU output signal and the
operating conditions of the pump motor and
ABS-ECU checks for any wheels that have not
solenoid valve agree with each other.
received wheel speed sensor signal from the
startup.
CAN COMMUNICATION
CONSTANT CHECK ABS-ECU outputs the ABS warning light and the
. EBD warning light* illumination request signals to the
ABS-ECU constantly checks the following items. combination meter through CAN communication.
1. ABS-ECU
NOTE: *: The brake warning light is used as EBD
Performs self-diagnosis in ECU. control warning light.
FAIL-SAFE FUNCTION
If any malfunction is detected by the self-diagnostic NOTE: *: The brake warning light is used as EBD
function, ABS-ECU illuminates the ABS warning light control warning light.
and brake warning light*, and it disables ABS and
EBD control.
DTC Item Countermeasures for failure
No. EBD control ABS control Brake ABS warning
warning light light
C100A Abnormality in FL wheel speed Executed Prohibited Extinguished*2 Illuminated*3
sensor circuit (Prohibited
C1015 Abnormality in FR wheel speed when two or
sensor circuit more wheels
are faulty.)
C1020 Abnormality in RL wheel speed
sensor circuit
C102B Abnormality in RR wheel speed
sensor circuit
C1011 Abnormality in FL wheel speed
Executed Prohibited Extinguished*2 Illuminated*3
sensor signal (Prohibited
C101C Abnormality in FR wheel speed when two or
sensor signal more wheels
are faulty.)
C1027 Abnormality in RL wheel speed
sensor signal
C1032 Abnormality in RR wheel speed
sensor signal

warning light light
C1014 Mutual monitoring of FL wheel Executed Prohibited Extinguished*2 Illuminated*3
speed sensor (Prohibited
C101F Mutual monitoring of FR wheel when two or
speed sensor more wheels
are faulty.)
C102A Mutual monitoring of RL wheel
speed sensor
C1035 Mutual monitoring of RR wheel
speed sensor
C1041 Abnormality in periodical signal Executed Prohibited Extinguished*2 Illuminated*3
for FL wheel speed sensor (Prohibited
C1042 Abnormality in periodical signal when two or
for FR wheel speed sensor more wheels
are faulty.)
C1043 Abnormality in periodical signal
for RL wheel speed sensor
C1044 Abnormality in periodical signal
for RR wheel speed sensor
C1046 FL wheel speed sensor control Executed Prohibited Extinguished*2 Illuminated*3
phase time exceeded (Prohibited
C1047 FR wheel speed sensor control when two or
phase time exceeded more wheels
are faulty.)
C1048 RL wheel speed sensor control
phase time exceeded
C1049 RR wheel speed sensor control
phase time exceeded
C104B Abnormality in FL wheel inlet Prohibited Prohibited Illuminates Illuminates
valve system
C104F Abnormality in FR wheel inlet
valve system
C1053 Abnormality in RL wheel inlet
valve system
C1057 Abnormality in RR wheel inlet
valve system
C105F Abnormality in FL wheel outlet Prohibited Prohibited Illuminates Illuminates
valve system
C1063 Abnormality in FR wheel outlet
valve system
C1067 Abnormality in RL wheel outlet
valve system
C105B Abnormality in RR wheel outlet
valve system
C2104 Malfunction of valve power Prohibited Prohibited Illuminates Illuminates
supply circuit
C1073 Malfunction of motor drive Executed Prohibited Extinguished Illuminated*3
circuit
35B-11
warning light light
C2116 Abnormality in pump motor Executed Prohibited Extinguished Illuminated*3
power supply voltage
C1000 Abnormality in stop light switch Executed Executed Extinguished Extinguished
circuit
C2200 Abnormality in ABS-ECU Prohibited Prohibited Illuminates Illuminates
C2100 Battery 9.7 0.3 V or Executed Prohibited Extinguished Illuminates
voltage less*1
problem (low
8.0 0.5 V or Prohibited Prohibited Illuminates Illuminates
voltage)
less *1
C2101 Battery 18.0 1.0 V or Prohibited Prohibited Illuminates Illuminates
voltage more
problem (high
voltage)
C1395 Brake fluid filling not completed Executed Executed Extinguished Flashes (1 Hz)
C2203 VIN not written Executed Executed Extinguished Illuminates
C1608 Implausible diagnosis data Executed Executed Extinguished Extinguished
U0001 Bus off Executed Executed Extinguished Extinguished
U0100 Engine time-out error Executed Executed Extinguished Extinguished
U0141 ETACS time-out error Executed Executed Extinguished Extinguished
U1415 Variant coding not implemented Executed Prohibited Extinguished Illuminates
U1417 Invalid variant coding value Executed Prohibited Extinguished Illuminates
(including wrong assembly)
NOTE: . DIAGNOSTIC TROUBLE CODE SET
*1 This diagnostic trouble code is not set within There are 43 diagnosis items. Since all the diagnos-
the vehicle speed of 20 km/h (12 mph) or less. tic results are recorded in volatile memory
*2 Turns ON when two or more wheels are faulty. (EEPROM*), they are stored in the memory even
though the battery terminals are disconnected.
*3 Stays ON until the vehicle speed reaches 10
km/h (6 mph) when the ignition switch is turned to NOTE: .
ON next time. *EEPROM (Electrical Erasable & Programmable
ROM): Special type of memory that can be pro-
DIAGNOSTIC FUNCTION grammed or erased electrically
ABS-ECU has the following functions for easier sys- For each diagnosis item, refer to Service Manual.
tem checks. The following items can be diagnosed .
using scan tool. SERVICE DATA OUTPUT

Diagnostic trouble code set Using scan tool, the input data sent from the sensors
Service data output and switches can be read.
Actuator test NOTE: For service data items, refer to Service Man-
ual.
.
.
ACTUATOR TEST The actuator test can be performed only when

Using scan tool, the actuators can be forcibly oper- the vehicle is stationary. When the vehicle speed
ated. reaches 10 km/h (6 mph), the forcible actuator
operation is disabled.
NOTE: .
During actuator test, the ABS warning light
When ABS-ECU is disabled, the actuator test
flashes in 2Hz, and ABS control is prohibited.
cannot be performed.
For the actuator test specification, refer to Ser-
vice Manual.
36-1
GROUP 36
PARKING BRAKES
CONTENTS

36-2 PARKING BRAKES
GENERAL INFORMATION
GENERAL INFORMATION
M2360000100753
A parking brake lever is used to operate the mechan-
ical rear-wheel acting type parking brake.
<Vehicles with rear drum brake>
Parking brake rear cable
Parking brake lever
AC609233 AC
<Vehicles with rear disc brake>

<Vehicles with 16-inch wheel> <Vehicles with 18-inch wheel>
AC609235
Parking brake rear cable
Parking brake lever
AC609234 AB
37-1
GROUP 37
POWER STEERING
CONTENTS
GENERAL INFORMATION . . . . . . . . 37-2 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . 37-6
STEERING WHEEL . . . . . . . . . . . . . . 37-3 STEERING GEAR. . . . . . . . . . . . . . . . 37-7
STEERING SHAFT AND COLUMN. . 37-4 OIL RESERVOIR . . . . . . . . . . . . . . . . 37-8

37-2 POWER STEERING
GENERAL INFORMATION
GENERAL INFORMATION
M2370000101003
FEATURES Configuring the optimum flow characteristics and

A hydraulic power steering system has been adopted gear valve feature improves the handling stability.
to all models. Appropriate application of friction to the steering
This steering system offers the following features: gear cuts off the disturbance from the road sur-
The support method of the steering gear to the face and improves the stability during the
crossmember is realised by the left and right straight-ahead driving.
internal bushings with inner cylinders. This sup- Optimisation of the flexible tube in the high pres-
port method achieves higher rigidity of the steer- sure hose reduces the pump noise.
ing gear and improves the steering feeling.
SPECIFICATIONS
Items Specifications
Steering wheel Type Three-spoke type
Outside diameter mm (in) 375 (14.7)
Maximum number of turns 3.16
Steering column Column mechanism Shock absorbing
mechanism and Tilt steering
mechanism
Power steering type Integral type (Engine
speed-dependent type)
Oil pump Type Vane type with fluid flow
amount control system
Basic discharge amount cm3/rev. (cu in/rev) 8.1 (0.49)
Relief pressure MPa (psi) 8.8 (1,276)
Reservoir type Separate type (Resin made)
Steering gear Type Rack and pinion type
Stroke ratio (Rack stroke/Steering wheel 45.58 mm/rev (1.79 in/rev)
Maximum turning radius) mm/rev (in/rev)
Rack stroke mm (in) 144
Steering angle Inner wheel 40 50
Outer wheel 33 50
Power steering fluid Specified lubricants GENUINE MITSUBISHI
POWER STEERING FLUID
Quantity dm3 (qt) Approximately 1.0 (1.06)
POWER STEERING
STEERING WHEEL
37-3
Oil reservoir
Return hose
Pressure hose
Pressure switch assembly
Steering column
shaft assembly
Steering wheel
Suction hose
Heat protector
Oil pump assembly

Steering gear
AC607284 AB
STEERING WHEEL
M2370001000761
Air bag module Section A - A

A
Steering wheel
audio remote control switch Inflator
Air bag module
Steering wheel
voice control switch
Cruise control switch
A
AC607285 AB
The steering wheel is designed to improve operabil- Sporty and thick type grip shape has been
ity, safety and maintainability and has the following adopted.
features: Rigid core metal reduces steering wheel vibra-
Newly designed Three-spoke type has been tion.
adopted. For DE and ES, the steering wheel It incorporates an SRS airbag to protect the driver
made of urethane has been adopted. For GTS, in the event of a frontal collision.
the steering wheel made of genuine leather has The airbag module is equipped with an inflator
been adopted. that does not contain sodium azide.
Audio remote control, voice control, and cruise Optimisation of the airbag specifications reduces
control switches are available on some models. the risk of injury to the passengers in a collision.
37-4 POWER STEERING
STEERING SHAFT AND COLUMN

M2370002000667
To improve the feeling of steering (reduction of Tilt steering mechanism that the desired driving
torque fluctuation) covering the whole tilting position is obtained has been employed on all
range, the steering column layout has been opti- models (Tilt-up amount: 20mm/Tilt-down amount:
mised by focusing the tilting function. 25mm).
To reduce the separation load during a collision,
the sliding resistance reduction member has
been installed to the column bracket.
Column bracket
A B
Tilt point
A B Column pipe
Intermediate shaft
Tilt lever
Section A-A Section B-B One-way

capsule
Pin
AC607286 AB
POWER STEERING
37-5
IMPACT-ABSORBING MECHANISM
.
Primary collision
If the vehicle is involved in a crash and impact energy is trans-
mitted to the lower shaft from the gearbox side, the intermedi-
Before collision ate shaft (A) will be pushed into intermediate shaft (B) to
Intermediate shaft (A) absorb impact energy. Thus, the steering column will not be
projected into the passenger compartment.
Intermediate shaft (B)
After collision
AC504819AC
.
37-6 POWER STEERING
OIL PUMP
Secondary collision
Before collision When the driver's body falls against the steering wheel via the
Column Rivet pin deployed air bag, the column bracket moves forward by
One way
bracket
capsule deforming the rivet pin of the one-way capsule, and simulta-
neously the steering column assembly frees from the pin of col-
umn bracket to move forward and downwards.
A A
Column pipe
Section A - A
After collision
B B
Section B - B
AC611053 AB
Column
bracket A
A Column pipe
Section A - A
Pin
AC607645AB
OIL PUMP
M2370004000373
The oil pump is a vane type with a fluid flow control The oil pump is essentially the same as the conven-
system which functions so the steering wheel turning tional one in construction.
effort will be reduced at low engine speeds and
increase at higher speeds.
POWER STEERING
STEERING GEAR
37-7
STEERING GEAR
M2370003000499
View A
Section B - B
One way
check valve
B B
Tie-rod end
Gear housing
Tie-rod bellows
Gear housing

Bushing
Inner pipe Front suspension

crossmember
AC607287AB
The steering gear and linkage is mounted on the One-way check valve for the power steering fluid
suspension crossmember via two bushings with has been added in the steering gear. By reducing
inner cylinders. the kickback due to the disturbance from the
The inner bushing with inner cylinder supports uneven road surface, the handling stability has
the steering gear and linkage in the vertical and been improved.
fore-and-aft direction with high rigidity, improving
the feeling of steering considerably.
37-8 POWER STEERING
OIL RESERVOIR
OIL RESERVOIR
M2370005000376
The resin oil reservoir is used to reduce weight. The oil reser-
voir is translucent and has fluid level marks (MAX and MIN
lines), facilitating inspection.
Scale
Cap
O-ring
Oil reservoir
Filter
Return
Suction
AC200365AC
42-1
GROUP 42
BODY
CONTENTS
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42A
KEYLESS OPERATION SYSTEM (KOS). . . . . . . . . . . . . . . . . . 42B
WIRELESS CONTROL MODULE (WCM) . . . . . . . . . . . . . . . . . 42C

NOTES
42A-1
GROUP 42A
BODY
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 42A-2 POWER WINDOW . . . . . . . . . . . . . . . . . . . 42A-15

WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . 42A-17
MAIN BODY . . . . . . . . . . . . . . . . . . . . 42A-3
BODY PANELING. . . . . . . . . . . . . . . . . . . . 42A-3 PROTECTOR FILM
BODY SHELL . . . . . . . . . . . . . . . . . . . . . . . 42A-4 <Vehicles without side air dam> . . . 42A-18
QUIETNESS . . . . . . . . . . . . . . . . . . . . . . . . 42A-8
BODY COLOR CHARTS . . . . . . . . . . . . . . 42A-8 TRUNK LID . . . . . . . . . . . . . . . . . . . . . 42A-19
HOOD AND FENDER . . . . . . . . . . . . 42A-9 WINDOW GLASS . . . . . . . . . . . . . . . . 42A-20
FUEL FILLER LID . . . . . . . . . . . . . . . 42A-10 SUNROOF. . . . . . . . . . . . . . . . . . . . . . 42A-21
STRUT TOWER BAR <GTS> . . . . . . 42A-11 LOOSE PANELS . . . . . . . . . . . . . . . . 42A-24
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 42A-12 CUSTOMIZATION FUNCTION . . . . . . 42A-24

DOOR LOCK. . . . . . . . . . . . . . . . . . . . . . . . 42A-12
42A-2 BODY
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M2420000100949
FEATURES The shock absorbing hole has been adopted to

. the cowl top outer reinforcement.
LIGHT WEIGHT, HIGH RIGIDITY, The fender padding structure has been adopted.
ANTI-CORROSIVE .
The application ranges of high-tensile steel pan- IMPROVEMENTS IN OPERATION

els, and anti-corrosion steel panels have been PERFORMANCE
expanded.
The central door locking system which can
The ring structure for the side structure reinforce-
lock/unlock all the doors has been adopted.
ment has been adopted.
<Vehicles with power window (auto down and
The 3-way support structure for the front frame
auto up mechanism)>
has been adopted.
The override function which allows to open the
The strut tower bar has been installed.<GTS>
driver's door by pulling the driver's inside handle
The front floor backbone brace has been
when all the doors are locked has been adopted.
installed.
The power window (operative after ignition switch
The upper frame to front pillar brace has been
is turned OFF) has been installed. <Vehicles with
installed.
auto down mechanism (Driver's seat only)>
.
REDUCTION IN VIBRATION AND NOISE .
IMPROVEMENTS IN MARKETABILITY
More sound absorption/insulator and styrene
foam filler have been adopted.
AND APPEARANCE
Adoption of closed section roof bow and roof rail By improving the clicking sound when the door
latch and striker are engaged, the door locking
.
sound quality has been enhanced.

IMPROVEMENT IN SAFETY The high rigidity pressed door has been adopted
The one-touch power window (operative after to improve the rigidity of the door sash bottom
ignition switch is turned OFF) with safety mecha- section.
nism has been installed. <Vehicles with auto The protector film has been adopted onto the
down and auto up mechanism (Driver's seat side sill. <Vehicles without side air dams>
only)> The sunroof with safety mechanism has been
The direct combination key cylinder and inside installed as an option. <ES, GTS>
lock cables for the front doors have been adopted
to improve door opening operation upon impact. .
RISE (Reinforced Impact Safety Evolution) has

IMPROVEMENTS IN FUNCTIONALITY
been adopted for the main body. A fuel filler cap holder has been installed to the
The side door beam has been adopted. fuel door in order to prevent the fuel cap from
The crush box structure has been adopted to the being left open.
side member front end. The selector "P" position-linked door unlocking
function has been introduced to the central door
locking system.
BODY
MAIN BODY
42A-3
MAIN BODY
BODY PANELING
M2420002000788
* *
* *
*
*
*
**
* **
* *
* *
* *
* *
**
*
: Anti-corrosion steel panels
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)
(**: Indicates 980MPa-ultra-high-tensile steel panels.)
AB601700AC
42A-4 BODY
MAIN BODY
RISE (Reinforced Impact Safety Evolution) has High-tensile steel panels of 590MPa-grade and
been adopted for the main body in order to 980MPa-grade have been used for some panels
improve all-round impact safety at high level. to improve collision safety and reduce weight.
The applications of anti-corrosion steel plates
have been expanded to the hood, doors, inner
panel of the trunk lid and reinforcements to
improve the anti-corrosive properties of the main
body.
BODY SHELL
M2420003000758
IMPACT SAFETY BODY RISE (REINFORCED IMPACT SAFETY EVOLUTION)
4
B
1 2 3
AB601441AB
D
C
5
AB601452AB
BODY
MAIN BODY
42A-5
1 1 Section B - B
Crush box
Crush box
3 View A 5 Section C - C
Dash
crossmember Fender bracket
center upper center 2
Front
sidemember
rear
Front fender
Dash crossmember lower When hood is removed
Cowl top outer

6 Section D - D reinforcement
upper
Cowl top
panel
outer
Cowl top
panel Cowl top
lower panel inner
When hood is removed AB601678 AB
The front and rear structures to absorb high energy, 3. The front frame structure is supported in three
and the highly tough cabin structure is adopted to directions by the dash crossmember center, dash
reduce the risk of passenger injuries at front-, rear-, crossmember lower, and front sidemember rear
and side-impact collisions, secure the space for life in order to improve the frontal collision character-
protection, and facilitate rescuing passengers. The istics, and increase the vehicle body rigidity.
structures also have the following features: 4. An annular construction has been used for the
1. The crush box structure, which has an octagonal side structure reinforcement to improve collision
cross-section at the front end of the front side- safety and vehicle body rigidity.
member, has been adopted. This structure can 5. The padding structure of the fender has been
effectively absorb energy upon frontal impact and adopted to efficiently absorb energy upon impact
reduces the vehicle repair cost caused by a light and improve the pedestrian protection capability.
collision. 6. The impact absorbing opening on the cowl top
2. The straight frame structure has been adopted outer reinforcement has been added to efficiently
for the front sidemember to improve performance absorb energy upon impact and improve the
upon frontal impact. pedestrian protection capability.
42A-6 BODY
MAIN BODY
STEEL PLATE WITH UNEVEN THICKNESS
Front door inner panel Rear door inner panel

Thickness is thicker on the forward
Thickness is thicker on the forward
part of the vehicle from this line.
part of the vehicle from this line.
AB601455AB
The uneven thickness steel panels* (in uneven thick- NOTE: *: A steel sheet of varying thickness that is
ness integrated structure) have been adopted for the welded into one steel sheet.
parts shown in the figure to improve safety upon
impact and reduce weight.
BODY
MAIN BODY
42A-7
STEERING ABILITY
2
B
A C
AB601990AB
1 2 Section A - A
Upper frame to
front pillar brace
Roof front rail upper

Roof front rail lower
2 Section B - B 3 View C
Roof rail center
extension
Roof rail front

extension
Roof center bow upper Roof rail rear
Roof center bow lower extension
AB601770AB
1. Rigidity was heightened and driving stability was and front pillar by the upper frame to front pillar
improved by bonding the front upper frame outer brace.
42A-8 BODY
MAIN BODY
2. The closed section structure has been adopted 3. Rigidity was heightened and driving stability was
for the roof bow and roof rail to heighten rigidity, improved by bonding the roof bow and roof rail
improve driving stability, and to reduce vibration and the side outer panel by the brace.
and noise.
QUIETNESS
M2420004000568
AB601548
Sound dampening foam material
Sound dampening foam material AB601682AB
The front pillar upper and lower, center pillar lower,

side roof rail and the rear wheel house front have
been filled with the sound dampening foam material
to reduce noise.
BODY COLOR CHARTS
M2420005001360
Check the vehicles body color code, and then use
this body color chart to determine the refinishing
paint supplier from which the color can be pur-
chased.
BODY
HOOD AND FENDER
42A-9
Color Color code Color number Color name (Previous name) Composition of film
SILVER A31 CMA10031 Cool Silver Metallic Metallic
MEDIUM A39 CMA10039 Medium Purplish Gray Mica Metallic +
PURPLISH GRAY Interferenced Pearl
GREENISH A86 CMA10086 Greenish Silver Metallic Metallic +
SILVER Interferenced Pearl
BLUE T70 CMT10070 Blue Mica Pearl
BEIGE S18 CMS10018 Platinum Beige Metallic Metallic +
Interferenced Pearl
BLACK X42 AC11342 Black Mica (Amethyst Black) Interferenced Pearl
WHITE W37 CMW10037 White Solid Solid
RED P26 CMP10026 Red Metallic Metallic
NOTE: .
It is a solid, but clear coating is applied.
For painting, inner panel colors should be similar to the outer panel colors.
HOOD AND FENDER

M2420001400125
PANEL
A shock absorbing structure has been adopted for
Hood
the insertion in between hood and the engine room
and the frame between the fender and the body to
secure the space for shock absorbing, reducing a
risk of injury to a pedestrian's head area during a col-
lision.
Fender
AC608745AB
HOOD HINGE
The bolt type hook has been adopted for the hood
hinge to suppress cabin deformation and improve
Hood hinge safety upon impact.
Hook
AC608747AB
42A-10 BODY
FUEL FILLER LID
FUEL FILLER LID

M2420014000257
Fuel filler cap holder
Fuel filler lid

Fuel filler cap
<When using fuel filler cap holder> Fuel filler cap
Fuel filler lid
AC608385AB
The fuel filler cap holder has been installed to the

fuel lid, holding the removed cap in refueling to pre-
vent the fuel cap from being left open.
BODY
STRUT TOWER BAR <GTS>
42A-11
STRUT TOWER BAR <GTS>
M2420001300236
Strut tower bar
AC608384AC
The strut tower bar has been adopted to the strut

attachment point to improve steering ability
42A-12 BODY
DOOR
DOOR
DOOR LOCK
M2420009000660
CENTRAL DOOR LOCKING <Except DE>

<Rear door> <Front door>
Outside handle Outside handle
Inside lock cable Inside lock cable

Key cylinder
Inside lock knob
Door latch Inside lock knob
assembly
Door latch
assembly
Door check Door check

Door lock
actuator
Door lock
actuator
Inside handle cable
Inside handle Inside handle cable
Inside handle
AC608386AB
Location of the door lock switches

Driver's side Passenger's side
CK
LO
LO
CK
Door lock switch Door lock

ck switch
AC608439AB
The central door locking system that The key-in prevention function has been intro-
locks/unlocks all the doors using the door lock duced.
switch has been installed. The selector "P" position-linked door unlocking
The child protection function has been introduced function has been introduced.
to prevent the rear doors from being opened acci- The direct combination key cylinder mechanism
dentally during driving. has been adopted.
BODY
DOOR
42A-13
DESCRIPTION OF CONSTRUCTION AND When the door is locked and unlocked by drivers
OPERATION or passenger's door lock switch consecutively,
.
the ETACS-ECU operates its door lock relay and
CENTRAL DOOR LOCKING passes a current through the door lock actuators
All the doors can be locked/unlocked, using the of all the doors for 0.25 second to lock all the
drivers side door lock switch or the passengers doors. Then, the ETACS-ECU operates its door
side door lock switch. unlock relay and passes a current through the
The function that allows the driver's door to be door lock actuators of all the doors for 0.25 sec-
opened by pulling the driver's door inside handle ond to unlock all the doors. Due to this, there may
even when the driver's door inside lock knob is in be a time lag between the drivers or passenger's
the lock position is called "override function". door lock switch actuation and the time when all

the doors are unlocked.
.
SELECTOR "P" POSITION-LINKED DOOR

ON
(LOCK)
UNLOCKING FUNCTION
Driver's or
passenger's OFF When the selector lever is shifted to the "P" (park-
door lock
ON ing) position with the ignition switch turned ON,
switch (UNLOCK) all the doors will be unlocked automatically,
improving passengers' convenience for getting
ON
Lock relay
t t out. Using a customization feature, the selector
output OFF
"P" position-linked door unlocking function can be
switched (Refer to P.42A-24).

Unlock relay ON
output OFF t t t
Time lag
ON
All doors LOCK Inhibitor switch "P"
lock OFF
actuator UNLOCK
ON T
t: 0.25 Second Unlock relay output
OFF t
ZC600257 t: 0.25 second

AC607040AB
T: 0.3 second
AC208135AF
When the door is locked by the drivers or pas-
sengers door lock switch, the ETACS-ECU oper- When the selector lever is shifted to the P posi-
ates its door lock relay and passes a current tion with the ignition switch turned ON, the inhibi-
through the door lock actuators of all the doors tor switch "P" turns ON, ETACS-ECU turns the
for 0.25 second to lock all the doors. unlock relay output ON for 0.25 seconds to
When the door is unlocked by the drivers or pas- unlock all the doors.
senger's door lock switch, the ETACS-ECU oper- .
ates its door unlock relay and passes a current KEY-IN PREVENTION FUNCTION
through the door lock actuators of all the doors When the driver's door inside lock knob is operated
for 0.25 second to unlock all the doors. to the lock position with the driver's door opened, the
driver's door cannot be locked, preventing it from
being locked with the key inside the vehicle.
.
42A-14 BODY
DOOR
DIRECT COMBINATION KEY CYLINDER The impact of a side collision is not easily trans-
MECHANISM ferred to the door latch with the doors unlocked
(to prevent passengers from falling out of the
Key cylinder vehicle).
Even if any door key cylinder is attempted to be
tampered with the doors locked, the tampering
force is not easily transferred to the door latch, to
deter thieves.
Direct combination
key cylinder mechanism
Door latch
ZC600137
AC607042 AB
CENTRAL DOOR LOCKING SYSTEM

DOOR LOCK OPERATION TABLE
Operation Drivers side Passengers Rear door Trunk lid
door side door
Door lock key Drivers side Lock Lock
cylinder door Unlock Unlock
Passengers Lock Lock
side door Unlock Unlock
<Vehicles with
WCM (without
keyless entry
system)>
Trunk lid lock key cylinder Lock Lock
<Vehicles with WCM (without Unlock Unlock
keyless entry system)>
Door lock switch Drivers side Lock Lock Lock Lock
door Unlock Unlock Unlock Unlock
Passengers Lock Lock Lock Lock
side door Unlock Unlock Unlock Unlock
BODY
DOOR
42A-15
POWER WINDOW
M2420022000274
<Rear door> <Front door>
Stationaly window glass
Door window glass

Door window glass
Power window motor
Power window motor
Power window regulator assembly
Power window regulator assembly
Power window main switch (Driver's side)

Power window
Power window switch lock switch
AC608748
AC608387AB
The power window has the following features: DESCRIPTION OF CONSTRUCTION AND
Safety mechanism <Vehicles with auto down and OPERATION
auto up mechanism (Driver's door only)> .
Power window timer function POWER WINDOW SYSTEM <Vehicles

Power window lock switch with auto down and auto up mechanism>
The power window main switch has a waterproofing
structure which prevents water (such as rain drops)
from entering from above. Should water enter, it is
drained through the hole located on the lower area of
the switch, and no water may be accumulated.
.
42A-16 BODY
DOOR
POWER WINDOW SWITCH

.
POWER WINDOW TIMER FUNCTION

The power window switch has a push-pull operation
method to enhance safety. To open a door window ON
glass, press in the switch knob; and to close, pull it Ignition sswitch (IG1)
OFF
up.
ON
Driver's or (Open)
.
passenger's
SAFETY MECHANISM <Vehicles with door switch OFF
(Closed)
auto down and auto up mechanism
(Driver's door only)> Power window relay
ON
OFF
The power window with the safety mechanism t ZC600258
has been adopted to enhance safety. If any t: 30 seconds AC607043AB
obstacle such as a hand or a head is detected to Even after the ignition is switched off, the
be pinched during a door window glass closing ETACS-ECU keeps the power window relay acti-
operation, the door window glass is opened by vated for approximately 30 seconds, enabling raising
approximately 150 mm (6.0 inches). The safety or lowering of the power windows by using the power
mechanism is activated when the power window window switches. After approximately 30 seconds,
switch is operated by one-touch closing operation the power window relay is deactivated.
(the status when the hand is released from the During this timed operation, if the drivers or passen-
switch knob after one-touch closing operation). gers doors are opened, the power window relay is
To prevent anyone from intruding into the vehicle, deactivated from that moment.
by performing the manual-closing operation of
the power window switch, or by continuing the .
one-touch closing operation (keep pulling up the

POWER WINDOW LOCK SWITCH
switch knob), the door window glass can be forc- The driver power window switch is equipped with the
ibly closed without safety mechanism activation lock switch. This switch disables the opening/closing
even when the obstacle is detected to be operation of the door window glass using each pas-
pinched. senger's power window switch and rear power win-
When the power window switch manual-closing dow switch.
or one-touch closing operation is performed acci-
dentally, and an obstacle is detected, the power
window switch manual-closing and one-touch
closing operations are prohibited for 3 seconds
after the obstacle has been detected to be
pinched, and activates the safety mechanism.
BODY
DOOR
42A-17
WEATHERSTRIP
M2420020000320
A
A
A
A
B
B
B
B
AC607029
Section A A Section B B
Door opening
weatherstrip
Door opening weatherstrip
ZC600145
AC607044AB
The double weather strips have been installed along

the perimeter of the door window to improve the
sound-proof and water-proof performances.
42A-18 BODY
PROTECTOR FILM <Vehicles without side air dam>
PROTECTOR FILM <Vehicles without side air dam>

M2420021000226
Protector film
AC607397AC
The lower parts of the side sill are equipped with a

protector film to prevent paint chipping and scratches
caused by stone chips.
BODY
TRUNK LID
42A-19
TRUNK LID
M2420013000135
TRUNK LID LATCH
Emergency trunk lid release handle
<Vehicles with keyless operation system>
AC608555
Trunk lid open switch
Trunk lid release handle <Vehicles without keyless operation

system>
Trunk lid lock cylinder
AC607045
Trunk lid latch assembly
Trunk lid release cable
AC607046
Trunk lid latch assembly
AC609006 AB
The trunk lid latch prevents a person from being The emergency trunk lid release handle glows by
confined in the luggage compartment in an acci- absorbing light, so you can operate the handle
dent. even in a dark luggage compartment.
You can open the trunk lid by pulling an emer- NOTE: The glow time depends on the amount of
gency trunk lid release handle to the arrow direc- light absorption, but the handle will glow four
tion when you are confined in the luggage hours maximum when exposed to sunlight for 30
compartment in an accident. seconds or more. The glow performance
depends on environmental conditions.
42A-20 BODY
WINDOW GLASS
TRUNK LID GAS SPRING AND HINGE
Trunk lid hinge
Trunk lid gas spring
AC608743AB
The gas springs allow the customer to open or The link type hinge has been adopted to control
close the trunk lid easily. the backward protrusion on opening/closing the
trunk lid and to eliminate the protrusion on closing
the trunk lid, for retractility
WINDOW GLASS
M2420015000926
VISIBLE RAY TRANSMISSIVITY RATE FOR WINDOW GLASS
1 6
3
4
AC608392AB
BODY
SUNROOF
42A-21
No. Name Type Thickness Color Visible ray

mm (inch) transmissivity
rate (%)
1 Windshield Laminated glass 4.7 (0.185) Green 79
2 Front door window glass Tempered glass 3.5 (0.138) Green 81
3 Rear door window glass 3.1 (0.122) Green 82
4 Rear stationary window 3.1 (0.122) Green 82
glass
5 Rear window glass 3.1 (0.122) Green 82
6 Sunroof lid glass 3.5 (0.138) Dark gray 18
NOTE: The visible ray transmissivity rate (%) is a ref- The laminated glass has been adopted for the wind-
erence value. shield, and the reinforced glass has been adopted for
other windows.
SUNROOF
M2420016000491
Drain pipe
Sunroof lid glass
Drain
r pipe
Sunshade
Sunroof motor assembly

(integrated into sunroof ECU) Drain pipe
AC608393AB
42A-22 BODY
SUNROOF
Close/down switch
Tilt-up switch
AC505240
Sunroof switch Open switch
AC505239
AC506511AC
The electric sliding glass sunroof with tilt-up mecha- During the sunroof lid glass closing operation, by
nism has been adopted as an option. This sunroof continuing the sunroof close switch operation, the
has the following characteristics: sunroof can be forcibly closed without activating
A lightweight sunroof has been adopted. the safety mechanism even when the obstacle is
The sunroof tilts up for approximately 30 mm (1.2 detected to be pinched.
inches) to improve ventilation. During the safety mechanism activation, when
The integrated switch for the sunroof allows for all the sunroof close switch is operated, the sunroof
slide open/close, tilt up/down and stop opera- lid glass stops. By continuing the close switch
tions. Operations other than open are available at operation, the sunroof lid glass can be forcibly
one touch. When the open switch is operated, the closed without activating the safety mechanism
sunroof lid glass stops approximately 30 mm (1.2 even when the obstacle is detected to be
inches) before the fully-open position. This posi- pinched.
tion is called comfort position. The sunroof lid .
glass can be fully opened by operating the open SUNROOF TIMER FUNCTION
switch again.
If external force is applied during slide closing or ON
tilt down operations that obstructs operations, the Ignition switch (IG1)
OFF
sunroof lid glass will move in the reverse direc- ON
tion. Driver's or passenger's
(Open)
By turning ON the sunroof window lock switch door switch OFF
(Close)
(integrated in the power window main switches)
of the driver's power window switch, the sunroof (Enabled) ON
operation is prevented. Sunroof operation
(Disabled) OFF
t: 30 Seconds t ZC600258
DESCRIPTION OF CONSTRUCTION AND (Short of timer operation time) AC607037AB
OPERATION The sunroof ECU (integrated into the sunroof motor

. assembly) receives the ignition switch (IG1) signal
SAFETY MECHANISM transmitted by ETACS-ECU. If the ignition switch
If any obstacle such as a hand or a head is (IG1) signal turns OFF, the sunroof ECU allows the
detected to be pinched during a sunroof lid glass sunroof switch to open/close (timer activation) the
closing operation, the sunroof lid glass is opened sunroof for approximately 30 seconds. During the
by approximately 200 mm (7.9 inches) or more. timer operation, if the drivers or passengers door
open is detected from the door switch signal trans-
mitted by ETACS-ECU, the sunroof timer function
stops at this time.
.
BODY
SUNROOF
42A-23
SUNROOF MOTOR ASSEMBLY The sunroof motor assembly, which consists of the
motor main body, drive gear, and sunroof ECU, is
Sunroof ECU Drive gear installed in front of the housing.
.
Sunroof motor AC506532 AD
SUNROOF ECU
ETACS-ECU
7
Ignition switch
3
Driver
circuit M Motor
Tilt-up switch
4 Sunroof-ECU
Open switch
5
Close/Tilt-down Sensor
switch
10
Sunroof switch
EEPROM
1
2
1 2 3 4 5 Sunroof motor assembly
6 7 8 9 10
ZC604430
AC609032AB
The sunroof ECU incorporates a microcomputer and

controls motor operations with the sunroof switch
signals, depending on various conditions.
42A-24 BODY
LOOSE PANELS
LOOSE PANELS
M2420000200195
Front floor backbone brace
AC609212
AC609216AB
The front floor backbone brace has been installed to

improve the body rigidity.
CUSTOMIZATION FUNCTION
M2420002500169
With the scan tool MB991958 (M.U.T.-III sub assem-
bly) operation, the following functions can be pro-
grammed. The programmed information is kept in
memory even when the battery is disconnected.
Adjustment Adjustment item Adjusting contents Adjusting contents
item (scan tool (scan tool MB991958
MB991958 display)
M.U.T.-III
display)
Auto door Auto door unlock by Disable No function (default)
unlock by P P position function Always enabled Always with function
position <Vehicles with
central door locking
system>
42B-1
GROUP 42B
KEYLESS
OPERATION
SYSTEM (KOS)
CONTENTS
GENERAL INFORMATION . . . . . . . . 42B-2 ENGINE STARTING FUNCTION . . . . . . . . 42B-17

SYSTEM OPERATION. . . . . . . . . . . . 42B-8 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . 42B-20
DOOR ENTRY FUNCTION. . . . . . . . . . . . . 42B-8 WARNINGS/ALARMS . . . . . . . . . . . . . . . . . 42B-22
KEYLESS ENTRY FUNCTION . . . . . . . . . . 42B-13
CONFIGURATION FUNCTION. . . . . . 42B-27
42B-2 KEYLESS OPERATION SYSTEM (KOS)
GENERAL INFORMATION
GENERAL INFORMATION
M2421000100102
NOTE: In this manual, F.A.S.T.-key (Free-hand The keyless operation key incorporates a
Advanced Security Transmitter) is described as Key- lock/unlock button, trunk lid button, and panic
less Operation System (KOS). (KOS is indicated as button, and can be operated by remote control in
F.A.S.T. in the M.U.T.-III display.) the same manner as the conventional keyless
The keyless operation system (KOS) is an integrated entry system. The keyless operation key also
system of the following functions: the door entry incorporates an indicator light that enables the
function which enables the driver to unlock the door driver to check if the signal is transmitted cor-
(only the driver's door when the driver's door outside rectly or if the battery in the key is discharged.
handle is operated, and all the doors when the front (Refer to P.42B-13.)
passenger's door outside handle is operated) by The keyless operation key incorporates the
gripping the front door outside handle without taking immobilizer function that inhibits the engine star-
the key out from his/her pocket or bag when he/she tup by using an unauthorized key.
is carrying a keyless operation key which has been Two keyless operation keys are provided for each
registered in the vehicle's KOS-ECU. It also allows vehicle, and up to four keyless operation keys
the driver to unlock the trunk lid by operating the can be registered.
trunk opener switch and to lock all the doors by The keyless operation key incorporates an emer-
pressing the lock switch on the front door outside gency key to lock/unlock the doors and start the
handle or to lock the trunk lid just by closing; the engine when the battery in the keyless operation
engine start function which starts the engine without key is discharged or the keyless operation sys-
using the conventional mechanical key; and the tire tem malfunction occurs.
pressure monitoring system (TPMS) which warns the The driver can customize KOS; enabling the door
driver of low tire pressure by illuminating the warning entry/engine start function, disabling the door
light. The KOS has the following features: entry/engine start function, enabling the door
locking/unlocking function only, or enabling the
engine starting function only. (Refer to P.42B-27.)
.
KEYLESS OPERATION SYSTEM (KOS)
GENERAL INFORMATION
42B-3
Steering lock
(Push switch, Steering lock unit)
IG knob Receiver
antenna module
ABS-ECU
Interior transmitter
TPMS transmitter
antenna assembly (Front)
(Tire pressure sensor)
IG knob cap AC507163
KOS-ECU Lock switch and

ECM Unlock sensor
(Passenger's side door)
Exterior transmitter
antenna assembly
(Passenger's side)
Interior transmitter
antenna assembly (Rear)
TPMS transmitter
ETACS-ECU
Lock switch and

Unlock sensor
(Driver's side door)
TPMS transmitter
(Tire pressure sensor) Exterior transmitter
antenna assembly
(Driver's side) AC609217
Antenna and tone alarm assembly
<Exterior transmitter antenna
TPMS transmitter assembly (Trunk lid),
(Tire pressure sensor) Outer tone alarm>
Lock switch and Unlock sensor Section A - A

(Driver's side door, Passenger's side door) Front door
outside
A handle
A
Unlock
Door Trunk lid
Unlock sensor Lock switch sensor
assembly opener switch
AC506891 AC506892 AC609218
AC609980AB
GENERAL INFORMATION
Multi information display

(Built in combination meter) TPMS
warning light
LOW SERVICE
TIRE PRESSURE REQUIRED
AC609833
ZC610056AB
Indicator light Lock button Emergency key

Keyless operation key
(Front view)
(Rear view)
Unlock button
Trunk lid button

Emergency key
AC608093 AC608095
Panic button
AC609683AB
.
GENERAL INFORMATION
42B-5
Main components and functions
Parts name Functional description
KOS-ECU Controls KOS by using the following inputs/outputs and
communications.
Input from the unlock sensor and lock switch on each door,
input from the push switch on the IG knob
Communications with ETACS-ECU, ECM, ABS or ASC-ECU
and combination meter via CAN
Wire communication with the steering lock unit
Wireless communication with the keyless operation key via
the receiver antenna module and interior/exterior transmitter
antennas
Wireless communication with the TPMS transmitter
Output to the outer tone alarm
Steering lock (incorporates push switch The steering lock has two unlocking mechanisms; a mechanical
and steering lock unit) mechanism that uses an emergency key and an electrical
mechanism. In the electrical unlocking mechanism, the steering
lock communicates with KOS-ECU via wire, and when
requested by KOS-ECU, the steering lock unlocks for two
seconds.
Keyless operation key (incorporates The keyless operation key receives signals sent from each
emergency key) interior/exterior transmitter antenna, certifies the keyless
operation key ID code, calculates the key ID, and sends the
reply data signal to KOS-ECU via the receiver antenna
module. The lock button, unlock button, and trunk lid button
operations of keyless operation key transmit signals to
KOS-ECU via the receiver antenna module.
If two or more keyless operation keys registered in
KOS-ECU respond at the same time, their signals would
interfere. To avoid this interference, each signal from
KOS-ECU is given the priority*1 data, and the keyless
operation keys respond in accordance with this priority.
Lock switch Driver's door Locks all the doors when a driver carrying the keyless operation
Front passenger's key presses the lock switch on the front door outside handle.
door
Unlock sensor Driver's door The unlock sensors incorporated in the drivers front door
outside handles unlock drivers the door when a driver carrying
the keyless operation key pulls the drivers door outside handle.
Front passenger's The unlock sensors incorporated in the passenger's front door
door outside handles unlock all the doors when a driver carrying the
keyless operation key pulls the front door outside handle.
Trunk lid opener switch By pressing the trunk lid opener switch on the trunk lid while
he/she is carrying the keyless operation key, the trunk lid is
unlocked.
Exterior transmitter Driver's side Converts the data output from KOS-ECU via wire into a signal,
antenna assembly Front passenger's and sends it to the keyless operation key. (For the transmission
side area, refer to Operation Manual Door Entry Function P.42B-8.)
GENERAL INFORMATION

Interior transmitter Front Converts the data output from KOS-ECU via wire into a signal,
antenna assembly Rear and sends it to the keyless operation key. (For the transmission
area, refer to Operation Manual Engine Start Function
P.42B-17.)
Antenna & tone Exterior transmitter Converts the data output from KOS-ECU via wire into a signal,
alarm assembly antenna assembly and sends it to the keyless operation key. (For the transmission
(trunk lid) area, refer to Operation Manual Door Entry Function P.42B-8.)
Outer tone alarm The outer tone alarm sounds when:
The doors are locked or unlocked by the door entry function.
The lock switch on the keyless operation switch is pressed
when the IG knob is in the "LOCK" (OFF) position and the
push switch is in other than the "ON" position.
The lock switch is pressed on the keyless operation key from
inside the car.
The lock switch on the keyless operation key is pressed
when the door is ajar.
Receiver antenna module Receives the operation signals from the lock/unlock switches
and panic alarm switch on the keyless operation key, and the
air pressure signal from the TPMS transmitter, and then
converts them into data and sends them to KOS-ECU.
TPMS transmitter Measure tire pressure directly, then send radio frequency signal
to receiver antenna module.
Combination meter (Multi information Communicates with KOS-ECU via CAN. Receives the warning
display, TPMS warning light) request or warning information from KOS-ECU, activates*2 the
warning light. Warning symbol and message is additionally
displayed on the multi information display
ETACS-ECU Communicates with KOS-ECU via CAN. Receives the door
lock/unlock request from KOS-ECU, outputs the lock/unlock
signal, and flashes the turn signal light to inform the driver that
the doors are locked/unlocked.
ECM Communicates with KOS-ECU via CAN. Permits/inhibits the
engine starting and controls the engine operation. Send
atmospheric pressure data. Sends the vehicle speed data
<Vehicles without ABS>.
ABS-ECU <Vehicles with ABS> Communicates with KOS-ECU via CAN. Sends the vehicle
speed data <Vehicles with ABS>.
NOTE: *1: When registering the keyless operation NOTE: *2: Illuminates for tire pressure warning.
keys, KOS-ECU numbers each key (1 to 4) in the Flashes for about 1 minute and then continuously
order they are registered (initial priority). This priority illuminated for TPMS malfunction warning.
is renewed each time the doors are locked/unlocked .
and the IG knob is pressed. For example, when only

keys 1 and 3 have responded to the signal sent from
KOS-ECU, the new priority of the keys would be
1-3-2-4. When keys 3 and 4 have responded, then
the priority of the keys becomes 3-4-1-2.
GENERAL INFORMATION
42B-7
System configuration
Dome light,
Ignition key cylinder
illumination light
Horn
CAN-B
Steering unit communi- Door lock actuator
cation
ETACS-ECU
Push switch
Trunk lid latch
Steering lock unit CAN-C comm-

unication
Turn-signal light
ECM
ABS-ECU
Unlock sensor and
lock switch
Combination meter
(Driver's side door)
(Multi information display, TPMS warning light)
KOS-ECU
Unlock sensor and
lock switch
(Passenger's side door)
Interior transmitter Exterior transmitter
antenna assembly antenna assembly
Trunk lid opener switch

Driver's side
Front
Outer tone alarm Passenger's side
Rear
Trunk lid
Receiver antenna module
Radio Radio Low Low

frequency frequency frequency frequency
signal signal signal signal

Lock/Unlock/Trunk lid button
Antenna
Transmission
Front tire (LH) Front tire (RH) Emergency key
circuit
CPU Battery
Panic button
Pressure ACC. Indicator light

sensor sensor
TPMS transmitter Rear tire (LH) Rear tire (RH)

AC608842AB
SYSTEM OPERATION
SYSTEM OPERATION
DOOR ENTRY FUNCTION
M2421009100109
DESCRIPTION OF CONSTRUCTION AND OPERATION

.
<Vehicles outside area>

Front door outside handle (passenger's side)
AC608092
Front door outside handle (driver's side)
AC608093
AC609438 AB
Front door outside handle (driver's side, passenger's side)
Lock switch AC608091

AC505249
View A

Unlock sensor AC505250 AC609034
AC609439 AB
SYSTEM OPERATION
42B-9
When a driver carrying a keyless operation key KOS-ECU creates an encrypted code calculation
presses the lock switch and the unlock sensor (door factor in random number, and sends it to the keyless
outside handle) on the driver's/passenger's door out- operation key together with the transmit data. The
side handle or the trunk lid opener switch, the key- keyless operation key calculates the code by using
less operation key and KOS-ECU communicate to the received factor, and sends the result to
certify* the keyless operation key. When KOS-ECU KOS-ECU together with the response data.
certifies the registered keyless operation key within KOS-ECU determines that the communication is
70 cm (28 inches) in radius from the outer side of the established only when the code calculation results of
vehicle, it requests ETACS-ECU to lock/unlock the both parties coincided.
doors (Even within this range, the key may not be .
certified when it is positioned too high or too low). UNLOCKING OPERATION OF DOOR
NOTE: *: In the communication for certification of the ENTRY FUNCTION
keyless operation key, KOS-ECU judges if the key- The keyless operation key and KOS-ECU communi-
less operation key ID (specified to keyless operation cate to certify the keyless operation key when the
key) contained in the response data from the keyless unlock sensor on the driver-side/front passen-
operation key coincides with the ID that has been ger-side door outside handle or the trunk lid opener
stored in ECU by registration operation. The keyless switch is turned ON. When KOS-ECU certifies the
operation key sends the response to KOS-ECU only registered keyless operation key on the outer side of
when the KOS ID (specific to KOS-ECU) contained the vehicle, it requests ETACS-ECU to unlock the
in the received data coincided with the stored ID. In doors.
the beginning of the communication for certification,
.
CONTROL OF UNLOCKING OPERATION

Jamming is not transmitted at If there is no keyless operation key
the time of trunk lid operation. response, retry is performed once.
The unlock sensor of door outside handle ON
(driver's side, passenger's side) or the
trunk lid opener switch OFF
Exterior transmitter antenna Transmission
assembly operation side Un-transmitting
Exterior transmitter antenna Transmission
assembly opposite side
Un-transmitting
Interior transmitter antenna Transmission
assembly
Un-transmitting
Keyless operation key Response
1 to 4 response Un-answering
c
a b d
e
f
h
g g g g
Communication
CAN
Un-communicating
a: Exterior data transmitting start: 0.015 to 0.04 sec e: Keyless operation key 3 response time of onset 0.135 to 0.18 sec
b: Interior data transmitting start: 0.03 to 0.05 sec d: Keyless operation key 2 response time of onset 0.205 to 0.26 sec
c: Keyless operation key 1 response time of g: CAN communication time of onset: to 0.3 sec
onset 0.035 to 0.06 sec h: Retry time: It is variable by the registration number
d: Keyless operation key 2 response time of (at the time of 4 pieces registration 3.1 sec).
onset 0.08 to 0.115 sec AC500829AD
SYSTEM OPERATION
1. When KOS-ECU detects that the unlock sensor

.
UNLOCKING OPERATION INHIBITION

on the driver-side/front passenger-side door
outside handle or the trunk lid opener switch is TIME
turned ON, it transmits the exterior data from the Considering the customer pulls the door outer handle
exterior transmitter antenna assembly on the to make sure the doors are locked, unlocking opera-
operation side. At the same time, KOS-ECU tion is inhibited for three seconds after the doors are
transmits the interfering radio wave* (reversal locked by the lock switches on the driver-side/front
code) from the exterior transmitter antenna passenger-side door outside handle or on the trunk
assembly on the other side (The interfering radio lid opener switch. This duration can be selected from
wave will be transmitted from the front zero, three seconds, and five seconds, and can be
passenger-side antenna assembly when the switched using a customization function (Refer to
driver-side door outside handle is operated, and P.42B-27). The initial setting at factory is 3 seconds.
vice versa. It will not be transmitted when the .
trunk lid opener switch is operated). UNLOCKING OPERATION INHIBITION

NOTE: *: The interfering radio wave is transmitted CONDITIONS
to disable the door lock operation by a person The door unlocking operation is inhibited when:
without the keyless operation key while a user The emergency key is in the ignition switch.
with the keyless operation key is operating the The push switch in the steering lock is ON.
door lock from the opposite side of the vehicle. The IG knob is in other than LOCK (OFF) posi-
2. After the exterior data is transmitted from the tion.
exterior transmitter antenna assembly, the interior During the unlocking operation inhibition time
data is transmitted from the interior transmitter
antenna assembly (front, rear).
.
LOCKING OPERATION OF DOOR ENTRY

3. For the specified time period (varies with the FUNCTION
number of the keyless operation keys registered
The keyless operation key and KOS-ECU communi-
in KOS-ECU), KOS-ECU monitors the response
cate to certify the keyless operation key when the
from the keyless operation key that meets the
lock switch on the driver-side/front passenger-side
unlock conditions.
door outside handle is turned ON. When KOS-ECU
When the keyless operation key receives the
certifies the registered keyless operation key only on
exterior data only, KOS-ECU transmits the unlock
the outer side of the vehicle, it requests ETACS-ECU
request (request to unlock the applicable posi-
to lock all the doors.
tion) to ETACS-ECU.
When KOS-ECU received no response that .
enables the unlocking after the specified time

period has passed, it performs the retry cycle
once (When no response after the retry,
KOS-ECU terminates the unlocking operation).
SYSTEM OPERATION
42B-11
CONTROL OF LOCKING OPERATION
If there is no keyless operation key response,

retry that keyless operation key located outside.
The lock switch of door ON
outside handle (driver's
side, passenger's side) OFF
Exterior transmitter Transmission
antenna assembly
operation side Un-transmitting
Exterior transmitter Transmission
antenna assembly
opposite side Un-transmitting
Interior transmitter Transmission
antenna assembly
Un-transmitting
Keyless operation key Response
1 to 4 response
Un-answering
a b c d
e
f
g g
Communication
CAN
Un-communicating
a: Exterior data transmitting start: 0.03 to 0.04 sec e: Keyless operation key 3 response time of onset 0.135 to 0.18 sec
b: Interior data transmitting start: 0.03 to 0.05 sec d: Keyless operation key 2 response time of onset 0.205 to 0.26 sec
c: Keyless operation key 1 response time of g: Retry time: It is variable by the registration number
onset 0.035 to 0.06 sec (at the time of 4 pieces registration 0.31 sec).
d: Keyless operation key 2 response time of h: CAN communication time of onset: to 0.65 sec
onset 0.08 to 0.115 sec AC607100AB
1. When KOS-ECU detects that the lock switch on 4. KOS-ECU transmits the interior data from the
the driver-side/front passenger-side door outside interior transmitter antenna assembly (Front).
handle is turned ON, it transmits the exterior data 5. After the specified time period (varies with the
from the exterior transmitter antenna assembly on number of the keyless operation keys registered
the operation side. At the same time, KOS-ECU in KOS-ECU) has passed, confirm that the lock
transmits the interfering radio wave (reversal conditions are met.
code) from the exterior transmitter antenna When KOS-ECU receives the response from the
assembly on the other side. (The interfering radio keyless operation keys that received the interior
wave will be transmitted from the front data, KOS-ECU cancels the locking operation.
passenger-side antenna assembly when the When all the responding keyless operation keys
driver-side door outside handle is operated, and receive the exterior data only, KOS-ECU trans-
vice versa.) mits the lock request to ETACS-ECU.
2. After the exterior data is transmitted from the If there is no response from the keyless operation
exterior transmitter antenna assembly, the interior keys, perform step 6 once.
data is transmitted from the interior transmitter 6. KOS-ECU transmits the exterior data from the
antenna assembly (front, rear). exterior transmitter antenna assembly on the
3. After the specified time period (varies with the operation side. At the same time, KOS-ECU
number of the keyless operation keys registered transmits the interfering radio wave (reversal
in KOS-ECU) has passed, confirm that there is no code) from the exterior transmitter antenna
keyless operation key in the interior. assembly on the other side. (The interfering radio
When KOS-ECU receives the response from the wave will be transmitted from the front
keyless operation keys that received the interior passenger-side antenna assembly when the
data, KOS-ECU cancels the locking operation. driver-side door outside handle is operated, and
vice versa.)
SYSTEM OPERATION
7. After the specified time period (varies with the Any door is open/ajar (door switch is ON).
number of the keyless operation keys registered (including door ajar)
in KOS-ECU) has passed, confirm that the lock The emergency key is in the ignition switch.
conditions are met. The push switch in the steering lock is ON.
When the responded keyless operation keys after The IG knob is in other than LOCK (OFF) posi-
the retry receives the exterior data only, tion.
KOS-ECU transmits the lock request (request to .
lock the actuated position) to ETACS-ECU. ANSWERBACK FUNCTIONS

. When KOS-ECU sends a signal to ETACS-ECU,
LOCKING OPERATION INHIBITION ETACS-ECU outputs the lock/unlock signal and acti-
CONDITIONS vates the hazard warning light and the outer buzzer
In the following cases, the door locking operation is to notify the driver the doors are locked/unlocked.
inhibited.
Lock signal received Unlock signal received
ETACS-ECU Lock signal output Unlock signal output
Hazard warning light Flashes once Flashes twice
Outer buzzer Sounds once (initial setting) or none Sounds twice (initial setting) or none
KOS TIMER LOCK FUNCTION

.
When none of the doors are opened within 30 sec-

onds after the doors are unlocked by KOS,
ETACS-ECU automatically outputs the door lock sig-
nal to lock the doors. This function prevents the
doors from being unlocked accidentally.
SYSTEM OPERATION
42B-13
KEYLESS ENTRY FUNCTION
M2421000400084
Receiver antenna module
KOS-ECU
AC608090
Radio frequency signal
Lock button
Keyless operation key Trunk lid button
ETACS-ECU
Electric signal
Unlock button
Door lock actuators (lock/unlock)

Panic button
The signal causes the hazard warning light to flash once AC608093
when the doors are locked, or flash twice when unlocked (Initial setting).
The signal causes the dome light to extinguish when
the doors are locked, or come on for 15 seconds when unlocked.
AC609440 AB
Up to four encrypted codes can be registered

.
This keyless entry function has the following fea-

tures: A keyless entry system enables locking and using scan tool MB991958 (M.U.T.-III
unlocking of all doors, the trunk lid from 12m (39.4 sub-assembly).
feet) away from the vehicle. The following features Answerback functions
are also available. NOTE: The answerback function can be changed
A four-knob type keyless operation key with lock, using a customisation function (Refer to
unlock, trunk lid and panic buttons. P.42B-27).
The receiver antenna module incorporates a Keyless entry timer lock
receiver and a receiving antenna. NOTE: Timer of the keyless entry timer lock can
be changed using a customization function (Refer
to P.42B-27).
SYSTEM OPERATION
DESCRIPTION OF CONSTRUCTION AND The keyless operation key is integrated into the
OPERATION master key. The four-knob button is adopted, and
.
the specific encrypted code is transmitted as
KEYLESS OPERATION KEY radio wave signal.
A brilliant silver three-diamond mark is stamped
<Front view> Indicator light on the back side of the key grip to improve
Lock button appearance.
Trunk lid button An indicator light, which illuminates when signals
are sent, is added on the key grip. This indicator
light informs you of the signal transmission status
and warns you of flat battery.
A signal transmission circuit (printed circuit) and
Unlock button a battery are housed in one case. The case is
Panic button housed in the key grip, thus improving resistance
AC608093
to water ingress.
<Rear view> A coin type battery, CR2032 is used in the key-
less operation key.
Using a customization feature, the keyless opera-
tion key operation can be changed (Refer to
P.42B-27).
The keyless operation key button operation
allows the system to operate as follows:
Three-diamond mark
AC608094
AC609441 AB
KEYLESS OPERATION SYSTEM OPERATION TABLE (DEFAULT)

OPERATION OF KEYLESS OPERATION KEY SYSTEM OPERATION
Lock button Press once Lock all doors
Unlock button Press once Unlock the drivers door
Press twice Unlock all doors
Trunk lid button Press twice (press once, Open the trunk lid
and then press again within
5 seconds)
Panic alarm Panic button Press once (press and hold Starts the panic alarm (headlights flash and
system for 1 second). horn honks for three minutes)
Lock button, Press again Stops the panic alarm in progress
unlock button,
trunk lid button
or panic button
.
SYSTEM OPERATION
42B-15
ENCRYPTED CODE when they coincided, a signal is output from
ETACS-ECU. By connecting scan tool MB991958
Transmitter lock or unlock button (M.U.T.-III sub-assembly) to the data link connector,
ON
up to four encrypted codes of keyless operation keys
can be registered.
OFF
NOTE: IA keyless operation key can be added with-
out using the scan tool. <USA only>
Data .
code FUNCTION FOR CONFIRMING RECEIVER

ANTENNA MODULE OUTPUT AND
AC508281AB
OPERATION
Four data codes are transmitted when a switch is When the KOS-ECU receives an electric wave signal
operated once. The encrypted code for user identifi- of the identification code stored in the receiver
cation is a combination of 0 and 1, and more than 1 antenna module, the KOS-ECU outputs
million different combinations are available. To pre- LOCK/UNLOCK signal to the ETACS-ECU and
vent theft by copying signal codes, the data code informs the driver of the keyless entry system opera-
includes a rolling code with the encrypted code. The tion by flashing the light and blowing horn (Answer-
rolling code changes each time a signal is sent. back). The initial setting at factory for the
.
answerback function is as the following table. Using
RECEIVER a customization feature, the answerback function
The receiver is incorporated into the receiver can be changed (Refer to P.42B-27).
antenna module together with the receiving antenna. FUNCTION TABLE FOR CONFIRMING KEYLESS
It sends the signal the antenna received from the ENTRY OPERATION (DEFAULT)
keyless operation key to KOS-ECU. KOS-ECU com-
pares this signal with the ID code registered in it, and
ITEM OPERATION
DOORS LOCKED DOORS UNLOCKED
ETACS-ECU (receiver antenna Sends lock signal Sends unlock signal
module)
Dome light Flashes once Illuminates for 15 seconds
Turn-signal lights (RH and LH) Flashes once Flashes twice
Horn Sounds once if doors are already
locked
The hazard answerback function that allows check-

.
KEYLESS ENTRY HAZARD LIGHT ing the lock/unlock state of the door easily even in
ANSWERBACK FUNCTION the daytime is installed. When the LOCK signal from
the keyless operation key is input to ETACS-ECU, all
LOCK
Keyless entry
transmitter
doors are locked and the hazard warning light
OFF
switch flashes once. When UNLOCK signal is input, all
UNLOCK
ON doors are unlocked and the hazard warning light
Lock relay output
OFF flashes twice.
ON .
Unlock relay output

OFF
Hazard Illuminate
warning light Extinguish
AC207001AB
SYSTEM OPERATION
KEYLESS ENTRY DOME LIGHT

ANSWERBACK FUNCTION
ON
Unlock relay output
OFF
ON
Lock relay output
OFF
ON
Door lock switch

output OFF
ON
Door unlock switch
output
OFF
Illuminate
Dome light
Extinguish
b a b
a: 0.6 second c
b: 1.2 seconds
c: 15 seconds AC404883AB
When LOCK signal from the keyless operation key is

.
input to the ETACS-ECU via receiver antenna mod-

KEYLESS ENTRY TIMER LOCK TIME
ule, all doors are locked and the dome light will extin- When none of the doors are opened within 30 sec-
guish*. When UNLOCK signal is input, all doors are onds after the doors are unlocked by the keyless
unlocked and the dome light illuminates for 15 sec- entry system, ETACS-ECU automatically outputs the
onds. The dome light fades in, keeps on, and fades door lock signal to lock the doors. This function pre-
out in 15 seconds after the door unlock relay is oper- vents the doors from being unlocked unexpectedly
ated. by operation errors. Using a customization function,
the timer lock period can be changed (Refer to
NOTE: *: If doors are locked with the keyless opera-
P.42B-27).
tion key when the dome light is ON while doors are
opened, the dome light is switched off in 1.2 sec- .
onds. In addition, if doors are locked with the keyless OPERATION INHIBITION CONDITIONS
operation key when the dome light is OFF, the dome The operation of the system is inhibited when:
light does not work. The ignition key is in the ignition switch.
SECURITY ALARM
.
KEYLESS ENTRY HORN ANSWERBACK

The security alarm function is based on the door lock
FUNCTION
operation by the keyless entry system or KOS. The
When the LOCK signal from the keyless operation
function warns when the doors are opened by any
key is received into ETACS-ECU via receiver
operation other than the keyless entry system or
antenna module, all doors are locked and the horn
KOS. Using a customization function, the security
sounds. If the driver's door cannot be locked even
alarm can be enabled/disabled (Refer to GROUP
when the keyless operation key is operated, the horn
54A, Security alarm P.54A-37). This customization
does not sound.
function is described in the owners manual.
.
SYSTEM OPERATION
42B-17
SECURITY INDICATOR LIGHT The security indicator light has been installed on the
center panel of the instrument panel.
Security indicator light

AC609031AB
ENGINE STARTING FUNCTION

M2421009200087
When carrying the keyless operation key, a driver
can start/stop the engine by operating the IG knob,
not using the ignition key.
Emergency key

Radio
frequency
signal
Keyless
operation key
(Rear view) AC608095
Interior Interior
Radio transmitter transmitter
antenna antenna
frequency assembly assembly
signal (Front) (Rear)
IG knob cap CAN-B CAN-C

communication communication
Ignition
IG knob CPU CPU
unlock signal
Push
switch Injector
OK status signal
IG knob
Steering lock Receiver KOS-ECU ETACS-ECU ECM
(Built in AC608964
antenna module
Steering lock unit) AC609284AB
SYSTEM OPERATION
OPERATION 7. When a keyless operation key certification agree-

.
ment memory "exists" *1 in KOS-ECU when it

WHEN THE USER IS CARRYING THE
received the OK status signal from the steering
KEYLESS OPERATION KEY lock unit, the engine start permission communica-
1. Press the IG knob on the steering lock, and the tion (CAN communication) is performed between
push switch inside the steering lock is turned ON. KOS-ECU and the ECM by turning the IG knob
2. When the push switch inside the steering lock is from the "ACC" position to the "ON"/"START"
turned ON, KOS-ECU activates the interior trans- position, and the engine starts. If the keyless
mitter antenna assembly to send the transmitter operation key certification agreement memory
signal to the keyless operation key. "does not exist" *2, the engine does not start.
3. On receiving the transmitter signal from NOTE: .
KOS-ECU, the keyless operation key performs *1: The keyless operation key certification agree-
the keyless operation key certification and the
ment memory "exists" means that a regis-
key ID calculation, and sends the keyless opera-
tered keyless operation key has been
tion key ID data to KOS-ECU. (The keyless oper-
recognized during the keyless operation key
ation key cannot receive the transmitter signal
certification communication.
from KOS-ECU when it is not located within the *2
engine starting function valid area .) : When the keyless operation key certification
4. The receiver antenna receives the signal from the agreement memory "does not exist," the "key-
keyless operation key, and then KOS-ECU com- less operation key bringing-out monitoring
pares the keyless operation key ID data sent from function" and the "keyless operation key
the key with the one registered in it. replacement monitoring function" (keyless
operation key monitoring controls) have
5. When this data coincides, KOS-ECU sends the
judged that the keyless operation key has
IG knob unlock signal to the steering lock unit
been carried out of the vehicle with the IG
inside the steering lock.
knob in the LOCK "(OFF)" position while turn-
6. On receiving the IG knob unlock signal, the steering ON the push switch or in the ACC, ON, or
ing lock unit performs processing (verification of START position.
the KOS ID, etc.) based on the received data.
When no problem is found during the processing,
the unit sends the OK status signal to KOS-ECU,
and at the same time, electrically disengages the
steering lock mechanism to make the IG knob
rotatable.
When none of the registered keyless operation keys
.
KEYLESS OPERATION KEY TAKE OUT (up to four) respond during the communication,
MONITORING FUNCTION KOS-ECU determines that the key has been brought
To prevent the engine from starting when the keyless out of the car, and the keyless operation key certifi-
operation key is carried out of the vehicle with the IG cation agreement memory "does not exist," and does
knob in the LOCK "(OFF)" position and the push not permit starting of the engine.
switch OFF, KOS-ECU performs the certification NOTE: The monitoring function is inhibited when:
communication with the keyless operation key inside
.
the vehicle and monitors if it is carried out of the vehi-
The keyless operation key certification agree-
cle.
ment memory "does not exist" from the start.
The emergency key is in the IG knob.
The IG knob is in LOCK "(OFF)" position and the
push switch is OFF.
The vehicle is judged running (shift lever in "P" or
"N", or vehicle speed is 6 km/h or higher).
.
SYSTEM OPERATION
42B-19
KEYLESS OPERATION KEY tered keyless operation keys sends a responce,
REPLACEMENT MONITORING KOS-ECU determines that the key has been brought
into the vehicle (replaced), and sets the keyless
FUNCTION operation key certification agreement memory to
If the keyless operation key carrying-out monitoring "exist," and permits starting of the engine.
function once detects that the key has been carried
NOTE: The monitoring function is inhibited when:
out of the vehicle with the IG knob in the LOCK
"(OFF)" position and with the push switch in other .
than OFF, and then the key is brought into the vehi- The keyless operation key certification agree-
cle, the engine must be started when the IG knob is ment memory "exists" from the start.
turned to the ON or START position. For this pur- The emergency key is in the IG knob.
pose, KOS-ECU performs the certification communi- The IG knob is in LOCK (OFF) position and the
cation with the keyless operation key inside the push switch is OFF.
vehicle every 5 seconds to monitor the replacement The vehicle is judged running (shift lever in "P" or
of the keyless operation key. When any of the regis- "N", or vehicle speed is 6 km/h or higher).
.
WHEN USING EMERGENCY KEY

Receiver KOS-ECU ETACS-ECU ECM
antenna
Transponder
module
CPU CAN-B CAN-C CPU Ignition
Key ID
CAN Injection
CAN
Keyless operation key Steering lock
Emergency key
AC609294AB
Receiver antenna 3. The KOS-ECU compares the ID code that was

module sent with pre-registered ID codes, and only when
the code matches, the KOS-ECU controls the
IG knob ECM.
4. Since the power to the transponder incorporated
in the keyless operation key is supplied from the
receiver antenna module, the keyless operation
Emergency key key can be used even when its battery is dis-
charged. Two keyless operation keys are pro-
Keyless operation key AC609293AB vided for each vehicle, and up to four keys can be
registered as needed. In addition, the emergency
The engine can be started by removing the IG knob
keys can be registered as many as the keyless
cap and inserting the emergency key in KOS steer-
operation keys. There are one trillion possible
ing lock. In this case, the system operates as follows:
combination for the registered ID codes which
1. Inversely insert the emergency key in the keyless improves security by preventing theft using a cop-
operation key, insert that in KOS steering lock, ied ID code.
and then press and turn the emergency key using
NOTE: If KOS-ECU is replaced, or if the keyless
the keyless operation key.
operation key is lost or the additional key is added,
2. When the emergency key is turned to the ON
all the keyless operation key ID codes must be
position, the transponder (a small transmitter)
re-registered using the scan tool. (A key can be
incorporated in the keyless operation key trans-
added without using the scan tool. <USA only>)
mits a key-specific ID code (key ID) to the
receiver antenna module by radio wave.
SYSTEM OPERATION
ENGINE STARTING FUNCTION VALID

AREA
The engine can be started only when the keyless
operation key is within the interior antenna receiving
area.
Inside transmission antenna assembly (Front) Inside transmission antenna assembly (Rear)
Antenna receiving area Antenna receiving area

AC609222AB
TIRE PRESSURE MONITORING SYSTEM (TPMS) FUNCTION

M2421000600011
When the tire pressure becomes under the specified
value, the TPMS function warns the driver of that
state by illuminating the TPMS warning light.
OPERATION
The signals from the TPMS transmitter are NOTE: *: Change to continuous illumination after
received by the KOS-ECU. flashing for about 1 minute.
KOS-ECU processes input signals from each For 3 seconds after the ignition switch is turned to
TPMS transmitter as well as vehicle speed sig- the "ON" position, KOS-ECU illuminates the
nals from the ABS-ECU. It receives the atmo- TPMS warning light to check any breaks in the
spheric pressure signal from ECM, and when the TPMS warning light circuit.
atmospheric pressure is low (such as at high alti- By connecting the scan tool to the data link con-
tude), it calibrates the tire pressure received from nector, data stored in KOS-ECU (data of tire
TPMS transmitter and makes a judgment of pressure and TPMS transmitter ID, the alarm sta-
warning. When the road tire pressure is low, it tus and warning history, etc.) can be displayed
sends a warning signal causing the TPMS warn- and TPMS transmitter ID can be registered.
ing light to be illuminated. When the TPMS has NOTE: If the TPMS transmitter is replaced, regis-
problems, it sends a warning signal causing the ter the ID codes of all the TPMS transmitters
TPMS warning light to be flashed*. again using the M.U.T.-III.
SYSTEM OPERATION
42B-21
TPMS WARNING LIGHT
The TPMS warning light on the combination meter illuminates
or flashes* to alert the driver by request from KOS-ECU. When
the tire pressure warning or the fault warning is activated, a
warning symbol and a message are displayed on the multi
information display.
WARNING DISPLAY PATTERN OF TPMS WARNING LIGHT
AND MULTI INFORMATION DISPLAY
Circumstance Warning light Multi
information
display
For 3 seconds Illuminates No indication
after the ignition
LOW
TIRE PRESSURE
switch is turned to
the "ON" position
(warning light
circuit self-check)
SERVICE
TPMS problems Flashes* Symbol and
REQUIRED
"SERVICE
REQUIRED" is
AC609362 displayed
Low tire pressure Illuminates Symbol and
"LOW TIRE
PRESSURE"
is displayed
TIRE PRESSURE THRESHOLD VALUES

Item Tire pressure kPa (psi)
Standard pressure at 220 (32)
cold (reference)
Alarm ON pressure 174 (25.2) or less
Alarm OFF pressure 189 (27.4) or more
TPMS TRANSMITTER (TIRE PRESSURE SENSOR)

The TPMS transmitter combines the valve and tire
.
pressure sensor in a single unit. The TPMS transmit-

TIRE PRESSURE SAMPLING TIMING
ters are mounted inside the tires. The TPMS trans-
Vehicle status Sampling timing
mitter measures tire pressure directly with its tire
pressure sensor and sends radio frequency signals At vehicle moving once every 5 seconds
to KOS-ECU. The TPMS transmitter includes accel- At vehicle stationary once every 1 minute
eration sensor that senses tire rotation, and change
NOTE: Vehicle moving = vehicle speed: approxi-
tire pressure sampling and data transmission timing
mately 25 km/h (15 mph) or more
when vehicle is running.
NOTE: Use only genuine wheels. The use of .
non-genuine wheels may cause the improper instal-

lation of the TPMS transmitters, possibly resulting in
air leakage and damage to the TPMS transmitter.
SYSTEM OPERATION
DATA TRANSMISSION TIMING If a sampled pressure varies by 10 kPa

(1.5psi) from the last transmitted pressure
Vehicle status Transmission timing value, an additional transmission will occur.
At vehicle moving once every 1 minute* NOTE: *: Once every 15 seconds for first 30 trans-
mission after vehicle starts moving.
At vehicle stationary once every 13 hours
WARNINGS/ALARMS
M2421009300062
If the KOS failed, operated improperly, KOS-ECU
warns the driver of this by setting off the outer tone
alarm and the keyless operation warning indicator,
on the multi information display in the combination
meter. If the TPMS fails or the tire pressure is low,
KOS-ECU warns the driver of that state by the
TPMS warning light and the multi information display
in the combination meter.
Display Item State Warning operations Warning
contents TPMS Multi cancellation
warning information conditions
light display (Cancels warning
operations when
one of the
conditions met)
Low keyless The keyless Warning IG knob in
operation key operation key with indicator "LOCK" (OFF)
KEY BATTERY
LOW
AC610126AB
battery voltage low battery voltage is flashes for position and
warning detected when the IG 30 seconds. push switch OFF
knob is pressed. The outer are detected.
tone alarm 30 seconds have
will not passed after the
sound. warning output
started.
No keyless No keyless operation The warning IG knob in
operation key key is detected inside indicator "LOCK" (OFF)
KEY MISSING
AC610127AB
detected inside the car when the IG flashes for 5 position and
the car knob is pressed. minutes. push switch OFF
The outer are detected.
tone alarm 5 minutes have
will not passed after the
sound. warning output
started.
SYSTEM OPERATION
42B-23
operations when
one of the
conditions met)
IG knob is not Opening of the The warning The IG knob in
returned driver's door is indicator the "RUN" or
properly. detected when the IG flashes for 5 "START"
STEERING
WHEEL LOCK
AC610124AB
knob is in ACC or minutes. position, or the
LOCK position and The outer IG knob in the
the push switch is tone alarm "LOCK" (OFF)
ON. will not position, and the
sound. push switch OFF
Key are detected.
reminder The driver's door
warning tone is detected
alarm closed from the
sounds until open position.
closing of the 5 minutes have
driver's door passed after the
is detected. warning output
started.
Keyless The keyless The warning IG knob in
operation key operation key is indicator "LOCK" (OFF)
brought out of brought out of the car flashes for 5 position and
CONFIRM
KEY LOCATION
AC610128 AC
the car warning when the IG knob is minutes. push switch OFF
in other than the Outer tone are detected.
LOCK position. alarm KOS-ECU has
sounds for detected a
5.69 keyless
seconds in operation key
pattern 2. inside the
vehicle.
5 minutes have
passed after the
warning output
started.
SYSTEM OPERATION

operations when
one of the
conditions met)
Door lock does Push switch is Warning IG knob in
not operate. pressed ON when indicator "LOCK" (OFF)
CHECK DOORS
AC610129 AB
the IG knob is in flashes for 5 position and
other than LOCK seconds. push switch OFF
position. Outer tone are detected.
alarm 5 seconds have
sounds for passed after the
2.96 warning output
seconds in started.
Push switch is pattern 1. Lock switch on
pressed ON when the keyless
the keyless operation operation switch
key is inside the car. is pressed again.
5 seconds have
passed after the
warning output
started.
Push switch is All doors are
pressed ON when closed.
the door is ajar. 5 seconds have
passed after the
warning output
started.
SYSTEM OPERATION
42B-25
operations when
one of the
conditions met)
System error Push switch is The warning 5 minutes have
pressed ON from indicator passed after the
REMOVE KEY
OFF when an error flashes for 5 push switch was
has been detected in minutes. pressed ON and IG
AC610118 AB
EEPROM in The outer knob is in "LOCK"

KOS-ECU. tone alarm (OFF) position.
Push switch is will not
pressed ON from sound.
OFF while open
circuit in the
transmitter antennas
are being detected.
The push switch is
pressed ON from
OFF while short
circuit in the power
supply output
(steering lock,
transmitter antennas,
receiver antenna
module, etc.) is
detected.
Steering lock
communication error
has been detected
when the push switch
was pressed ON.
The IG knob is in
other than the LOCK
position while some
error is being
detected.
TPMS warning The ignition switch is Illuminate 3 seconds have
light bulb open turned from "LOCK" s for 3 passed after the
circuit check (OFF) to "ON." seconds. TPMS warning light
is lit.
a Tire pressure The received tire Illuminate Symbol and The received tire
alarm pressure value is s. "LOW TIRE pressure value is
LOW
TIRE PRESSURE under the alarm ON PRESSURE" is over the alarm OFF
AC610119 AB
threshold value. displayed. threshold value.
SYSTEM OPERATION

operations when
one of the
conditions met)
b
TPMS ID not The TPMS Flashes * Symbol and ID is registered
failure stored transmitter ID is not "SERVICE normally.
SERVICE
REQUIRED warnin registered in the REQUIRED" is
g KOS-ECU. displayed.
AC610120AB
Defectiv Abnormality of data Data in the

e in the EEPROM of EEPROM of the
EEPRO the KOS-ECU is KOS-ECU is
M detected. checked to be
normal.
Problem The signals from The signal from the
in signal TPMS transmitters TPMS transmitter
receptio cannot be received that was warned is
n while driving for received.
about 20 minutes.
Defectiv The sensor failure A normal signal is
e signal is received received from the
sensor from the TPMS TPMS transmitter
transmitter. that was warned.
The The reception The signal of normal
battery problem warning is battery voltage is
voltage activated because of received from the
of the the low battery TPMS transmitter
TPMS voltage of the TPMS that was warned.
transmit transmitter.
ter is
low.
Vehicle The vehicle speed is The vehicle speed
speed not input. is input.
input
problem
Abnorm The vehicle speed The normal vehicle
al value is abnormal. speed value is
vehicle received.
speed
value
NOTE:
*: Change to continuous illumination after flashing for
about 1 minuite.
CONFIGURATION FUNCTION
42B-27
<Sound pattern 1> <Sound pattern 2>

T7
T3 T3 T3 T3
T1 T4 T4 T4
T1
T2 T3 : 1.01 seconds
T4 : 0.55 seconds
T1 : 0.08 0.01 seconds T5 : 0.17 0.01 seconds
T2 : 2.96 seconds T6 : 0.11 0.01 seconds
T5 T5 T5 T5
T6 T6 T6 T7 : 5.69 seconds
AC501053AC
M2421000300076
Using the scan tool, the following functions can be
programmed. The programmed information is held
even when the battery is disconnected.
MB991958 display)
display)
Hazard answer Adjustment of the Lock:1, Unlock:2 LOCK: Flashes once, UNLOCK: Flashes
back number of keyless twice (default)
hazard warning light Lock:1, Unlock:0 LOCK: Flashes once, UNLOCK: No flash
answer back
flashes Lock:0, Unlock:2 LOCK: No flash, UNLOCK: Flash twice
Lock:2, Unlock:1 LOCK: Flash twice, UNLOCK: Flash once
Lock:2, Unlock:0 LOCK: Flash twice, UNLOCK: No flash
Lock:0, Unlock:1 LOCK: No flash, UNLOCK: Flash once
Lock:0, Unlock:0 No function
Dome light Adjustment of 0sec 0 second (no delay shutdown time)
delay timer with interior light delay (default <Vehicles without central door
door shutdown time locking system>)
7.5sec 7.5 seconds
15sec 15 seconds
30sec 30 seconds (default <Vehicles with central
door locking system>)
60sec 60 seconds
120sec 120 seconds
180sec 180 seconds

MB991958 display)
display)
Door unlock Door lock system All doors unlock All the doors are unlocked when the
mode driver's side door is unlocked.
Dr door unlock Only the driver's side door is unlocked
when the driver's side door is unlocked.
(default)
position
P/W unlocked With function (with power window
unlocked)
Duration of horn Horn sounding time Short 0.01 second (default)
chirp during horn answer Long 0.02 second
back
Horn chirp by Horn chirp by RKE Not sound horn No horn answerback function
RKE Lock any time The horn sounds when the lock button of
keyless entry transmitter is pressed once.
W lock any time The horn sounds when the lock button of
keyless entry transmitter is pressed twice.
(default)
Tone alarm Adjusts the tone Not sound tone alarm No function
answer back alarm answer back At keyless key Sounds when the keyless entry system is
function. activated.
At keyless Sounds when KOS is activated (default).
At Both Sounds when the keyless entry system or
KOS is activated.
Timer lock timer Timer lock period 30sec 30 seconds (default)
adjustment 60sec 60 seconds
120sec 120 seconds
180sec 180 seconds
system>
back
Horn chirp by Horn chirp by Not sound horn No horn answerback function
keyless keyless entry Lock any time The horn sounds when the lock button of
system keyless entry transmitter is pressed once.
(default)
42B-29
MB991958 display)
display)
Buzzer answer Adjusts the tone Not sound buzzer No function
back alarm answer back At keyless Sounds when the keyless entry system is
function. activated.
At F.A.S.T. Sounds when KOS is activated (default).
KOS is activated.
120sec 120 seconds
180sec 180 seconds
Panic alarm With/without panic Disable No function
switch alarm function Enable With function (default)
F.A.S.T. key out With/without KOS Enable No function
of car key exterior Disable With function (default)
detection function
F.A.S.T. feature KOS function Both enable All KOS functions are enabled (default).
adjustment DoorEntry enable Only door entry function is enabled.
ENG strt enable Only engine starting function is enabled.
Both disabled All KOS functions are disabled.
F.A.S.T. unlock Adjusts the door 0sec 0 seconds
disable time unlock inhibition 3sec 3 seconds (default)
period after door
lock is activated. 5sec 5 seconds
NOTES
42C-1
GROUP 42C
WIRELESS
CONTROL MODULE
(WCM)
CONTENTS
GENERAL INFORMATION. . . . . . . . 42C-2 TIRE PRESSURE MONITORING SYSTEM (TPMS)

FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . 42C-9
SYSTEM OPERATION. . . . . . . . . . . . 42C-5 WARNINGS/ALARMS . . . . . . . . . . . . . . . . . 42C-11
KEYLESS ENTRY FUNCTION . . . . . . . . . . 42C-5
IMMOBILIZER FUNCTION . . . . . . . . . . . . . 42C-9
CONFIGURATION FUNCTION. . . . . . 42C-13
42C-2 WIRELESS CONTROL MODULE (WCM)
GENERAL INFORMATION
GENERAL INFORMATION
M2422000100075
The wireless control module (WCM) is a system that The ignition key incorporates the immobilizer
integrates the keyless entry function, immobilizer function that inhibits starting the engine by using
function, and the TPMS function, and it has the fol- an unauthorized key.
lowing features: The incorporated TPMS function monitors the air
The ignition key (transmitter) incorporates a pressure of all the tires (except spare tire).
lock/unlock/trunk lid button and a panic button. Each vehicle is provided with two ignition keys
The ignition key also incorporates an indicator (transmitter), and up to eight ignition keys can be
light that enables the driver to check if the signal registered.
is transmitted correctly or if the battery in the key Settings of the keyless entry function can be
is discharged. (Refer to P.42C-5.) adjusted using a customization function (Refer to
P.42C-13).
.
Multi information display TPMS

(Built in combination meter) warning light
LOW
TIRE PRESSURE
TPMS transmitter
ABS-ECU
WCM Indicator light

Lock button
ETACS-ECU Panic button
Unlock button
TPMS transmitter ECM Trunk lid Ignition key
(Tire pressure sensor) button (Transmitter)
AC609302 AC
.
WIRELESS CONTROL MODULE (WCM)
GENERAL INFORMATION
42C-3
Main components and functions
WCM Controls the keyless entry functions, TPMS functions and starting of the engine
by using the following communications.
Communications with ETACS-ECU, ECM, ABS-ECU <vehicles for ABS>
and combination meter via CAN
Wireless communication with the ignition key (transmitter)
Wireless communication with the TPMS transmitter
Ignition key (transmitter) The ignition key (transmitter) also sends signals to WCM when the
lock/unlock/trunk lid button and the panic button on it are operated.
Combination meter (Multi Communicates with WCM via CAN. Send ignition switch status. Receives the
information display, TPMS warning request or warning information about TPMS from WCM, activates* the
warning light) TPMS warning iight. Warning symbol and message is additionally displayed on
the multi information display.
ETACS-ECU Communicates with WCM via CAN send ignition switch status. Receives the
door lock/unlock request from WCM, outputs the lock/unlock signal and flashes
the turn signal light, dome light and horn to inform the driver that the doors are
locked/unlocked.
ABS-ECU Communicates with WCM via CAN. Sends the vehicle speed data <Vehicles
with ABS>.
ECM Communication with WCM via CAN. Send atmospheric pressure data. Sends
the vehicle speed data <Vehicles without ABS>.
TPMS transmitter Measure tire pressure directly, then send radio frequency signal to WCM.
NOTE: .
*: Illuminates for tire pressure warning.
*: Flashes for about 1 minute and then continuously illuminated for TPMS malfunction warning.
.
GENERAL INFORMATION
System configuration
Ignition key TPMS transmitter

Panic button Front tire (LH)
Indicator light Front tire (RH)
Trunk lid
button Antenna
Transmission
circuit
Lock button Unlock button
Rear tire (LH) Rear tire (RH)
CPU Battery
Pressure Acc.
Dome light,
sensor sensor Ignition key cylinder
illumination light
Radio Radio
frequency frequency
Horn
signal signal
CAN-B
communi- Door lock actuator
cation
ETACS-ECU
Wireless control module Trunk lid latch
CAN-C comm-
unication
Turn-signal light
ECM
ABS-ECU
Combination meter
(Multi information display,
TPMS warning light)
AC609283 AB
NOTE: In case of replacement of WCM, all keyless

ID, key ID and tire pressure sensor ID should be
re-registered using scan tool MB991958 (M.U.T.-III
sub-assembly).
SYSTEM OPERATION
42C-5
SYSTEM OPERATION
KEYLESS ENTRY FUNCTION
M2422000400076
WCM
AC608090
Radio frequency signal
Transmitter
Lock button
ETACS-ECU
Panic button
Electric signal
NIC
PA
Door lock actuators (lock/unlock)

The signal causes the hazard warning lamp to flash once
when the doors are locked, or flash twice when unlocked (Initial setting). Unlock button
The signal causes the room lamp to extinguish when AC405616
the doors are locked, or come on for 15 seconds when unlocked. Trunk lid button
AC609428 AB
Up to eight encrypted codes can be registered

.
This keyless entry function has the following fea-

tures: A keyless entry system enables locking and using scan tool MB991958 (M.U.T.-III
unlocking of all doors, the trunk lid from 12m (39.4 sub-assembly).
feet) away from the vehicle. The following features Answerback functions
are also available. NOTE: The answerback function can be changed
A four-knob type transmitter with lock, unlock, using a customization function (Refer to
trunk lid and panic buttons. P.42C-13).
The WCM incorporates a receiver and a receiv- Keyless entry timer lock
ing antenna. NOTE: Timer of the keyless entry timer lock can
be changed using a customization function (Refer
to P.42C-13).
SYSTEM OPERATION
DESCRIPTION OF CONSTRUCTION AND The transmitter is integrated into the master key.
OPERATION The four-knob button is adopted, and the specific
.
encrypted code is transmitted as radio wave sig-
TRANSMITTER nal.
An indicator light, which illuminates when signals
<Front view > are sent, is added on the key grip. This indicator
Lock button light informs you of the signal transmission status
Panic button
and warns you of flat battery.
A signal transmission circuit (printed circuit) and
a battery are housed in one case. The case is
Indicator light
PA
NIC housed in the key grip, thus improving resistance
to water ingress.
Unlock button A coin type battery, CR1620 is used in the trans-
mitter.
Trunk lid button
AC405616 The functions of the immobilizer system are inte-
<Back view> grated (Refer to P.42C-9).
Using a customization feature, the transmitter
button operation can be changed (Refer to
P.42B-27).
The transmitter button operation allows the sys-
tem to operate as follows:
Three-diamond mark AC405617

AC405710 AF
KEYLESS ENTRY SYSTEM OPERATION TABLE (DEFAULT)

OPERATION OF TRANSMITTER OPERATION OF KEYLESS ENTRY SYSTEM
Lock button Press once Lock all doors
Unlock button Press once Unlock the drivers door
Press twice Unlock all doors
Trunk lid button Press twice (press once, Open the trunk lid
and then press again within
5 seconds)
Panic alarm Panic button Press once (press and hold Starts the panic alarm (headlights flash and
system for 1 second). horn honks for three minutes)
Lock button, Press again Stops the panic alarm in progress
unlock button,
trunk lid button
or panic button
.
SYSTEM OPERATION
42C-7
ENCRYPTED CODE RECEIVER
The receiver is incorporated into WCM together with
Transmitter lock or unlock button the receiving antenna. The receiver compares the
ON signal the antenna received from the transmitter with
OFF the encrypted code registered in it, and when they
coincide, outputs a signal from WCM. By connecting
scan tool MB991958 (M.U.T.-III sub-assembly) to the
Data
data link connector, encrypted codes of up to eight
code transmitters can be registered.
NOTE: IA transmitter can be added without using the
AC508281AB scan tool. <USA only>
Four data codes are transmitted when a switch is .
operated once. The encrypted code for user identifi- FUNCTION FOR CONFIRMING WCM
cation is a combination of 0 and 1, and more than 1 (RECEIVER) OUTPUT AND OPERATION
million different combinations are available. To pre- When the ETACS-ECU receives can command from
vent theft by copying signal codes, the data code WCM, the ETACS-ECU outputs LOCK/UNLOCK sig-
includes a rolling code with the encrypted code. The nal and informs the driver of the keyless entry sys-
rolling code changes each time a signal is sent. tem operation by flashing the light and blowing horn
.
(Answerback). The initial setting at factory for the
answerback function is as following table. Using a
customization feature, the answerback function can
be changed (Refer to P.42C-13).
FUNCTION TABLE FOR CONFIRMING KEYLESS
ENTRY OPERATION (DEFAULT)
ITEM OPERATION
DOORS LOCKED DOORS UNLOCKED
ETACS-ECU (WCM) Sends lock signal Sends unlock signal
Dome light Flashes once Illuminates for 15 seconds
Turn-signal lights (RH and LH) Flashes once Flashes twice
Horn Sounds once if doors are already
locked
The hazard answerback function that allows check-

.
KEYLESS ENTRY HAZARD LIGHT ing the lock/unlock state of the door easily even in
ANSWERBACK FUNCTION the daytime is installed. When the LOCK signal from
the transmitter is input to ETACS-ECU, all doors are
LOCK
Keyless entry
transmitter
locked and the hazard warning light flashes once.
OFF
switch When UNLOCK signal is input, all doors are
UNLOCK
ON unlocked and the hazard warning light flashes twice.
Lock relay output
OFF .
ON
Unlock relay output
OFF
Hazard Illuminate
warning light Extinguish
AC207001AB
SYSTEM OPERATION
KEYLESS ENTRY DOME LIGHT

ANSWERBACK FUNCTION
ON
Unlock relay output
OFF
ON
Lock relay output
OFF
ON
Door lock switch

output OFF
ON
Door unlock switch
output
OFF
Illuminate
Dome light
Extinguish
b a b
a: 0.6 second c
b: 1.2 seconds
c: 15 seconds AC404883AB
When LOCK signal from the transmitter is input to

.
the ETACS-ECU via WCM, all doors are locked and

OPERATION INHIBITION CONDITIONS
the dome light will extinguish*. When UNLOCK sig- The operation of the system is inhibited when:
nal is input, all doors are unlocked and the dome light The ignition key is in the ignition switch.
illuminates for 15 seconds. The dome light fades in,
keeps on, and fades out in 15 seconds after the door SECURITY ALARM
unlock relay is operated. The security alarm function is based on the door lock
operation by the keyless entry system. The function
NOTE: *: If doors are locked with the transmitter
warns when the doors are opened by any operation
when the dome light is ON while doors are opened,
other than the keyless entry system. Using a custom-
the dome light is switched off in 1.2 seconds. In addi-
ization function, the security alarm can be
tion, if doors are locked with the transmitter when the
enabled/disabled (Refer to GROUP 54A, Security
dome light is OFF, the dome light does not work.
alarm P.54A-37). This customization function is
.
described in the owners manual.
KEYLESS ENTRY HORN ANSWERBACK .
FUNCTION SECURITY INDICATOR LIGHT

When WCM receives the LOCK signal from the
transmitter and send LOCK signal to ETACS-ECU,
all doors are locked and the horn sounds. If the
driver's door cannot be locked even when the key-
less entry transmitter is operated, the horn does not
sound.
.
KEYLESS ENTRY TIMER LOCK TIME

When none of the doors is opened within 30 seconds Security indicator light
after the doors are unlocked by the keyless entry AC609031AB
system, ETACS-ECU automatically outputs the door The security indicator light has been installed on the
lock signal to lock the doors. This function prevents center panel of the instrument panel.
the doors from being unlocked unexpectedly by
operation errors. Using a customization function, the
timer lock time can be changed (Refer to P.42C-13).
SYSTEM OPERATION
42C-9
IMMOBILIZER FUNCTION
M2422000500062
The immobilizer function prevents the engine from
starting and immobilizes the vehicle if a key other
than the key registered for that vehicle is used in an
attempt to start the engine after forced entry.
Ignition key WCM ETACS-ECU ECM
CPU CAN-B CAN-C CPU Ignition

Key ID
Transponder
CAN
CAN Injection
Steering lock
AC507888AE
OPERATION 3. Since the power to the transponder incorporated

1. With the ignition key turned ON, the transponder in the ignition key is supplied from the WCM, the
(a small transmitter) integrated in the ignition key ignition key can be used even when its battery is
transmits its own ID code (key ID) to WCM via discharged. Two ignition keys are provided, and
radio wave. up to eight ignition keys can be registered to one
2. According to the sent key ID, WCM controls the vehicle as needed. More than one trillion of ID
ECM only when the sent ID code agrees with the code combinations can be registered. This fea-
pre-registered one. ture prevents code copying, resulting in higher
security of the system.
NOTE: In case of replacement of WCM, or loss or
addition of the ignition key, all key ID codes should
be re-registered using scan tool. (A key can be
added without using the scan tool. <USA only>)
TIRE PRESSURE MONITORING SYSTEM (TPMS) FUNCTION

M2422000800018
When the tire pressure becomes under the specified
value, the TPMS function warns the driver of that
state by illuminating the TPMS warning light.
OPERATION
The signals from the TPMS transmitter are warning. When the road tire pressure is low, it
received by the WCM. sends a warning signal causing the TPMS warn-
WCM processes input signals from each TPMS ing light to be illuminated. When the TPMS has
transmitter as well as vehicle speed signals from problems, it sends a warning signal causing the
the ABS-ECU if equipped. It receives the atmo- TPMS warning light to be flashed*.
spheric pressure signal from ECM, and when the
NOTE: *: Change to continuous illumination after
atmospheric pressure is low (such as at high alti-
flashing for about 1 minute.
tude), it calibrates the tire pressure received from
For 3 seconds after the ignition switch is turned to
TPMS transmitter and makes a judgment of
the "ON" position, WCM illuminates the TPMS
warning light to check any breaks in the TPMS
warning light circuit.
SYSTEM OPERATION
By connecting the scan tool to the data link con- NOTE: If the TPMS transmitter is replaced, regis-
nector, data stored in WCM (data of tire pressure ter the ID codes of all the TPMS transmitters
and TPMS transmitter ID, the alarm status and again using the M.U.T.-III.
warning history, etc.) can be displayed and TPMS
transmitter ID can be registered.
TPMS WARNING LIGHT

The TPMS warning light on the combination meter illuminates
or flashes* to alert the driver by request from WCM. When the
tire pressure warning or the fault warning is activated, a warn-
ing symbol and a message are displayed on the multi informa-
tion display.
WARNING DISPLAY PATTERN OF TPMS WARNING LIGHT
AND MULTI INFORMATION DISPLAY
Circumstance Warning light Multi
information
display
For 3 seconds Illuminates No indication
after the ignition
LOW
TIRE PRESSURE
switch is turned to
the "ON" position
(warning light
circuit self-check)
SERVICE
TPMS problems Flashes* Symbol and
REQUIRED
"SERVICE
REQUIRED" is
AC609362 displayed
Low tire pressure Illuminates Symbol and
"LOW TIRE
PRESSURE"
is displayed
TIRE PRESSURE THRESHOLD VALUES

Item Tire pressure kPa (psi)
Standard pressure at 220 (32)
cold (reference)
Alarm ON pressure 174 (25.2) or less
Alarm OFF pressure 189 (27.4) or more
TPMS TRANSMITTER (TIRE PRESSURE SENSOR)

The TPMS transmitter combines the valve and tire NOTE: Use only genuine wheels. The use of
pressure sensor in a single unit. The TPMS transmit- non-genuine wheels may cause the improper instal-
ters are mounted inside the tires. The TPMS trans- lation of the TPMS transmitters, possibly resulting in
mitter measures tire pressure directly with its tire air leakage and damage to the TPMS transmitter.
pressure sensor and sends radio frequency signals .
to WCM. The TPMS transmitter includes accelera-

tion sensor that senses tire rotation, and change tire
pressure sampling and data transmission timing
when vehicle is running.
SYSTEM OPERATION
42C-11
TIRE PRESSURE SAMPLING TIMING DATA TRANSMISSION TIMING
Vehicle status Sampling timing Vehicle status Transmission timing
At vehicle moving once every 5 seconds At vehicle moving once every 1 minute*
At vehicle stationary once every 1 minute At vehicle stationary once every 13 hours
NOTE: Vehicle moving = vehicle speed: approxi- If a sampled pressure varies by 10 kPa
mately 25 km/h (15 mph) or more (1.5psi) from the last transmitted pressure
.
value, an additional transmission will occur.
NOTE: *: Once every 15 seconds for first 30 trans-
mission after vehicle starts moving.
WARNINGS/ALARMS
M2422000900015
If the TPMS fails or the tire pressure is low, the WCM
warns the driver of that state by the TPMS warning
light and the multi information display in the combina-
tion meter.
warning light information conditions (Cancels
display warning operations
when one of the
conditions met)
TPMS warning light The ignition Illuminates for 3 seconds have
bulb open circuit switch is 3 seconds. passed after the
check turned from TPMS warning light is
"LOCK" lit.
(OFF) to
"ON."
a Tire pressure alarm The received Illuminates. Symbol and The received tire
tire pressure "LOW TIRE pressure value is
value is PRESSURE" over the alarm OFF
LOW
TIRE PRESSURE
AC610119 AB
under the is displayed. threshold value.

ararm ON
threshold
value.
SYSTEM OPERATION

warning light information conditions (Cancels
display warning operations
when one of the
conditions met)
b TPMS ID not The TPMS Flashes * Symbol and ID is registered
failure stored transmitter ID "SERVICE normally.
SERVICE
REQUIRED
AC610120AB
warning is not REQUIRED" is
registered in displayed.
the WCM.
Defective Abnormality Data in the EEPROM
EEPROM of data in the of the WCM is
EEPROM of checked to be
the WCM is normal.
detected.
Problem in The signals The signal from the
signal from TPMS TPMS transmitter
reception transmitters that was warned is
cannot be received.
received
while driving
for about 20
minutes.
Defective The sensor A normal signal is
sensor failure signal received from the
is received TPMS transmitter
from the that was warned.
TPMS
transmitter.
The The The signal of normal
battery reception battery voltage is
voltage of problem received from the
the TPMS warning is TPMS transmitter
transmitter activated that was warned.
is low. because of
the low
battery
voltage of the
TPMS
transmitter.
Vehicle The vehicle The vehicle speed is
speed speed is not input.
input input.
problem
Abnormal The vehicle The normal vehicle
vehicle speed value speed value is
speed is abnormal. received.
value
NOTE: *: Change to continuous illumination after
flashing for about 1 minuite.
42C-13
M2422000600070
Using the scan tool, the following functions can be
MB991958 display)
display)
answer back
Dome light Adjustment of 0sec 0 second (no delay shutdown time)
7.5sec 7.5 seconds
15sec 15 seconds
30sec 30 seconds (default <Vehicles with central
60sec 60 seconds
120sec 120 seconds
180sec 180 seconds
mode <Vehicles with driver's side door is unlocked.
central door locking Dr door unlock Only the driver's side door is unlocked
system> when the driver's side door is unlocked.
(default)
system>
back
(default)

MB991958 display)
display)
120sec 120 seconds
180sec 180 seconds
51-1
GROUP 51
EXTERIOR
CONTENTS
GENERAL INFORAMATION . . . . . . . 51-2 WINDSHIELD WIPER AND WASHER 51-6
BUMPER AND RADIATOR GRILLE . 51-3 DOOR MIRRORS . . . . . . . . . . . . . . . . 51-9
AERO PARTS . . . . . . . . . . . . . . . . . . 51-5 CONFIGURATION FUNCTION. . . . . . 51-10

51-2 EXTERIOR
GENERAL INFORAMATION
GENERAL INFORAMATION
M2510000101799
Taking over previous model heritages; 5. Air dam skirt panels <GTS: Standard, ES:
Advanced, aggressive styling with sophisticated Optional>
surfacing 6. Engine room under cover with bulges at left and
Highly competitive body size in the current sporty right (Refer to P.51-3)
sedan market 7. Side air dams <GTS: Standard, ES: Optional>
Impressive front face as the next generation vehi- 8. Rear spoiler <GTS: Standard, ES: Optional>
cle of Mitsubishi identity 9. Aerodynamic rear bumper
High-positioned beltline creates a speedy atmo- .
sphere BETTER USER-FRIENDLINESS

Solid and rigid construction with simple and clean 10. Electric remote-controlled door mirrors
surface 11. Heated door mirrors <Vehicles for Canada>
FEATURES .
.
BETTER PRODUCT PACKAGE
BETTER APPEARANCE 12. Vehicle speed sensitive intermittent time variable
1. Radiator grille integrated front bumper windshield wiper
2. Side air dams <GTS: Standard, ES: Optional> .
3. Rear spoiler <GTS: Standard, ES: Optional> SUPPORT RECYCLING OF RESOURCES

. Uses PP (polypropylene) materials that are easy to
BETTER AERODYNAMIC recycle and easy to stamp material symbols on the
CHARACTERISTICS plastic (resin) parts.
4. Aerodynamic front bumper
.
12
10, 11
1
3, 8
6 5
2,7
9
AC607908AC
EXTERIOR
BUMPER AND RADIATOR GRILLE
51-3
M2510001300113
<Front bumper assembly> <Rear bumper assembly>

Front bumper
Front bumper reinforcement
core
Rear bumper reinforcement
Front bumper
side bracket
Rear bumper face

support bracket
Radiator grille
Front bumper assembly
Rear bumper assembly

AC608649AB
The front bumper has an opening at the center Resin-made front bumper side brackets and rear
lower to guide air to the condenser and radiator. bumper face support brackets have been
The front and rear bumpers incorporate highly adopted to improve the alignment with the body.
rigid bumper reinforcements and bumper core The rear bumper which is detachable from the
(front bumper) for excellent energy-absorption to body has been abolished to improve maintain-
reduce chassis deformation upon impact. ability and convertibility.
With the bumper reinforcements and bumper
core (front bumper) remaining on the body, the
front/rear bumper can be removed as a unit.
AC607908
Air dam skirt panel
Bulge
Engine room under cover Air dam skirt panel
AC608737AB
Air dam skirt panels and overhung front bumper against the tires and smoothen the airflow along
corners at the right and left located in front of tires the bumper sides.
have been adopted to suppress the airflow
51-4 EXTERIOR
End of the engine room under cover at the right

and left is bulged to the bottom for covering front
area of tires so that it works as the front air dam.
With this, the wind blown in airflow coming to
under the bumper to induce negative pressure
underneath the body, increasing the down force
to the front tires.
Radiator grille
Three-diamond mark
AC608754AB
Radiator grille is integrated with the front bumper. The three-diamond mark is protruded from the
Mesh type radiator grille gives a sleek front mask installation surface of the radiator grille to
and sporty image. improve the brand appeal.
EXTERIOR
AERO PARTS
51-5
AERO PARTS
M2510003000679
Aerodynamic
front bumper
Rear spoiler
Engine room
under cover Air dam skirt panel
Side air dam
Aerodynamic rear bumper

AC608757AB
The following aero parts provide better aerodynamic Side air dams:
performance and an appealing look. Smoothens the airflow under the floor and around
Body and under floor: the wheels to decrease the air resistance and lift-
The body shape has been optimized to improve ing force.
aerodynamic characteristic, and the under covers Aerodynamic rear bumper:
have been adopted to achieve the rectification The rear bumper is set to the optimum height to
effect, smoothing the under floor airflow. With this decrease the air resistance and lifting force.
modification, the air resistance has been reduced Rear spoiler:
to improve fuel economy and driving stability Separates the air vortex induced at the rear of the
while driving at high speed. vehicle to smoothen the airflow. In addition, the
Aerodynamic front bumper: Refer to BUMPER rear spoiler horizontal wing has been enlarged
AND RADIATOR GRILLE P.51-3. and the helix angle has been optimized to reduce
Engine room under cover front: Refer to the air resistance and to generate the down force,
BUMPER AND RADIATOR GRILLE P.51-3. and thus, the road holding quality of rear wheel
Air dam skirt panels: Refer to BUMPER AND has been increased to improve the driving stabil-
RADIATOR GRILLE P.51-3. ity while driving at high speed.
51-6 EXTERIOR
WINDSHIELD WIPER AND WASHER

M2510007000604
Windshield wiper blade
Windshield washer hose

Windshield wiper arm
Windshield
washer nozzle
Windshield wiper
motor
Windshield washer tank

Wiper link assembly
AC607909AB
2-speed (low/high speed) windshield wiper has Mist type 2-nozzle has been adpopted for the
been adopted. windshield washer.
The intermittent wiper features a vehicle The mist type washer nozzle has been adopted.
speed-dependent variable intermittent time sys- The washer fluid is injected to a large area,
tem*. improving the wiping performance.
The mist wiper is turned ON by operating the mist Washer-linked wiper function* has been adopted.
switch in the opposite direction of the wiper The washer fluid can be injected without operat-
switch for easy operation. The mist wiper is ing the wiper. When the ignition switch is turned
equipped with the function that quickly wipes ON while the washer switch is ON, the washer
raindrops away at high speed when the mist motor operates but the wiper does not.
switch is ON, and when the mist switch is OFF, at NOTE: *: Using the customisation function, the vehi-
low speed until the stop position is reached. cle speed-dependent variable intermittent time sys-
When the mist switch is briefly turned ON, the tem and the washer-linked wiper function can be
wiper operates once at low speed. adjusted (Refer to P.51-10).
Wiper motor torque has been increased to
improve the wiping performance while driving at
high speed.
EXTERIOR
51-7
DESCRIPTION OF CONSTRUCTION AND OPERATION
.
Intermittent control (Vehicle speed-dependent

variable type) <Initial condition: with function>
Change in intermittent time by variable 1. ETACS calculates the windshield intermittent wiper interval
intermittent wiper control switch T1 from the position of the windshield intermittent wiper
(when vehicle is stationary)
30
switch on the column switch and the vehicle speed signal
(sent from the combination meter to ETACS via CAN com-
munication).
Intermittent
time T1 NOTE: Using the customisation function, the vehicle
(seconds) speed-dependent intermittent function can be invalidated
(Refer to P.51-10).
0
FAST SLOW
Variable intermittent wiper
control switch position
Change in intermittent time according
to vehicle speed
30
When at SLOW position
Intermittent
time T1
(seconds) When at FAST position
0 100(62)
Vehicle speed km/h(miles)
AC101502AD
2. When ETACS receives the ON signal of the windshield

intermittent wiper switch, it turns the windshield wiper relay
ON
ON. When the wiper reaches the stop position, the wind-
Windshield
wiper auto- shield wiper auto-stop signal turns OFF, and the windshield
stop signal OFF wiper relay turns OFF.
ON
When the intermittent time T1 calculated by step 1 has
Windshield
wiper relay T1 T1 T1
elapsed after the windshield wiper relay ON, the windshield
OFF wiper relay turns ON again, and the above-mentioned oper-
ation is repeated.
.
AC101493AJ
Mist wiper control
When the windshield wiper mist switch on the column switch is
ON
Windshield mist
wiper switch
turned ON while the ignition switch is in ACC or ON position,
OFF
the column switch turns the windshield wiper relay ON. At the
Windshield wiper
same time, the wiper speed switching relay turns ON (HI).
ON
auto-stop signal When the windshield mist wiper switch is ON, the windshield
OFF
wiper operates at high speed.
Windshield wiper ON
relay
OFF
Windshield wiper ON (HIGH)

speed switching
relay OFF (LOW)
AC207004AI
.
51-8 EXTERIOR
Low speed wiper and high speed wiper control
ON
Windshield low-speed
wiper switch OFF
ON
Windshield high-speed
wiper switch
OFF
ON
Windshield wiper auto-stop
signal
OFF
ON
Windshield wiper
relay
OFF
(HI) ON
Windshield wiper speed
switching relay
(LO) OFF
Low speed operations High speed operations
AC506610AH
When the windshield low speed wiper switch on the When the windshield high speed wiper switch is
column switch is turned ON while the ignition switch turned ON, the windshield wiper relay turns ON.
is in ACC or ON position, the column switch turns the Also, the wiper speed switching relay turns ON (HI),
windshield wiper relay ON. Also, the wiper speed and the windshield wiper operates at high speed.
switching relay turns OFF (LO), and the windshield .
wiper operates at low speed.
Windshield wiper linked with washer function

<Initial condition: with function, with windshield washer check valve>
ON
Windshield washer switch
OFF
t t
ON
Windshield washer relay
OFF
Windshield wiper ON
auto stop signal OFF
ON
Windshield wiper relay
OFF
T T
Wiper switch in Wiper switch in intermittent

off position operation position AC309988AJ
t: 0.3 second
T: Intermittent wiper intermittent time
EXTERIOR
DOOR MIRRORS
51-9
Wiper switch OFF position Intermittent operation position Low-speed or

high-speed
operation
position
Washer switch ON 0.3 0.3 to 0.5 0.2 0.2 to 0.4 to 0.6 -
time second 0.5 second second 0.4 0.6 second
or less second or more or less second second or more
Intermittent wiper 0 2 3 0 1 2 3 3 seconds
time (T) second seconds seconds second second seconds seconds
When the windshield washer switch on the column If the ignition switch is turned to ACC position while
switch is turned ON while the ignition switch is in the windshield washer switch is ON, the windshield
ACC or ON position, ETACS turns the windshield washer relay turns ON, but the windshield wiper
washer relay ON. does not perform the linked operation. When the
When the windshield washer switch is kept ON for windshield washer switch is turned OFF and then
0.3 seconds or longer, the windshield wiper relay (the ON, the windshield wiper starts the linked operation.
wiper relay output time varies depending on the con- NOTE: .
ditions. For details, see the table.) is turned ON, and Using the customisation function, the washer
the windshield wiper operates at high speed. The linked windshield wiper function can be invali-
windshield wiper is turned OFF with 3 seconds delay dated (Refer to P.51-10).
after the windshield washer switch is turned OFF. Using the customisation function, when the
Even when the windshield washer switch is turned washer linked windshield wiper function is invali-
ON while the windshield wiper is operating intermit- dated, only the washer operates. It is useful to
tently, the intermittent action starts again after the melt down the ices of the frozen windshield.
linked operation is finished.
DOOR MIRRORS
M2510008100336
Door mirror assembly
Remote control
mirror switch
Mirror glass
AC607910AC
The outside mirror (door mirror) is a folded type and

has the following characteristics.
51-10 EXTERIOR
Aerodynamic door mirror shape reduces wind Electric remote-controlled door mirrors
noises, and the door glasses and mirrors do not Heated door mirror (works with the defogger)
easily get wet while driving in a rainy day. <Vehicles for Canada>
M2510001400091
Using the M.U.T.-III, the following functions can be
item (M.U.T.-III (M.U.T.-III display)
display)
Front wiper Adjustment of the Normal INT Intermittent wiper interval is fixed to 4
operation intermittent seconds.
windshield wiper Variable INT Intermittent wiper interval is calculated only
operation by the wiper volume control.
Speed sensitive Intermittent wiper interval is calculated
according to the intermittent wiper volume
control and vehicle speed (default).
Front wiper Disabling or Only washer No function
washer enabling Washer and wiper With function (default)
washer-linked wiper
function
51-1
GROUP 51
EXTERIOR
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . 51-2 WINDSHIELD WIPER AND WASHER 51-17

SERVICE SPECIFICATIONS . . . . . . . . . . . 51-2 GENERAL INFORMATION . . . . . . . . . . . . . 51-17
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 51-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 51-20
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-2 WINDSHIELD WIPER AND WASHER
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . 51-21
AERO PARTS . . . . . . . . . . . . . . . . . . 51-2 TROUBLESHOOTING STRATEGY . . . . . . 51-21
REMOVAL AND INSTALLATION . . . . . . . . 51-2 TROUBLE SYMPTOM CHART . . . . . . . . . . 51-21
FRONT BUMPER ASSEMBLY AND GENERAL DESCRIPTION CONCERNING
RADIATOR GRILLE. . . . . . . . . . . . . . 51-3 THE WINDSHIELD WIPER AND WASHER 51-21
REMOVAL AND INSTALLATION . . . . . . . . 51-3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-46
DISASSEMBLY AND ASSEMBLY . . . . . . . 51-4 WINDSHIELD INTERMITTENT WIPER
INTERVAL CHECK . . . . . . . . . . . . . . . . . . . 51-46
REAR BUMPER ASSEMBLY . . . . . . 51-6 CONFIGURATION FUNCTION . . . . . . . . . . 51-46
WINDSHIELD WIPER . . . . . . . . . . . . . . . . . 51-47
GARNISHES AND MOLDINGS . . . . . 51-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-51
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 51-7 WINDSHIELD WASHER . . . . . . . . . . . . . . . 51-53
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-54
DOOR SASH TAPE . . . . . . . . . . . . . . 51-8
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 51-8 MARK . . . . . . . . . . . . . . . . . . . . . . . . . 51-56
SIDE AIR DAM . . . . . . . . . . . . . . . . . . 51-13 DOOR MIRROR . . . . . . . . . . . . . . . . . 51-59

REMOVAL AND INSTALLATION . . . . . . . . 51-13 GENERAL INFORMATION . . . . . . . . . . . . . 51-59
HEATED DOOR MIRROR DIAGNOSIS . . . 51-59
REAR SPOILER. . . . . . . . . . . . . . . . . 51-15 TROUBLESHOOTING STRATEGY . . . . . . 51-59
REMOVAL AND INSTALLATION . . . . . . . . 51-15 SYMPTOM CHART . . . . . . . . . . . . . . . . . . . 51-59
UNDER COVER . . . . . . . . . . . . . . . . . 51-16 DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . 51-69
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-71
51-2 EXTERIOR
SPECIFICATIONS
SPECIFICATIONS
M1511000300949
Item Standard value

Set position of windshield wiper arm/blade assembly mm (in) Ceramic end line 5.0(0.20)
Heated door mirror resistance value ohm 8.4 1.2 at 25 C (77 F)
LUBRICANT
M1511000400098
Item Specified lubricant Quantity

Wiper motor link rod Contact joint between Multipurpose grease SAE J310, As required
link rod and wiper motor NLGI No.2 or equivalent
link plate
ADHESIVE
M1511000501656
ITEM SPECIFICATION
Front three-diamond mark Adhesive tape: Double-sided tape
0.6 mm (0.02 inch) thickness
Side air dam Adhesive tape: Double-sided tape
(a): 4 mm (0.16 in) width and 1.2 mm (0.05 in) thickness
(b): 8 mm (0.32 in) width and 1.2 mm (0.05 in) thickness
Adhesive tape remover: 3M AAD Part number 8906 or equivalent
AERO PARTS
M1511005000051
Front bumper and radiator grille assembly
1
AC608628 AB
Removal step
Under cover(Refer to P.51-16)
1. Air dam skirt panel
TSB Revision
EXTERIOR
FRONT BUMPER ASSEMBLY AND RADIATOR GRILLE
51-3
M1511025400211
Claw
Screw 4 1
20 5 Nm
4 15 3 ft-lb
Boss
7
5.0 2 Nm
45 17 ft-lb
B
6
B
1
5
20 5 Nm
15 3 ft-lb
A
4
Engine room
under cover Splash shield
: Bosses (triangle marks indicating the boss

locations are inscribed on the top surface) 3
AC607932 AB

Air cleaner intake duct (Refer to 4. Front bumper and radiator grille
GROUP 15, Air cleaner P.15-4) assembly
1. Headlamp support panel cover 5. Front bumper side bracket
2. Splash shield mounting clips and 6. Front bumper core
screws Horn (Refer to GROUP 54A, Horn
3. Engine room under cover mounting P.54A-222)
clips and bolts Ambient temperature sensor (Refer to
Front bumper harness connector GROUP 55A, Ambient temperature
connection sensor P.55A-126)
7. Front bumper reinforcement
TSB Revision
51-4 EXTERIOR

M1511025500177
4
9
6
8
5N
15
1
14
5N 7
3.5 1.5 Nm
31 9 ft-lb
A
View A
3
2 1
13
10 Adhesive tape: Double-sided tape
[0.6 mm (0.02 in) thickness]
12
11
AC607933AB

1. Front grille side cover 10. Air dam skirt panel
2. Radiator grille 11. Air intake bezel <Vehicles without
3. Front three-diamond mark front fog lights>
4. Hood weatherstrip front 12. Front fog light bezel <Vehicles with
<<A>> >>A<< 5. Rivet front fog lights>
6. Front bumper reinforcement 13. Front fog light <Vehicles with front
7. Front bumper support fog lights>
8. Front bumper grille 14. Front bumper cover
Front fog light connector connection 15. Front bumper face
9. Front bumper harness
TSB Revision
EXTERIOR
51-5
.
<<A>> RIVETS REMOVAL

Use a drill ( 4.0 mm) to make a hole in the rivet to break it, and
Drill
remove the rivet.
Rivet
Bracket
AC303663AD

.
>>A<< RIVETS INSTALLATION

Use a rivet tool shown in the illustration to connect the parts
Rivet tool with rivets by the following procedures.
Front bumper 1. Insert the rivet into a corresponding location.
face
2. Set the rivet tool at a section A of rivet.
3. While pushing the flange surface of the rivet onto parts to be
fixed with the rivet tool, press the handle of the tool.
Fixing parts
4. Thin part of section A of the rivet will be cut off and the parts
Front bumper face is fixed in position.
Section A
1
Rivet
3 Rivet tool
Flange
Rivet AC205918AE
TSB Revision
51-6 EXTERIOR
REAR BUMPER ASSEMBLY
REAR BUMPER ASSEMBLY

M1511001901431
Claw Boss Screw
9 Boss
Screw
3
7
20 5 Nm
3 15 3 ft-lb
4
10 5 2 Nm
45 17 in-lb
2 5
20 5 Nm
15 3 ft-lb
A
A A
9 A
A
A 8
B 6
B
1 3 7
AC607928AB

1. Rear splash shield 4. Rear bumper harness
Rear combination light (Refer to 5. License plate light and bracket
GROUP 54A, Rear combination light assembly
P.54A-172) 6. Bracket
2. Rear bumper harness connector 7. Reflector
connection 8. Rear bumper cover
3. Rear bumper face 9. Rear bumper face support bracket
License plate light connector 10. Rear bumper reinforcement
connection
TSB Revision
EXTERIOR
GARNISHES AND MOLDINGS
51-7
GARNISHES AND MOLDINGS
SPECIAL TOOL
M1511000602065

NAME
MB990784 General service tool Removal of front delta garnish
Ornament remover
MB990784

M1511004700789
Section A A
Clip
1
B
2 Front
fender
B Section B B
2
Clip
Roof panel
1
A
AC607963AB
AB
Removal Roof drip molding removal

Front delta garnish removal <<A>> 2. Roof drip molding
1. Front delta garnish Required Special Tool:
MB990528: Stripe Tape Spatula
TSB Revision
51-8 EXTERIOR
DOOR SASH TAPE

.
<<A>> ROOF DRIP MOULDING REMOVAL
AC604306
NOTE: Use a commercial available ornament remover

(resin-made) as shown to pry out the roof drip moulding.
DOOR SASH TAPE

SPECIAL TOOL
M1511000601716

NAME
MB990528 General service tool Installation of door sash tape
Stripe tape spatula
MB990528
TSB Revision
EXTERIOR
DOOR SASH TAPE
51-9
M1511024100422

Door Window Glass Runchannel Removal and Installation
(Refer to GROUP 42 Window Glass Runchannel and
Door Opening Weatherstrip P.42A-164).
Door Beltline Moulding Removal and Installation (Refer to
GROUP 42 Window Glass Runchannel and Door Open-
ing Weatherstrip P.42A-164).
2N
1N
AC607959AB
Removal steps Required Special Tool:

<<A>> >>A<< 1. Front door sash tape, rear MB990528: Stripe Tape Spatula
<<A>> >>A<< 2. Rear door sash tape, front

.
<<A>> DOOR SASH TAPES REMOVAL

CAUTION
Pay attention to keep from getting burned by hot door
panel or tapes.
1. Use a hair drier to warm the tape.
2. Peel the tip of the tape with your finger, and then peel off the
tape in parallel with the application surface.
TSB Revision
51-10 EXTERIOR
DOOR SASH TAPE

.
>>A<< DOOR SASH TAPES INSTALLATION

CAUTION
The ambient temperature should be 20(68) to
30 C(86 F). Ensure that the working area is clean. Ide-
ally, the tape application should be done at ambient
temperature of 25 C(77 F).
If ambient temperature is less than 15 C(59 F), heat the
tape and application surface to a temperature of 20(68)
to 30 C(86 F). If ambient temperature is 35 C(95 F) or
higher, cool down them. The adhesive property of the
tape is deteriorated at low temperature, so the tape may
come loose easily. Meanwhile, it gets softened at hot
temperature.
When beginning to apply the tape, pay particular atten-
tion. If the end of the tape cannot be applied to the
specified position with an accuracy of less than 1
mm(0.04 in), it may cause the poor appearance or adhe-
sion.
Use the special tool MB990528 to apply the tape with a
<Pushing direction> Unit: mm(in)
steady pace and pressure. If you do not apply the tape
with a steady pace or pressure, or abort the application,
3 to 7 cm/sec. 40 to 50 a shallow groove (lateral groove called as "Shock line")
may be present on the tape surface. Meanwhile, if you
MB990528 10 to 20 apply it too quickly, air bubbles may be formed under
(0.39 to 0.79) the tape.
Door sash tape 1. Wrap a soft cloth (synthetic fibre) around the tip of the
special tool.
Backing paper 2. Use white gasoline to degrease the tape application surface.
3. Wipe away dirt from the tape.
<Pulling direction>
3 to 7 cm/sec.
10 to 20
(0.39 to 0.79)
MB990528
30 to 45
Door sash tape
Backing paper
AC303428AD
TSB Revision
EXTERIOR
DOOR SASH TAPE
51-11
AC506859
36(1.42) 1(0.04)
3(0.12) 3(0.12) 3(0.12)
4(0.16) 4(0.16) 4(0.16)
A A
Unit: mm (in)
A A
4(0.16) B
4(0.16)
: Tape locating points

: T-stud for door opening weatherstrip attaching locations (5 places in all).
AC607960AB
4. Apply the door sash tape according to the procedure below.
(1) Position the tape at the upper and lower locating points.
(2) Peel of backing strip from the top of the tape and attach it
temporarily.
(3) Peel off the backing strip to the half length of the tape.
(4) Apply the tape using the special tool while peeling off the
remaining backing strip.
MB990528
Door sash
tape
Backing paper
AC402197AI
TSB Revision
51-12 EXTERIOR
DOOR SASH TAPE
Rear door sash tape front (5) For the rear door sash tape, apply it to plain surface (A).
Then apply it to stepped surface (B).
A Plain part
B Stepped part
AC506860AB
(6) Press the folded area of the tape by three stages (60
60 degrees, 120 degrees, and holding), rolling in toward the
vehicle inside direction.
120
MB990528 Hemming part
AC303415AG
TSB Revision
EXTERIOR
SIDE AIR DAM
51-13
SIDE AIR DAM
M1511005500506
Section A A
Side outer
panel
A Clip
1
Grommet
1
A Screw
Double-sided tape affixed location

1
a
b
Double-sided tape:
a: 4 mm (0.16 in) width and 1.2 mm (0.05 in) thickness, b: 8 mm (0.32 in) width and 1.2 mm (0.05 in) thickness
AC607961AB
Removal
<<A>> >>A<< 1. Side air dam

.
<<A>> SIDE AIR DAM REMOVAL

Gently lift and remove the side air dam. If there is any dou-
ble-sided tape remaining on the side air dam, remove accord-
ing to the following instructions.
1. Remove double-sided tape remaining on the body surface
TSB Revision
51-14 EXTERIOR
SIDE AIR DAM
(1) Attach protection tape all the way along the edges of the
double-sided tape which is still adhering to the body.
Double-sided tape
Protection tape
AC200049AC
(2) Scrape off the double-sided tape with a resin spatula as

possible.
Double-sided tape
(3) Peel off the protection tape.
(4) Use a shop towel moistened with 3M AAD Part number
8906 or equivalent to wipe the body.
AC200050AC
2. Remove double-sided tape remaining on side air dam and

adhere double-sided tape (when re-using side air dam)
(1) Scrape off the double-sided tape on the side air dam with
a resin spatula as much as possible.
(2) Wipe the side air dam surface and clean it with a rag
moistened with isopropyl alcohol.
(3) Remove only a small amount of the residual adhesive.
(4) Apply the primer as specified on the residual adhesive.
(5) Adhere the double-sided tape as specified on the side air
dam.
AC103187

.
>>A<< SIDE AIR DAM INSTALLATION

1. Tear off the double-sided tape backing paper.
Backing paper NOTE: Attach the adhesive tape to the edge of the backing
paper makes the backing paper tear off easier.
2. Install the side air dam.
NOTE: If the double-sided tape is difficult to affix in cold tem-
perature, etc., warm the bonding surfaces of the body and
side air dam to about 40 60 C (104 140 F) before affixing
Adhesive tape the tape.
3. Firmly press in the side air dam.
AC103247AE
TSB Revision
EXTERIOR
REAR SPOILER
51-15
REAR SPOILER
M1511006100299
5.0 1.0 Nm
3 44 9 in-lb
5.0 1.0 Nm
44 9 in-lb
2
5.0 1.0 Nm
5.0 1.0 Nm
44 9 in-lb 3 44 9 in-lb
AC607962 AB

1. Rear spoiler assembly >>A<< 2. Tape
3. Grommet

.
>>A<< TAPE INSTALLATION

1. Installation position
Tape
CAUTION
The ambient temperature should be 15 (59) to
40 C(104 F). Ensure that the working area is clean.
If ambient temperature is less than 15 C (59 F), heat
the tape and application surface to a temperature of 15
(59) to 40 C (104 F).
Rear spoiler Be careful that air bubbles are not formed under the
assembly
tape.
AC609932AB
2. Installation procedure
(1) Wipe the tape application surface and clean it with a rag
moistened with isopropyl alcohol.
(2) Remove backing paper from the tape, and apply it to the
rear spoiler assembly.
TSB Revision
51-16 EXTERIOR
UNDER COVER
UNDER COVER
M1511019600313
5
4
Splash shield
1 Splash shield
2
1
AC607925AB

1. Front bumper mounting clips and 3. Engine room under cover front B
bolts 4. Engine room side cover
2. Engine room under cover front A 5. Front floor panel rear
TSB Revision
EXTERIOR
51-17
GENERAL INFORMATION
M1511000101249
WINDSHIELD WIPER AND WASHER OPERATION

.
Intermittent control (Vehicle speed-dependent

variable type) <Initial condition: with function>
Change in intermittent time by variable 1. ETACS calculates the windshield intermittent wiper interval
intermittent wiper control switch T1 from the position of the windshield intermittent wiper
(when vehicle is stationary)
30
switch on the column switch and the vehicle speed signal
(sent from the combination meter to ETACS via CAN com-
munication).
Intermittent
time T1 NOTE: Using the configuration function, the vehicle
(seconds) speed-dependent intermittent function can be invalidated
(Refer to P.51-46).
0
FAST SLOW
Variable intermittent wiper
control switch position
Change in intermittent time according
to vehicle speed
30
When at SLOW position
Intermittent
time T1
(seconds) When at FAST position
0 100(62)
Vehicle speed km/h(miles)
AC101502AD
2. When ETACS receives the ON signal of the windshield

intermittent wiper switch, it turns the windshield wiper relay
ON
ON. When the wiper reaches the stop position, the wind-
Windshield
wiper auto- shield wiper auto-stop signal turns OFF, and the windshield
stop signal OFF wiper relay turns OFF.
ON
When the intermittent time T1 calculated by step 1 has
Windshield
wiper relay T1 T1 T1
elapsed after the windshield wiper relay ON, the windshield
OFF wiper relay turns ON again, and the above-mentioned oper-
ation is repeated.
.
AC101493AJ
Mist wiper control
When the windshield wiper mist switch on the column switch is
ON
Windshield mist
wiper switch
turned ON while the ignition switch is in ACC or ON position,
OFF
the column switch turns the windshield wiper relay ON. At the
Windshield wiper
same time, the wiper speed switching relay turns ON (HI).
ON
auto-stop signal When the windshield mist wiper switch is ON, the windshield
OFF
wiper operates at high speed.
Windshield wiper ON
relay
OFF
Windshield wiper ON (HIGH)

speed switching
relay OFF (LOW)
AC207004AI
TSB Revision
51-18 EXTERIOR
Low speed wiper and high speed wiper control
ON
Windshield low-speed
wiper switch OFF
ON
Windshield high-speed
wiper switch
OFF
ON
Windshield wiper auto-stop
signal
OFF
ON
Windshield wiper
relay
OFF
(HI) ON
Windshield wiper speed
switching relay
(LO) OFF
Low speed operations High speed operations
AC506610AH
When the windshield low speed wiper switch on the When the windshield high speed wiper switch is
column switch is turned ON while the ignition switch turned ON, the windshield wiper relay turns ON.
is in ACC or ON position, the column switch turns the Also, the wiper speed switching relay turns ON (HI),
windshield wiper relay ON. Also, the wiper speed and the windshield wiper operates at high speed.
switching relay turns OFF (LO), and the windshield .
wiper operates at low speed.
Windshield wiper linked with washer function <Initial condition: with function, with
windshield washer check valve>
ON
Windshield washer switch
OFF
t t
ON
Windshield washer relay
OFF
Windshield wiper ON
auto stop signal OFF
ON
Windshield wiper relay
OFF
T T
Wiper switch in Wiper switch in intermittent

off position operation position AC309988AJ
t: 0.3 second
T: Intermittent wiper intermittent time
TSB Revision
EXTERIOR
51-19
Wiper switch OFF position Intermittent operation position Low-speed or

high-speed
operation
position
Washer switch ON 0.3 0.3 to 0.5 0.2 0.2 to 0.4 to 0.6 -
time second 0.5 second second 0.4 0.6 second
or less second or more or less second second or more
Intermittent wiper 0 2 3 0 1 2 3 3 seconds
time (T) second seconds seconds second second seconds seconds
When the windshield washer switch on the column If the ignition switch is turned to ACC position while
switch is turned ON while the ignition switch is in the windshield washer switch is ON, the windshield
ACC or ON position, ETACS turns the windshield washer relay turns ON, but the windshield wiper
washer relay ON. does not perform the linked operation. When the
When the windshield washer switch is kept ON for windshield washer switch is turned OFF and then
0.3 seconds or longer, the windshield wiper relay (the ON, the windshield wiper starts the linked operation.
wiper relay output time varies depending on the con- NOTE: .
ditions. For details, see the table.) is turned ON, and Using the configuration function, the washer
the windshield wiper operates at high speed. The linked windshield wiper function can be invali-
windshield wiper is turned OFF with 3 seconds delay dated (Refer to P.51-46).
after the windshield washer switch is turned OFF. Using the configuration function, when the
Even when the windshield washer switch is turned washer linked windshield wiper function is invali-
ON while the windshield wiper is operating intermit- dated, only the washer operates. It is useful to
tently, the intermittent action starts again after the melt ice from a frozen windshield.
linked operation is finished.
TSB Revision
51-20 EXTERIOR
SPECIAL TOOLS
M1511000602076
Tool Number Name Use

MB991955 M.U.T.-III CAUTION
a sub-assembly
a. MB991824 For vehicles with CAN
b. MB991827 a. Vehicle communication, use M.U.T.-III
c. MB991910 Communication main harness A to send
d. MB991911 Interface (V.C.I.) simulated vehicle speed. If you
MB991824
e. MB991825 b. M.U.T.-III USB connect M.U.T.-III main harness
b cable B instead, the CAN
f. MB991826
c. M.U.T.-III main communication does not
harness A function correctly.
(Vehicles with CAN Windshield intermittent wiper
MB991827
communication check
c system)
d. M.U.T.-III main
harness B
(Vehicles without
MB991910 CAN
d communication
system)
DO NOT USE e. M.U.T.-III measure
adapter
MB991911 f. M.U.T.-III trigger
harness
e
MB991825
MB991826
MB991955
TSB Revision
EXTERIOR
51-21
WINDSHIELD WIPER AND WASHER DIAGNOSIS
M1511014600534
Diagnosis should be carried out by the following pro- 3. Find the malfunction by the following Symptom
cedures. Chart.
1. Gather the information from the customer. 4. Verify the malfunction is eliminated.
2. Verify that the condition described by the
customer exists.
TROUBLE SYMPTOM CHART
M1511015000687
TROUBLE SYMPTOM Inspection Reference

procedure page
No.
Windshield wipers do not work at all 1 P.51-23
Windshield wipers do not work when wiper switch is at "INT", "Washer" or 2 P.51-29
"Mist" position. However, wipers work at low speed when switch is at "Lo" or
"Hi" position
Windshield wipers do not stop at specified park position 3 P.51-31
Windshield wipers do not work normally 4 P.51-34
Windshield intermittent wiper interval cannot be adjusted by operating 5 P.51-37
windshield intermittent wiper volume control switch
Windshield intermittent wiper interval is not changed according to vehicle 6 P.51-39
speed
Windshield washer does not work normally 7 P.51-42
NOTE: Even when the ETACS-ECU has failed, the
windshield wipers can work at low speed as fail-safe
mode.
SYMPTOM PROCEDURES
GENERAL DESCRIPTION CONCERNING THE WINDSHIELD WIPER AND WASHER
M1511000101272
The following ECUs affect the functions and control
of the windshield wiper and washer.
FUNCTION CONTROL ECU
Windshield wiper and washer Intermittent control (Vehicle ETACS-ECU, column switch
control function speed-dependent variable type)
Mist wiper control ETACS-ECU, column switch
Low speed wiper and high speed ETACS-ECU, column switch
wiper control
Washer control ETACS-ECU, column switch
TSB Revision
51-22 EXTERIOR
GENERAL CIRCUIT DIAGRAM FOR THE WINDSHIELD WIPER AND WASHER
FUSIBLE IGNITION FUSIBLE

ETACS-ECU LINK 36 SWITCH (IG1) LINK 34
JOINT
CONNECTOR (2)
COLUMN-ECU
WINDSHIELD WINDSHIELD (MIST) (INT) (LO) (HI)

INTERMITTENT WASHER
WIPER INTERVAL SWITCH
ADJUSTING KNOB WINDSHIELD
WIPER SWITCH
COLUMN SWITCH
DATA LINK
CONNECTOR
WASHER
MOTOR
TRANSAXLE
IGNITION CONTROL
SWITCH (ACC) MODULE
WINDSHIELD
WIPER
MOTOR
ENGINE
CONTROL
MODULE
JOINT
CONNECTOR (CAN3)
TSB Revision
EXTERIOR
51-23
INSPECTION PROCEDURE 1: The windshield wipers do not work at all.
Windshield Wiper Power Supply Circuit

FUSIBLE
LINK 34
WHITE
C-309
ETACS-ECU
ACC
RELAY3
WINDSHIELD WINDSHIELD
WIPER WIPER
SPEED AUTOMATIC
CHANGEOVER STOP RELAY
RELAY
YELLOW
GREEN
WHITE
BLUE
4 1 3 5
WINDSHIELD
WIPER
MOTOR
A-04
CIRCUIT
BRAKER
AC609136AB
Connector: A-04 A-04 (GR) Connectors: C-304

Junction block
C-304
AC608141AD AC608152 AG
TSB Revision
51-24 EXTERIOR
Connectors: C-309
Junction block
C-309 (B)
AC608152AH
. .
CIRCUIT OPERATION TECHNICAL DESCRIPTION (COMMENT)

The windshield wiper and washer switch sends a If the windshield wiper does not work at all, the wind-
signal through the column-ECU (incorporated in shield wiper motor, column switch (windshield wiper
the column switch) to the ETACS-ECU. If the col- and washer switch) or the ETACS-ECU may be
umn-ECU sends a windshield wiper and washer defective.
switch "ON" signal to the ETACS-ECU, the .
ETACS-ECU turns on the relay (incorporated in TROUBLESHOOTING HINTS

the ETACS-ECU), thus causing the windshield Trouble in input signal system
wiper and washer motor to be turned on. The wiring harness or connectors may have
If the LIN communication line is defective, the loose, corroded, or damaged terminals, or termi-
ETACS-ECU operates windshield wiper motor by nals pushed back in the connector
using the other communication lines (wiper The wiper motor may be defective
backup circuit) instead of that line. In this case, The column switch may be defective
the windshield wiper works at low speed regard- The ETACS-ECU may be defective
less of the windshield wiper and washer switch
positions ("LO" or "HIGH").
DIAGNOSIS
MB991223: Harness Set
MB992006: Extra Fine Probe
MB991824: V.C.I.
TSB Revision
EXTERIOR
51-25
STEP 1. Use the scan tool MB991958 to check if an

ETACS-related diagnostic trouble code is set.
Connect the scan tool. Refer to GROUP 54A ETACS, "How to
connect the scan tool (M.U.T.-III) P.54A-479."
Data link connector Q: Is the diagnostic trouble code set?
YES : Diagnose the ETACS-ECU. Refer to GROUP 54A
ETACS, "Diagnostic trouble code chart P.54A-482."
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Check the input signal related to the windshield

wiper operation.
Ignition switch: ACC
Item No. Item name Normal condition
Item 288 ACC switch ON
Item 235 Front wiper ACT ON
OK: Normal condition is displayed.

NO : Go to Step 3.
YES : Refer to GROUP 54A ETACS, Input signal chart
P.54A-528.
STEP 3. Check windshield wiper motor connector A-04 for

loose, corroded or damaged terminals, or terminals
pushed back in the connector.
Q: Is windshield wiper motor connector A-04 in good
condition?
YES : Go to Step 4.
NO : Repair or replace the damaged component(s). Refer
to GROUP 00E, Harness Connector Inspection
P.00E-2. Verify that the windshield wiper works
normally.
TSB Revision
51-26 EXTERIOR
STEP 4. Check the windshield wiper motor.

(1) Disconnect windshield wiper motor connector A-04.
(2) Connect a battery to the windshield wiper motor as shown.
Then check that the windshield wiper motor operates
normally at high and low speeds.
Q: Does the windshield wiper motor operate normally?
YES : Go to Step 5.
NO : Replace the windshield wiper motor. Verify that the
windshield wiper works normally.
1 2 3
4 5
Operation check
1 2 3
4 5
Low speed
1 2 3
4 5
High speed AC608787AB
STEP 5. Check the ground circuit to the windshield wiper

motor. Measure the resistance at the windshield wiper
motor connector A-04.
(1) Disconnect windshield wiper motor connector A-04 and
measure the resistance available at the wiring harness side
of the connector.
(2) Measure the resistance value between terminal 2 and
Harness side: A-04
ground.
The resistance should be 2 ohms or less.
Q: Is the measured resistance 2 ohms or less?
YES : Go to Step 7.
NO : Go to Step 6.
AC608255AI
STEP 6. Check the wiring harness between windshield

wiper motor connector A-04 (terminal 2) and ground.
Q: Is the wiring harness between windshield wiper motor
connector A-04 (terminal 2) and ground in good
condition?
YES : No action is necessary and testing is complete.
NO : The wiring harness may be damaged or the
connector(s) may have loose, corroded or damaged
terminals, or terminals pushed back in the connector.
Repair the wiring harness as necessary. Verify the
windshield wiper works normally.
TSB Revision
EXTERIOR
51-27
STEP 7. Check ETACS-ECU connector C-304 for loose,

corroded or damaged terminals, or terminals pushed back
in the connector.
Q: Is ETACS-ECU connector C-304 in good condition?
YES : Go to Step 8.
normally.
STEP 8. Measure the voltage at ETACS-ECU connector

C-304.
(1) Disconnect ETACS-ECU connector C-304 and measure the
resistance available at the wiring harness side of the
connector.
(2) Measure the voltage between terminal 4 and ground.
The voltage should measure approximately 12 volts
(battery positive voltage).
Q: Is the measured voltage approximately 12 volts (battery
positive voltage)?
NO : Go to Step 9.
Harness side: C-304
AC608254AN
STEP 9. Check the wiring harness between ETACS-ECU

connector C-309 (terminal 1) and the fusible link (34).
Check the power supply line for open circuits.
Q: Is the wiring harness between ETACS-ECU connector
C-309 (terminal 1) and the fusible link (34) in good
condition?
YES : Intermittent malfunction. Refer to GROUP 00, How to
cope with intermittent malfunction P.00-13.
to GROUP 00E, Cables and wire check P.00E-12.

connector C-304 (terminals 5, 6) and windshield wiper
motor connector A-04 (terminals 4, 1).
Check the input and output lines for open or short ciruit.
C-304 (terminals 5, 6) and windshield wiper motor
connector A-04 (terminals 4, 1) in good condition?
TSB Revision
51-28 EXTERIOR

Check that the windshield wipers work normally.
NO : Replace the ETACS-ECU.
TSB Revision
EXTERIOR
51-29
INSPECTION PROCEDURE 2: The windshield wipers do not work when the wiper switch is at the
"INT", "Washer" or "Mist" position. However, the wipers work at low speed when the switch is at the
"Lo" or "Hi" position.
Windshield Wiper Motor Circuit
ETACS-ECU
ACC
RELAY3
WINDSHIELD INPUT SIGNAL

WIPER SPEED WINDSHIELD WIPER HI SPEED SWITCH
SWITCHING WINDSHIELD WIPER INTERMIT SWITCH
RELAY WINDSHIELD WIPER LO SPEED SWITCH
WINDSHIELD WIPER MIST SWITCH
WINDSHIELD
WIPER
MOTOR
A-04
CIRCUIT
BRAKER
AC609153 AB
If the system cannot receive any signal from the col-

.
TECHNICAL DESCRIPTION (COMMENT) umn switch (windshield wiper and washer switch)
This system may be at fail-safe mode if the LIN com- due to a open circuit in the LIN communication line or
munication line is defective. other reasons, the system will enter the fail-safe
mode when the ignition switch is at the "ACC" posi-
tion.
.
TSB Revision
51-30 EXTERIOR
TROUBLESHOOTING HINTS The column switch may be defective

The wiring harness or connectors may have The ETACS-ECU may be defective
loose, corroded, or damaged terminals, or termi- The LIN bus line may be defective
nals pushed back in the connector
DIAGNOSIS
MB991824: V.C.I.

NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

Check that the windshield wipers work normally.
TSB Revision
EXTERIOR
51-31
INSPECTION PROCEDURE 3: Windshield wipers do not stop at the specified park position.
Windshield Wiper Automatic Stop Relay Circuit
ETACS-ECU
WINDSHIELD
WIPER
AUTOMATIC
STOP RELAY
YELLOW
WHITE
3 5
WINDSHIELD
WIPER
MOTOR
A-04
AC609162 AB

Junction block
C-304
AC608141AD AC608152 AG
TROUBLESHOOTING HINTS
.
TECHNICAL DESCRIPTION (COMMENT)

If the windshield wipers do not stop at predetermined The wiring harness or connectors may have
park position, the windshield wiper motor or the loose, corroded, or damaged terminals, or termi-
ETACS-ECU may be defective. nals pushed back in the connector
The windshield wiper motor may be defective
.
The ETACS-ECU may be defective
TSB Revision
51-32 EXTERIOR
DIAGNOSIS
STEP1. Check windshield wiper motor connector A-04 for

condition?
YES : Go to Step 2.
normally.

(2) Connect the vehicle battery to the windshield wiper motor
connector as shown, and operate the windshield wiper at
low speed. While the windshield wiper is working,
disconnect the battery at positions other than the specified
park position to stop the windshield wiper motor.
(3) When the battery is connected as shown, the motor should
run at low speed, and then stop at the specified park
position.
1 2 3
4 5 Q: Does the windshield wiper motor operate normally?
Stop position check YES : Go to Step 3.
NO : Replace the windshield wiper motor. The windshield
1 2 3 wiper should now stop at the specified park position.
4 5
(A) Low speed
1 2 3
4 5
(B) Automatic stop AC608788AB
TSB Revision
EXTERIOR
51-33
STEP 3. Check the fusible link (34) circuit to the windshield

wiper motor. Measure the voltage at windshield wiper
motor connector A-04.
(1) Disconnect windshield wiper motor connector A-04 and
measure the voltage available at the wiring harness side of
the connector.
(2) Turn the ignition switch to the "ACC" position.
Harness side: A-04
positive voltage)?
YES : Go to Step 5.
NO : Go to Step 4.
AC608254AO

wiper motor connector A-04 (terminal 3) and the fusible
link (34).
Check the power supply line for open circuits.
connector A-04 (terminal 3) and the fusible link (34) in
good condition?

in the connector.
YES : Go to Step 6.
P.00E-2.

connector C-304 (terminals 8, 12) and windshield wiper
motor connector A-04 (terminals 3, 5).
Check the output lines for open or short circuits.
C-304 (terminals 8, 12) and windshield wiper motor
connector A-04 (terminals 3, 5) in good condition?
YES : Go to Step 7.
TSB Revision
51-34 EXTERIOR

Check that the windshield wipers stops at the specified park
position.
INSPECTION PROCEDURE 4: Windshield Wipers do not work normally.
Windshield Wiper Motor Drive Circuit
ETACS-ECU
WINDSHIELD
WIPER INPUT SIGNAL (COLUMN-ECU)
SPEED WINDSHIELD WIPER HI SPEED SWITCH
SWITCHING
RELAY WINDSHIELD WIPER INTERMIT SWITCH
WINDSHIELD WIPER LO SPEED SWITCH
WINDSHIELD WIPER MIST SWITCH
GREEN
BLUE
4 1
WINDSHIELD
WIPER
MOTOR
A-04
CIRCUIT
BRAKER
AC609164 AB

Junction block
C-304
AC608141AD AC608152 AG
TSB Revision
EXTERIOR
51-35
TECHNICAL DESCRIPTION (COMMENT) TROUBLESHOOTING HINTS
If either of the windshield wiper switch positions is Trouble in input signal system
defective, the windshield wiper motor, column switch The wiring harness or connectors may have
(windshield wiper and washer switch) or the loose, corroded, or damaged terminals, or termi-
ETACS-ECU may be defective. nals pushed back in the connector
.
The wiper motor may be defective
DIAGNOSIS
MB991824: V.C.I.

Connect the scan tool. Refer to "How to connect the scan tool
(M.U.T.-III) P.54B-4."
YES : Diagnose the ETACS-ECU. Refer to Diagnostic
trouble code chart P.54A-482."
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
51-36 EXTERIOR

wiper operation.
Item 235 Front wiper ACT ON
Item 236 Front wiper Lo/Hi ON

NO : Go to Step 3.
P.54A-528.
STEP 3. Check windshield wiper motor connector A-04 for

condition?
YES : Go to Step 4.
P.00E-2. Verify that the windshield wiper operates
normally when the windshield wiper switch is moved
to each position.

(2) Connect a battery to the windshield wiper motor as shown.
Then check if the windshield wiper motor operates normally
at high and low speeds.
Q: Does the windshield wiper motor operate normally?
YES : Go to Step 5.
NO : Replace the windshield wiper motor. Verify that the
windshield wiper operates normally when the
1 2 3
windshield wiper switch is moved to each position.
4 5
Operation check
1 2 3
4 5
Low speed
1 2 3
4 5
TSB Revision
EXTERIOR
51-37

in the connector.
YES : Go to Step 6.
P.00E-2. Verify that the windshield wiper operates
normally when the windshield wiper switch is moved
to each position.

wiper motor connector A-04 (terminals 4 and 1) and
ETACS-ECU connector C-304 (terminals 5 and 6).
connector A-04 (terminals 4 and 1) and ETACS-ECU
connector C-304 (terminals 5 and 6) in good condition?
Repair the wiring harness as necessary. Verify that
the windshield wiper operates normally when the
windshield wiper switch is moved to each position.
INSPECTION PROCEDURE 5: The windshield intermittent wiper interval cannot be adjusted by

operating the windshield intermittent wiper interval control switch.
Windshield Intermittent Wiper Control Circuit
LIN CAN COMMUNICATION

COMMUNICATION LINE (CAN_H LINE)
LINE CAN COMMUNICATION TCM <CVT>
COLUMN-ECU ETACS-ECU or ECM<M/T>
LINE (CAN_L LINE)
INPUT SIGNAL INPUT SIGNAL

WINDSHIELD INTERMITTENT VEHICLE SPEED
WIPER INTERVAL
ADJUSTING KNOB
AC609166AC
. .

If the windshield intermittent wiper interval is not Trouble in input signal system
changed by operating the windshield intermittent The wiring harness or connectors may have
wiper interval adjusting knob or according to the loose, corroded, or damaged terminals, or termi-
vehicle speed, the column switch or the ETACS-ECU nals pushed back in the connector
may be defective. The ETACS-ECU may be defective
TSB Revision
51-38 EXTERIOR
DIAGNOSIS
MB991824: V.C.I.

NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Check the ETACS configuration function.

Use the ETACS configuration function to check that "Front
wiper operation" is set to "Variable INT" or "Speed sensitive".
YES : Go to Step 3.
NO : Use the ETACS configuration function to set "Front
wiper operation" to "variable INT" or "Speed
sensitive". (Refer to P.51-46.)

Check that the windshield wiper interval changes when the
windshield wiper interval control is rotated.
TSB Revision
EXTERIOR
51-39
INSPECTION PROCEDURE 6: The windshield intermittent wiper interval is not changed according to
the vehicle speed.
Windshield Intermittent Wiper Control Circuit
LIN CAN COMMUNICATION

COMMUNICATION LINE (CAN_H LINE)
LINE CAN COMMUNICATION TCM <CVT>
COLUMN-ECU ETACS-ECU or ECM<M/T>
LINE (CAN_L LINE)
INPUT SIGNAL INPUT SIGNAL

WINDSHIELD INTERMITTENT VEHICLE SPEED
WIPER INTERVAL
ADJUSTING KNOB
AC609166AC
. .

If the intermittent wiper interval does not depend on The wiring harness or connectors may have
the vehicle speed, the input circuit of the vehicle loose, corroded, or damaged terminals, or termi-
speed signal and the ETACS-ECU may be defective. nals pushed back in the connector
Alternatively, the vehicle speed-dependent wiper The CAN bus line may be defective
may be set to "disabled" by using the configuration The ETACS-ECU may be defective
function.
DIAGNOSIS
MB991824: V.C.I.

Check that the windshield intermittent wiper interval can be
adjusted by operating the windshield intermittent wiper interval
control switch.
YES : Go to Step 2.
NO : Refer to Inspection Procedure 5 "The windshield
intermittent wiper interval cannot be adjusted by
operating the windshield intermittent wiper interval
control switch" P.51-37.
TSB Revision
51-40 EXTERIOR
STEP 2. Check the ETACS configuration function.

Use the ETACS configuration function to check that "Front
wiper operation" is set to "Variable INT" or "Speed sensitive".
YES : Go to Step 3.
NO : Use the ETACS configuration function to set "Front
wiper operation" to "variable INT" or "Speed
sensitive". (Refer to P.51-46.)
STEP 3. Use the scan tool MB991958 to diagnose the CAN

bus lines.
Data link connector Q: Is the check result normal?
YES <CVT> : Go to Step 4.
YES <M/T> : Go to Step 5.
NO : Repair the CAN bus line (Refer to GROUP 54C CAN
bus diagnosis chart P.54C-16).
MB991910
MB991824
MB991827 AC608435 AB
STEP 4. Use the scan tool MB991958 to diagnose other

system diagnostic trouble code
Connect the scan tool. Refer to GROUP 54A ETACS, "Diag-
nostic function P.54A-479."
Check that the TCM sets a diagnostic trouble code.
Q: Is the diagnostic trouble code set?
YES : Diagnose the TCM (Refer to GROUP 23 Diagnostic
trouble code chart P.23A-29).
NO : Go to Step 6.
TSB Revision
EXTERIOR
51-41
STEP 5. Use the scan tool MB991958 to diagnose other

system diagnostic trouble code
Connect the scan tool. Refer to GROUP 54A ETACS, "Diag-
nostic function P.54A-479."
Check that the ECM sets a diagnostic trouble code.
YES : Diagnose the ECM (Refer to GROUP 13A
Diagnostic trouble code chart P.13A-46).
NO : Go to Step 6.

Check that the intermittent wiper interval depends on the vehi-
cle speed.
TSB Revision
51-42 EXTERIOR
INSPECTION PROCEDURE 7: The windshield washer does not work normally.
Windshield Washer Motor Circuit

FUSIBLE
LINK 34
WHITE
C-309
ACC
RELAY3
INPUT SIGNAL
NO (COLUMN-ECU)
WINDSHIELD
WASHER USED WINDSHIELD
RELAY RELAY WASHER
BLUE-RED
RED
WASHER
MOTOR
A-45
AC609470AB
Connector: A-45 Connectors: C-304

Junction block
C-304
A-45 (B)
AC608141AI AC608152 AG
TSB Revision
EXTERIOR
51-43
Connectors: C-309
Junction block
C-309 (B)
AC608152AH

.
CIRCUIT OPERATION
The windshield washer switch sends a signal If the windshield washer does not work normally, the
through the column-ECU (incorporated in the column washer motor, the column switch (windshield wiper
switch) to the ETACS-ECU. If the column-ECU sends and washer switch) or the ETACS-ECU may be
a windshield washer switch "ON" signal to the defective.
ETACS-ECU, the ETACS-ECU turns on the relay .
(incorporated in the ETACS-ECU), thus causing the TROUBLESHOOTING HINTS

washer motor to be turned on. The wiring harness or connectors may have
.
loose, corroded, or damaged terminals, or termi-
The washer motor may be defective
The column switch may be defective
DIAGNOSIS
MB991824: V.C.I.
STEP 1. Verify the windshield wiper operation.

Q: Does the windshield wiper operate normally?
YES : Go to Step 2.
NO : Refer to Inspection Procedure 1 "The windshield
wipers do not work at all P.51-23."
TSB Revision
51-44 EXTERIOR

NO : Go to Step 3.
MB991910
MB991824
MB991827 AC608435 AB

washer operation.
Windshield washer switch: ON
Item 237 Front washer ON

NO : Go to Step 4.
P.54A-528.
STEP 4. Check windshield washer motor connector A-45

for loose, corroded or damaged terminals, or terminals
Q: Is windshield washer motor connector A-45 in good
condition?
YES : Go to Step 5.
normally.
TSB Revision
EXTERIOR
51-45
STEP 5. Check the operation of windshield washer motor.

(1) Disconnect windshield washer motor connector A-45 and
check at windshield washer motor connector side.
(2) Fill the windshield washer tank with washer fluid.
(3) When battery voltage is applied between terminals 1 and 2,
washer fluid should spray out.
Q: Does the washer motor operate normally?
YES : Go to Step 6.
NO : Replace the washer motor. Verify that the windshield
washer works normally.
AC608513AB

in the connector.
YES : Go to Step 7.
P.00E-2. Verify that the windshield washer works
normally.

washer motor connector A-45 (terminal 2) and ETACS-ECU
connector C-304 (terminal 13).
Check the input lines for open or short ciruit.
Q: Is the wiring harness between windshield washer motor
connector A-45 (terminal 2) and ETACS-ECU connector
C-304 (terminal 13)in good condition?
YES : Go to Step 8.

washer motor connector A-45 (terminal 1) and ETACS-ECU
Check the input lines for open or short ciruit.
Q: Is the wiring harness between windshield washer motor
C-304 (terminal 14)in good condition?
YES : Go to Step 9.
TSB Revision
51-46 EXTERIOR

Check that the windshield washers work normally.
ON-VEHICLE SERVICE
WINDSHIELD INTERMITTENT WIPER INTERVAL CHECK
M1511018900087
1. Check that the intermittent wiper interval is 2. Turn the windshield intermittent wiper switch to
changed as the windshield intermittent wiper the intermittent operation position. Use the
interval control is operated. M.U.T.-III to set a simulated vehicle speed with
the wiper volume held. The intermittent wiper
interval should be changed as the simulated vehi-
cle speed is changed.
3. If either of above is defective, carry out the trou-
bleshooting. (Refer to P.51-37)
M1511027400217
Using the M.U.T.-III, the following functions can be
item (M.U.T.-III (M.U.T.-III display)
display)
operation by the wiper interval control.
according to the intermittent wiper interval
washer-linked wiper
function
TSB Revision
EXTERIOR
51-47
WINDSHIELD WIPER
M1511007900663
Section B B View A
5 10
2 27 3 Nm 27 3 Nm
<Front>
20 2 ft-lb 20 2 ft-lb
8.0 2.0 Nm 1 9
71 18 in-lb Specified grease: Multipurpose
5 A grease SAE J310, NLGI No. 2 or
7.4 1.4 Nm 3 equivalent
B 65 13 in-lb
4
8.0 2.0 Nm
8.0 2.0 Nm 71 18 in-lb
71 18 in-lb
B 9
32.0 2.0 Nm
24 1 fn-lb 8
10 8.0 2.0 Nm
71 18 in-lb
4
7
6 AC607945AB
TSB Revision
51-48 EXTERIOR
7
A F
6 E
F
B
A
C D E
D
NOTE
B C
: Clip positions
Section A A Section B B Section C C
5 Hood
5
Hood Windshield
7 Bolt 6 6
Clip
Section D D 6 Section E E Windshield Section F F

4 4 5 Claw
4
Windshield
Boss
Claw Windshield
AC607946 AB
Wiper blade removal steps Windshield wiper motor and

1. Wiper blade assembly wiper link assembly removal
>>A<< 2. Wiper blade steps (Continued)
Windshield wiper motor and 7. Front deck cover
wiper link assembly removal <<A>> >>B<< 8. Wiper link assembly
steps <> 9. Wiper motor link plate
>>C<< 3. Wiper arm and blade assembly <> 10. Windshield wiper motor
4. Front deck garnish cover NOTE: For removal and installation of the wiper and
5. Hood weatherstrip washer switch, refer to GROUP 54A, Column switch
6. Front deck garnish P.54A-230.
TSB Revision
EXTERIOR
51-49
.
<<A>> WIPER LINK ASSEMBLY REMOVAL
Wiper link assembly
<Right> <Left>
<Front>
1 Link rod 2
3
(A)
(B)
AC609130AB
1. Manually turn the link rod at the right of the wiper link
assembly forward to the position indicated in the figure.
CAUTION
Another mechanic fully pushes up the hood so that the left
side of link assembly is pulled out easily.
2. Pull out the attachment section of the left side of link
assembly forward.
CAUTION
When pulling out the link assembly forward, be careful not
to make a contact with the windshield glass.
3. While turning the link assembly upward (A), pull out the
entire link assembly diagonally forward left (B).
.
TSB Revision
51-50 EXTERIOR
<> WIPER MOTOR LINK PLATE/WINDSHIELD

WIPER MOTOR REMOVAL
1. To disconnect the wiper motor link plate from the wiper
motor shaft, use an appropriate tool to counter-hold the
Wiper motor plate to prevent it from turning.
link plate
2. Remove the wiper motor from the wiper link assembly.
AC609250AB

.
>>A<< WIPER BLADE INSTALLATION

CAUTION
Backing Section A A For good windshield wiper wiping performance, use wind-
Wiper blade shield wipers without a curve in the backing of the wiper
blade.
Wiper
blade Backing
.
>>B<< WIPER LINK ASSEMBLY/WIPER MOTOR

A
LINK PLATE/WINDSHIELD WIPER MOTOR
A INSTALLATION
Backing 1. Confirm that the wiper motor has set to automatic stop
AC609740AB
position (Refer to P.51-51).
CAUTION
Always replace the wiper motor link plate with new one.
Wiper motor
link plate 2. Set the wiper motor link plate onto the wiper motor shaft;
aligning the triangle mark on the plate to the center line (of 3
lines) on the wiper link assembly as shown in the illustration.
3. Tighten the attaching nut of wiper motor link plate and wiper
motor shaft. Use an appropriate tool to counter-hold the
plate to prevent it from turning.
Link rod
4. Apply grease to the inside of link rod joint (as required) and
Link rod joint connect the link rod to wiper motor link plate.
AC609252AB
Specified grease: Multipurpose grease SAE J310,
NLGI No.2 or equivalent
.
TSB Revision
EXTERIOR
51-51
>>C<< WIPER ARM AND BLADE ASSEMBLY
INSTALLATION
Section A A Unit: mm(in)
Wiper blade
Wiper arm and blade
assembly Ceramic end Ceramic end
line line
A 5(0.20)
Ceramic end
line
A
A 5(0.20)
Front deck garnish

A
Front deck garnish AC607947AB

Set the wiper arm and blade assembly at the specified posi-
tions.
(A): Ceramic end line 5.0 mm(0.20 in)
INSPECTION
M1511008000317
WINDSHIELD WIPER MOTOR CHECK

The windshield wiper motor assembly should be installed to
the vehicle body and the harness connector should be discon-
nected when checking the wiper motor.
.
WINDSHIELD WIPER MOTOR AT LOW OR HIGH

SPEED OPERATION
Connect the battery to the windshield wiper motor to inspect
the operation of motor rotation at low or high speed.
1 2 3
4 5
Operation check
1 2 3
4 5
Low speed
1 2 3
4 5
TSB Revision
51-52 EXTERIOR
WINDSHIELD WIPER MOTOR AT STOP POSITION

OPERATION
1. Connect the battery to the windshield wiper motor as shown
in the illustration (A).
2. Run the windshield wiper motor at low speed, then
disconnect the battery in the middle of the motor rotation
1 2 3 and check to see that the motor stops.
4 5
3. Connect the battery to the windshield wiper motor as shown
Stop position check in the illustration (B).
4. Connect the terminals of the windshield wiper motor
connector as shown in the illustration (B).
1 2 3
4 5
5. Check to see that the windshield wiper motor runs at low

(A) Low speed speed and then stops at the automatic stop position.
.
1 2 3 WINDSHIELD WIPER SWITCH CHECK

4 5
(B) Automatic stop AC608788AB
Check continuity between the switch terminals.

1
2 Switch position Tester Specified
3 connectio condition
4
5 n
6
7 OFF 6 11, 6 Open
8 10, 6 9, 6 circuit
9 8
10
11 Windshield mist wiper 6 11 Continuity
AC609144AB switch (Less than
2 ohms)
Windshield intermittent 6 10
wiper switch
Windshield low-speed 6 9
wiper switch
Windshield high-speed 6 8
wiper switch
TSB Revision
EXTERIOR
51-53
WINDSHIELD WASHER
M1511008200991
Section A A
1
1 Claw
Claw
2
4.0 2.0 Nm
36 17 in-lb A
10.5 2.5 Nm
93 22 in-lb
4
3
6
10.5 2.5 Nm
93 22 in-lb
5
AC607948 AB
Front bumper and radiator grille Washer tank removal steps

assembly (Refer to P.51-3) 3. Windshield washer tank assembly
Windshield washer nozzle removal 4. Windshield washer motor
steps 5. Windshield washer tank
Connection of windshield washer Washer motor removal steps
hose Front bumper and radiator grille
1. Windshield washer nozzle assembly (Refer to P.51-3)
Washer hose removal steps Connection of windshield washer
Front bumper and radiator grille hose
assembly (Refer to P.51-3) 4. Windshield washer motor
Connection of washer nozzle/washer 6. Grommet
motor NOTE: For removal and installation of the wiper and
2. Windshield washer hose washer switch, refer to GROUP 54A, Column switch
Washer tank removal steps P.54A-230.
Front bumper and radiator grille
assembly (Refer to P.51-3)
Connection of windshield washer
hose
TSB Revision
51-54 EXTERIOR
INSPECTION
M1511008300363
WINDSHIELD WASHER MOTOR CHECK

1. Remove the washer tank assembly with the washer hose
attached. Then fill the washer tank with water.
2. Check to see that the water is vigorously sprayed when
connecting the positive battery terminal to terminal number
2 and terminal number 1 to ground.
AC608513AB
WINDSHIELD WASHER SWITCH CHECK

1 SWITCH POSITION TESTER SPECIFIED
2
3 CONNECTION CONDITION
4
5
OFF 6 7 Open circuit
6
7
Windshield washer 6 7 Continuity (Less
8 switch ON than 2 ohms
9
10
11
AC609144AB
TSB Revision
EXTERIOR
51-55
WINDSHIELD WASHER FLUID EJECTION CHECK
Move the nozzle to adjust the position so that the spray is in
area shown in the area shown in the illustration.
Unit: mm(in)
400(15.74) 400(15.74)
15
45 (0.59)
(1.77)
90(3.54)
80 80
(3.14) (3.14)
105(4.13) 105(4.13)
40 210(8.27) 40
(1.57) (1.57) <Left>
<Right>
105(4.13) 105(4.13)
140 140
(5.51) (5.51)
70(2.75) 70
90(3.54) (2.76)
15
315 (0.59) 315
(12.40) 445 (12.40)
445
(17.52) 45 (17.52)
(1.77)
Ceramic line terminal
Vehicle center
Windshield line Windshield
washer washer
nozzle Windshield washer nozzle
perpendicular nozzle perpendicular
250(9.85) 250(9.85)
: Right side washer
: Left side washer

AC611986AB
TSB Revision
51-56 EXTERIOR
MARK
MARK
M1511011801941
N3
N4
5N
AC609420AB
1. Front three-diamond mark (Refer to >>A<< 4. LANCER mark <Vehicles for Puerto
P.51-4.) Rico>
>>A<< 2. Rear three-diamond mark >>A<< 5. LANCER mark <Vehicles for USA
>>A<< 3. MITSUBISHI mark <Vehicles for and Canada>
USA and Canada>
TSB Revision
EXTERIOR
MARK
51-57
.
>>A<< MARK INSTALLATION

2. Rear three-diamond mark
Trunk lid panel

press line
61.5 mm High mount stop light
(2.42 in)
Center line of vehicle 116.3 mm
(4.58 in)
AC609448AB
3. MITSUBISHI mark <Vehicles for USA and Canada>
30.5 mm
(1.20 in)
Trunk lid panel
press line
Trunk lid panel
end line
44.7 mm 45.5 mm
(1.76 in) (1.79 in)
AC609134 AB
4. LANCER mark <Vehicles for Puerto Rico>
30.5 mm
(1.20 in)
Trunk lid panel
Trunk lid panel press line
end line
44.7 mm 45.7 mm
(1.76 in) (1.80 in)
AC609254 AB
TSB Revision
51-58 EXTERIOR
MARK
6. LANCER mark <Vehicles for USA and Canada>
Trunk lid panel

press line
30.5 mm
(1.20 in)
Trunk lid panel

Trunk lid open switch end line
or trunk lid lock cylinder
45.7 mm 44.7 mm
(1.80 in) (1.76 in)
AC609253 AB
1. Installation position
Attach each mark to the position shown in the illustration.
2. Installation procedure
(1) Use 3M AAD Part number 8906 or equivalent to clean
the mark installation surfaces on the body.
CAUTION
When attaching the marks, the ambient temperature
should be 20 38 C (68 100 F) and the air should be com-
pletely free of dust. If the ambient temperature is lower
than 20 C (60 F), the marks and the places on the vehicle
body where the marks are to be attached should be heated
to 20 30 C (68 86 F).
(2) Peel off the protection sheet on the back of the marks to
affix it in position.
TSB Revision
EXTERIOR
DOOR MIRROR
51-59
DOOR MIRROR
GENERAL INFORMATION
M1511000101250
DOOR MIRROR OPERATION plied to the rear window defogger, and the heater
of the door mirror (heated door mirror) starts
Remote Controlled Mirror Operation operation. The rear window defogger comes with
The mirror on the door mirror moves up/down a timer function and will automatically turn OFF
and left/right by operating the remote controlled the switch approximately 20 minutes after the
door mirror switch when the ignition switch is at rear window defogger switch is turned ON. The
the "ON" or "ACC" position. heated door mirror operations are also termi-
Heated Door Mirror Operation nated along with the rear window defogger, at this
The rear window defogger relay switch is acti- time.
vated (ON) by turning on the A/C-ECU built-in
rear window defogger switch when the ignition
switch is in the "ON" position. When the rear win-
dow defogger relay is turned ON, power is sup-
HEATED DOOR MIRROR DIAGNOSIS

M1511014600523
Diagnosis should be carried out by the following pro- 3. Find the malfunction by the following Symptom
cedures. Chart.
1. Gather the information from the customer. 4. Verify the malfunction is eliminated.
2. Verify that the condition described by the
customer exists.
SYMPTOM CHART
M1511015000665
SYMPTOM INSPECTION REFERENCE

PROCEDURE PAGE
All heated door mirrors do not operate 1 P.51-60
The right or left heated door mirror does not operate 2 P.51-63
TSB Revision
51-60 EXTERIOR
DOOR MIRROR
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: All Heated Door Mirrors do not Operate
Door Mirror Relay Circuit
REAR WINDOW
DEFOGGER
RELAY
C-306
BROWN
RELAY BOX
(PASSENGER
COMPARMENT)
BLACK-
WHITE
JOINT CONNECTOR
(3)
BLACK-
WHITE
BLACK-
WHITE
BROWN
BLACK-
WHITE
DOOR MIRROR DOOR MIRROR

ASSEMBLY (LH) ASSEMBLY (RH)
BLACK
BLACK
C-125 C-114
BLACK
BLACK
AC609477AB
Connector: C-07 Connector: C-115
C-115 (BR)
AC608145AP AC608146BD
TSB Revision
EXTERIOR
DOOR MIRROR
51-61
Connectors: C-126 Connectors: C-306
Junction block
C-306
C-126 (BR)
AC608145BR AC608152 AQ
Connectors: E-04 Connectors: E-01
E-04 E-01
AC608168AE AC608167AG
.
CIRCUIT OPERATION
If both of the door mirror heaters do not operate nor- Malfunction of the rear window defogger system
mally it may be due to a malfunction in the rear win- The wiring harness or connectors may have
dow defogger system. loose, corroded or damaged terminals, or termi-
nals pushed back in the connector.
.
DIAGNOSIS
STEP 1. Check the rear window defogger.

Check that the rear window defogger works normally as fol-
lows.
(1) Turn the ignition switch to the "ON" position.
(2) Push the rear window defogger switch to operate the
defogger.
Q: Does the defogger work normally?
YES : Go to Step 2.
NO : Because of malfunction of the rear window defogger,
carry out the troubleshooting (Refer to GROUP 55A,
Manual A/C Diagnosis P.55A-8).
TSB Revision
51-62 EXTERIOR
DOOR MIRROR
STEP 2. Check the door mirror (RH) connector E-04and

rear window defogger relay connector C-306 for loose,
in the connector.
Q: Is the door mirror (RH) connector E-04 and rear window
defogger relay connector C-306 in good condition?
YES : Go to Step 3.
P.00E-2. Check if the door mirrors works normally.
STEP 3. Check the wiring harness between the door mirror

(RH) connector E-04 (terminal 1) and rear window defogger
relay connector C-306 (terminal 3).
NOTE: Also check joint connector C-07 and intermediate con-
nector C-115 for loose, corroded or damaged terminals, or ter-
minals pushed back in the connector. If joint connector C-07
and intermediate connector C-115 is damaged, repair or
replace the damaged component(s) as described in GROUP
00E, Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between door mirror (RH)
connector E-04 (terminal 1) and rear window defogger
relay connector C-306 (terminal 3) in good condition?
YES : Go to step 4.
NO : Repair the wiring harness as necessary. Check if all
heated door mirrors work normally.
STEP 4. Check door mirror (LH) connector E-01.

Q: Is the door mirror (LH) connector E-01 in good
condition?
YES : Go to Step 5.
NO : Repair or replace the damaged component(s). Check
if all heated door mirrors work normally.
STEP 5. Check the wiring harness between door mirror

(LH) connector E-01 (terminal 1) and rear window defogger
Q: Is the wiring harness between door mirror (LH)
NO : Repair the wiring harness as necessary. Check if the
all heated door mirrors work normally.
TSB Revision
EXTERIOR
DOOR MIRROR
51-63
INSPECTION PROCEDURE 2: The Right or Left Heated Door Mirror does not Operate
Door Mirror Relay Circuit
REAR WINDOW
DEFOGGER
RELAY
C-306
BROWN
RELAY BOX
(PASSENGER
COMPARMENT)
BLACK-
WHITE
JOINT CONNECTOR
(3)
BLACK-
WHITE
BLACK-
WHITE
BROWN
BLACK-
WHITE
DOOR MIRROR DOOR MIRROR

ASSEMBLY (LH) ASSEMBLY (RH)
BLACK
BLACK
C-125 C-114
BLACK
BLACK
AC609477AB
Connector: C-07 Connectors: C-114
C-114
AC608145AP AC608146 BF
TSB Revision
51-64 EXTERIOR
DOOR MIRROR
Connector: C-115 Connectors: C-125
C-115 (BR)
C-125
AC608146BD AC608145BS
Connectors: C-126 Connectors: C-306

Junction block
C-306
C-126 (BR)
AC608145BR AC608152 AQ
Connectors: E-01 Connectors: E-04
E-01 E-04
AC608167AG AC608168AE
.
CIRCUIT OPERATION
If either of the heated door mirror do not operate nor- Malfunction of the heated door mirror circuit
mally, it may be due to malfunctions in the heated Malfunction of the door mirror
door mirror circuit or door mirror. The wiring harness or connectors may have
loose, corroded or damaged terminals, or termi-
.
DIAGNOSIS
STEP 1. Verify the operation of each heated door mirror.

Q: Which door mirror does not heat?
Door mirror (LH) : Go to Step 2.
Door mirror (RH) : Go to Step 8.
TSB Revision
EXTERIOR
DOOR MIRROR
51-65
STEP 2. Check door mirror (LH) connector E-01 for loose,

in the connector.
Q: Is door mirror (LH) connector E-01 in good condition?
YES : Go to Step 3.
P.00E-2. And then check to see that the heater
function of the door mirror (LH) operates normally.
STEP 3. Check the heater of the door mirror (LH).

CAUTION
When relocating the car between locations of extremely
different temperatures (warm and cold), leave the car in a
location for a while to adapt to the temperature prior to
checking it.
Check to see that the resistance between terminal 1 and 5 of
the door mirror (LH) connector E-01.
The resistance should be 8.4 1.2 at 25 C (77 F).
Q: Is the resistance normal?
YES : Go to Step 4.
NO : Replace the door mirror (LH). And then check to see
that the heater function of the door mirror (LH) is
operating normally.
AC609133 AB
STEP 4. Check the ground circuit between door mirror

(LH) connector E-01 and ground for open circuit. Measure
the resistance at door mirror (LH) connector E-01.
(1) Disconnect door mirror (LH) connector E-01 and check at
the wiring harness side connector.
Harness side: E-01
ground.
YES : Go to Step 6.
NO : Go to Step 5.
AC608255 AJ
TSB Revision
51-66 EXTERIOR
DOOR MIRROR

(LH) connector E-01 (terminal 5) and ground.
nector C-125 and C-126 for loose, corroded or damaged termi-
nals, or terminals pushed back in the connector. If joint
connector C-07 and intermediate connector C-125 and C-126
is damaged, repair or replace the damaged component(s) as
described in GROUP 00E, Harness Connector Inspection
P.00E-2.
connector E-01 (terminal 5) and ground in good
condition?
NO : The wiring harness may be damaged. Repair the
wiring harness as necessary. And then check to see
that the heater function of the door mirror (LH)
operates normally.
STEP 6. Check rear window defogger relay connector

C-306 for loose, corroded or damaged terminal, or
terminals pushed back in the connector.
Q: Is rear window defogger relay connector C-306 in good
condition?
YES : Go to Step 7.
function of the door mirror (LH) operates normally.

(LH) connector E-01 (terminal 1) and rear window defogger
NO : Repair the wiring harness as necessary. And then
check to see that the heater function of the door
mirror (LH) operates normally.
TSB Revision
EXTERIOR
DOOR MIRROR
51-67
STEP 8. Check the door mirror (RH) connector E-04 for

Q: Is the door mirror (RH) connector E-04 in good
condition?
YES : Go to Step 9.
function of the door mirror (RH) operates normally.
STEP 9. Check the heater function of the door mirror (RH).

CAUTION
When relocating the car between locations of extremely
different temperatures (warm and cold), leave the car in a
location for a while to adapt to the temperature prior to
checking it.
Check to see that the resistance between terminal 1 and 5 of
the door mirror (RH) connector E-04.
The resistance should be 8.4 1.2 at 25 C (77 F).
Q: Is the resistance normal?
NO : Replace the door mirror (RH). And then check to see
that the heater function of the door mirror (RH)
operates normally.
AC609133 AB
STEP 10. Check the ground circuit between door mirror

(RH) connector E-04 and ground for open circuit. Measure
the resistance at door mirror (RH) connector E-04.
(1) Disconnect door mirror (RH) connector E-04, and check at
the wiring harness side connector.
Harness side: E-04 ground.
NO : Go to Step 11.
AC608255AK
TSB Revision
51-68 EXTERIOR
DOOR MIRROR

(RH) connector E-04 (terminal 5) and ground.
nector C-114 and C-115 for loose, corroded or damaged termi-
nals, or terminals pushed back in the connector. If joint
connector C-07 and intermediate connector C-114 and C-115 is
damaged, repair or replace the damaged component(s) as
P.00E-2.
connector E-04 (terminal 5) and ground in good
condition?
NO : The wiring harness may be damaged. Repair the
wiring harness as necessary. And then check to see
that the heater function of the door mirror (RH)
operates normally.

C-306 for loose, corroded or damaged terminal, or
condition?
function of the door mirror (RH) operates normally.

(RH) connector E-04 (terminal 1) and rear window defogger
NO : Repair the wiring harness as necessary. And then
check to see that the heater function of the door
mirror (RH) operates normally.
TSB Revision
EXTERIOR
DOOR MIRROR
51-69
DOOR MIRROR
M1511006400870
A
3
Power window
switch panel
A
A
4
1
Section A A
: Claw positions
5.0 2.0 Nm
45 17 in-lb
2
AC607955AB
Door mirror outer cover claw positions Section A A

Claw
A A
3 3
2
Claw
A
A A
A
: Claw positions
AC607956AB
Door mirror assembly removal Door mirror outer cover removal

steps steps
Tweeter (Refer to GROUP 54A, 2. Mirror
Speaker P.54A-443) <<A>> >>A<< 3. Door mirror outer cover
Door mirror connector connection Remote controlled mirror switch
1. Door mirror assembly removal steps
Front door trim (Refer to GROUP
52A, Door Trim P.52A-13)
4. Remote controlled mirror switch
TSB Revision
51-70 EXTERIOR
DOOR MIRROR

.
<<A>> DOOR MIRROR OUTER COVER REMOVAL

CAUTION
The tab of the mirror is prone to breakage when working in
cold temperatures. Always use a hair drier or the like to
warm up the mirror tab and its periphery to 20 C or higher
prior to works. When the mirror is heated too quickly from
its cold state, it may be broken.
1. Slant the mirror upward with your hands. Then insert a
Mirror
Claw positions flat-tipped screwdriver wrapped with protective tape
between the pivot plate and mirror through the cut-out from
behind the mirror. Now pry off the mirror tab and release the
lower side of the mirror as shown in the illustration.
A 2. Release the upper side of the mirror from the tab as shown
A while pulling out the mirror.
3. Disconnect the connectors of the heated mirror.
Protective tape
Flat-tipped screwdriver
Section A A
Mirror
Flat-tipped screwdriver
Pivot plate
Claws
Claw
Claw
Flat-tipped screwdriver AC605127AC
4. Remove the door mirror outer cover by disengaging the

1
1 claws in the numerical order of the illustration from the mirror
body side.
2 2
2
: Claw positions AC608686AB
TSB Revision
EXTERIOR
DOOR MIRROR
51-71
.
>>A<< DOOR MIRROR OUTER COVER INSTAL-

LATION
CAUTION
Tap the claw positions securely to confirm that they are
engaged securely.
2 Install the door mirror outer cover by engaging the claws in the
2 numerical order of the illustration.
1 1
1
: Claw positions AC608686AC
INSPECTION
M1511006500510
REMOTE CONTROLLED MIRROR OPERATION

CHECK
Check that the mirror moves as described in the table when
each terminal is connected to the battery.
BATTERY CONNECTION DIRECTION
OPERATION
Connect terminal 8 to the negative Up
battery terminal.
Connect terminal 6 to the positive battery
terminal.
AC608725AB Connect terminal 8 to the positive battery Down
terminal.
Connect terminal 6 to the negative
battery terminal.
Connect terminal 8 to the negative Right
battery terminal.
Connect terminal 7 to the positive battery
terminal.
Connect terminal 8 to the positive battery Left
terminal.
Connect terminal 7 to the negative
battery terminal.
TSB Revision
51-72 EXTERIOR
DOOR MIRROR
DOOR MIRROR CONTROL SWITCH CONTINUITY

CHECK
SWITCH TESTER CONNECTION SPECIFIED

POSITION CONDITION
OFF 9 2, 9 3, 9 6, 9 10, 9 Open circuit
1 2 3 4 11, 1 2,1 3, 1 6,
5 6 7 8 9 10 11 1 10, 1 11
Left OFF 9 6, 9 10, 9 11, Open circuit
side 1 6, 1 10, 1 11
AC406691 Up 1 6, 9 11 Continuity
(Less than 2
Down 1 11, 6 9
ohms)
Right 1 6, 9 10
Left 1 10, 6 9
Right OFF 9 2, 9 3, 9 6, Open circuit
side 1 2, 1 3, 1 6
Up 1 6, 3 9 Continuity
(Less than 2
Down 1 3, 6 9
ohms)
Right 1 6, 2 9
Left 1 2, 6 9
HEATED DOOR MIRROR CHECK

CAUTION
When relocating the car between locations with extremely
different temperatures (warm and cold), leave the car in
the location for a while to adapt to the temperature prior to
checking it.
Check that the resistance value between the connector termi-
nals is at the standard value.
Standard value: 8.4 1.2 at 25 C(77 F)
AC609133 AB
TSB Revision
52-1
GROUP 52
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . 52B

NOTES
52A-1
GROUP 52A
INTERIOR
CONTENTS
GENERAL INFORMATION . . . . . . . . 52A-2 SEAT BELT. . . . . . . . . . . . . . . . . . . . . 52A-8
INSTRUMENT PANEL AND FLOOR TRIMS . . . . . . . . . . . . . . . . . . . . . . . . . 52A-10

CONSOLE . . . . . . . . . . . . . . . . . . . . . 52A-3 INTERIOR TRIMS . . . . . . . . . . . . . . . . . . . . 52A-10
DOOR TRIM . . . . . . . . . . . . . . . . . . . . . . . . 52A-11
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . 52A-5
FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . 52A-5 HEADLINING . . . . . . . . . . . . . . . . . . . 52A-12
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . 52A-7
52A-2 INTERIOR
GENERAL INFORMATION
GENERAL INFORMATION
M2520000101013
Functionality, interior comfort, and safety have been 2. ISO-FIX lower anchor (rear seat outside)
emphasized, giving interior design for elegance and 3. Upper tether anchor (rear shelf)
relaxation space. Various measures have been taken 4. ELR 3-point seat belt (drivers seat)
to protect the environment and recycle resources.
5. ELR/ALR 3-point seat belt (front passenger, rear)
FEATURES 6. Seat belt retractor with a driver's side preten-
Quality improvement sioner and force limiter
1. Two-tone interior 7. Seat belt retractor with a passengers side pre-
2. Full interior trim tensioner and force limiter
8. Headliner energy absorption rib <Vehicles with-
Usability improvement out curtain air bag>
1. Armrest (floor console, rear seat, front door trim,
rear door trim) Consideration for the optimum driving position
2. Cup holder (floor console, rear seat armrest) 1. Seat height adjustment (drivers seat)
3. Bottle holder (front door trim) 2. Head restraint with height adjustment (front, rear)
3. Seat slide adjustment (front)
Convenient storage
1. Glove box Measures for resource recycling
2. Seatback pocket (drivers seat) 1. Aggressively use PP materials that are easy to
recycle and easy to stamp material symbols on
3. Card holder (glove box)
the plastic (resin) parts.
4. Tissue paper holder (floor console)
2. Reduction of chemical material (formaldehyde*,
5. Floor console box
organic solvent)
6. Door pocket (front door trim, rear door trim)
NOTE: *: Clear and colourless, toxic, irritating odour
Safety improvement
1. Front and rear collision protection seat mecha-
nism (front seat)
INTERIOR
INSTRUMENT PANEL AND FLOOR CONSOLE
52A-3
M2520001000793
Card holder
Glove box
Ornament panel
Armrest
Center tray
Glove box
Tray
Cup holder
Type B Type C
Console box
Tissue paper
holder
Console box
AC609712
The instrument panel and the floor console have the The division unit of each part has been enlarged,
following features. also the gap and level difference between the
The instrument panel is two-toned. instrument panel has been minimized to achieve
the delicate quality.
52A-4 INTERIOR
The decorated panel creating uniformity from the The cup holder which can hold two 20-oz bottles
instrument panel to the door trim has been has been equipped. The cup holder can store two
adopted. CDs in the upright position and pen-size long
The holder in which two cards can be stored has items horizontally.
been installed in the glove box. Under the arm rest of type B, a large box that can
The glove box with damper function has been store 6 CDs has been equipped. (9 CDs for type
installed. <Except DE> C)
The center tray for storing small items has been A tray that can store cigarettes and lighters has
installed in front of the selector or shift lever cen- been equipped. <Vehicles without console
ter panel. switch>
The synthetic cloth is used for the arm rest lid to
enhance luxury and soft feelings.
INTERIOR
SEAT
52A-5
SEAT
FRONT SEAT
M2520004000996
<Standard type> <Sports type>
Head restraint Head restraint

vertical adjustment vertical adjustment
Reclining adjustment Reclining adjustment
Height adjustment Height adjustment

(Driver's side) (Driver's side)
Sliding adjustment Sliding adjustment
<Driver's seat>
<Heated seat>
Seat heater Seatback pocket

<Except DE>
Heated seat
switch
AC609378 AB
The front seats offer the following advantages. The cross frame has been installed below the
seat cushion to reduce a risk of injury by restrain-
ing the forward travel of the passenger. (Waist
position travel reduction frame structure)
52A-6 INTERIOR
SEAT
The seat frame and head restraint have been The variable hardness pad has been adopted for
installed to the proper positions to minimize the the sporty-look seat with increased bucket
severity of whiplash injury at rear-end collision at amount of side bolster in order to establish the
a low speed. (Whiplash injury reduction seat sporty shape with support function <GTS>, and
structure) the standard shape which is basic and for actual
The overall height mechanism raises and lowers use and comfortable driving.
the seat cushion together with the seatback, thus Heated seats are available for the driver's and
the driver's posture is always kept at the best passenger's seats. <ES, GTS: Option>
position, resulting in the improved riding comfort. The genuine leather for the seat has been
The pump-type height lever has been adopted for upgraded to enhance the texture and luxury feel-
easier operation with a light force by the vertical ing. <GTS: Option>
adjustment system. Also, the height adjustment
amount has been increased for more optimum
driving position.
SPECIFICATIONS FOR HEATED SEAT
Item Specifications
ENERGY CONSUMPTION W HIGH 61 6.1
LOW 16 1.6
THERMOSTAT C ON OFF 40 4
OFF ON 30 5
INTERIOR
SEAT
52A-7
REAR SEAT
M2520007000605
<Lower anchorage for child seat>
<Bench seat>
Head restraint
vertical adjustrment
<Trunk through seat>

Head restraint
vertical adjustrment
Rear seatback
forward folding
<Uper tether anchor>
Cup holder
AC609174 AB
A low-back bench seat is used for rear seat. The rear An upper tether anchor has been installed on the
seat offer the following advantages: rear shelf trim, and an ISO-FIX lower anchor has
The center armrest has a cup holder. been installed on the body side.
52A-8 INTERIOR
SEAT BELT
SEAT BELT
M2520010000683
<USA>
Seat belt warning lamp
<CANADA> Seat belt warning lamp
ELR/automatic locking retractor

(ALR) switching three-point seat belt
One-touch push button style

adjustable seat belt
shoulder anchor Seat belt
retractor
ELR/automatic locking
retractor (ALR) switching
three-point seat belt
Seat belt retractor

with a pre-tensioner
and force limiter
ELR three-point
seat belt
AC608590 AB
FRONT SEAT BELT The seat belt retractor with the force limiter for
An ELR three-point seat belt (driver's side) and the drivers seat and the front passengers seat
three-point seat belt with ELR/ALR changeover increase safety.
mechanism (passenger's side) is used. A seat belt warning light is installed to the drivers
One-touch push button style adjustable seat belt and passengers seat.
anchor and retractable buckle provide the most
REAR SEAT BELT
suitable belt fitting.
3-point seat belt with Automatic Locking Retrac-
tor (ALR)/ELR changeover mechanism
(LH/RH/Center) is used for the rear seat.
INTERIOR
SEAT BELT
52A-9
SEAT BELT RETRACTOR WITH FORCE LIMITER
.
The drivers/front passengers seat belt retractor has been

equipped with a force limiter. The force limiter is a device which
operates when a predetermined force is applied, and limits the
force.
.
OPERATION
1. If a collision energy is transmitted to the seat belt, the ELR
mechanism will operate to lock the seat belt.
2. If the energy increases to a predetermined value, the torsion
TORSION BAR bar will be distorted. As the spindle rotates together with the
BELT
torsion bar, the seat belt webbing is pulled out, reducing the
impact to the occupants.
SPINDLE
AC100083 AB
52A-10 INTERIOR
TRIMS
TRIMS
INTERIOR TRIMS
M2520012000559
Center pillar trim upper Rear pillar trim

Trunk lid trim
Front pillar trim
Cowl side trim
Rear end trim
Rear scuff plate Trunk side trim

Center pillar trim lower
Front scuff plate
Rear shelf trim
Energy absorption rib
Front pillar trim

(back side)
AC608126 AB
The interiors are fully covered by trims. Use of nonflammable materials for the trims has
The energy absorption rib molding located in the increased safety as outstanding interiors. Also,
back side of the front pillar trim and the rear pillar material codes are indicated to deal with recy-
trim protect head from side impacts and the resin cling easily.
materials for the trims are unbreakable materials.
INTERIOR
TRIMS
52A-11
DOOR TRIM
M2520012300594
<Rear door trim> <Front door trim>
Ornament panel
Armrest Armrest
Door pocket Door pocket
Bottle holder
AC608432AB
The decorated panel has been adopted for the The shock absorbing arm rest has been adopted
front door trim. which reduces the mid section injuries to passen-
The bottle holder for bottles with shapes that are gers by collapsing upon side impact.
difficult to keep upright has been adopted for the The arm rest which is formed with cloth has been
front door pocket. adopted to create a continuous flow with the
The front door pocket with a large capacity has ornament section.
been adopted for items such as A4-size map.
Also, the rear door pocket has been added.
52A-12 INTERIOR
HEADLINING
HEADLINING
M2520014000306
Headliner
NOTE
: Energy absorption box positions
AC608128AC
Interior design with safe material has been adopted, Energy absorption pad and rib have been
achieving more safe and comfortable interior. adopted to the inside of headliner. This reduces
head injuries upon the secondary impact against
the cabin during a collision, and improves safety.
52B-1
GROUP 52B
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
GENERAL INFORMATION . . . . . . . . 52B-2 SIDE-AIRBAG MODULE . . . . . . . . . . . . . . . 52B-13

CURTAIN AIR BAG MODULE. . . . . . . . . . . 52B-14
SYSTEM OPERATION. . . . . . . . . . . . 52B-10 FRONT IMPACT SENSOR . . . . . . . . . . . . . 52B-14
ADVANCED AIR BAG AND SEAT BELT WITH SIDE IMPACT SENSOR . . . . . . . . . . . . . . . 52B-14
PRE-TENSIONER. . . . . . . . . . . . . . . . . . . . 52B-10 SEAT SLIDE SENSOR . . . . . . . . . . . . . . . . 52B-15
SIDE AND CURTAIN AIR BAGS . . . . . . . . 52B-11 OCCUPANT CLASSIFICATION-ECU AND
WEIGHT SENSOR . . . . . . . . . . . . . . . . . . . 52B-15
SYSTEM CONSTRUCTION . . . . . . . . 52B-11 SEAT BELT WITH PRE-TENSIONER. . . . . 52B-18
DRIVER'S SIDE AIR BAG MODULE . . . . . 52B-11 PASSENGER SEAT BELT WARNING
CLOCK SPRING . . . . . . . . . . . . . . . . . . . . . 52B-12 LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B-20
PASSENGER'S (FRONT) AIR BAG PASSENGER'S AIR BAG OFF INDICATOR
MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . 52B-12 LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B-20
KNEE AIR BAG MODULE . . . . . . . . . . . . . 52B-13 SRS-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . 52B-21
SRS AIR BAG SPECIAL CONNECTOR . . . 52B-25
52B-2 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
GENERAL INFORMATION
GENERAL INFORMATION
M2521000100994
CAUTION The advanced air bag system has been adopted

Driver and passengers (front) air bags, knee to the driver's and passenger's (front) sides.
air bag and seat belt pre-tensioner deploy and When a frontal impact exceeds the threshold
operate in frontal collisions that exceed the upon a frontal collision, or depending on the seat
threshold to activate the SRS (Supplemental position (driver's seat side), the air bag inflates
Restraint System). the cushion air bag in two stages, improving the
protection for the front seat passengers.
The front air bag deploys when a vehicle col-
When a frontal impact exceeds the threshold, the
lides head-on with a concrete (fixed) wall at
knee air bag is instantaneously inflated to protect
approximately 25 km/h (15 mph) or more, or
the passenger's feet (knee and leg).
when a vehicle suffers a severe impact from
The side-airbag is activated when an impact
the front side.The side air bag deploys when a
exceeds the threshold upon a side collision, and
center of side body suffers a severe impact.
the cushion air bag is instantaneously inflated to
The front air bags and pre-tensioner may not
protect the chest area of the front seat passen-
work under the following conditions:
gers.
A frontal collision is less than the specific The curtain air bag is activated simultaneously
value. with the side-airbag upon a side collision to pro-
The collision is from the rear tect the heads of the front seat and second seat
The collision is from the side passengers.
The vehicle rolls over or is in a similar All the air bag modules are equipped with the
position. inflator that does not contain toxic sodium azide.
The side-airbags and curtain air bags may not The seat belt pre-tensioner is activated simulta-
work under the following conditions: neously with the deployment of driver's and pas-
The collision is from the front senger's (front) air bags in case of a frontal
The collision is from the rear collision. Seat belts are pulled in to eliminate the
Driver's and passenger's (front) air bags, side-air- slack upon a collision, thus improving the initial
bags, knee air bag, curtain air bags and seat occupant restraint, and reducing the travel dis-
belts with pre-tensioner have been installed to all tance of the occupants. For the driver's seat, in
the vehicles as standard. addition to the seat belt pre-tensioner for the
The SRS is a system that is effective with the shoulder side, the lap pre-tensioner has been
seat belt fastened, and it is designed as a supple- installed on the outer seat belt lower anchor side
mental system of the seat belt. in order to improve the restraining performance in
the waist and the chest areas.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
GENERAL INFORMATION
52B-3
Driver's air bag module Passenger's (front)

Seat belt with air bag module
pre-tensioner
Side-airbag module
Knee air bag module
AC609360 AB
System Component Parts bag analog G-sensor and a side-airbag safing

The SRS consists of drivers and passengers (front) G-sensor. The front impact sensor is assembled in
air bag modules, knee air bag modules, side-airbag the front end upper bar to monitor impact in case of
modules, curtain air bag modules, SRS-ECU (air bag front impact. The side impact sensors inside the cen-
control unit), front impact sensors, side impact sen- ter pillars monitor the shock incurred by the sides of
sors, SRS warning light, passengers air bag OFF the vehicle. The SRS warning light on the combina-
indicator light, passengers seat belt warning light, tion meter indicates the operational status of the
clock spring, seat belt pre-tensioner, seat belt switch, SRS. The clock spring is installed in the steering col-
seat slide sensor, occupant classification-ECU and umn. The seat belt pre-tensioner is built into the
weight sensor. Drivers and passengers (front) air driver's and passenger's front seat belt retractor. The
bag modules are located in the center of the steering seat slide sensor is installed at the seat adjuster sec-
wheel and above the glove box. The knee air bag tion of the driver seat in order to detect the driver
module has been installed to the instrument panel seat slide position. The weight sensor is installed
lower section under the steering column.Side-air- underneath a rail of the passenger seat to detect the
bags are located inside the front seatback frame. load on the seat. The occupant classification-ECU
The curtain air bag module has been installed onto mounted under the front passenger's seat deter-
the roof side section (from front pillar and back end of mines the occupant class according to the signals
rear pillar).Each air bag consists of a folded air bag from the weight sensors and sends signals to
and an inflator unit. On all air bag modules, the infla- SRS-ECU.The passengers air bag OFF indicator
tor does not contain sodium azide. The SRS-ECU light is installed to the lower left of the center panel,
placed on the forefront of the floor monitors the sys- and illuminates when the passengers (front) air bag
tem and has a front air bag safing G-sensor, front air
GENERAL INFORMATION
is inactive. The passengers seat belt warning light is front air bag analog G-sensor. It will also supply a
installed to the lower right of the center panel, and squib ignition current to the side-airbag module and
illuminates when the passenger is not wearing the curtain air bag module when simultaneously detect-
seat belt. The seat belt switch detects whether the ing side impact with the side impact sensor and
seat belt is used. side-airbag safing G-sensor.
The SRS-ECU will start a squib ignition current to the
driver's/passengers (front) air bag module, knee air
bag module and seat belt pre-tensioner when simul-
taneously detecting frontal impact with the front
impact sensor, front air bag safing G-sensor and
GENERAL INFORMATION
52B-5
<Vehicles for USA> SRS warning light
Vehicle
identification
code chart plate
AC100836
SRS warning light

<Vehicles for CANADA>
Passenger's (front)
Driver's air bag module Clock spring
air bag module
Diagnosis
connector
Passenger's seat belt warning light
Passenger's air bag OFF indicator light

SRS-ECU
Knee air bag module

Side-airbag module
Weight sensor
Weight sensor
Occupant
classification-ECU
Side impact sensor Seat slide sensor
Seat belt pre-tensioner
Front impact sensor
AC609363 AB
GENERAL INFORMATION
SRS SYSTEM CIRCUIT DIAGRAM

Fusible link Ignition switch (IG1)
No. No. SRS-ECU

ETACS-ECU 18 12 Front impact sensor
7.5A 7.5A (LH)
Passenger's air bag

OFF indicator light CONNECTOR CONNECTOR
LOCK SWITCH* LOCK SWITCH* Front impact sensor
OFF OFF (RH)
OFF
ON
ON ON
OFF OFF
Clock spring OFF
Driver's air bag module ON ON Date link connector
OFF ON
OFF (For scan tool)
* OFF
ON ON ON
OFF OFF OFF
Can bus line
ON ON
OFF ON
OFF
ON
CONNECTOR ON
Passenger's (front) OFF LOCK SWITCH* OFF Combination meter,
air bag module ON Front seat assembly
ON
OFF OFF
ON CONNECTOR ON
OFF LOCK SWITCH*
OFF
ON
ON
OFF OFF
Side impact
Knee air bag module ON CONNECTOR ON
LOCK SWITCH* sensor (LH)
(Driver's side) OFF OFF
ON ON
OFF OFF
ON CONNECTOR ON
Seat belt pre-tensioner
OFF LOCK SWITCH* OFF
(LH)
ON ON Side impact
OFF
OFF sensor (RH)
ON CONNECTOR ON
Seat belt pre-tensioner OFF LOCK SWITCH* OFF
(RH ON ON
OFF OFF Seat belt switch
Side-airbag module ON CONNECTOR ON (Driver's side)
OFF LOCK SWITCH*
(LH) OFF
ON
ON Seat belt switch
OFF OFF (Passenger's side)
Side-airbag module ON ON
CONNECTOR
(RH) OFF LOCK SWITCH* OFF
ON ON
OFF OFF OFF
ON ON
Curtain air bag module OFF
ON
OFF OFF
(LH)
ON ON ON Note
OFF OFF OFF * : Connector connected: ON
Curtain air bag module ON ON Connector disconnected: OFF
ON
(RH) OFF OFF OFF
ON ON ON
AC609377AB
GENERAL INFORMATION
52B-7
CAUTION LABELS
The labels indicating the precautions for handling and maintenance of SRS air bags and seat belt with
pre-tensioner are adhered to the locations shown in the above figures.
Driver's air bag module Clock spring Passenger's (front)
air bag module
C
B
A
AC611162
ZC601274
SRS-ECU Knee air bag module Sunvisor
D E
F
F
AC608596
AC506231 AC608592
Seat belt with pre-tensioner Side-airbag module Curtain air bag module
(right and left) (right and left) (right and left)
G H
AC608562 AC609483 AC608953
Center pillar (right and left) Glove box
AC608655 K AC608593
AC609443 AB
GENERAL INFORMATION
Label contents
A, C DANGER
FLAMMABLE EXPLOSIVE
DO NOT:
DISASSEMBLE; HEAT; INCINERATE; APPLY ELECTRICITY;
OR STORE AT HIGH TEMPERATURE (93 C or HIGHER).
REFER TO WORKSHOP MANUAL FOR DETAILS.
B CAUTION: SRS CLOCK SPRING
PLEASE DO NOT TURN EXCEPT WHEN REQUIRED.
THIS IS NOT A REPAIRABLE PART. IF DEFECTIVE, PLEASE REPLACE ENTIRE UNIT
ACCORDING TO THE SERVICE MANUAL INSTRUCTIONS. ALIGNMENT OF
MODULES IS NECESSARILY WHEN THEY ARE ADJUSTED AND/OR INSTALLED
FOR THE ALIGNMENT PROCEDURES, FOLLOW THE SERVICE MANUAL
INSTRUCTIONS.
D CAUTION:
DO NOT DISASSEMBLE OR DROP. IF DEFECTIVE, REFER TO SERVICE MANUAL.
E DANGER
FLAMMABLE EXPLOSIVE
SRS AIR BAG MODULE
Do not disassemble or shock.
Do not heat or incinerate.
Do not contact with electricity or tester probes.
Do not test or diagnose.
Do not store in more than 200 F (93 C).
Store the air bag cover is top.
For information on handing, replacement, and disposal methods, refer to the service
manual.
F <EXCEPT WARNING
CANADA> EVEN WITH ADVANCED AIR BAGS
Children can be killed or seriously injured by the air bag
The back seat is the safest place for children
Never put a rear-facing child seat in the front
Always use seat belts and child restraints
AC306673 See owners manual for more information about air bags
F WARNING
<CANADA> DEATH or SERIOUS INJURY can occur
Children 12 and under can be killed by the air bag.
The BACK SEAT is the SAFEST place for children.
NEVER put a rear-facing child seat in the front.
Sit as far back as possible from the air bag.
ALWAYS use SEAT BELTS and CHILD RESTRAINTS.
G SEAT BELT PRETENSIONER CAUTION

THIS ASSEMBLY CONTAINS AN EXPLOSIVE INITIATOR.
DANGER FLAMMABLE MATERIAL
TO PREVENT PERSONAL INJURY
DO NOT REMOVE. INSTALL IT INTO ANOTHER VEHICLE.
SERVICE OR DISPOSE OF IT AS DIRECTED IN THE REPAIR MANUAL.
DO NOT DISMANTLE INCINERATE OR BRING INTO CONTACT WITH
ELECTRICITY.
GENERAL INFORMATION
52B-9
Label contents
H WARNING
SRS AIR BAG MODULE FLAMMABLE/EXPLOSIVE
TO AVOID SERIOUS INJURY:
DO NOT REPAIR, DISASSEMBLE OR TAMPER.
AVOID CONTACT WITH FLAME OR ELECTRICITY.
DO NO DIAGNOSIS/USE NO TEST EQPT OR PROBES.
STORE BELOW 200 F (93 C).
BEFORE DOING ANY WORK INVOLVING MODULE, READ SERVICE MANUAL
FOR IMPORTANT FURTHER DATA.
I DANGER CONTAINS HIGH-PRESSURE GAS AND FLAMMABLE MATERIAL
To avoid injury, NEVER; [Repair, Disassembly, Incinerate, Bring into contact with
electricity, Install onto another vehicle or Store where the temperature is above 93 C
(200 F)] -See Repair Manual for details.-
J SRS SIDE AIRBAG
WARNING
TO AVOID SERIOUS
INJURY OR DEATH:
Do not lean against the door.
Do not use seat covers.
See owners manual for more information
K <EXCEPT This Vehicle is Equipped with Advanced Air Bags
CANADA> Even with Advanced Air Bags
Children can be killed or seriously injured by the air bag.
The back seat is the safest place for children.
Never put a rear-facing child seat in the front.
Always use seat belts and child restraints.
See owners manual for more information about air bags.
Not to be removed except by owner.
K <CANADA> WARNING
MISE EN GARDE
Children Can Be KILLED or INJURED by Passenger Air Bag
The back seat is the safest place for children 12 and under.
Make sure all children use seat belts or child seats.
Not to be removed except by owner.
SYSTEM OPERATION
SYSTEM OPERATION
ADVANCED AIR BAG AND SEAT BELT WITH PRE-TENSIONER
M2521000700349
Dual stage air bags

<Only 1st stage>
Front impact Front impact

sensor (LH) sensor (RH)
<1st and 2nd stage>
Frontal collision against SRS-ECU

another vehicle
Shock Analog G-sensor
above a
certain
Ignition signal
level
Ignition judgment
or Knee air bag

Frontal collision against a <driver's seat>
solid surface G-sensor
(Front air bag)
Seat slide sensor
Occupant
classification-ECU
Air bag OFF
indicator light
Seat belt switch
AC609449AB
In case of a frontal collision, when the front The seat slide sensor to detect the driver's seat
impact sensor inside the engine room and the position judges the deployment in two stages,
G-sensor inside SRS-ECU simultaneously detect and deploys the driver's air bag.
an impact that exceeds a certain threshold The occupant classification-ECU has been added
(turned ON), SRS-ECU energizes the driver's to recognize the passenger's seat occupant. The
and passenger's (front) air bag modules (squibs), occupant classification-ECU identifies the occu-
knee air bag module (squib) and driver's and pas- pant class based on the signals from weight sen-
senger's seat belt pre-tensioners (squibs), thus sors, and sends the signal to SRS-ECU.
deploying the air bags and triggering the seat belt
pre-tensioners. Also, the advanced air bag has
been adopted to optimize the air bag deployment
control by adjusting the inflation pressure.
SYSTEM CONSTRUCTION
52B-11
SIDE AND CURTAIN AIR BAGS
M2521000800250
Curtain air bag modules
Side impact Side impact

sensor sensor
(front: RH) (front: LH)
AC608667
Shock
above a Side-airbag modules
certain
Ignition signal
level
Ignition judgment
G-sensor (Side-airbag,
curtain air bag)
Side impact against another vehicle SRS-ECU

AC608515
AC609451AB
SRS-ECU uses data of the side impact sensor and

G-sensor (in SRS-ECU) to calculate collision sever-
ity, during side collision. SRS-ECU judges necessity
of side-airbag and curtain air bag based on the cal-
culated collision severity.
SYSTEM CONSTRUCTION
DRIVER'S SIDE AIR BAG MODULE
M2521002000432
Air bag module Section A - A

A
Inflator
Air bag module
A
AC607285 AC
The drivers air bag module incorporates a

three-spoke steering wheel. The drivers air bag
module is an assembly part consisting of an air bag,
inflator, and their fasteners. The air bag is made from
nylon and inflates by gas from the inflator. As a driver
SYSTEM CONSTRUCTION
is being pressed to the air bag, it deflates discharg-

ing gas from two vents at the rear of the air bag to
reduce the shock from the impact. The driver's air
bag deploys by changing its inflation pressure in two
steps. The inflator has two squib connectors to
deploy the air bag in two steps. The inflator does not
contain sodium azide.
CLOCK SPRING
M2521001100072
The clock spring consists of a flat cable, rotator, stator, etc. The
Rotator Damper plate flat cable is loosely wound in the case in coil-form. One end is
Flat cable attached to the rotator and the other end is attached to the sta-
tor. By turning the steering wheel, the clock spring rotator turns
along with the steering shaft. The flat cable is wound or
unwound by the rotator according to how the steering wheel
turns. It must be in the neutral position when assembling the
Stator clock spring.
Anti-vibration sheet NOTE: For the clock spring centering procedures, refer to the
AC101314 AD SERVICE MANUAL.
PASSENGER'S (FRONT) AIR BAG MODULE

M2521002100116
Squib connectors
Air bag
Air bag module
Inflator AC608598
AC609452 AB
The passengers (front) air bag module consists of The inflator has two squib connector to deploy the air
an air bag, and their fasteners. bag in two steps.
The air bag is made from nylon and inflates by the The front passenger air bag does not deploy at the
gas from the inflator. As a passenger is being front passenger seat is not occupied and when the
pressed to the air bag, it deflates, discharging gas occupant classification sensor in the front passenger
from two vents at the side of the air bag to reduce the seat senses a weight on the seat of less than 66
shock from the impact. pounds (30 kg).
The front passengers air bag deploys by changing An inflator that does not contain sodium azide is
its inflation pressure in two steps. used.
SYSTEM CONSTRUCTION
52B-13
KNEE AIR BAG MODULE
M2521002600014
Section A-A
A
Inflator
A
Air bag
Cover
AC608525
AC609476 AB
The knee air bag consists of the air bag, inflator, and At the frontal collision, the knee air bag deploys by
fixing gear relating to those parts, and is installed the gas generated from the inflator to protect passen-
onto the instrument panel lower under the steering ger's feet (knee and leg). Like the air bags for frontal
column. collision, the side air bags are made of nylon whose
inside is rubber-coated, and is folded up and housed
in a cover. Gas exhaust openings are provided at the
sewed sections of the air bags to reduce the impacts
on the passenger's feet at deployment.
An inflator that does not contain sodium aziae is
used.
SIDE-AIRBAG MODULE
M2521004000290
Air bag module
AC609459AB
The side-airbag module consists of an air bag, air The side-airbag made of nylon fabric. The air bags
bag cover, inflator and their fasteners. The modules are compactly folded and stored under the cover. On
are installed in the outer side supports of the drivers the side of the air bag, there are holes through which
and front passengers seatbacks. The side-airbags gas is partially released to alleviate shock to the
help protect the occupants regardless of the seat occupant when the air bag is deployed. An inflator
position and seatback angle. that does not contain sodium azide is used.
SYSTEM CONSTRUCTION
CURTAIN AIR BAG MODULE

M2521000500226

Inflator
AC608585 AB
The curtain air bag module consists of an air bag, an The inflator is of a cold gas type filled with high-pres-
inflator, and the fixing gear relating to those parts, sure gas (major component: Argon). When current
and is installed in the roof side sections (from the passes through the squib to ignite the igniter powder,
driver's and the passenger's front pillars to the rear the burst disk bursts, emitting the gas into the air
pillars). bag.
The air bag is made from nylon with the inside
coated with silicon, and housed in the roof side sec-
tions, folded up compactly.
FRONT IMPACT SENSOR
M2521005000442
The front impact sensor is installed on the front end upper in
the engine room, and the analogue G-sensor is housed in
the front impact sensor.
The front impact sensor transmits the coded acceleration
data to SRS-ECU. Based on the data, SRS-ECU deter-
mines the deployment stage of the front air bag, then ener-
gizes appropriate squib.
SRS-ECU performs the diagnostics of the front impact sen-
Front impact sensor sor internal components. If a malfunction occurs, it sets the
AC608583 AB
diagnostic trouble code.
SIDE IMPACT SENSOR

M2521006000371
The side impact sensors are installed to the lower
Center pillar part of the center pillars on both sides and to the
quarter panels on both sides, and the analogue
G-sensor is housed in the side impact sensor.
The side impact sensor transmits the coded
acceleration data to SRS-ECU. Based on the
data, SRS-ECU determines the deployment of
the side-airbags and curtain air bags, then ener-
Side impact sensor
gizes appropriate squib(s).
SRS-ECU performs the diagnostics of the side
AC605684AD
impact sensor internal components. If a malfunc-
tion occurs, it sets the diagnostic trouble code.
SYSTEM CONSTRUCTION
52B-15
SEAT SLIDE SENSOR
M2521001400103
View A
A
Seat slide
Shield
sensor
plate AC609298
AC609466 AB
The seat slide sensor is attached to the slide The seat slide sensor outputs the current by
adjuster on the driver's seat side, and the seat is switching high output current and low output cur-
moved forward/backward by seat sliding. When rent from the seat slide position as shown in the
the seat is slid forward, the shield plate covers figure. Based on the output current, SRS-ECU
the sensor, and the sensor determines that the determines the deployment stage of the front air
seat slide position is set forward. bag, and then energizes the squib.
Shield plate position Current value Deployment stage
When the shield plate is in the detection range of the Low output current Only 1 stage
seat slide sensor
When the shield plate is not in the detection range of the High output current 1st and 2nd stage
seat slide sensor
OCCUPANT CLASSIFICATION-ECU AND WEIGHT SENSOR

M2521001300032
Weight sensor
Weight sensor
Occupant classification-ECU
AC608516 AB
SYSTEM CONSTRUCTION
The weight sensors are attached to the seat rails and The occupant classification-ECU identifies the occu-
provide SRS-ECU with information on the weight pant class based on the signals from weight sensors,
applied to the front passenger seat. and sends the signal to SRS-ECU. When the occu-
pant is determined to be less than 66 lbs (30 kg), the
passenger's (front) air bag is not deployed.
DIAGNOSTIC TROUBLE CODE OUTPUT

The occupant classification-ECU diagnoses the fol-
lowing items and stores a diagnostic trouble code in
the non-volatile memory (EEPROM*1) when a prob-
lem is detected. Therefore, the memory is not
deleted after a battery terminal is disconnected, (The
diagnostic trouble code memory can be deleted by
the scan tool.)
Diagnostic trouble Inspection item
Code No.
B1B78 Passenger seat weight sensor (front) (LH) performance
B1B79 Passenger seat weight sensor (ground side) short-circuited (front) (LH)
B1B7A Passenger seat weight sensor (power supply side) short-circuited (front) (LH)
B1B7D Passenger seat weight sensor (front) (RH) performance
B1B7E Passenger seat weight sensor (ground side) short-circuited (front) (RH)
B1B7F Passenger seat weight sensor (power supply side) short-circuited (front) (RH)
B1B82 Passenger seat weight sensor (rear) (LH) performance
B1B83 Passenger seat weight sensor (ground side) short-circuited (rear) (LH)
B1B84 Passenger seat weight sensor (power supply side) short-circuited (rear) (LH)
B1B87 Passenger seat weight sensor (rear) (RH) performance
B1B88 Passenger seat weight sensor (ground side) short-circuited (rear) (RH)
B1B89 Passenger seat weight sensor (power supply side) short-circuited (rear) (RH)
B1B8C Seat slide sensor circuit performance
B1B8D Seat slide sensor open circuit
B1B8E Seat slide sensor short circuit
B1B91 Driver seat slide sensor configuration mismatch
B1BA7 Occupant classification system verification required
B1BA8 Occupant classification-ECU out of calibration/Not calibrated
B1BBA Passenger seat weight sensor supply circuit
B1BBC Occupant classification system negative system weight
B1BBD Occupant classification-ECU current configuration table unprogrammed
B1C23 Passenger seat weight sensor (front) (LH) configuration mismatch
B1C24 Passenger seat weight sensor (front) (RH) configuration mismatch
B1C25 Passenger seat weight sensor (rear) (LH) configuration mismatch
B1C26 Passenger seat weight sensor (rear) (RH) configuration mismatch
B1CB2 Occupant classification-ECU parameter table incompatible
B210D Battery voltage low
B210E Battery voltage high
SYSTEM CONSTRUCTION
52B-17
Code No.
B2206 Chassis number does not match
B2212 Occupant classification-ECU internal
B2250 Occupant classification-ECU not programmed/Flash required
B2262 Occupant classification-ECU electrostatic discharge event detected
U0020 CAN-B Bus off performance
U0021 CAN-B Bus(+) circuit open
U0022 CAN-B Bus(+) shorted to circuit ground
U0023 CAN-B Bus(+) shorted to circuit power supply
U0024 CAN-B Bus(-) circuit open
U0025 CAN-B Bus(-) shorted to circuit ground
U0026 CAN-B Bus(-) shorted to circuit power supply
U0141 ETACS CAN timeout
U0151 SRS-ECU CAN timeout
U0155 Combination meter CAN timeout
U0164 A/C-ECU CAN timeout
U0168 KOS-ECU or WCM CAN timeout
U0184 Audio CAN timeout
U0195 Satellite radio tuner CAN timeout
U0197 Hands free module CAN timeout
U0245 Audio visual navigation unit CAN timeout
U1419 The signal from a weight sensor (front) (LH) is unusual
U141A The signal from a weight sensor (front) (RH) is unusual
U141B The signal from a weight sensor (rear) (LH) is unusual
U141C The signal from a weight sensor (rear) (RH) is unusual
U1423 The signal from a weight sensor is unusual
DATA LIST OUTPUT

.
The following items can be read by the scan tool

from the occupant classification-ECU input data.
Item No. Display on M.U.T.-III Check conditions Normal conditions
01 Passenger weight Apply a load to the passenger 2,048 Kg (4,515 Ib) to 2,048
seat. Kg (4,515 Ib)
02 Dr seat position sensor Slide the seat the back-end to 0 to 4,095.93 mA
current the front-position.
03 Dr seat position sensor Slide the seat the back-end to 0 to 5,000 mV
voltage the front-position.
07 Dr seat position sensor Slide the seat the back-end to Not in Frontal Zone/In Frontal
status the front-position. Zone/Undetermined
08 occupant classification Apply a load to the passenger Empty/PFIS/Child/More
status seat. 5th%/Undermined
10 Battery voltage Always 0 to 30 V
SYSTEM CONSTRUCTION

21 Pa seat weight sensor 1 Apply a load to the passenger 2,048 Kg (4,515 Ib) to 2,048
RR seat. Kg (4,515 Ib)
22 Pa seat weight sensor 1 Apply a load to the passenger 0 to 5,000 mV
RR volt seat.
RF seat. Kg (4515 Ib)
RF volt seat.
LF seat. Kg (4,515 Ib)
LF volt seat.
LR seat. Kg (4,515 Ib)
LR volt seat.
30 VIN Information Always
ACCURACY CHECK OCCUPANT classification sensor

The scan tool can be used to perform the next func- seat weight sensor Accuracy Check
tion. Zero-calibration
SEAT BELT WITH PRE-TENSIONER
M2521008000429
Spiral spring unit
Plate cover
Piston (Rack)
Bushing Piston ring
Roller
Sleeve
Pinion
Cap
Spool
Gas generator
Base cartridge
Case gear
AC609471AB
The seatbelt pretensioner automatically winds the restrain the forward travel of the passenger at the
seatbelt at the frontal collision to restrain the forward frontal collision, for achieving the effective SRS air-
travel of the passenger. The seatbelt pretensioner bag.
operates in ahead of the SRS airbag deployment to
SYSTEM CONSTRUCTION
52B-19
Seatbelt pretensioner operation
1. When the pretensioner is inactivated, the clearance
between the roller and the sleeve is secured, and thus the
sleeve rotates freely. The spool which winds the seatbelt
rotates together as with the sleeve.
Roller Clearance
Sleeve
AC105418 AC
2. At the frontal collision, SRS-ECU which has detected the

impact exceeding the threshold from the front impact
Roller sensors is energized to ignite the gas generator. Then the
Connection
gas is generated, and the gas pressure moves up the piston.
Pinion 3. When the piston moves up, the rack gear of the piston is
Sleeve
engaged with the pinion gear of the pinion to rotate the
pinion. When the pinion rotates, the pinion is tilted to move
the roller to the center, and the pinion, sleeve, and spool are
incorporated.
Pinion gear
Rack gear
Piston
Gas generator
:Force direction
AC105077 AC
SYSTEM CONSTRUCTION
4. The gas pressure moves up the piston farther, and the

pinion rotates the spool to wind the belt.
Rotates with spool
:Force direction
AC105078 AC
PASSENGER SEAT BELT WARNING LIGHT

M2521001500036
The passenger's seat belt warning light turns ON when the pas-
senger's seat occupant is determined to be 66 lbs (30 kg) or
Passenger's seat belt more by the occupant classification-ECU and his seat belt is
warning light
not fastened.
AC608501AB
PASSENGER'S AIR BAG OFF INDICATOR LIGHT

M2521001600055
The indicator normally comes on when the ignition switch is
turned to the "ON" position and goes off a few seconds later.
Passenger's air bag OFF
In the following situations, the indicator will stay on to show that
indicator light
the passengers (front) air bag is not operational.
The occupant is determined to be less than 66 lbs (30 kg)
by the occupant classification-ECU.
The front passengers seat is not occupied.
The indicator goes off when the occupant is determined to be
66 lbs (30 kg) or more by the occupant classification-ECU, indi-
AC608501AC
cating that the passenger's (front) air bag is operational.
SYSTEM CONSTRUCTION
52B-21
SRS-ECU
M2521007000631
The SRS-ECU incorporates a front analog G-sensor The SRS-ECU is provided with the following capabil-
and front safing G-sensor for frontal collisions and a ities:
side-airbag safing G-sensor for side collisions. Backup power supply in case of power failure in
SRS-ECU enters an ignite signal to the driver's and collisions
passenger's (front) air bag modules if the front Boosting function in case of battery voltage drop
impact sensor in the engine compartment, the front Self-diagnosis function to avoid systems opera-
analog G-sensor and front safing G-sensor in the tion errors and improve its reliability
SRS-ECU simultaneously detect gravitational impact
upon front impact. Further, SRS-ECU starts an ignite DIAGNOSTIC FUNCTION
signal for the side and curtain air bag module upon The SRS-ECU has the following functions to make
sideways gravitational impact that is simultaneously system checking using the scan tool easy.
detected by the analog G-sensor of the side impact Diagnostic trouble code output
sensor and the side-airbag safing G-sensor inside Service data output
the SRS-ECU. Actuator test
DIAGNOSTIC TROUBLE CODE OUTPUT

The SRS-ECU diagnoses the following items and
stores a diagnostic trouble code in the non-volatile
memory (EEPROM*1) when a problem is detected.
Therefore, the memory is not deleted after a battery
terminal is disconnected, (The diagnostic trouble
code memory can be deleted by the scan tool.)
Code No.
B1206 Passenger's air bag OFF indicator light (open circuit)
B1207 Passenger's air bag OFF indicator light (short circuit between circuit terminal)
B1B00 Driver's air bag module (1st squib) system (shorted to squib circuit ground)
B1B01 Driver's air bag module (1st squib) system (shorted to squib circuit power supply)
B1B02 Driver's air bag module (1st squib) system (squib circuit open)
B1B03 Driver's air bag module (1st squib) system (short circuit between squib circuit
terminals)
B1B04 Driver's air bag module (2nd squib) system (shorted to squib circuit ground)
B1B05 Driver's air bag module (2nd squib) system (shorted to squib circuit power supply)
B1B06 Driver's air bag module (2nd squib) system (squib circuit open)
B1B07 Driver's air bag module (2nd squib) system (short circuit between squib circuit
terminals)
B1B08 Passenger's (front) air bag module (1st squib) system (shorted to squib circuit
ground)
B1B09 Passenger's (front) air bag module (1st squib) system (shorted to squib circuit
power supply)
B1B0A Passenger's (front) air bag module (1st squib) system (squib circuit open)
B1B0B Passenger's (front) air bag module (1st squib) system (short circuit between squib
circuit terminals)
B1B0C Passenger's (front) air bag module (2nd squib) system (shorted to squib circuit
ground)
B1B0D Passenger's (front) air bag module (2nd squib) system (shorted to squib circuit
power supply)
SYSTEM CONSTRUCTION

Code No.
B1B0E Passenger's (front) air bag module (2nd squib) system (squib circuit open)
B1B0F Passenger's (front) air bag module (2nd squib) system (short circuit between squib
circuit terminals)
B1B10 Drivers knee air bag module (squib) system (shorted to squib circuit ground)
B1B11 Drivers knee air bag module (squib) system (shorted to squib circuit power supply)
B1B12 Drivers knee air bag module (squib) system (squib circuit open)
B1B13 Drivers knee air bag module (squib) system (short circuit between squib circuit
terminals)
B1B18 Curtain air bag module (LH) (squib) system (shorted to squib circuit ground)
B1B19 Curtain air bag module (LH) (squib) system (shorted to squib circuit power supply)
B1B1A Curtain air bag module (LH) (squib) system (squib circuit open)
B1B1B Curtain air bag module (LH) (squib) system (short circuit between squib circuit
terminals)
B1B20 Curtain air bag module (RH) (squib) system (shorted to squib circuit ground)
B1B21 Curtain air bag module (RH) (squib) system (shorted to squib circuit power supply)
B1B22 Curtain air bag module (RH) (squib) system (squib circuit open)
B1B23 Curtain air bag module (RH) (squib) system (short circuit between squib circuit
terminals)
B1B50 seat belt switch (LH) circuit (ground side) shorted
B1B51 seat belt switch (LH) circuit (power supply side) shorted
B1B52 seat belt switch (LH) circuit open
B1B54 seat belt switch (RH) circuit (ground side) shorted
B1B55 seat belt switch (RH) circuit (power supply side) shorted
B1B56 seat belt switch (RH) circuit open
B1B70 Malfunction of G-sensor inside front impact sensor (LH)
B1B71 Malfunction of G-sensor inside front impact sensor (RH)
B1B72 Malfunction of G-sensor inside side impact sensor (LH)
B1B75 Malfunction of G-sensor inside side impact sensor (RH)
B1BA3 Drivers seat slide sensor malfunction (occupant classification-ECU)
B1BA5 SRS-ECU squib count mismatch
B1BAA Occupant classification-ECU configuration mismatch
B1BC7 SRS-ECU (record data full) system
B1C27 Side-airbag module (LH) (squib) system (shorted to squib circuit ground)
B1C28 Side-airbag module (LH) (squib) system (shorted to squib circuit power supply)
B1C29 Side-airbag module (LH) (squib) system (squib circuit open)
B1C2A Side-airbag module (LH) (squib) system (short circuit between squib circuit
terminals)
B1C2B Side-airbag module (RH) (squib) system (shorted to squib circuit ground)
B1C2C Side-airbag module (RH) (squib) system (shorted to squib circuit power supply)
B1C2D Side-airbag module (RH) (squib) system (squib circuit open)
SYSTEM CONSTRUCTION
52B-23
Code No.
B1C2E Side-airbag module (RH) (squib) system (short circuit between squib circuit
terminals)
B1C38 Driver's pre-tensioner (squib) system (shorted to squib circuit ground)
B1C39 Driver's pre-tensioner (squib) system (shorted to squib circuit power supply)
B1C3A Driver's pre-tensioner (squib) system (squib circuit open)
B1C3B Driver's pre-tensioner (squib) system (short circuit between squib circuit terminals)
B1C47 Front passenger's pre-tensioner (squib) system (shorted to squib circuit ground)
B1C48 Front passenger's pre-tensioner (squib) system (shorted to squib circuit power
supply)
B1C49 Front passenger's pre-tensioner (squib) system (squib circuit open)
B1C4A Front passenger's pre-tensioner (squib) system (short circuit between squib circuit
terminals)
B210D Battery abnormal low voltage
B212C Open circuit to IG1 power supply (fuse No. 12 circuit)
B212D Open circuit to IG1 power supply (fuse No. 18 circuit)
B2207 Occupant restraint controller internal 1
B220A Occupant restraint controller internal 4
B220B Occupant restraint controller firing stored energy
B220C Occupant restraint controller accelerometer 1
B220D Occupant restraint controller accelerometer 2
B223D OCM (Occupant Classification-ECU) DTC present
U0019 Bus off (CAN-B)
U0141 ETACS CAN timeout
U0154 Occupant classification-ECU CAN timeout
U0155 Combination meter CAN timeout
U0164 A/C -ECU CAN timeout
U0168 KOS -ECU or WCM CAN timeout
U0170 Front impact sensor (LH) communication error
U0171 Front impact sensor (RH) communication error
U0172 Side impact sensor (LH) communication error
U0175 Side impact sensor (RH) communication error
U0184 Audio CAN timeout
U0195 Satellite radio tuner CAN timeout
U0197 Hands free Module CAN timeout
U1414 Defective Coding Data
U1415 Coding not completed/Data fail
SYSTEM CONSTRUCTION
DATA LIST OUTPUT

.
The following items can be read by the scan tool

from the SRS-ECU input data.
01 SRS warning light "ON" Ignition switch: ON OFF
request After warning lamp pre-check
Ignition switch: ON ON
During warning lamp pre-check
02 Pass. SRS light "ON" Ignition switch: ON OFF
request After warning light pre-check
Ignition switch: ON ON
During warning light pre-check
03 Drivers seatbelt switch Ignition switch: ON Fastened
After warning light pre-check
Wear the driver seatbelt.
Ignition switch: ON Unfastened
Undo the driver seatbelt.
04 Passengers seatbelt Ignition switch: ON Fastened
switch After warning light pre-check
Wear the passenger seatbelt.
Ignition switch: ON Unfastened
Undo the passenger seatbelt.
05 Passenger seat airbag Ignition switch: ON Permission
ignition After warning light pre-check
Apply a load to the passenger
seat.
Ignition switch: ON Prohibition
Undo a load from a passenger
seat.
ACTUATOR TEST
The scan tool can be used to forcibly operate the
next actuator.
Item No. Display on M.U.T.-III Test item Driven
component
01 SRS warning light SRS warning light illumination ON
SYSTEM CONSTRUCTION
52B-25
SRS AIR BAG SPECIAL CONNECTOR
M2521009000466
.
A A
A
Curtain air bag module (RH)
A Side-airbag module (RH)
A
A
Seat belt with pre-tensioner (RH)
Passenger's (front) air bag module
Clock spring
SRS-ECU
Driver's air bag module
Seat belt with pre-tensioner (LH)

A
A
Driver's knee air bag module
A
Side-airbag module (LH)
Curtain air bag module (LH)

A
A A AC607646 AD
To enhance the system reliability, a connector short

.
circuiting mechanism is integrated in the SRS-ECU

connector, air bag module connectors, clock spring
connector, and pre-tensioner connectors (black con-
nector "A" shown in the figure).
SYSTEM CONSTRUCTION
CONNECTOR SHORT-CIRCUIT MECHANISM

SRS-ECU connector Wiring harness-side connector Connector connected
Wiring harness-side connector
(terminal to short-circuit) Terminal to short-circuit
Short spring Partition panel Short spring

Partition panel (SRS-ECU-side (wiring harness-side
connector) connector)
AC507316 AC
This mechanism prevents the improper deployment SRS-ECU connector

of air bag module because of the current application Connector between the clock spring and
to the squib due to the static electricity when connec- body-side wiring harness
tors between SRS-ECU and air bag modules Each air bag module connector
(squibs) are disconnected. When the connector is Each pre-tensioner connector
disconnected, the short spring short circuits the
power supply side terminal and ground side terminal
of squibs, and prevents the static electricity from
generating the potential difference. This connector
mechanism is adopted for the following connectors.
54-1
GROUP 54
CHASSIS
ELECTRICAL
CONTENTS
CHASSIS ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54A
LOCAL INTERCONNECT NETWORK (LIN) . . . . . . . . . . . . . . . 54B
CONTROLLER AREA NETWORK (CAN) . . . . . . . . . . . . . . . . . 54C

NOTES
54-1
GROUP 54
CHASSIS
ELECTRICAL
CONTENTS
CHASSIS ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54A
LOCAL INTERCONNECT NETWORK (LIN) . . . . . . . . . . . . . . . 54B
CONTROLLER AREA NETWORK (CAN) . . . . . . . . . . . . . . . . . 54C

NOTES
54A-1
GROUP 54A
CHASSIS
ELECTRICAL
CONTENTS
BATTERY. . . . . . . . . . . . . . . . . 54A-5 SERVICE SPECIFICATIONS . . . . . 54A-18
ON-VEHICLE SERVICE. . . . . . . . . 54A-5 SPECIAL TOOLS . . . . . . . . . . . . . . 54A-19

BATTERY CHECK. . . . . . . . . . . . . . . . . 54A-5 TROUBLESHOOTING . . . . . . . . . . 54A-20
BATTERY CHARGING . . . . . . . . . . . . . 54A-6 STANDARD FLOW OF DIAGNOSTIC
BATTERY TEST . . . . . . . . . . . . . . . . . . 54A-6 TROUBLESHOOTING . . . . . . . . . . . . . . 54A-20
BATTERY REMOVAL AND DIAGNOSIS FUNCTION . . . . . . . . . . . . 54A-20
INSTALLATION . . . . . . . . . . . . . . . 54A-8 DIAGNOSTIC TROUBLE CODE CHART 54A-23
DIAGNOSTIC TROUBLE CODE
IGNITION SWITCH* . . . . . . . . . 54A-9 PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-24
TROUBLE SYMPTOM CHART . . . . . . . 54A-53
SPECIAL TOOLS. . . . . . . . . . . . . . 54A-9 SYMPTOM PROCEDURES . . . . . . . . . . 54A-54
SERVICE DATA . . . . . . . . . . . . . . . . . . . 54A-71
TROUBLESHOOTING . . . . . . . . . . 54A-10
ACTUATOR TEST TABLE . . . . . . . . . . . 54A-74
STANDARD FLOW OF DIAGNOSTIC TROUBLE
CHECK PROCEDURE FOR EACH MULTI
SHOOTING . . . . . . . . . . . . . . . . . . . . . . 54A-10
INFORMATION DISPLAY SCREEN . . . 54A-75
DIAGNOSIS FUNCTION . . . . . . . . . . . . 54A-10
CHECK AT ECU TERMINALS . . . . . . . . 54A-78
SYMPTOM PROCEDURES . . . . . . . . . 54A-12 ON-VEHICLE SERVICE . . . . . . . . . 54A-79
SPEEDOMETER CHECK . . . . . . . . . . . 54A-79
ON-VEHICLE SERVICE. . . . . . . . . 54A-15
TACHOMETER CHECK. . . . . . . . . . . . . 54A-81
CHECK OF IGNITION KEY REMINDER WARNING
FUEL LEVEL SENSOR CHECK . . . . . . 54A-81
FUNCTION (STEERING LOCK REMINDER
METER INFORMATION SWITCH CHECK 54A-82
BUZZER BY KOS) . . . . . . . . . . . . . . . . . 54A-15
SERVICE REMINDER FUNCTION SET 54A-82
REMOVAL AND INSTALLATION . 54A-16
COMBINATION METER . . . . . . . . . 54A-90
INSPECTION . . . . . . . . . . . . . . . . . 54A-17 REMOVAL AND INSTALLATION. . . . . . 54A-90
DISASSEMBLY AND ASSEMBLY . . . . . 54A-91
COMBINATION METER . . . . . 54A-18
Continued on next page
WARNING
NOTE
54A-2
HEADLIGHT. . . . . . . . . . . . . . . 54A-91 SERVICE SPECIFICATIONS . . . . . 54A-173

GENERAL INFORMATION . . . . . . 54A-91 SPECIAL TOOLS . . . . . . . . . . . . . . 54A-174
SERVICE SPECIFICATIONS. . . . . 54A-92 DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-175
STANDARD FLOW OF DIAGNOSTIC
SPECIAL TOOLS. . . . . . . . . . . . . . 54A-93
TROUBLESHOOTING . . . . . . . . . . . . . . . . 54A-175
DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-94 TROUBLE SYMPTOM CHART . . . . . . . . . . 54A-175
STANDARD FLOW OF DIAGNOSTIC SYMPTOM PROCEDURES . . . . . . . . . . . . 54A-176
TROUBLESHOOTING. . . . . . . . . . . . . . 54A-94
DIAGNOSTIC FUNCTION . . . . . . . . . . . 54A-94 ON-VEHICLE SERVICE . . . . . . . . . 54A-189
DIAGNOSTIC TROUBLE CODE CHART 54A-96 FRONT FOG LIGHT AIMING . . . . . . . . . . . 54A-189
DIAGNOSTIC TROUBLE CODE BULB REPLACEMENT . . . . . . . . . . . . . . . . 54A-190
PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-96
TROUBLE SYMPTOM CHART . . . . . . . 54A-110 REMOVAL AND INSTALLATION . 54A-191
SYMPTOM PROCEDURES . . . . . . . . . 54A-111
INSPECTION . . . . . . . . . . . . . . . . . 54A-191
HEADLIGHT AIMING. . . . . . . . . . . . . . . 54A-146 SIDE TURN-SIGNAL LIGHT . . 54A-192
LUMINOUS INTENSITY
MEASUREMENT . . . . . . . . . . . . . . . . . . 54A-148
REPLACE THE BULB . . . . . . . . . . . . . . 54A-148 DOME LIGHT . . . . . . . . . . . . . . 54A-193
HEADLIGHT AUTOMATIC-SHUTDOWN
FUNCTION CHECK. . . . . . . . . . . . . . . . 54A-149 GENERAL INFORMATION . . . . . . 54A-193
CONFIGURATION FUNCTION . . . . . . . 54A-150
SPECIAL TOOLS . . . . . . . . . . . . . . 54A-194
DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-196
INSPECTION . . . . . . . . . . . . . . . . . 54A-152 STANDARD FLOW OF DIAGNOSTIC
TROUBLESHOOTING . . . . . . . . . . . . . . 54A-196
REAR COMBINATION LIGHT. 54A-153 DIAGNOSTIC FUNCTION . . . . . . . . . . . 54A-196
GENERAL INFORMATION . . . . . . 54A-153 TROUBLE SYMPTOM CHART . . . . . . . 54A-197
SYMPTOM PROCEDURES . . . . . . . . . . 54A-198
SPECIAL TOOLS. . . . . . . . . . . . . . 54A-154
ON-VEHICLE SERVICE . . . . . . . . . 54A-212
DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-155 CONFIGURATION FUNCTION . . . . . . . 54A-212
DOME LIGHT REMOVAL AND
DIAGNOSTIC FUNCTION . . . . . . . . . . . 54A-155 INSTALLATION . . . . . . . . . . . . . . . 54A-212
DIAGNOSTIC TROUBLE CODE LUGGAGE COMPARTMENT LIGHT
CHART. . . . . . . . . . . . . . . . . . . . . . . . . . 54A-157
PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-158 HIGH-MOUNTED
SYMPTOM PROCEDURES . . . . . . . . . 54A-165 STOPLIGHT . . . . . . . . . . . . . . . 54A-213
REAR COMBINATION LIGHT REMOVAL REMOVAL AND INSTALLATION . 54A-213
AND INSTALLATION . . . . . . . . . . 54A-172
LICENSE PLATE LIGHT . . . . . 54A-214
TAILLIGHT REMOVAL AND REMOVAL AND INSTALLATION . . . . . . . . 54A-214
INSTALLATION . . . . . . . . . . . . . . . 54A-172
FOG LIGHT . . . . . . . . . . . . . . . 54A-173 Continued on next page

54A-3
HAZARD WARNING LIGHT SPECIAL TOOLS . . . . . . . . . . . . . . 54A-234

SWITCH . . . . . . . . . . . . . . . . . . 54A-215 DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-236
SPECIAL TOOLS. . . . . . . . . . . . . . 54A-215 TROUBLESHOOTING . . . . . . . . . . . . . . 54A-236
DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-216 TROUBLESHOOTING FOR NOISE. . . . 54A-236
STANDARD FLOW OF DIAGNOSTIC DATA LIST REFERENCE TABLE . . . . . 54A-237
TROUBLESHOOTING. . . . . . . . . . . . . . 54A-216 DIAGNOSIS FUNCTION . . . . . . . . . . . . 54A-237
DIAGNOSTIC FUNCTION . . . . . . . . . . . 54A-216 DIAGNOSIS CODE CHART. . . . . . . . . . 54A-239
DIAGNOSTIC TROUBLE CODE DIAGNOSTIC TROUBLE CODE
CHART. . . . . . . . . . . . . . . . . . . . . . . . . . 54A-218 PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-239
DIAGNOSTIC TROUBLE CODE TROUBLE SYMPTOM CHART . . . . . . . 54A-267
PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-218 SYMPTOM PROCEDURES . . . . . . . . . . 54A-268
TROUBLE SYMPTOM CHART . . . . . . . 54A-219 ON-VEHICLE SERVICE . . . . . . . . . 54A-307
SYMPTOM PROCEDURES . . . . . . . . . 54A-219 ADJUSTMENT OF VOLUME AND SOUND
REMOVAL AND INSTALLATION . 54A-221 QUALITY AUTOMATIC CORRECTION
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 54A-307
INSPECTION . . . . . . . . . . . . . . . . . 54A-221
HORN . . . . . . . . . . . . . . . . . . . . 54A-222
MMCS . . . . . . . . . . . . . . . . . . . . 54A-309
GENERAL INFORMATION . . . . . . 54A-309
INSPECTION . . . . . . . . . . . . . . . . . 54A-222
SPECIAL TOOLS . . . . . . . . . . . . . . 54A-311
ACCESSORY SOCKET. . . . . . 54A-223 DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-312
GENERAL INFORMATION . . . . . . 54A-223 STANDARD FLOW OF DIAGNOSTIC
REMOVAL AND INSTALLATION . 54A-223 DIAGNOSIS FUNCTION . . . . . . . . . . . . 54A-326
DIAGNOSTIC TROUBLE CODE CHART 54A-328
CIGARETTE LIGHTER . . . . . . 54A-224 DIAGNOSTIC TROUBLE CODE
INSPECTION . . . . . . . . . . . . . . . . . 54A-224 PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-329
COLUMN SWITCH* . . . . . . . . . 54A-224 SYMPTOM PROCEDURES . . . . . . . . . . 54A-351

SPECIAL TOOLS. . . . . . . . . . . . . . 54A-225 STEERING WHEEL AUDIO REMOTE

TROUBLESHOOTING . . . . . . . . . . 54A-226 CONTROL SWITCH* . . . . . . . . 54A-393
STANDARD FLOW OF DIAGNOSTIC DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-393
TROUBLESHOOTING. . . . . . . . . . . . . . 54A-226 STANDARD FLOW OF DIAGNOSTIC
DIAGNOSTIC FUNCTION . . . . . . . . . . . 54A-226 TROUBLESHOOTING . . . . . . . . . . . . . . 54A-393
DIAGNOSTIC TROUBLE CODE TABLE 54A-228 TROUBLE SYMPTOM CHART . . . . . . . 54A-393
DIAGNOSTIC TROUBLE CODE SYMPTOM PROCEDURES . . . . . . . . . . 54A-394
PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-228
STREERING WHEEL AUDIO REMOTE
INSPECTION . . . . . . . . . . . . . . . . . 54A-231
CONTROL SWITCH INSPECTION 54A-406
RADIO AND CD PLAYER . . . . 54A-232
54A-4
HANDS-FREE CELLULAR PHONE REAR WINDOW DEFOGGER RELAY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 54A-477
SYSTEM. . . . . . . . . . . . . . . . . . 54A-407
DEFOGGER SWITCH . . . . . . . 54A-478
DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-409
STANDARD FLOW OF DIAGNOSTIC ETACS* . . . . . . . . . . . . . . . . . . 54A-478
TROUBLE SYMPTOM CHART . . . . . . . 54A-409 SPECIAL TOOL . . . . . . . . . . . . . . . 54A-478
REMOVAL AND INSTALLATION . 54A-435 STANDARD FLOW OF DIAGNOSTIC
AMPLIFIER*. . . . . . . . . . . . . . . 54A-438 DIAGNOSTIC FUNCTION . . . . . . . . . . . 54A-479
REMOVAL AND INSTALLATION . 54A-438 DIAGNOSTIC TROUBLE CODE CHART 54A-482
DIAGNOSIS TROUBLE CODE
SPEAKER . . . . . . . . . . . . . . . . 54A-439 PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-483
DATA LIST REFERENCE TABLE . . . . . 54A-522
GENERAL INFORMATION . . . . . . 54A-439 TROUBLE SYMPTOM CHART . . . . . . . 54A-524
TROUBLE SYMPTOM CHART FOR INPUT
SPEAKER TEST . . . . . . . . . . . . . . . . . . 54A-441
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . 54A-528
REMOVAL AND INSTALLATION . 54A-443 INPUT SIGNAL PROCEDURES . . . . . . 54A-529
ANTENNA . . . . . . . . . . . . . . . . 54A-446 ON-VEHICLE SERVICE . . . . . . . . . 54A-561

CONFIGURATION FUNCTION . . . . . . . 54A-561
GENERAL INFORMATION . . . . . . 54A-446 ETACS-ECU . . . . . . . . . . . . . . . . . . 54A-564
SATELLITE RADIO TUNER . . 54A-449 THEFT ALARM . . . . . . . . . . . . 54A-571
DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-449
TROUBLESHOOTING. . . . . . . . . . . . . . 54A-449 SPECIAL TOOLS . . . . . . . . . . . . . . 54A-572
DIAGNOSIS FUNCTION . . . . . . . . . . . . 54A-449
DIAGNOSTIC TROUBLE CODE CHART 54A-451
DIAGNOSIS . . . . . . . . . . . . . . . . . . 54A-574
PROCEDURES . . . . . . . . . . . . . . . . . . . 54A-452
DIAGNOSTIC FUNCTION . . . . . . . . . . . 54A-574
ON-VEHICLE SERVICE . . . . . . . . . 54A-594
DEFOGGER . . . . . . . . . . . . . . . 54A-476 CONFIGURATION FUNCTION . . . . . . . 54A-594

INSPECTION . . . . . . . . . . . . . . . . . 54A-594
PRINTED HEATER CHECK . . . . . . . . . 54A-476
CHASSIS ELECTRICAL
BATTERY
54A-5
BATTERY
ON-VEHICLE SERVICE
BATTERY CHECK
M1541001000591
WARNING
HANDLING.
.
BATTERY VISUAL INSPECTION (1)

The battery contains a visual test indicator which gives a blue
Indicator
signal when an adequate charge level exists, and a white sig-
nal when charging is required.
White Blue
.
BATTERY VISUAL INSPECTION (2)

Make sure the ignition switch is in "LOCK" (OFF) position and
all battery fed accessories are OFF.
Charging Good 1. Disconnect the negative cable from battery before
necessary condition disconnecting the positive cable.
WARNING
Care should be taken in the event battery case is
cracked or leaking to protect hands from the electro-
lyte. A suitable pair of rubber gloves (not the house-
hold type) should be worn when removing battery by
hand.
2. Remove the battery from the vehicle.
3. Inspect the battery carrier for damage caused by loss of acid
from battery. If acid damage is present, it is necessary to
clean area with a solution of clean warm water and baking
AC608764AB soda. Scrub area with a stiff bristle brush. Wipe clean with a
cloth moistened with ammonia or baking soda in water.
4. Clean the battery, especially the top, with the same solutions
as described in step 3.
5. Inspect the battery case and cover for cracks. If cracks are
present, battery must be replaced.
6. Clean the battery post with a suitable battery post cleaning
tool.
7. Clean the inside surfaces of the terminal clamps with a
suitable battery terminal cleaning tool. Replace damaged or
frayed cables and broken terminal clamps.
8. Install the battery in the vehicle.
9. Connect the positive and negative cables to the battery in
the order of mention.
10.Tighten the clamp nut securely.
TSB Revision
54A-6 CHASSIS ELECTRICAL
BATTERY
BATTERY CHARGING
M1541001101193
WARNING
When batteries are being charged, an explo-
sive gas forms beneath the cover of each
cell. Do not smoke near batteries on charge
or which have recently been charged. Do not
break live circuits at the terminals of the bat-
teries on charge. A spark will occur where
the live circuit is broken. Keep all open
flames away from the battery.
Battery electrolyte temperature may temporarily be
allowed to rise to 55 C (131 F). Increase of electro-
lyte temperature above 55 C (131 F) is harmful to
the battery, causing deformation of battery cell,
decrease in life of battery, etc.
CHARGE RATE
If the test indicator is white, the battery should be
.
charged as outlined below. When the dot appears or

when maximum charge shown below is reached,
charging should be stopped.
Charge Rate Chart

Battery 75D23L
Slow charging 5 amps 11 hours
10 amps 6 hours
Fast charging 20 amps 3 hours
30 amps 2 hours
BATTERY TEST
M1541001201242
BATTERY TESTING PROCEDURE STEP 3. Check the battery case.
(1) Remove the hold-downs.
STEP 1. Check the battery cables. (2) Check for broken/cracked case.
Remove the negative cable, then the positive cable. Q: Is the battery case faulty?
Check for dirty or corroded connections. YES : Replace the battery. Then go to Step 4.
Q: Are the battery cables dirty or have corroded NO : Go to Step 4.
connections?
YES : Clean the battery cables. Then go to Step 2.
STEP 4. Check the open circuit voltage.
NO : Go to Step 2.
(1) Turn headlights on for 15 seconds.
(2) Turn headlights off for two minutes to allow
STEP 2. Check the battery post. battery positive voltage to stabilize.
Check for loose battery post. (3) Disconnect the battery cables.
Q: Are the battery posts faulty? (4) Read open circuit voltage.
YES : Replace the battery. Then go to Step 4. Q: Is open circuit voltage 12.4 volts or more?
NO : Go to Step 3. YES : Go to Step 5.
NO : Charge the battery at 5 amps for 10.4 hours.
Then re-test.
TSB Revision
CHASSIS ELECTRICAL
BATTERY
54A-7
STEP 5. Check the load test.
(1) Connect a load tester to the battery.
(2) Load the battery at the recommended discharge
rate (See LOAD TEST RATE CHART) for 15
seconds.
(3) Read voltage after 15 seconds, then remove
load.
(4) Compare the measured value with the minimum
voltage (See LOAD TEST CHART).
Q: Is the voltage higher than minimum voltage?
YES : The battery is normal.
NO : Replace the battery. Then go to Step 4.
LOAD TEST CHART
Temperature C 21 (70) 16 (60) 10 (50) 4 (40) 1 (30) 7 (20) 12 (10) 18 (0)
( F) and
above
Minimum voltage 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
LOAD TEST RATE CHART

Load test 260 amps
Cranking ratio [18 C (0 F)] 520 amps
Reserve capacity 118 minutes
Application 75D23L
TSB Revision
BATTERY
BATTERY REMOVAL AND INSTALLATION

M1541001300376
8.5 1.5 Nm
3 76 13 in-lb
4.0 1 Nm
36 8 in-lb 12 2 Nm
102 22 in-lb
7 6.0 2.0 Nm
53 18 in-lb
2
4
6 5
5.0 1.0 Nm
44 9 in-lb
1
8
9
10
AC608766AB

1. Connection of the battery harness 5. Connection of the battery harness
[negative battery terminal] [positive battery terminal]
Air cleaner intake duct (Refer to GROUP 6. Battery terminal assembly
15 Air Cleaner P.15-4). 7. Battery holder
2. Fusible link box cover 8. Battery bolt
3. Connection of the battery harness 9. Battery
[positive battery terminal] 10. Battery tray
4. Connection of the fusible link block
TSB Revision
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-9
IGNITION SWITCH
SPECIAL TOOLS
M1543000603432

name
a
a. MB991824 NOTE: G: MB991826 M.U.T.-III main harness A
b. MB991827 M.U.T.-III Trigger (MB991910) should be used.
c. MB991910 Harness is not M.U.T.-III main harness B and C
d. MB991911 necessary when should not be used for this
MB991824 e. MB991914 pushing V.C.I. ENTER vehicle.
b key. ETACS-ECU check (Diagnostic
f. MB991825
trouble code, service data)
g. MB991826
M.U.T.-III sub
assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
MB991910 c. M.U.T.-III main
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE
CAN
communication
MB991914 system)
f e. M.U.T.-III main
harness C (for
Daimler Chrysler
models only)
MB991825 f. M.U.T.-III
g measurement
adapter
g. M.U.T.-III trigger
harness
MB991826
MB991958
TSB Revision
IGNITION SWITCH

name
MB991223 General service tools Continuity check and voltage
a
a. MB991219 measurement at harness wire or
b. MB991220 connector for loose, corroded or
c. MB991221 damaged terminals, or terminals
b d. MB991222
Harness set a. Connector pin contact
pressure inspection
a. Test harness
b. Power circuit inspection
b. LED harness
c. Power circuit inspection
c c. LED harness
adaptor d. Commercial tester connection
d. Probe
d
DO NOT USE
MB991223BA
MB992006 Making voltage and resistance

Extra fine probe measurement during
troubleshooting
MB992006
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLE SHOOTING
M1543006900937
Refer to Group 00 Contents of troubleshooting
P.00-6.
DIAGNOSIS FUNCTION
M1543007001093
HOW TO CONNECT THE SCAN TOOL (M.U.T.-III)

MB991824: Vehicle Communication Interface (V.C.I.)
MB991910: M.U.T.-III Main Harness A (Vehicles with
CAN communication system)
TSB Revision
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-11
CAUTION
1. Ensure that the ignition switch is at the "LOCK" (OFF)
position.
2. Start up the personal computer.
3. Connect special tool MB991827 to special tool MB991824
and the personal computer.
4. Connect special tool MB991910 to special tool MB991824.
MB991910
5. Connect special tool MB991910 to the data link connector.
MB991824 6. Turn the power switch of special tool MB991824 to the "ON"
position.
NOTE: When special tool MB991824 is energized, special
tool MB991824 indicator light will be illuminated in a green
color.
7. Start the M.U.T.-III system on the personal computer.
NOTE: Disconnecting scan tool MB991958 is the reverse of the
MB991827
connecting sequence, making sure that the ignition switch is at
AC608435 AB
the "LOCK" (OFF) position.
HOW TO READ AND ERASE DIAGNOSTIC

TROUBLE CODES
NOTE: If the battery voltage is low, diagnostic trouble codes will
not be set. Check the battery if scan tool MB991958 does not
display.
2. Turn the ignition switch to the "ON" position.
3. Select "System select" from the start-up screen.
4. Select "From 2006 MY" of "Model Year." When the "Vehicle
Information" is displayed, check the contents.
5. Select "ETACS" from "System List", and press the "OK"
button.
NOTE: When the "Loading Option Setup" list is displayed,
check the applicable item.
6. Select "Diagnostic Trouble Code."
7. If a DTC is set, it is shown.
8. Choose "Erase DTCs" to erase the DTC.
TSB Revision
IGNITION SWITCH

M1543007202454
Trouble symptom Reference

page
Ignition key cylinder illumination light does not vehicles with WCM P.54A-12
illuminate/extinguish normally.
SYMPTOM PROCEDURES
Ignition key cylinder illumination light does not illuminate/extinguish normally. <vehicles with WCM>
CAUTION
Whenever the ECU is replaced, ensure that the
input and output signal circuits are normal.
Ignition Key Cylinder Illumination Light Circuit <Vehicles with WCM>
ETACS-ECU
KEY
REMINDER IGNITION KEY
SWITCH HOLE
WHEN ILLUMINATION
REMOVING LIGHT
KEY: ON

Junction block
AC608147AF AC608152 AL
.
TSB Revision
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-13
OPERATION
.
The ETACS-ECU operates this function in accor- The key reminder switch may be defective
dance with the input signals below. The driver's door switch may be defective
Ignition switch (IG1) The driver's door lock actuator may be defective
Key reminder switch The ignition key cylinder illumination light bulb
Driver's door switch may be defective
Driver's door lock actuator The ETACS-ECU may be defective
. The wiring harness or connectors may have
TECHNICAL DESCRIPTION (COMMENT) loose, corroded, or damaged terminals, or termi-
If this function does not work normally, these input nals pushed back in the connector
signal circuit(s), the ignition key cylinder illumination
light or the ETACS-ECU may be defective.
DIAGNOSIS
MB992006: Extra fine probe
MB991223: Harness set
STEP 1. Using scan tool MB991958, read the diagnostic

trouble code.
CAUTION
(1) Connect scan tool MB991958. Refer to "How to connect
scan too (M.U.T.-III) P.54A-10."
Data link connector (2) Turn the ignition switch to the "ON" position.
(3) Check whether the ETACS-ECU related DTC is set.
(4) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the DTC set?
YES : Diagnose the ETACS-ECU. Refer to P.54A-564.
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
IGNITION SWITCH
STEP 2. Using scan tool MB991958, check data list.

Use the ETACS-ECU data list to check the signals related to
the ignition key cylinder illumination light function.
Turn the ignition switch to the "LOCK" (OFF) position.
Remove the ignition key from the ignition key cylinder.
Open the driver's door.
Item No. Item name Normal
conditions
Item 228 Dr door unlock ON
Item 254 IG voltage 0V
Item 256 Dr door ajar switch Open
Item 264 Handle lock switch Key in Key
out
Item 270 Dr door lock switch Not lock
Item 271 Dr door unlock Unlock
switch
Q: Does scan tool MB991958 display the items "Dr door

unlock", "Dr door ajar switch", and "Handle lock
switch" as normal condition?
YES <Normal conditions are displayed for all the
items.> : Go to Step 3.
NO <Normal condition is not displayed for item No.
228.> : Troubleshoot the ETACS-ECU. Refer to GROUP
54A, Diagnosis - Inspection Procedure 4
"ETACS-ECU does not receive any signal from the
front door lock actuator" P.54A-536.
ignition switch (IG1)" P.54A-531.
front the front door switch (RH)" P.54A-545.
"ETACS-ECU does not receive any signal from key
reminder switch" P.54A-533.
NO <Normal condition is not displayed for item No. 270,
"ETACS-ECU does not receive any signal from front
door lock actuator" P.54A-536.
TSB Revision
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-15
STEP 3. Check key reminder switch connector C-213,

ETACS-ECU connector C-315 for loose, corroded or
damaged terminals, or terminals pushed back in the
connector.
Q: Is key reminder switch connector C-213, ETACS-ECU
connector C-315 in good condition?
YES : Go to Step 4.
NO : Repair the damaged parts.
STEP 4.Check the Wiring harness between key reminder

switch connector C-213 (terminal No. 3,5) and ETACS-ECU
connector C-315 (terminal No. 13,18).
Check the input/output line for open circuit.
YES : Go to Step 5.
NO : Repair the wiring harness between key reminder
switch connector C-213 and ETACS-ECU connector
C-315.
STEP 5. Check of ignition key cylinder illumination light

bulb.
Q: Is the ignition key cylinder illumination light bulb in
good condition?
YES : Go to Step 6.
NO : Replace the bulb of the ignition key cylinder
illumination light.

Q: Does the ignition key cylinder illumination light
illuminate/extinguish in good condition?
YES : The trouble can be an intermittent malfunction (Refer
to GROUP 00, How to use
Troubleshooting/inspection Service Points How to
ON-VEHICLE SERVICE
CHECK OF IGNITION KEY REMINDER WARNING

FUNCTION (STEERING LOCK REMINDER
BUZZER BY KOS)
M1541200700085
1. Driver's door: Release the closed and steering wheel lock,
or turn the ignition key <vehicles with WCM> or emergency
key <vehicles with KOS> to the LOCK (OFF) position (key
inserted).
2. Change the driver's door state from closed to open.
3. Check that the buzzer sounds normally.
4. If a malfunction is found, carry out the troubleshooting
TSB Revision
IGNITION SWITCH

M1541200300128
CAUTION
To remove the driver airbag module, refer to GROUP 52B Service Precautions P.52B-24 and Air Bag
Module(s) and Clock Spring P.52B-367.
Removal of clock spring/column switch assembly [Refer to Installation of clock spring/column switch assembly [Refer to
GROUP 37 Steering Shaft P.37-25 and GROUP 52B Air GROUP 37 Steering Shaft P.37-25 and GROUP 52B Air
bag module(s) and clock spring P.52B-367]. bag module(s) and clock spring P.52B-367].
<Vehicles with KOS>
1
AC506617
2
2.0 0.5 Nm
18 4 in-lb
<Vehicles with WCM>
3 5
4 AC506618
2.0 0.5 Nm
18 4 in-lb AC609970AC
Removal Steps Removal Steps (Continued)

1. Ignition switch 4. WCM <vehicles with
2. Key reminder switch WCM>/receiver antenna module
3. Key ring illumination light <Vehicles <vehicles with KOS>
for WCM> < <A> > 5. Steering lock cylinder <vehicles
with WCM>
TSB Revision
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-17
.
<<A>> STEERING LOCK CYLINDER REMOVAL

<VEHICLES WITH WCM>
1. Insert the key into the steering lock cylinder, and turn the
ignition key to the ACC position.
2. With using a cross-headed screw driver (small) or similar
items to press in the lock pin, remove the ignition key, and
Lock pin
then remove the steering lock cylinder.
AC506889AB
INSPECTION
IGNITION SWITCH CONTINUITY CHECK

M1541200400095
Column switch With the ignition switch mounted to the vehicle, disconnect and
check the ignition switch connection connector.
Ignition key Terminal Normal condition
position number
LOCK 1 2, 1 4, 1 5, No continuity
1 6
ACC 1 6 Continuity exists
(2 ohms or less)
AC506506AB
ON 1 2 4 6 Continuity exists
(2 ohms or less)
START 1 2 5 Continuity exists
(2 ohms or less)
KEY REMINDER SWITCH INSPECTION

M1541200500092
With the key reminder switch mounted to the vehicle, discon-
Column switch
nect the key reminder switch connection connector, and then
perform the continuity check.
Key status Terminal Normal
number condition
Key removed 2 3 Continuity
exists (2 ohms
or less)
AC506506AC Key inserted 2 3 No continuity
TSB Revision
COMBINATION METER
COMBINATION METER
M1540200200214
Item Standard Value

Speedometer indication tolerance {mph (km/h)} 10 (16) 8.5 11.5 (13.6 18.4)
<Except vehicles for CANADA> 25 (40) 23.5 26.5 (37.6 42.4)
50 (80) 48.5 51.5 (77.6 82.4)
75 (120) 73.5 76.5 (117.6 122.4)
100 (161) 98.5 102.5 (158.6 165.0)
125 (201) 123.5 127.5 (198.6 205.0)
Speedometer indication tolerance {km/h (mph)} 20 (12.4) 19 24 (11.8 14.9)
<Vehicles for CANADA> 40 (24.8) 40 44 (24.8 27.3)
80 (49.7) 80 85 (49.7 52.8)
120 (74.6) 120.5 125.5 (74.9 78.0)
160 (99.4) 160.5 165.5 (99.7 102.8)
200 (124.3) 200.5 207.0 (124.6 128.6)
Tachometer indication tolerance (r/min) 600 550 650
(The value in parentheses is a reference value.) (2,000) (1,950 2,050)
3,000 2,950 3,050
(4,000) (3,950 4,050)
5,000 4,950 5,050
6,000 5,950 6,050
(7,000) (6,950 7,050)
(8,000) (7,950 8,050)
Fuel level sensor resistance (ohms) Stopper position "F" 13.0 1.0
Stopper position "E" 120.0 1.0
Fuel level sensor float height {mm (in)} Stopper position "F" 181.5 (7.1)
Stopper position "E" 26.7 (1.0)
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-19
SPECIAL TOOLS
M1540200300147

name
a
a. MB991824 NOTE: G: M.U.T.-III main harness A
b. MB991827 MB991826 (MB991910) should be used.
c. MB991910 M.U.T.-III Trigger M.U.T.-III main harness B and C
d. MB991911 Harness is not should not be used for this
MB991824 e. MB991914 necessary when vehicle.
b pushing V.C.I. DTC, data list and actuator test
f. MB991825
ENTER key. check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles
DO NOT USE without CAN
communication
MB991914 system)
harness C (for
Daimler
Chrysler
MB991825
models only)
g
f. M.U.T.-III
measurement
adapter
harness
MB991826
MB991958
TSB Revision
COMBINATION METER

name
MB991223 General service Continuity check and voltage
a
a. MB991219 tool (jumper) measurement at harness wire or
b. MB991220 connector
c. MB991221 a. For checking connector pin
d. MB991222 contact pressure
b
Harness set b. For checking power supply
a. Check harness circuit
b. LED harness c. For checking power supply
circuit
c. LED harness
c adapter d. For connecting a locally sourced
tester
d. Probe
d
DO NOT USE
MB991223BA
MB992006 Continuity check and voltage

Extra fine probe measurement at harness wire or
connector
MB992006
TROUBLESHOOTING

TROUBLESHOOTING
M1540203800152
Refer to GROUP 00, Contents of troubleshooting P.00-6.
DIAGNOSIS FUNCTION
M1540200500077

MB991824: Vehicles Communication Interface (V.C.I.)
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-21
CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
display.
5. Select "Meter" from "System List," and press the "OK"
button.
TSB Revision
COMBINATION METER
HOW TO DIAGNOSE THE CAN BUS LINES

3. Select "CAN bus diagnosis" from the start-up screen.
4. When the vehicle information is displayed, confirm that it
matches the vehicle being diagnosed.
If they match, go to step 8.
If not, go to step 5.
5. Select the "view vehicle information" button.
6. Enter the vehicle information and select the "OK" button.
7. When the vehicle information is displayed, confirm again
that it matches the vehicle being diagnosed.
8. Select the "OK" button.
9. When the optional equipment screen is displayed, choose
the one which the vehicle is fitted with, and then select the
"OK" button.
CHECK OF FREEZE FRAME DATA When detecting fault and storing the DTC, the ECU
The freeze frame data can be checked by using the connected to CAN bus line obtains the data before
scan tool (GROUP 00, How to Cope with Intermittent the determination of the DTC and the data when the
Malfunction P.00-13). DTC is determined, and then stores the ECU status
. of that time. By analyzing each data from scan tool,
the troubleshooting can be performed more effi-
ciently. The displayed items are as the table below.
Display item list
Item No. Item name Data item Unit
01 Odometer Total driving distance after the diagnosis code is km*
generated
02 Ignition cycle Number of times the ignition switch is turned "ON" or Number of
"LOCK (OFF)" after the past failure transition counts is
displayed.
04 Current trouble Cumulative time for current malfunction of diagnosis min
accumulative time code
NOTE: *: If a failure occurs to both the ABS-ECU and
ETACS-ECU, 0000 km or FFFF km is displayed on
the scan tool MB991958.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-23
DIAGNOSTIC TROUBLE CODE CHART
M1540200600115
CAUTION
During troubleshooting, a DTC code associated with other system may be set when the ignition
switch is turned on with connector(s) disconnected. On completion, check all systems for DTC
code(s). If DTC code(s) are set, erase them all.
When the combination meter is required to be replaced as a result of the troubleshooting, the cur-
rent driving distance and number of elapsed days to be used for service reminder function must
be entered into the meter after the replacement. Therefore, read "Integrated mileage for reminder,"
"Integrated days for reminder," "Mileage until Extra reminder," "Months until Extra reminder," and
"Current Schedule" from the meter before the replacement using the special function of scan tool
MB991958, and note them. For the operation method of scan tool MB991958, refer to P.54A-82. If
"Integrated mileage for reminder" or "Integrated days for reminder" cannot be read by the scan
tool MB991958, follow the method described below.
a. For the driving distance for check warning, use the driving distance displayed on the multi
b. For the elapsed days for check warning, calculate the number of elapsed days from the deliv-
ery date to the customer (service remainder function start date) and current date.
Diagnostic trouble code Diagnostic item Reference page

number
B1200 Malfunction of odometer P.54A-24
B1201 Abnormal fuel information P.54A-25
B1208 Malfunction of LCD heater P.54A-28
B1209 Test mode P.54A-29
B2203 VIN not programmed P.54A-29
B2463 The sticking of rheostat switch P.54A-31
B2464 The sticking of meter information switch P.54A-32
B2465 Ignition switch signal error P.54A-35
U0019 Bus off (CAN-B) P.54A-36
U0100 Engine control module CAN timeout P.54A-38
U0141 ETACS CAN timeout P.54A-39
U0151 SRS-ECU CAN timeout P.54A-41
U0154 Occupant classification-ECU CAN timeout P.54A-42
U0164 A/C-ECU CAN timeout P.54A-44
U0168 KOS-ECU or WCM CAN timeout P.54A-45
U0184 Audio CAN timeout P.54A-47
U0197 Hands free module CAN timeout P.54A-48
U0245 Audio visual navigation unit CAN timeout P.54A-50
U1415 Coding not completed/Data fail P.54A-51
TSB Revision
COMBINATION METER
DIAGNOSTIC TROUBLE CODE PROCEDURES
DTC B1200: Malfunction of odometer

. .
TROUBLE JUDGEMENT TROUBLESHOOTING HINTS

If the odometer information, which is stored in the The combination meter may be defective.
combination meter, is abnormal when the ignition
switch at the ON position and the system voltage is
10 16 volts (data from ETACS-ECU), DTC B1200 is
stored.
DIAGNOSIS
STEP 1. Using scan tool MB991958, read the combination

meter diagnostic trouble code.
Check if DTC is set to the combination meter.
CAUTION
(1) Connect scan tool MB991958. Refer to "How to connect the
Scan Tool (M.U.T.-III) P.54A-20."
(3) Erase the DTC.
(4) Turn the ignition switch from "LOCK" (OFF) position to "ON"
position.
MB991910 (5) Check if diagnosis code is set.
Q: Is the DTC set?
MB991824
YES : Replace the combination meter, and then go to Step
2.
NO : The trouble can be an intermittent malfunction (Refer
to GROUP 00, How to Cope with Intermittent
Malfunction P.00-13).
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-25
STEP 2. Recheck for diagnostic trouble code.

(1) Erase the DTC.
position.
(3) Check if diagnosis code is set.
Q: Is the DTC set?
YES : Go to Step 1.
DTC B1201: Abnormal fuel information
CAUTION
Whenever the ECU is replaced, ensure that the communication circuit is normal.
Fuel Gauge Unit Circuit
COMBINATION
METER
CPU
INTERFACE
CIRCUIT
JOINT
CONNECTOR (5)
FUEL
FUEL LEVEL PUMP
SENSOR MODULE
TSB Revision
COMBINATION METER
.
Connectors: C-04, C-35 TROUBLE JUDGEMENT

With the ignition switch at the ON position and the
C-04 system voltage at 10 16 volts (data from
ETACS-ECU), if the combination meter detects the
abnormal resistance of fuel level sensor circuit for 64
seconds continuously, DTC B1201 is stored.
.
C-35
AC608145CG
The fuel pump module [fuel level sensor] may be
defective.
Connectors: D-08, D-18, D-23 The combination meter may be defective.
The wiring harness or connectors may have
D-08
D-18 (GR)
D-23 AC608166AR
DIAGNOSIS
STEP 1. Check fuel pump module connector D-18 for

Q: Is fuel pump module connector D-18 in good condition?
YES : Go to Step 2.
NO : Repair the connector.
STEP 2. Check the fuel level sensor.

Check to see if the fuel level sensor is normal (Refer to
P.54A-81).
YES : Go to Step 3.
NO : Replace the fuel level sensor.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-27
STEP 3. Measure the resistance at fuel pump module

connector D-18.
(1) Disconnect pump module connector D-18, and measure at
the wiring harness side.
ground.
The measured value should be 2 ohm or less.
Q: Does the measured resistance value correspond with
this range?
YES : Go to Step 5.
NO : Go to Step 4.
Harness side: D-18
AC608255 BB
STEP 4. Check the wiring harness between fuel pump

module connector D-18 (terminal 1) and ground.
Q: Is the wiring harness between fuel pump module
connector D-18 (terminal 1) and ground in good
condition?
YES : There is no action to be taken.
STEP 5. Check combination meter connector C-04 for

Q: Is combination meter connector C-04 in good
condition?
YES : Go to Step 6.
STEP 6. Check the wiring harness between fuel pump

module connector D-18 (terminal 2) and combination
meter connector C-04 (terminal 17 or 18).
NOTE: Also check intermediate connectors C-35, D-08 and
joint connector D-23. If intermediate connectors C-35, D-08
and joint connector D-23 are damaged, repair or replace the
connector as described in GROUP 00E, Harness Connector
Inspection P.00E-2.
Q: Are the wiring harness between fuel pump module
connector D-18 (terminal 2) and combination meter
connector C-04 (terminal 17 or 18) in good condition?
YES : Go to Step 7.
NO : Repair the wiring harness. The fuel gauge should
work normally.
TSB Revision
COMBINATION METER
STEP 7. Using scan tool MB991958, perform actuator test.

Item 03: Fuel gauge (target value): 0 100%
Fuel gauge shows 100 %
YES : Go to Step 8.
NO : Replace the combination meter.

Check again if the DTC is set to the combination meter.
(1) Erase the DTC.
position.
(3) Check if DTC is set.
Q: Is the DTC set?
YES : Replace the combination meter.
DTC B1208: Malfunction of LCD heater

. .

With the ignition switch at the ON position and the The combination meter may be defective
system voltage at 10 16 volts (data from
ETACS-ECU), if the combination meter detects the
LCD heater malfunction, the DTC B1208 is stored.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-29
Recheck for diagnostic trouble code.

CAUTION
position.
MB991910 Q: Is the DTC set?
MB991824
MB991827 AC608435 AB
DTC B1209: Test mode
.
TROUBLE JUDGEMENT
When the mode is changed to the meter test mode The combination meter may be defective
(supplier mode), the combination meter stores the
DTC B1209. DIAGNOSIS
Replace the combination meter.
.
DTC B2203: VIN not programmed

. .

With the ignition switch at the ON position, if the VIN The CAN bus line may be defective.
code is not written to the combination meter, DTC The ETACS-ECU may be defective.
B2203 is stored. The combination meter may be defective.
DIAGNOSIS
TSB Revision
COMBINATION METER
STEP 1. Using scan tool MB991958, diagnose the CAN bus

line.
CAUTION
(3) Diagnose the CAN bus line.
Q: Is the CAN bus line found to be normal?
MB991910 YES : Go to Step 2.
MB991824
NO : Repair the CAN bus line (Refer to GROUP 54C,
Diagnosis P.54C-16).
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958, read the ETACS-ECU

diagnostic trouble code
Check again if the DTC is set to the ETACS-ECU.
Q: Is the DTC set?
YES : Troubleshoot the ETACS-ECU (Refer to P.54A-482).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
to GROUP 00 How to use
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-31
DTC B2463: Sticking of rheostat switch

. .

If the combination meter detects the rheostat switch The combination meter may be defective.
pressed state for 60 seconds or more continuously, The meter hood assembly (rheostat switch knob)
DTC B2463 is stored. may be defective.
DIAGNOSIS PROCEDURE
STEP 1. Check the rheostat switch.

Check whether an abnormality is present to the combination
meter and the rheostat switch knob attached to the meter hood
assembly.
YES : Go to Step 2.
NO : Replace the combination meter or meter hood
assembly.

CAUTION
(3) Erase the DTC.
position.
MB991910 (5) Check if diagnosis code is set.
Q: Is the DTC set?
MB991824
YES : Replace the combination meter, and then go to Step
3.
MB991827 AC608435 AB
TSB Revision
COMBINATION METER

(1) Erase the DTC.
position.
(3) Check if diagnosis code is set.
Q: Is the DTC set?
YES : Go to Step 1.
DTC B2464: The sticking of meter information switch
CAUTION
Whenever the ECU is replaced, ensure that the communication circuit is normal.
Meter Information Switch Circuit
COMBINATION
METER
CPU
INTERFACE
CIRCUIT
METER
INFOMATION
SWITCH

If the combination meter detects the meter informa-
C-04 tion switch pressed state for 60 seconds or more
continuously, DTC B2464 is stored.
C-01 .
The meter information switch may be defective
The combination meter may be defective
AC608145CI loose, corroded, or damaged terminals, or termi-
.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-33
DIAGNOSIS
STEP 1. Check meter information switch connector C-01

Q: Is meter information switch connector C-01 in good
condition?
YES : Go to Step 2.
STEP 2. Check the meter information switch.

Check the meter information switch (Refer to P.54A-82).
YES : Go to Step 3.
NO : Replace the meter information switch.
STEP 3. Measure at meter information switch connector

C-01 in order to the ground circuit to the meter information
switch.
(1) Disconnect meter information switch connector C-01, and
measure at the wiring harness side.
ground.
The measured value should be 2 ohm or less.
Harness side: C-01
this range?
YES : Go to Step 5.
NO : Go to Step 4.
AC608255 BD
STEP 4. Check the wiring harness between meter

information switch connector C-01 (terminal 4) and
ground.
Q: Is the wiring harness between fuel meter information
switch connector C-01 (terminal 4) and ground in good
condition?
YES : Go to Step 7.
TSB Revision
COMBINATION METER

condition?
YES : Go to Step 6.
STEP 6. Check the wiring harness between meter

information switch connector C-01 (terminal 1) and
combination meter connector C-04 (terminal 3).
Q: Are the wiring harness between meter information
switch connector C-01 (terminal 1) and combination
meter connector C-04 (terminal 3) in good condition?
YES : Go to Step 7.

CAUTION
(3) Erase the DTC.
position.
MB991910 (5) Check if DTC is set.
Q: Is the DTC set?
MB991824
YES : Go to Step 1.
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-35
DTC B2465: Ignition switch signal error

. .

If 5 seconds or more elapses with the ignition switch The CAN bus line may be defective
state and the data from the CAN communication con- The ETACS-ECU may be defective
tradicted, the combination meter stores the DTC The combination meter may be defective
B2465.
DIAGNOSIS

Check if DTC is set to the ETACS-ECU.
CAUTION
position.
MB991824
NO : Go to Step 2.
MB991827 AC608435 AB

line.
YES : Go to Step 3.
TSB Revision
COMBINATION METER
STEP 3. Combination meter operation check

Check that the combination meter works normally.
YES : Go to Step 4.
NO : Check the power supply circuit of combination meter

(1) Erase the DTC.
position.
Q: Is the DTC set?
Troubleshooting/Inspection Service Points How to
DTC U0019: Bus off (CAN-B)
CAUTION JUDGEMENT CRITERIA

If DTC U0019 is set, be sure to diagnose the With the ignition switch at the ON position and the
CAN bus line. system voltage at 10 16 volts (data from
When replacing the ECU, always check that ETACS-ECU), if the combination meter becomes
the communication circuit is normal. unable to transmit data normally due to the CAN-B
.
bus circuit malfunction, the combination meter deter-
DIAGNOSTIC FUNCTION mines that a problem has occurred.
If the CAN-B circuit malfunction occurs, the combina- .
tion meter sets DTC U0019. TROUBLESHOOTING HINTS

.
The CAN bus line may be defective
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-37
STEP 1.Recheck for diagnostic trouble code.

CAUTION
position.
MB991824
YES : Go to Step 2.
MB991827 AC608435 AB

line.
TSB Revision
COMBINATION METER
DTC U0100: Engine control module CAN timeout

If DTC U0100 is set, be sure to diagnose the With the ignition switch in the ON position, system
CAN bus line. voltage between 1016 volts (data from
When replacing the ECU, always check that ETACS-ECU), power supply fuse is OK, or odometer
the communication circuit is normal. value is 80.5 km (50 miles) or more, and the commu-
.
nication with engine control module cannot be estab-
DIAGNOSTIC FUNCTION lished for 600 ms or more, the combination meter
The combination meter sets DTC U0100 when it can- determines that a problem has occurred.
not receive "CHECK ENGINE" signals from the .
engine control module. PROBABLE CAUSES

.
The CAN bus line may be defective.
The combination meter may be defective.
The engine control module may be defective.
DIAGNOSIS

line
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-39
STEP 2. Using scan tool MB991958, read the MFI

Check if DTC is set to the engine control module.
Q: Is the DTC set?
YES : Troubleshoot the MFI (Refer to GROUP 13A,
Diagnosis Code Chart P.13A-46).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC U0141: ETACS CAN timeout

CAN bus line. voltage between 10 16 volts (data from
.
nication with ETACS-ECU cannot be established for
DIAGNOSTIC FUNCTION 2,500 ms or more, the combination meter determines
If the signal from ETACS-ECU cannot be received, that a problem has occurred.
the combination meter sets the DTC U0141. .
. TROUBLESHOOTING HINTS
DIAGNOSIS
TSB Revision
COMBINATION METER

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
YES : Diagnose the ETACS-ECU (Refer to P.54A-482).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-41
DTC U0151: SRS-ECU CAN timeout

.
nication with SRS-ECU cannot be established for
If the signal from SRS-ECU cannot be received, the that a problem has occurred.
combination meter sets DTC U0151. .
The SRS-ECU may be defective
DIAGNOSIS

line
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
COMBINATION METER
STEP 2. Using scan tool MB991958, read the SRS-ECU

Check again if the DTC is set to the SRS-ECU.
Q: Is the DTC set?
YES : Troubleshoot the SRS (Refer to GROUP 52B,
Troubleshooting P.52B-31).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC U0154: Occupant classification-ECU CAN timeout

.
nications with occupant classification-ECU cannot be
DIAGNOSTIC FUNCTION established for 2,500 ms or more, the combination
When the signals from occupant classification-ECU meter determines that a problem has occurred.
cannot be received, the combination meter sets DTC .
U0154. TROUBLESHOOTING HINTS

.
The occupant classification-ECU may be defec-
tive.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-43

line.
CAUTION
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958, read the occupant

classification-ECU diagnostic trouble code.
Check if DTC is set to the occupant classification-ECU.
Q: Is the DTC set?
Diagnosis P.52B-280).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
COMBINATION METER
DTC U0164: A/C-ECU CAN timeout

.
nication with A/C-ECU cannot be established for
If the signal from A/C-ECU cannot be received, the that a problem has occurred.
combination meter sets DTC U0164. .
The A/C-ECU may be defective.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-45
STEP 2. Using scan tool MB991958, read the A/C

Check if DTC is set to the A/C-ECU.
Q: Is the DTC set?
YES : Troubleshoot the A/C (Refer to GROUP 55A, Manual
A/C Diagnosis P.55A-8 or GROUP 55B, Auto A/C
Diagnosis P.55B-7).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC U0168: KOS-ECU or WCM CAN timeout

CAN bus line. voltage between 10 16 V (data from ETACS-ECU),
When replacing the ECU, always check that power supply fuse is OK, or odometer value is 80.5
the communication circuit is normal. km (50 miles) or more, and the communication with
.
KOS-ECU or WCM cannot be established for 2,500
DIAGNOSTIC FUNCTION ms or more, the combination meter determines that a
If the signal from KOS-ECU or WCM cannot be problem has occurred.
received, the combination meter sets DTC U0168. .
Malfunction of CAN bus line may be defective.
Malfunction of the KOS-ECU may be defective.
Malfunction of the WCM may be defective.
Malfunction of combination meter may be defec-
tive.
DIAGNOSIS
TSB Revision
COMBINATION METER

line.
CAUTION
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958, read the KOS-ECU or

WCM diagnostic trouble code.
Check again if the DTC is set to the KOS-ECU or WCM.
Q: Is the DTC set?
YES : Troubleshoot the KOS or WCM (Refer to GROUP
42B, Troubleshooting P.42B-20 <KOS> or 42C,
Troubleshooting P.42C-14 <WCM>).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-47
DTC U0184: Audio CAN timeout

.
nications with radio and CD player or CD changer
DIAGNOSTIC FUNCTION cannot be established for 2,500 ms or more, the
When the signals from radio and CD player or CD combination meter determines that a problem has
changer cannot be received, the combination meter occurred.
sets the DTC U0184. .
The radio and CD player or CD changer may be
defective.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
COMBINATION METER
STEP 2. Using scan tool MB991958, read the audio

Check again if the DTC is set to the audio.
Q: Is the DTC set?
YES : Troubleshoot the radio and CD player (Refer to
P.54A-239).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC U0197: Hands free module CAN timeout

.
nications with hands free module cannot be estab-
DIAGNOSTIC FUNCTION lished for 2,500 ms or more, the combination meter
When the signals from hands free module cannot be determines that a problem has occurred.
received, the combination meter sets DTC U0197. .
The hands free module may be defective.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-49

line.
CAUTION
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958, read the hands free

module diagnostic trouble code.
Check again if the DTC is set to the hands free module.
Q: Is the DTC set?
YES : Troubleshoot the hands-free cellular phone system.
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
COMBINATION METER
DTC U0245: Audio visual navigation unit CAN timeout

.
nications with audio visual navigation unit cannot be
DIAGNOSTIC FUNCTION established for 2,500 ms or more, the combination
When the signals from audio visual navigation unit meter determines that a problem has occurred.
cannot be received, the combination meter sets DTC .

.
The audio visual navigation unit may be defec-
tive.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-51
STEP 2. Using scan tool MB991958, read the audio visual

navigation unit diagnostic trouble code.
Check if DTC is set to the audio visual navigation unit.
Q: Is the DTC set?
YES : Troubleshoot the MMCS (Refer to P.54A-328).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC U1415: Coding not completed/Data fail

.

If DTC U1415 is set, diagnose the CAN bus With the global coding counter value "0," if all the glo-
lines. bal coding data (vehicle information) are not stored,
When replacing the ECU, always check that the combination meter determines that a problem
the communication circuit is normal. has occurred.
.
DIAGNOSTIC FUNCTION .
If the vehicle information data is not registered to the TROUBLESHOOTING HINTS

combination meter, the combination meter sets DTC The CAN bus line may be defective.
U1415. The combination meter may be defective.
The ETACS-ECU may be defective.
DIAGNOSIS
TSB Revision
COMBINATION METER

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-53
M1540200800175
CAUTION
During troubleshooting, a DTC code associated with another system may be set when the ignition
switch is turned on with connector(s) disconnected. On completion, confirm all systems for DTC
When the combination meter is required to be replaced as a result of the troubleshooting, the cur-
rent driving distance and number of elapsed days to be used for service reminder function must
be entered into the meter after the replacement. Therefore, read "Integrated mileage for reminder,"
"Integrated days for reminder," "Mileage until Extra reminder," "Months until Extra reminder," and
"Current Schedule" from the meter before the replacement using the special function of scan tool
MB991958, and note them. For the operation method of scan tool MB991958, refer to P.54A-82. If
"Integrated mileage for reminder" or "Integrated days for reminder" cannot be read by the scan
tool MB991958, follow the method described below.
a. For the driving distance for check warning, use the driving distance displayed on the multi
b. For the elapsed days for check warning, calculate the number of elapsed days from the deliv-
ery date to the customer (service remainder function start date) and current date.
Trouble symptom Inspection Reference

Procedure page
No.
Power supply circuit check. 1 P.54A-54
The speedometer does not work (the other meters work). 2 P.54A-60
The tachometer does not work (the other meters work). 3 P.54A-62
Tone alarm does not sound normally. 4 P.54A-64
The combination meter light does not illuminate normally or the multi information 5 P.54A-66
display is not displayed normally.
The multi information display screen cannot be changed with the operation of 6 P.54A-69
the meter information switch.
TSB Revision
COMBINATION METER
SYMPTOM PROCEDURES
Inspection Procedure 1: Power supply circuit check.
Combination Meter Power Supply Circuit
FUSIBLE FUSIBLE IGNITION

LINK 36 LINK 34 SWITCH (IG1)
RELAY
BOX
ENGINE
COMPAPT
MENT
ETACS-
ECU
IG1
RELAY
JOINT
CONNECTOR (3)
COMBINATION
METER
TACHO
CPU
LCD
LED DRIVE ODO/TRIP
CIRCUIT T/GA F/GA SPEED
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-55
.
Connectors: C-04, C-07 TECHNICAL DESCRIPTION (COMMENT)

If the odometer and tripmeter do not display or all the
C-04 meter needles do not move, the power supply to the
combination meter, or the combination meter itself
may have a problem.
C-07
.
AC608145CH
Connectors: C-307, C-309, C-317 The combination meter may be defective
Junction block
C-317
C-307 (B)
C-309 (B)
AC608152 AX
DIAGNOSIS
TSB Revision
COMBINATION METER

CAUTION
position.
MB991824
YES : Troubleshoot the combination meter (Refer to
P.54A-23).
NO : Go to Step 2.
MB991827 AC608435 AB

condition?
YES : Go to Step 3.
STEP 3. Check the battery power supply circuit to the

combination meter. Measure the voltage at combination
meter connector C-04.
(1) Disconnect the connector, and measure at the wiring
harness side.
(2) Turn the ignition switch to the LOCK (OFF) position.
(3) Measure the voltage between terminals 1, 24 and ground.
Harness side: C-04 (battery positive voltage).
positive voltage)?
YES : Go to Step 5.
NO : Go to Step 4.
AC608254 BB
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-57
STEP 4. Check the wiring harness between combination

meter connector C-04 (terminal 1, 24) and the fusible link
(36).
NOTE: Also check ETACS-ECU connectors C-307, C-317 and
joint connector C-07 for loose, corroded, or damaged terminals,
or terminals pushed back in the connector. If ETACS-ECU con-
nector C-307, C-317 or joint connector C-07 is damaged, repair
or replace the damaged component(s) as described in GROUP
Q: Is the wiring harness between combination meter
connector C-04 (terminal 1, 24 and the fusible link (36)
in good condition?
to GROUP 00 How to Cope with Intermittent

combination meter. Measure the voltage at combination
meter connector C-04.
harness side.
(2) Turn the ignition switch to the ON position.
(3) Measure the voltage between terminals 2 and ground.
positive voltage)?
YES : Go to Step 8.
Harness side: C-04
NO : Go to Step 6.
AC608254 BC
TSB Revision
COMBINATION METER

Check the input signal from the ignition switch (IG1) in the
ETACS-ECU.
(2) Check the ETACS data list.
Turn the ignition switch to the "ON" position.
condition
Item 254 IG voltage Approximately 12
volts (battery
positive voltage)

Q: Do the scan tool MB991958 display the item "IG voltage"
is normal condition?
YES : Go to Step 7.
NO : Troubleshoot the ETACS-ECU. Refer to Inspection
Procedure 2 "The ignition switch (IG1) signal is not
received P.54A-531."

meter connector C-04 (terminal 2) and the fusible link (34).
NOTE: Also check ETACS-ECU connectors C-309 and C-317
for loose, corroded, or damaged terminals, or terminals pushed
back in the connector. If ETACS-ECU connector C-309 or
C-317 is damaged, repair or replace the damaged compo-
nent(s) as described in GROUP 00E, Harness Connector
Inspection P.00E-2.
connector C-04 (terminal 2) and the fusible link (34) in
good condition?
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-59
STEP 8. Check the ground circuit to the combination

meter. Test at combination meter connector C-04.
(1) Disconnect combination meter connector C-04 and
of the connector.
ground.
Harness side: C-04 The resistance should be 2 ohms or less.
NO : Go to Step 9.
AC608255 BC

meter connector C-04 (terminal 13) and ground.
connector C-04 (terminal 13) and ground in good
condition?

Check that the combination meter works normally.
Q: Is the check result satisfactory?
TSB Revision
COMBINATION METER
Inspection Procedure 2: The speedometer does not work (the other meters work).
. .

If only the speedometer does not operate, the tran- The transaxle control module may be defective
saxle control module and combination meter may The combination meter may be defective
have a problem.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
P.54A-23).
NO : Go to Step 3.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-61
STEP 3. Using scan tool MB991958, read the CVT

Check if diagnosis code is set to the CVT.
Q: Is the DTC set?
YES : Troubleshoot the CVT (Refer to GROUP 23A,
Automatic Transaxle Diagnosis P.23A-29).
NO : Go to Step 4.

(2) Check the data list on the combination meter.
Item 80: Speedometer
Should read vehicle speed.
Q: Does it read vehicle speed?
NO : Go to Step 5.
STEP 5. Check the speedometer

Use scan tool MB991958 to enter simulated vehicle speed.
(2) Select "System select" from the start-up screen.
(3) Select "From 2006 MY" under "Model Year". Check that
"Vehicle Information" contents are correct.
(4) Select "Meter" from "System List", and then press "OK"
button.
NOTE: If "Loading Option Setup" list is shown, tick appro-
priate box.
(5) Select "Simulated vehicle Speed Output."
OK: The speedometer shows that simulated vehi-
cle speed.
YES : Go to Step 6.

Check that the speedometer works normally.
NO : Go to Step 1.
TSB Revision
COMBINATION METER
Inspection Procedure 3: The tachometer does not work (the other meters work).
. .

If only the tachometer does not operate, the ignition The combination meter may be defective
signal from the engine ECU may not be received or The engine control module may be defective
the combination meter may have a problem.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
P.54A-23).
NO : Go to Step 3.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-63
STEP 3. Using scan tool MB991958, read the MFI

Q: Is the DTC set?
YES : Troubleshoot the MFI (Refer to GROUP 13A,
Diagnosis P.13A-46).
NO : Go to Step 4.

(2) Check the data list on the combination meter.
Item 87: Tachometer
Should read engine speed.
Q: Does it read engine speed?
YES : Go to Step 5.
NO : Troubleshoot the MFI (Refer to GROUP 13A,
Diagnosis P.13A-46). Complete the engine
troubleshooting, and then go to Step 6.
STEP 5. Using scan tool MB991958, check actuator test.

(2) Conduct the actuator test of the combination meter.
Item 2: Tachometer
The tachometer operates up to the set position.
Q: Is the check result normally?
YES : Go to Step 6.
STEP 6. Retest the system

Check that the tachometer works normally.
NO : Go to Step 1.
TSB Revision
COMBINATION METER
Inspection Procedure 4: Tone alarm does not sound normally.
CAUTION Freeze warning tone alarm

Before replacing the combination meter, be sure Ignition switch ON signal
to check that the power supply circuit, earth cir- Ambient temperature signal
cuit, and communication circuit are normal. Parking brake reminder tone alarm function
Ignition switch ON signal
.
TECHNICAL DESCRIPTION (COMMENT) Parking brake switch ON signal

When the following signals are received via the CAN Vehicle speed signal
communication, the combination meter sounds the Engine speed
incorporated tone alarm according to the each pat-
tern. Multi information display interrupt display tone
alarm
Seat belt reminder function Display condition signal of information display
Ignition switch ON signal from each warning (When there is a fixed tone
Vehicle speed signal alarm sounding pattern for each warning, that
Driver's seat belt switch signal pattern has the priority.)
Front passenger's seat belt switch signal
Meter information switch operation tone alarm
Keyless operation key reminder tone alarm func- ON signal for combination meter information
tion (vehicles with KOS) switch
Ignition switch OFF signal
IG knob push switch ON signal Turn-signal light tone alarm function
Driver's door switch ON signal Turn-signal light switch ON signal
Ignition key reminder tone alarm function (vehi- Paddle shift cancel tone alarm, Theft-alarm func-
cles without KOS) tion, ETACS-ECU function customise tone
Ignition switch OFF signal alarm, A/C operation tone alarm, audio opera-
Key reminder switch OFF signal tion tone alarm
Driver's door switch ON signal Sounding request signal from the ETACS-ECU
If the tone alarm does not sound normally, the con-
Light reminder tone alarm function nector(s) and wiring harness in the CAN bus lines, or
Ignition switch OFF signal each ECU or the combination meter may have a
Lighting switch ON signal problem.
Driver's door switch ON signal
.
Door-ajar warning tone alarm function TROUBLESHOOTING HINTS

Ignition switch ON signal The combination meter may be defective
Any door switch or liftgate switch ON signal The each ECU may be defective
Vehicle speed signal
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-65

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
P.54A-23).
NO : Go to Step 3.
STEP 3. Using scan tool MB991958, read for any

Check if diagnosis code is set to the CVT, ETACS-ECU, WCM,
KOS-ECU, audio and A/C-ECU.
Q: Is the DTC set to the any of the above?
YES <Set to the CVT.> : Troubleshoot the CVT (Refer to
GROUP 23A, Diagnosis P.23A-29).
YES <Set to the ETACS.> : Troubleshoot the ETACS
YES <Set to the WCM.> : Troubleshoot the WCM (Refer to
GROUP 42C, diagnosis P.42C-14).
YES <Set to the KOS.> : Troubleshoot the KOS (Refer to
GROUP 42B, Diagnosis P.42B-20).
YES <Set to the audio.> : Troubleshoot the audio (Refer
to P.54A-239).
YES <Set to the A/C.> : Troubleshoot the A/C (Refer to
GROUP 55A, Manual A/C Diagnosis P.55A-8 or
GROUP 55B, Automatic A/C Diagnosis P.55B-7).
NO <The diagnosis code is not set.> : Go to Step 4.
TSB Revision
COMBINATION METER

Item 12: Buzzer
The tone alarms sound normally.
YES : Go to Step 5.

Check that the tone alarm normally.
Inspection Procedure 5: The combination meter light does not illuminate normally or the multi
information display is not displayed normally.
CAUTION If the lights do not illuminate or the multi information

Before replacing the combination meter, be sure display does not display normally, the wiring harness
to check that the power supply circuit, earth cir- and connector(s) in the CAN bus lines, or the each
cuit, and communication circuit are normal. ECU or the combination meter may have a problem.
.

.
When the signal from each ECU is received via the The combination meter may be defective
CAN communication, the combination meter illumi- The each ECU may be defective
nates the corresponding display light or warning
light, or has the multi information display to display
corresponding information.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-67

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
P.54A-23).
NO : Go to Step 3.
TSB Revision
COMBINATION METER
STEP 3. Using scan tool MB991958, read for any

Check again if the DTC is set to the MFI,CVT, WCM, KOS,
ABS, SRS, ETACS and A/C.
Q: Is the DTC set to the any of the above?
YES <Set to the MFI.> : Troubleshoot the MFI (Refer to
YES <Set to the CVT.> : Troubleshoot the CVT (Refer to
YES <Set to the ABS.> : Troubleshoot the ABS (Refer to
YES <Set to the WCM.> : Troubleshoot the WCM (Refer to
GROUP 42C, diagnosis P.42C-14).
YES <Set to the KOS.> : Troubleshoot the KOS (Refer to
YES <Set to the SRS.> : Troubleshoot the SRS (Refer to
YES <Set to the ETACS.> : Troubleshoot the ETACS
YES <Set to the A/C.> : Troubleshoot the A/C (Refer to
GROUP 55A, Manual A/C Diagnosis P.55A-8 or
GROUP 55B, Automatic A/C Diagnosis P.55B-7).
NO <The diagnosis code is not set.> : Go to Step 4.

Item 7: Indicator1
Item 8: Indicator2
Item 9: Indicator3
Item 10: Indicator4
Item 11: Shift indicator
Perform the actuator test, and check that display
lights or warning lights are illuminated normally, or
multi information display is displayed normally.
YES : Go to Step 5.

Check that display lights or warning lights are illuminated nor-
mally, or multi information display is displayed normally.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-69
Inspection Procedure 6: The multi information display screen cannot be changed with the operation
of the meter information switch.
.
CAUTION TROUBLESHOOTING HINTS

Before replacing the combination meter, be sure The meter information switch may be defective
to check that the power supply circuit, ground The combination meter may be defective
circuit, and communication circuit are normal. The wiring harness or connectors may have
.

When the signal from the meter information switch is
received, the combination meter switches the multi
information display screen. If the multi information
display screen does not switch normally, the meter
information switch, wiring harness, connector(s), or
combination meter may have a problem.
DIAGNOSIS

CAUTION
position.
MB991824
P.54A-23).
NO : Go to Step 2.
MB991827 AC608435 AB
TSB Revision
COMBINATION METER

Check that the multi information display screen switches nor-
mally when the meter information switch is operated.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-71
SERVICE DATA
M1540201000097
Item Scan tool display Check condition Normal condition

No.
1 Illumination When the meter illumination is ON
illuminated
2 Outside temperature Always 30 +50 C
3 Frost warning indicator When the freeze warning light is ON
illuminated
4 Engine coolant temp. light (HOT) When the high coolant temperature ON
warning light is illuminated
6 Oil level indicator When the oil level warning light is ON
illuminated
23 A/T failure indicator (Symbol) When the A/T malfunction warning ON
light is illuminated
26 Key reminder indicator When the key reminder warning ON
27 Headlight reminder indicator When the headlight reminder ON
28 Brake reminder indicator When the brake reminder warning ON
29 F.A.S.T. indicator1 (Low battery) When the malfunction occurs to ON
30 F.A.S.T. indicator2 (No key) keyless operation system ON
31 F.A.S.T. indicator3 (IG knob) ON
32 F.A.S.T. indicator4 (Take out key) ON
33 F.A.S.T. indicator5 (Take out key) ON
34 F.A.S.T. indicator6 (Lock disable) ON
37 F.A.S.T. indicator9 (System error) ON
40 Buzzer (cutting into LCD display) When the standard LCD interrupt ON
buzzer becomes active
42 ETACS answer back buzzer When the ETACS setting response ON
44 BEEP(A/C)1 A/C operation ON
45 BEEP(A/C)2 ON
46 BEEP(A/C)3 ON
47 BEEP(AUDIO)1 Audio operation ON
48 BEEP(AUDIO)2 ON
49 BEEP(AUDIO)3 ON
51 BEEP (AUDIO)4 ON
52 BEEP (AUDIO)5 ON
50 Seatbelt reminder buzzer When the seat belt reminder ON
65 Meter SW push buzzer Meter information switch: ON ON
TSB Revision
COMBINATION METER

No.
66 Turn signal buzzer When turn-signal buzzer becomes ON
active.
67 Shift cancel buzzer When the AT shift cancel buzzer ON
becomes active
68 Meter SW long push buzzer Meter information switch: ON ON
(press and hold)
69 Security alarm buzzer When the security alarm becomes ON
70 Presecurity alarm buzzer active ON
71 Rest reminder buzzer1 When the rest sign buzzer ON
72 Rest reminder buzzer2 becomes active ON
74 Parking brake reminder buzzer When the brake reminder buzzer ON
becomes active
75 IG knob reminder buzzer When the insufficient IG knob ON
return buzzer becomes active
76 Key reminder buzzer When the key reminder buzzer ON
becomes active
77 Headlight reminder buzzer When the headlight reminder ON
78 Door ajar warning buzzer When the door ajar warning buzzer ON
becomes active
79 Frost warning buzzer When the freeze warning buzzer ON
becomes active
80 Speed meter Perform a test run of the vehicle. Speedometer displayed
value and scan tool
displayed value agree
with each other.
87 Tachometer Start the engine. Tachometer displayed
value and scan tool
displayed value agree
with each other.
89 Fuel gauge Ignition switch: ON Fuel gauge unit
resistance value and scan
tool displayed value agree
with each other.
8A Fuel gauge (Target) Ignition switch: ON Fuel gauge and scan tool
displayed values agree
with each other.
8C Engine coolant temperature Ignition switch: ON Coolant temperature and
gauge scan tool displayed
values agree with each
other.
90 Odometer Ignition switch: ON Odometer displayed value
and scan tool displayed
value agree with each
other.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-73
No.
91 Rheostat Ignition switch: ON Lighting change by
rheostat switch operation
and scan tool displayed
change agree with each
other.
92 Trip meter A Ignition switch: ON Tripmeter displayed value
93 Trip meter B and scan tool displayed
value agree with each
other.
94 Power source voltage Always 0 20 V
A1 SRS warning light When the SRS warning light is ON
illuminated
A2 ABS warning light When the ABS warning light is ON
illuminated
A3 Oil pressure indicator When the hydraulic pressure ON
A4 Charge indicator When the charging warning light is ON
illuminated
A5 Engine malfunction indicator When the engine warning light is ON
illuminated
A6 Fuel Warning (step1) When the fuel remaining amount ON
warning light (first step) is
illuminated
A7 Brake warning light When the brake warning light is ON
illuminated
A8 Driver seatbelt indicator When the driver's seat belt warning ON
B1 Turn signal indicator (Right) Turn-signal light switch (RH): ON ON
B2 Turn signal indicator (Left) Turn-signal light switch (LH): ON ON
B3 Front fog light indicator Front fog light switch: ON ON
B4 High beam indicator Dimmer switch: ON ON
B5 Door indicator (Front Left) When the driver's door is opened ON
B6 Door indicator (Front Right) When the front passenger's door is ON
opened
B7 Door indicator (Rear Left) When the rear left door is opened ON
B8 Door indicator (Rear Right) When the rear right door is opened ON
B9 Door indicator (Tailgate) When the trunk is opened ON
D8 Car symbol When the vehicle mark is ON
illuminated
E2 A/T Oil TEMP.indicator When the A/T oil temperature ON
indicator is illuminated
E6 Rest reminder indicator When the rest sign indicator is ON
illuminated
TSB Revision
COMBINATION METER

No.
E7 Service reminder indicator When the service reminder ON
indicator is illuminated
F2 FL corner sensor indicator When each corner sensor ON
F3 FR corner sensor indicator responds ON
F4 RL corner sensor indicator ON
F5 RR corner sensor indicator ON
F7 Cruise control indicator When the cruise control indicator is ON
illuminated
100 Distance to empty Ignition switch: ON Displayed values and
102 Average fuel consumption scan tool displayed
103 Instant fuel consumption other.
104 Average speed
108 Fuel Warning (step2) When fuel remaining amount ON
warning light (second step) is
illuminated.
113 Rest reminder time (Hour) Ignition switch: ON Displayed values and
114 Rest reminder time (Minute) scan tool displayed
other.
ACTUATOR TEST TABLE

M1540201100094
Item No. Item name Test item Value

1* Speedometer Pointer position setting (km/h or mph) km/h or mph
2 Tachometer Pointer position setting (r/min) r/min
3 Fuel gauge(Target) Status setting (%) %
4 Water Temperature gauge Status setting ( F) F
5 Meter illumination Status setting (%) %
6 Outside temperature Status setting ( F) F
7 Indicator1 By turning ON/OFF the item values, indicators OFF/ON
8 Indicator2 can be illuminated/extinguished and buzzers OFF/ON
can be sounded.
9 Indicator3 OFF/ON
10 Indicator4 for Japan OFF/ON
11 Shift indicator OFF/ON
12 Buzzer OFF/ON
13 Indicator4 for US OFF/ON
*
NOTE: : Depending on the main scale of the speed-
ometer, the unit that can be tested changes. Unit is
displayed as "" on the scan tool MB991958 screen.
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-75
CHECK PROCEDURE FOR EACH MULTI INFORMATION DISPLAY SCREEN
M1540201900078
CAUTION WARNING SCREEN

When there are TV towers, substations, or broad- When malfunctions occur to the vehicle, the following
casting stations which emit strong radio waves warning screens are displayed. If these screens are
in proximity, on rare occasions, a warning is dis- not displayed normally or if they continue to be dis-
played on the multi information screen for a few played even after the factor is eliminated, take mea-
seconds. This is caused by the reception of sures according to the action procedure.
strong radio waves, and there is no functional
problem.
Display content Factor Action procedure
Displayed with the sounding of If the ignition key reminder warning tone
tone alarm when the driver's door alarm is not being sounded, perform the
is opened with the key inserted in troubleshooting for the ignition key reminder
REMOVE KEY the ignition switch key cylinder. warning tone alarm (Refer to P.54A-64).
AC509825
Displayed with the sounding of If the lighting monitor warning buzzer is not
buzzer when the driver's door is being sounded, perform the troubleshooting
opened with the ignition switch at for the lighting monitor warning buzzer
TURN OFF the LOCK (OFF) position and the (Refer to P.54A-64).
LIGHTS
AC509826 lighting switch at the tail or head
position.
Displayed while the theft alarm is in If the warning screen is not displayed
operation. normally or if the screen continues to be
displayed, carry out the troubleshooting for
the theft alarm (Refer to P.54A-575).
AC505679
Displayed when a malfunction If the warning screen is not displayed

a occurs to KOS. Refer to GROUP normally or if the screen continues to be
42B Diagnosis . displayed, perform the troubleshooting for
a. Displayed when an IG knob the KOS (Refer to GROUP 42B Diagnosis
b return failure occurs or the door code chart P.42B-20).
lock does not operate.
b. Displayed when the KOS key
battery is running low.
c
c. Displayed if carrying a KOS key
with different ID code or the
KOS key is outside the
d operative range.
d. Displayed when the KOS key
removal monitoring function or
KOS key confinement
e
prevention function is in
operation.
e. Displayed when the door ajar
f prevention function is in
operation.
f. Displayed when there is a
AC606877AB
malfunction to KOS.
TSB Revision
COMBINATION METER

a. Displayed when the tire air If the warning screen is not displayed
a
pressure is an abnormality. normally or erased, carry out the
b. Displayed when the TPMS is an troubleshooting for the TPMS (Refer to
abnormality. GROUP 42B, Diagnosis P.42B-20).
AC609827AB
AC609828AB
a. Displayed when the brake fluid If the warning screen is not displayed
a
amount is insufficient or a normally or if the screen continues to be
malfunction occurs to the brake displayed, take the following measures for
CHECK device. each displayed item.
AC509829 AB b. Displayed if vehicle is driven a. Check the brake fluid or brake device.
with the parking brake engaged. b. Check the parking brake.
b
RELEASE
PARKING BRAKE
AC509830AB
Displayed when a malfunction If the warning screen is not displayed

occurs to the anti-skid braking normally or if the screen continues to be
system (ABS). displayed, perform the troubleshooting for
SERVICE the ABS (Refer to GROUP 35B Trouble
REQUIRED
AC509831 symptom chart P.35B-146).
If any of the doors or tailgate is not If the door ajar warning buzzer does not
closed completely, the location of sound, perform the troubleshooting for the
the ajar door is displayed with the door ajar warning buzzer (Refer to
sounding of buzzer. P.54A-64).
AC610018
Displayed when overheated. If the warning screen is not displayed

normally or if the screen continues to be
displayed, perform the troubleshooting for
CHECK the engine (Refer to GROUP 13A Trouble
AC509834 symptom chart P.13A-51).
a. Displayed when the If the warning screen is not displayed

a
transmission oil temperature normally or if the screen continues to be
becomes high. displayed, check the CVT diagnosis code
SLOW DOWN b. Displayed when there is a (Refer to GROUP 23A, Diagnosis P.23A-29).
AC509835AB malfunction to the CVT.
SERVICE
REQUIRED
AC509836AB
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-77
Displayed when the ignition switch If the warning screen is not displayed
is turned ON without the driver's normally or if the screen continues to be
seat belt fastened. displayed, perform the troubleshooting for
FASTEN the seat belt reminder warning lamp (Refer
SEAT BELT
AC509837 to P.54A-66).
Displayed when the remaining fuel If the warning screen is not displayed
amount is small. normally or if the screen continues to be
displayed, check the combination meter
REFUEL diagnosis code (Refer to P.54A-66).
AC509839
Displayed when there is a If the warning screen is not displayed

malfunction to the engine oil normally or if the screen continues to be
circulation system. displayed, check the engine oil amount.
CHECK
AC509840

malfunction to the charging normally or if the screen continues to be
system. displayed, check the battery.
SERVICE
REQUIRED
AC509841

malfunction to the SRS air bag or normally or if the screen continues to be
to the pre-tensioner mechanism. displayed, perform the troubleshooting for
SERVICE the SRS air bag/pre-tensioner mechanism
REQUIRED
AC509842 warning lamp (Refer to GROUP 52B
Trouble symptom chart P.52B-339).
Displayed with the sounding of If the freeze warning buzzer does not sound
buzzer when the ambient with the ambient temperature of 0 C or less,
temperature is 0 C or less. perform the troubleshooting for the freeze
POSSIBLE warning buzzer (Refer to P.54A-64).
ICY ROADS
AC509848
TSB Revision
COMBINATION METER
OTHER SCREENS
The screen displays the operation state of each sys-
tem, periodic checkup timing, or timing for taking a
rest during driving. If the screen display differs from
the actual system operation state or if the screen is
not displayed at the set timing, take measures
according to the action procedure.
Display content System operation state Action procedure
Displayed when the set period
elapses.
PERIODIC
INSPECTION
AC509849
Displayed when the set time

elapses.
REST REMINDER
AC509850
CHECK AT ECU TERMINALS

M1540201200165
Connector: C-04
AC606907AD
Terminal Check item Check condition Normal condition

No.
1 ECU power supply (battery) Always Battery voltage
2 ECU power supply (Ignition Ignition switch: ON Battery voltage
switch: IG1) Ignition switch: OFF 0V
3 Meter information switch Meter information switch: ON 0V
input Meter information switch: OFF Approximately 5 V
4 Parking brake switch input Parking brake switch: ON 0V
Parking brake switch: OFF Approximately 5 V
5 Seat belt switch (drivers Seat belt switch (drivers side): ON 0V
side) input Seat belt switch (drivers side): OFF Approximately 5 V
6 Headlamp leveling During headlamp leveling warning display 0V
Without headlamp leveling warning display Approximately 5 V
7 to 12
13 Earth (sensor) Always 0V
14, 15
16 Seat belt switch Seat belt switch (passengers side): ON 0V
(passengers side) input Seat belt switch (passengers side): OFF Approximately 5 V
17 Fuel level sensor input Fuel: FULL Approximately 1 V
Fuel: EMPTY Approximately 4 V
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-79
Terminal Check item Check condition Normal condition
No.
18 Fuel level sensor input Fuel: FULL Approximately 1 V
Fuel: EMPTY Approximately 4 V
19
20 Vehicle speed signal output Vehicle speed: Approximately 40 km/h Approximately 28 Hz
Vehicle speed change In accordance with
the vehicle speed, a
pulse is generated.
21 Earth (ECU) Always 0V
22 Illumination () output With daytime lighting control 0V
With nighttime lighting control In accordance with
the rheostat switch
operation, a pulse is
generated.
23 Illumination (+) output With lighting control Battery voltage
24 Illumination (power supply) Always Battery voltage
ON-VEHICLE SERVICE
SPEEDOMETER CHECK
M1540201400181
1. Adjust the pressure of tires to the specified level (Refer to
GROUP 31, On-vehicle Service P.31-7).
2. Where applicable, ensure that the TPMS warning light is not
illuminating or flashing.
CAUTION
Do not accelerate or decelerate suddenly during servicing
work.
3. For FWD vehicles, set the vehicle onto a speedometer
tester and use wheel chocks to hold the rear wheels.
Free roller
AC106044 AK
TSB Revision
COMBINATION METER
4. To prevent the front wheel from moving from side to side,

Tension bar attach tension bars to the tie-down hook, and secure both
ends to anchor plates.
5. To prevent the vehicle from moving, attach a chain or wire to
Front the rear retraction hook, and make sure the end of the chain
or wire is secured.
6. Check if the speedometer indicator range is within the
standard values.
Anchor plate Standard value <Except vehicles for CANADA>:
AC001288AC
Standard indication {mph Allowance range {mph

(km/h)} (km/h)}
10 (16) 8.5 11.5 (13.6 18.4)
25 (40) 23.5 26.5 (37.6 42.4)
50 (80) 48.5 51.5 (77.6 82.4)
75 (120) 73.5 76.5 (117.6 122.4)
100 (161) 98.5 102.5 (158.6 165.0)
125 (201) 123.5 127.5 (198.6 205.0)
Standard value <Vehicles for CANADA>:
standard indication {km/h Allowance range {km/h

(mph)} (mph)}
20 (12.4) 19 24 (11.8 14.9)
40 (24.8) 40 44 (24.8 27.3)
80 (49.7) 80 85 (49.7 52.8)
120 (74.6) 120.5 125.5 (74.9 78.0)
160 (99.4) 160.5 165.5 (99.7 102.8)
200 (124.3) 200.5 207.0 (124.6 128.6)
7. If not within the standard value, check the tire size. If an

incorrect size of tire is used, replace it and check again. If
the tire size is correct, a defect may be present in
components and circuit between the output shaft speed
sensor and the combination meter. Check the following
items.
output shaft speed sensor (Refer to GROUP23A, Diagnosis
P.23A-29).
Combination meter (refer to P.54A-23).
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-81
TACHOMETER CHECK
M1540201500177
When the actuator tests (item No.2) are performed using scan
tool MB991958, check that the tachometer indication error is
within the standard value.
NOTE: Values in ( ) indicates the reference value.
Standard value:
Engine speed (r/min) Tachometer indicating

error (r/min)
600 550 650
(2,000) (1,950 2,050)
3,000 2,950 3,050
(4,000) (3,950 4,050)
5,000 4,950 5,050
6,000 5,950 6,050
(7,000) (6,950 7,050)
(8,000) (7,950 8,050)
FUEL LEVEL SENSOR CHECK

M1540201600185
.
1. Remove the rear seat (Refer to GROUP 52A Rear Seat

Assembly P.52A-23).
2. Remove the floor inspection lid, and then remove the fuel
pump module (Refer to GROUP 13B Fuel Tank P.13B-9).
.
NOMINAL RESISTANCE OF THE FUEL LEVEL

SENSOR
When float of the fuel level sensor is in stopper positions F and
Fuel pump
module
E, ensure that resistance between the fuel level sensor terminal
and earth terminal is within the standard value.
Earth Standard value:
Float position Gauge resistance value

(ohms)
Stopper position "F" 13.0 1.0
Stopper position "E" 120.0 1.0
F stopper position When the float is moved slowly between stopper positions "F"
and "E", ensure that the resistance is smoothly changing.
E stopper position
AC609773AB
TSB Revision
COMBINATION METER
FUEL LEVEL SENSOR FLOAT HEIGHT

When float is moved to contact the float arm on the stopper,
F stopper point ensure that stopper positions "F" (height A) and "E" (height B)
are within the standard value.
Standard value:
A
Float position Float height {mm
(in)}
B
Stopper position "F" (height A) 181.5 (7.1)
E stopper point Stopper position "E" (height B) 26.7 (1.0)
AC609774AC
METER INFORMATION SWITCH CHECK

M1540202000067
Switch position Tester Specified condition

connection
Pressed 1-4 Continuity exists (2 ohms
or less)
Released 1-4 Open circuit
AC505421AD
SERVICE REMINDER FUNCTION SET

M1540208200155
HOW TO SET BY OPERATING THE SCAN date.

TOOL MB991958 After the service reminder function has
started, when the elapsed days for check
CAUTION warning is reset for the vehicle whose battery
If the combination meter needs to be is removed for a long period (15 days or
replaced, the current driving distance and more), calculate the elapsed days from the
elapsed days must be entered into the meter delivery date to the customer (service
after the replacement in order to be used for reminder function start date) and the current
service reminder function. Therefore, read date, and then input it.
"Integrated mileage for reminder," "Integrated Using the scan tool MB991958, the following service
days for reminder," "Mileage until Extra reminder functions can be set. Before setting, check
reminder," "Months until Extra reminder," and the current status (schedule, driving distance and
"Current schedule" from the meter before the elapsed days).
replacement using the special function of the
1. Reminder reset (Indicator off)
scan tool MB991958, and note them. If "Inte-
2. Next schedule reminder cancel
grated mileage for reminder" or "Integrated
days for reminder" cannot be read from the 3. Extra reminder setting
meter using the scan tool MB991958, use the 4. Extra reminder cancel
following method. 5. Periodic reminder schedule set
a. As for the driving distance for check warn- 6. Integrated value adjustment
ing, use the driving distance displayed on 7. Optional INT schedule setting
the multi information display.
b. As for the elapsed days for check warning,
calculate the number of elapsed days from
the delivery date to the customer (service
reminder function start date) and current
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-83
.
HOW TO OPERATE THE SCAN TOOL MB991958

CAUTION
Before setting, if the combination meter does not start
measuring the elapsed time, turn the ignition switch to the
ON position while pressing the meter information switch to
start a measurement.
1. Connect the scan tool MB991958 to the data link connector.
2. Start the M.U.T.-III system on the PC and turn the ignition
switch to the "ON" position.
3. Select "Meter" on the "System Select" screen, and press the
"OK" button.
4. Select "Special Function" on the next screen.
5. Select "Service Reminder" on the "Special function" screen.
DBA-CW5WXTHHZ1 2006MY - Service Reminder - 401430898
6. Select the function to be executed from "Function List."
Meter Special Function
Function List
Service Reminder
Data List
1 Reminder reset (Indicator off) (Refer to P.54A-83).
No.
1
Name No. Name Value
2 Next schedule reminder cancel (Refer to P.54A-84).
3 Extra reminder setting (Refer to P.54A-84).
Reminder reset (Indicator off) 1 Mileage until reminder 7500 mile
2 Next schedule reminder cancel
2 Months until reminder 6 month
3
4
Extra service reminder setting
Extra reminder cancel 4

Mileage until Extra 4 Extra reminder cancel (Refer to P.54A-85).
5 Periodic reminder schedule set (Refer to P.54A-85).
reminder
5 Periodic reminder schedule set
Months until Extra
5 reminder
6 Integrated value adjustment (Refer to P.54A-86).

6 Integrated value adjustment
7 Optional INT schedule setting 7 Current Schedule NAS 1-1
Click the name of item to execute, and press

the OK button.
8
Integrated mileage
for reminder 26 mile 7 Optional INT schedule setting (Refer to P.54A-87).
.
AC602555AE 1. REMINDER RESET (INDICATOR OFF)

CAUTION
Be careful not to execute "1 Reminder reset (Indicator
off)" again after erasing the service reminder warning
indicator which is currently output, because the next
warning period will be cancelled.
If the next warning period is cancelled by mistake, the
cancelled warning period can be restored by executing
"5 Periodic reminder schedule set" to set a schedule
different from the current one once, and then returning
it to the previous schedule.
The service reminder warning indicator which is currently out-
put can be cancelled.
NOTE: In addition to the operation of the scan tool MB991958,
the service reminder warning indicator can be cancelled by
operating the meter information switch on the combination
meter. Refer to P.54A-88.
DBA-CW5WXTHHZ1 2006MY - Service Reminder - 4014308A6
1. On the "Service Reminder" screen, select "1 Reminder reset
Meter
Selected
Special Function
Reminder reset
Service Reminder
Data List
(Indicator off)."
1
NOTE: The screen indicates that the warning period (Nos. 1

Item (Indicator off)
No. Name Value
1 Mileage until reminder 0 mile

and 2 in the data list) is "0 mile." and "0 month."
4
Mileage until Extra
reminder 2. Press the "OK" button.
Months until Extra
5 reminder
Press the OK button to execute.
AC602558AV
TSB Revision
COMBINATION METER

3. The current warning indicator is cancelled, and the next
Meter
Selected
Special Function
Reminder reset
Service Reminder
Data List
warning period is displayed.
1

Item (Indicator off)
No. Name Value

and 2 in the data list) is "7,500 km" and "6 month."
Mileage until Extra
4 reminder .
2. NEXT SCHEDULE REMINDER CANCEL

Months until Extra
5 reminder
Check the result. CAUTION

If the next warning period is cancelled by mistake, the can-
AC602558AW celled warning period can be restored by executing "5
Periodic reminder schedule set" to set a schedule different
from the current one once, and then returning it to the pre-
vious schedule.
The next warning period is cancelled, and its following warning
period can be set.
1. On the "Service Reminder" screen, select "2 Next schedule
Meter
Selected
Special Function
Next schedule
Service Reminder
Data List
reminder cancel."
2

Item reminder cancel
No. Name Value

and 2 in the data list) is "1,000 mile" and "1 month."
4
Mileage until Extra
reminder 2. Press the "OK" button.
Months until Extra
5 reminder
AC602558AX

3. The next warning period is cancelled, and its following
Meter
Selected
Special Function
Next schedule
Service Reminder
Data List
warning period is set.
2

Item reminder cancel
No. Name Value

and 2 in the data list) is changed to "8,500 km" and "7
4 Mileage until Extra
reminder
month."
Months until Extra
5
reminder
.
Check the result.

3. EXTRA REMINDER SETTING
In addition to the current warning period, the temporary service
reminder warning period can be set.
AC602558AY

1. On the "Service Reminder" screen, select "3 Extra reminder
Meter
Selected
Special Function
Extra service
Service Reminder
Data List
setting."
3
NOTE: The screen indicates that the temporary warning

Item reminder setting
No. Name Value
Set value
period (Nos. 4 and 5 in the data list) has not been set.
Name Value
Distance to setting point -Input the value- 2 Months until reminder 6 month
Months to setting point -Input the value- Mileage until Extra

4 reminder
Months until Extra

5 reminder
Input the value for the item that you want to

set up, and press the OK button.
AC602556 AG
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-85
2. Set the temporary warning period (distance or month) of the
Meter
Selected
Special Function
Extra service
Service Reminder
"Set value."
3
NOTE: Either input of distance or month can execute the

Set value
setting.
Name Value
Distance to setting point -Input the value-
7 8 9
Months to setting point 2
4 5 6 Tab
3. Press the "OK" button.
Back
1 2 3
Space
Input the value for the item that you want to 0 Clear
Range: 0-254, Unit: month,
AC602557 AE

4. The temporary warning period is set.
Meter
Selected
3
Special Function
Extra service
Service Reminder
Data List NOTE: The screen indicates that "2 month" has been added
to the temporary warning period (No. 5 in the data list). (The
No. Name Value

distance of No. 4 in the data list has not been set).
Mileage until Extra
4 reminder .
4. EXTRA REMINDER CANCEL

Months until Extra
5 2 month
reminder
Check the result.

The temporary service reminder warning period which has
been set can be cancelled.
AC602558AO

1. On the "Service Reminder" screen, select "4 Extra reminder
Meter
Selected
Special Function Service Reminder
Data List
cancel."
4 Extra reminder cancel
NOTE: The screen indicates that "3000 mile" and "2 month"
Item No. Name Value

have been set to the temporary warning period (Nos. 4 and
4
Mileage until Extra
reminder
3000 mile 5 in the data list).
Months until Extra
5 2 month
reminder
AC602558AP

3. The temporary warning period is cancelled.
Meter
Selected
4
Extra reminder cancel Data List NOTE: The screen indicates that the temporary warning
period (Nos. 4 and 5 in the data list) has been cancelled.
Item No. Name Value

.
4
Mileage until Extra
reminder
Months until Extra

5. PERIODIC REMINDER SCHEDULE SET
5 reminder
The service reminder schedule can be changed.
Check the result. NOTE: In addition to the operation of the scan tool MB991958,
the schedule can be changed by operating the meter informa-
AC602558AQ
tion switch on the combination meter. Refer to P.54A-88.

1. On the "Service Reminder" screen, select "5 Periodic
Meter
Selected
Periodic reminder Data List
reminder schedule set."
5
NOTE: The screen indicates that the current schedule (No.

Item schedule set
No. Name Value
Set value
7 in the data list) has been set to "NAS 1-1."

Name Value
Schedule Spec. -Input the value- 2 Months until reminder 6 month
Mileage until Extra

4 reminder
Months until Extra

5 reminder
7 Current Schedule NAS 1-1
Select the value and press the OK button.
AC602556 AN
TSB Revision
COMBINATION METER

2. Set the schedule to be changed from "Set value."
Meter
Selected
5
Item schedule set
No. Name Value
Set value
Name Value
Schedule Spec. NAS 1-2 2 Months until reminder 6 month
Mileage until Extra

4 reminder
Months until Extra

5 reminder
Select the value and press the OK button.
AC602556 AO

4. The schedule is changed.
Meter
Selected
5
NOTE: The screen indicates that the current schedule (No.
7 in the data list) has been changed to "NAS 1-2."
Item schedule set
No. Name Value
2 Months until reminder 3 month .
4
Mileage until Extra
reminder
Months until Extra

6. INTEGRATED VALUE ADJUSTMENT
At the combination meter replacement or for the vehicle with its
5
reminder
Check the result.

battery being removed for a long period (15 days or more), this
adjustment is used to reset the mileage and elapsed days for
check warning.
AC602558 AZ

1. On the "Service Reminder" screen, select "6 Integrated
Meter
Selected
Integrated value Data List
value adjustment."
6
NOTE: The screen indicates that the current mileage and

Item adjustment
No. Name Value
Set value
elapsed days (Nos. 8 and 9 in the data list) are "26 mile" and
Name Value
Running Distance -Input the value- 2 Months until reminder 6 month
Elapsed Days -Input the value-

4
Mileage until Extra
reminder
"0 day."
Months until Extra
5
reminder
Integrated mileage for

8 reminder
26 mile
Input the value to both items, and press the Integrated days for
9 0 day
OK button. reminder
AC602556 AP

2. To "Set value," input the mileage and elapsed days to be
Meter
Selected
Integrated value
reset.
6
NOTE: Always input both the mileage and elapsed days.

Item adjustment
Set value
Name Value
Running Distance 100
7 8 9
Elapsed Days 30
4 5 6 Tab
Back
1 2 3
Space
Input the value to both items, and press the 0 Clear

OK button.
Range: 0-32767, Unit: day,
AC602557 AF

4. The mileage and elapsed days are changed. The
Meter
Selected
Integrated value Data List
combination meter automatically recalculates the distance
and days to the nearest next check from the settings of
6
Item adjustment
No. Name Value
mileage and elapsed days for check warning, and then

4 Mileage until Extra displays them in "Data List."

reminder
5 Months until Extra

reminder NOTE: .
8
reminder
100 mile
The screen indicates that the current mileage and
elapsed days (Nos. 8 and 9 in the data list) have been
Integrated days for
Check the result. 9 30 day
reminder
changed to "100 mile" and "30 day."

AC602558 BA
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-87
Set the elapsed days for check warning to "0 day" by the
above resetting method, thereby the timer is reset indi-
rectly.
.
7. OPTIONAL INT SCHEDULE SETTING

CAUTION
If the current schedule is set to the "Optional INT" by exe-
cuting "5. Periodic reminder schedule set," the "set value"
cannot be input. Therefore, set it to the schedule other
than the "Optional INT" once, and then execute "7.
Optional INT schedule setting."
In addition to the existing schedule, the optional service
reminder schedule can be set.
1. On the "Service Reminder" screen, select "7 Optional INT
Meter
Selected
Optional INT schedule Data List
schedule setting."
7
setting
NOTE: The screen indicates that the optional schedule

Item No. Name Value
Set value
(Nos. 12 and 13 in the data list) has not been set.

Name Value
Optional INT for mileage -Input the value- 2 Months until reminder 6 month
Optional INT for month -Input the value- Integrated mileage for
8 reminder
26 mile
Integrated days for

9 0 day
reminder
Optional interval for

12 mileage
Input the value for the item that you want to Optional interval for
13 month
AC602556 AK

2. Set the optional schedule (distance or month) of the "Set
Meter
Selected
Optional INT schedule
value."
7
NOTE: Either input of distance or month can execute the

Item setting
Set value
setting.
Name Value
Optional INT for mileage -Input the value-
7 8 9
Optional INT for month 2
4 5 6 Tab
Back
1 2 3
Space
Input the value for the item that you want to 0 Clear
Range: 0-254, Unit: month,
AC602557 AG

4. The optional schedule is set. The set schedule becomes
Meter
Selected
Optional INT schedule Data List
effective by executing "5 Periodic reminder schedule set"
and setting the schedule to "Optional INT."
7
Item setting
No. Name Value
1 Mileage until reminder
2 Months until reminder 2 month NOTE: The screen indicates that "2 month" has been added
8
reminder
26 mile to the optional schedule (No. 13 in the data list). (The dis-
9
Integrated days for
reminder
0 day
tance of No. 12 in the data list has not been set).
Check the result.
Optional interval for
Please set up "Optional INT" in "Periodic 12 mileage
inspection schedule set" function.
When you start the service reminder at this Optional interval for
interval setting. 13 month
2 month
AC604401AC
TSB Revision
COMBINATION METER
Relationship between the elapsed months and the elapsed days which are used by
the service reminder function
Number Number of days Number Number of days Number Number of days Number Number of days
of of of of
months months months months
1 30 60 13 396 425 25 761 790 37 1,126 1,156

2 61 90 14 426 456 26 791 821 38 1,157 1,186
3 91 121 15 457 486 27 822 851 39 1,187 1,217
4 122 151 16 487 516 28 852 882 40 1,218 1,247
5 152 182 17 517 547 29 883 912 41 1,248 1,277
6 183 212 18 548 577 30 913 943 42 1,278 1,308
7 213 243 19 578 608 31 944 973 43 1,309 1,338
8 244 273 20 609 638 32 974 1,003 44 1,339 1,369
9 274 303 21 639 669 33 1,004 1,034 45 1,370 1,399
10 304 334 22 670 699 34 1,035 1,064 46 1,400 1,430
11 335 364 23 700 730 35 1,065 1,095 47 1,431 1,460
12 365 395 24 731 760 36 1,096 1,125 48 1,461 1,491
NOTE: . 3. Press the meter information switch once for 1.2
When the number of elapsed days is 0 to 29, the seconds or longer.
number of elapsed months is 0. 4. The service reminder indicator flashes.
The combination meter performs calculation
5. While the service reminder indicator flashes,
using 365.25 days for one year and 30.4375 days
press the meter information switch once for less
for one month.
than 1.2 seconds.
HOW TO SET BY SPECIAL OPERATION 6. The service reminder indicator is turned ON, and
"CLEAR" is displayed on the multi information
OF SWITCH display for 3 seconds.
By operating the meter information switch of the
7. After "CLEAR" is displayed for 3 seconds, the
combination meter, the service reminder warning
warning period to the next time is displayed.
cancellation and the schedule setting can be per-
formed. .
. HOW TO SET THE SCHEDULE

HOW TO CANCEL THE SERVICE 1. Turn the ignition switch to the "OFF" position.
REMINDER WARNING 2. By operating the meter information switch, the
CAUTION warning period is displayed on the multi
Be careful not to execute the service reminder information display.
warning cancellation by operating the switch 3. Press the meter information switch once for 1.2
again after erasing the service reminder warn- seconds or longer.
ing indicator which is currently output, 4. The service reminder indicator flashes.
because the next warning period will be can-
5. While the service reminder indicator flashes,
celled.
press the meter information switch for 1.2
If the next warning period is cancelled by mis- seconds or longer and 3 times consecutively.
take, the cancelled warning period can be
6. The service reminder indicator is turned ON, and
restored by setting a schedule different from
the current schedule is displayed on the multi
the current one once, and then returning it to
the previous schedule.
1. Turn the ignition switch to the "OFF" position. 7. While the current schedule is displayed, press the
meter information switch for less than 1.2 seconds
2. By operating the meter information switch, the and 3 times consecutively.
warning period is displayed on the multi
TSB Revision
CHASSIS ELECTRICAL
COMBINATION METER
54A-89
8. The multi information display is shifted to the NOTE: For schedule, "JPN", "GCC/EXP", "EU"
schedule selection mode. and "AUS" can also be selected. However, the
9. When the meter information switch is pressed for setting shall be for "NAS" only.
less than 1.2 seconds, the schedule is shifted, 10.The schedule set in Step 9 is displayed for 3
and when the meter information switch is pressed seconds, and the warning period to the next time
for 1.2 seconds or longer, the displayed schedule is displayed.
is set. .
SCHEDULE TABLE
Schedule Contents of schedule
NAS 10 (initial Elapsed time (month) Every 6 elapsed months
setting) Driving distance (miles) Every 7,500 miles of driving distance
Driving distance (km) Every 12,000 km of driving distance
NAS 11 Elapsed time (month) Every 3 elapsed months
Driving distance (miles) Every 3,750 miles of driving distance
Optional INT The optional schedule can be set. (Only M.U.T.-III can be set.)
OFF Display Without function. "OFF" is displayed on the multi information display.
Function OFF Without function (Only M.U.T.-III can be set.)
NOTE: For schedule, "JPN", "GCC/EXP", "EU" and When "OFF Display" is selected
"AUS" can also be selected. However, the setting Even if the service reminder screen is displayed
shall be for "NAS" only. by operating the meter information switch, "OFF"
is displayed.
HOW TO INACTIVATE THE SERVICE When "Function OFF" is selected
REMINDER FUNCTION Even when the check warning period is reached,
By setting to "OFF Display" or "Function OFF" when the service reminder display is not displayed.
the schedule is set, the service reminder function can Even with the meter information switch operation,
be inactivated. the service reminder screen is not displayed.
TSB Revision
COMBINATION METER
COMBINATION METER
M1540201700160
CAUTION
When the combination meter is required to be replaced, the current driving distance and number of
elapsed days must be entered into the meter after the replacement in order to be used for service
reminder function. Therefore, read "Integrated mileage for reminder," "Integrated days for reminder,"
"Mileage until Extra reminder," "Months until Extra reminder," and "Current Schedule" from the meter
before the replacement using the special function of scan tool MB991958, and note them. For the
operation method of scan tool MB991958, refer to P.54A-82. If "Integrated mileage for reminder" or
"Integrated days for reminder" cannot be read by the scan tool MB991958, follow the method
described below.
For the driving distance for check warning, use the driving distance displayed on the multi infor-
mation display.
For the elapsed days for check warning, calculate the number of elapsed days from the delivery
date to the customer (service remainder function start date) and current date.
2.5 0.5 Nm
23 4 in-lb
1
2.5 0.5 Nm
23 4 in-lb
4 3
2.5 0.5 Nm
23 4 in-lb
AC609711AB

Glove box side panel (Refer to Instrument panel air outlet
GROUP 52A, Glove box garnish lower (Left side) (Refer to
P.52A-5). GROUP 52A, Instrument lower
Instrument center panel (Refer to Panel P.52A-7).
GROUP 52A, Instrument Center Connection of meter information
Panel P.52A-6). switch connector
1. Combination meter bezel
2. Instrument meter cluster panel
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-91
Removal Steps (Continued)
3. Combination meter assembly
4. Meter information switch

M1540201800123
1
AC506448AB
Disassembly steps
1. Combination meter glass
2. Combination meter
HEADLIGHT
GENERAL INFORMATION
M1542000100316
Position light
Headlight (Low-beam)
Headlight
assembly
Headlight (High-beam)
Front turn-signal light
AC608726 AC
For the headlight assembly, the four-headlight incor-

porating the front turn-signal light and the position
light has been adopted. Also, the low-beam dimmer
daytime running light has been equipped as a stan-
dard.
TSB Revision
HEADLIGHT
M1540100200109

Headlight aiming Low-beam Vertical Horizontal line (H) 50.5
[at 7.62 m (25.0 ft)] direction mm ( 2.0 inches) ( 0.38
degrees angle)
Horizontal 126.4 mm ( 5.0 inches)
direction ( 0.95 degrees angle)
from the axis, which is
266.1 mm (10.5 inches) (2
degrees angle) rightward
from the vertical line (V)
Headlight intensity cd (at high-beam) 40,000 or more {when a screen
is set 18.3m(60 ft) ahead of the
vehicle}
PRECAUTIONS ON HOW TO USE THE HEADLIGHT ASSEMBLY
Be careful with the following items as resin lenses Don't scratch the outer lens surface with a sharp
are used in the headlight assembly. edged special tool.
Don't illuminate the headlight for three minutes or Use the specified wax remover and rinse the wax
more when the headlight is covered with scratch off cleanly.
protector. Use the specified genuine bulb.
Don't tape the outer lens.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-93
SPECIAL TOOLS
M1540104400116

name
a
f. MB991825
ENTER key. check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles
communication
MB991914 system)
harness C (for
Daimler
Chrysler
MB991825
models only)
g
f. M.U.T.-III
measurement
adapter
harness
MB991826
MB991958
TSB Revision
HEADLIGHT

name
a
b
circuit
c. LED harness
tester
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
DIAGNOSIS
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
M1540104200167
Refer to GROUP 00, How to use Troubleshoot-
ing/inspection Service Points, Troubleshooting Con-
tents P.00-6.
DIAGNOSTIC FUNCTION
M1540104300090

.

MB991910: M.U.T.-III Main Harness A (Vehicles with CAN
communication system)
.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-95
CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
.

.
CAUTION
display.
button.
TSB Revision
HEADLIGHT

M1540101400065
CAUTION
On troubleshooting, if the ignition switch is turned ON while disconnecting connector(s), diagnostic
trouble code(s) associated with other system may be set. On completion, confirm all systems for
diagnostic trouble code(s). If diagnostic trouble code(s) are set, erase them all.
Diagnostic trouble code No. Diagnostic item Reference page
B16A2 Blown turn-signal light (LH) bulb P.54A-96
B16A3 Turn-signal light (LH) short circuit P.54A-98
B16A4 Blown turn-signal light (RH) bulb P.54A-102
B16A5 Turn-signal light (RH) short circuit P.54A-104
DTC B16A2: Blown turn-signal light (LH) bulb
If there is a malfunction to the left turn-signal light

.
TROUBLE JUDGEMENT bulb, the blown left bulb counter counts once
When the left bulb of turn-signal light is blown, the when the illumination of hazard or turn-signal
ETACS-ECU sets DTC B16A2. light (left side) is attempted.
. After the bulb counter reaches "3," DTC B16A2 is
TECHNICAL DESCRIPTION (COMMENT) set.
The ETACS-ECU sets DTC B16A2 under the follow- .
ing conditions. TROUBLESHOOTING HINTS

Malfunction of turn-signal light bulb (left)
Malfunction of the ETACS-ECU
DIAGNOSIS
STEP 1. Bulb check.

Check whether the left turn-signal light illuminates normally.
YES : Go to Step 2.
NO : Replace the bulb of turn-signal light which does not
illuminate.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-97
STEP 2. Using scan tool MB991958, Check whether the

diagnostic trouble code is reset.
CAUTION
scan tool P.54A-94."
(3) Erase the DTC.
position.
(5) Check whether the ETACS-ECU DTC is set.
Q: Is the DTC set?
YES : Replace the ETACS-ECU.
MB991910 NO : The procedure is complete.
MB991824
MB991827 AC608435 AB
TSB Revision
HEADLIGHT
DTC B16A3: Turn-signal light (LH) short circuit
Turn-Signal Lights (LH) Circuit
ETACS-
ECU
SIDE TURN- HEADLIGHT REAR

SIGNAL LIGHT ASSEMBLY COMBINATION
(LH) (LH) LIGHT
(LH)
Connectors: A-08, A-31 A-08 (B) Connector: D-14
A-31 (B)
D-14 (BR)
AC608142AK AC608166AH
Connectors: C-304, C-311 Connector: F-20

Junction block
C-304
C-311 AC608152 AR AC608171AO

.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-99
TROUBLE JUDGMENT
.
When the left wiring harness of turn-signal light is The wiring harness or connectors may have
short circuited, the ETACS-ECU sets DTC B16A3. loose, corroded, or damaged terminals, or termi-
.
TECHNICAL DESCRIPTION (COMMENT) Malfunction of the ETACS-ECU
When the short circuit is detected three times con-
secutively, the ETACS-ECU sets the DTC B16A3.
DIAGNOSIS
STEP 1. Check headlight assembly (LH) connector A-31

<front>, side turn-signal light (LH) connector A-08 <side>,
rear combination light (LH) connector F-20 <rear> for
Q: Are headlight assembly (LH) connector A-31 <front>,
side turn-signal light (LH) connector A-08 <side>, rear
combination light (LH) connector F-20 <rear> in good
condition?
YES : Go to Step 2.
P.00E-2.
TSB Revision
HEADLIGHT
STEP 2. Resistance measurement at headlight assembly

(LH) connector A-31 <front>, side turn-signal light (LH)
connector A-08 <side>, and rear combination light (LH)
connector F-20 <rear>.
harness side.
(2) Measure the resistance between the connector terminal of
light which does not illuminate and ground.
Measure the resistance between the headlight assem-
bly (LH) connector A-31 (terminal 6) and body ground.
<Front>
Harness side: A-31
AC608255 AR
Measure the resistance between side turn-signal light

(LH) connector A-08 (terminal 1) and body ground.
<Side>
Harness side: A-08
AC608255 AS
Measure the resistance between rear combination light

(LH) connector F-20 (terminal 1) and body ground.
Harness side: F-20 <Rear>
OK: The measured value should be 2 or less.
this range?
YES : Go to Step 4.
NO : Go to Step 3.
AC608255 AT
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-101
STEP 3. Check the wiring harness between headlight

assembly (LH) connector A-31 (terminal 6) <front>, side
turn-signal light (LH) connector A-08 (terminal 1) <side>,
rear combination light (LH) connector F-20 (terminal 1)
<rear> and ground.
Check the ground wires for open circuit.
Q: Are the wiring harness between headlight assembly
(LH) connector A-31 (terminal 6) <front>, side
turn-signal light (LH) connector A-08 (terminal 1)
<side>, rear combination light (LH) connector F-20
(terminal 1) <rear> and ground in good condition?
YES : Go to Step 6.
the headlights illuminate normally.
STEP 4. Check ETACS-ECU connectors C-304 and C-311

Q: Are ETACS-ECU connectors C-304 <front or side> and
C-310 <rear> in good condition?
YES : Go to Step 5.
NO : Replace the bulb(s) of the light that does not
illuminate.

assembly (LH) connector A-31 (terminal 3) <front>, side
turn-signal light (LH) connector A-08 (terminal 2) <side>,
<rear> and ETACS-ECU connector C-304 (terminal 9)
<front or side> or C-311 (terminal 18) <rear>.
NOTE: Also check intermediate connector D-14 for loose, cor-
roded, or damaged terminals, or terminals pushed back in the
connector. If intermediate connector D-14 is damaged, repair or
replace the connector as described in GROUP 00E, Harness
Connector Inspection P.00E-2.
Check the communication line for open circuit.
(LH) connector A-31 (terminal 3) <front>, side
turn-signal light (LH) connector A-08 (terminal 2)
<side>, rear combination light (LH) connector F-20
(terminal 2) <rear> and ETACS-ECU connector C-304
(terminal 9) <front or side> or C-311 (terminal 18) <rear>
in good condition?
YES : Go to Step 6.
TSB Revision
HEADLIGHT

CAUTION
(3) Erase the DTC.
position.
Q: Is the DTC set?
MB991824
MB991827 AC608435 AB
DTC B16A4: Blown turn-signal light (RH) bulb
If there is a malfunction to the right turn-signal

.
DIAGNOSTIC FUNCTION light bulb, the blown right bulb counter counts
When the right bulb of turn-signal light is blown, the once when the illumination of hazard or turn-sig-
ETACS-ECU sets DTC B16A4. nal light (right side) is attempted.
. If the blown right bulb counter reaches "3," the
TECHNICAL DESCRIPTION (COMMENT) DTC B16A4 is set.
The ETACS-ECU sets DTC B16A4 under the follow- .
ing conditions. TROUBLESHOOTING HINTS

Malfunction of turn-signal light bulb (right side)
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-103
STEP 1. Bulb check.

Check whether the bulb of turn-signal light which does not illu-
minate is normal.
YES : Go to Step 2.
NO : Replace the bulb of turn-signal light which does not
illuminate.

CAUTION
(3) Erase the DTC.
position.
Q: Is the DTC set?
MB991824
MB991827 AC608435 AB
TSB Revision
HEADLIGHT
DTC B16A5: Turn-signal light (RH) short circuit
Turn-Signal Lights (RH) Circuit
ETACS-
ECU
JOINT CONNECTOR
SIDE TURN- HEADLIGHT

SIGNAL LIGHT ASSEMBLY
(RH) (RH)
REAR
COMBINATION
LIGHT
(RH)
Connectors: A-01, A-47 Connectors: D-11, D-23

A-01 (B)
A-47 (B) D-11
AC608141AM D-23 AC608166AQ
Connectors: C-304, C-311 Connector: F-06

Junction block
C-304
C-311 AC608152 AR AC608171AN

.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-105
TROUBLE JUDGEMENT
.
When the right wiring harness of turn-signal light is The wiring harness or connectors may have
short circuited, the ETACS-ECU sets DTC B16A5. loose, corroded, or damaged terminals, or termi-
.
When the short circuit is detected three times con-
secutively, the ETACS-ECU sets the DTC B16A5.
DIAGNOSIS
STEP 1. Check headlight assembly (RH) connector A-47

<front>, side turn-signal light (LH) connector A-01 <side>,
rear combination light (LH) connector F-06 <rear> for
Q: Are headlight assembly (RH) connector A-47 <front>,
side turn-signal light (RH) connector A-01 <side>, rear
combination light (LH) connector F-06 <rear> in good
condition?
YES : Go to Step 2.
P.00E-2.
TSB Revision
HEADLIGHT

(RH) connector A-47 <front>, side turn-signal light (RH)
connector A-01 <side>, and rear combination light (RH)
connector F-06 <rear>.
harness side.
(2) Measure the resistance between the connector terminal of
light which does not illuminate and body ground.
Measure the resistance between the headlight assem-
bly (RH) connector A-47 (terminal 6) and body ground.
<Front>
Harness side: A-47
AC608255 AU
Measure the resistance between the side turn-signal

light (RH) connector A-01 (terminal 1) and body ground.
<side>
Harness side: A-01
AC608255 AV
Measure the resistance between the rear combination

light (RH) connector F-06 (terminal 1) and body ground.
Harness side: F-06 <Rear>
OK: The measured value should be continuity
exists (2 ohm or less).
this range?
YES : Go to Step 4.
NO : Go to Step 3.
AC608255 AW
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-107

assembly (RH) connector A-47 (terminal 6) <front>, side
turn-signal light (RH) connector A-01 (terminal 1) <side>,
<rear> and ground.
(RH) connector A-47 (terminal 6) <front>, side
turn-signal light (RH) connector A-01 (terminal 1)
<side>, rear combination light (RH) connector F-06
(terminal 1) <rear> and ground in good condition?
YES : Go to Step 6.
Repair the wiring harness as necessary.

Q: Are ETACS-ECU connectors C-304 and C-311 in good
condition?
YES : Go to Step 5.
P.00E-2.
TSB Revision
HEADLIGHT

assembly (RH) connector A-47 (terminal 3) <front>, side
turn-signal light (RH) connector A-01 (terminal 2) <side>,
rear combination light (RH) connector F-06 (terminal 2)
<rear> and ETACS-ECU connector C-304 (terminal 16)
<front or side> or C-311 (terminal 19) <rear>.
NOTE: Also check intermediate connector D-11 and joint con-
nector D-23 for loose, corroded, or damaged terminals, or ter-
minals pushed back in the connector. If intermediate connector
D-11 or joint connector D-23 is damaged, repair or replace the
Inspection P.00E-2.
(RH) connector A-47 (terminal 3) <front>, side
turn-signal light (RH) connector A-01 (terminal 2)
<side>, rear combination light (RH) connector F-06
(terminal 2) <rear> and ETACS-ECU connector C-304
(terminal 16) <front or side> or C-311 (terminal 19)
<rear> in good condition?
YES : Go to Step 6.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-109

CAUTION
(3) Erase the DTC.
position.
Q: Is the DTC set?
MB991824
MB991827 AC608435 AB
TSB Revision
HEADLIGHT

M1540102100090
Inspection Trouble symptom Reference

Procedure page
No.
1 Headlight Headlights (low-beam) do not illuminate.. P.54A-111
2 and taillight Headlights (high-beam) do not illuminate.. P.54A-115
3 The headlights do not illuminate when the lighting switch is at the P.54A-118
"PASSING" position, but the low-beam illuminates (high-beam and
low-beam cannot be changed) with the switch at the "HEAD"
position.
4 Headlights do not illuminate when the passing switch is operated. P.54A-120
5 The headlight(s) do not illuminate. P.54A-122
6 High-beam indicator light does not illuminate normally. P.54A-125
7 The headlight automatic shutdown function does not work normally. P.54A-127
8 Daytime running light function does not work normally. P.54A-130
9 Any of position light, side marker lights or the license plate light do P.54A-133
not illuminate.
10 Turn-signal The turn-signal lights do not illuminate. P.54A-140
11 light The comfort flashing function does not work normally. P.54A-142
12 The turn-signal indicator lights do not illuminate. P.54A-144
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-111
SYMPTOM PROCEDURES
Inspection Procedure 1: Headlights (low-beam) do not illuminate.
CAUTION
Whenever the ECU is replaced, ensure that the power supply circuit, the ground circuit and the com-
munication circuit are normal.
Headlight Relay (Low-Beam) Circuit
FUSIBLE
LINK 36
RELAY BOX
ENGINE
COMPARTMENT
HEADLIGHT
RELAY (LOW)
FEELD EFFECT
TRANSISTOR
ETACS-ECU
Connector: A-25X Connector: C-312

Junction block
AC609409AC AC608152 AP
.

If both headlights (low-beam) do not illuminate nor-
mally, the headlight switch input circuit, headlight
relay (LOW), or ETACS-ECU may have a problem.
.
TSB Revision
HEADLIGHT
TROUBLESHOOTING HINTS Malfunction of the ETACS-ECU

Malfunction of column switch Damaged harness wires and connectors
Malfunction of headlight relay (LOW)
DIAGNOSIS

trouble code.
CAUTION
Q: Is the DTC set?
YES : Diagnose the ETACS-ECU. Refer to ETACS,
Diagnosis P.54A-482.
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Check headlight relay (LOW) connector A-25X for

Q: Is headlight relay (LOW) connector A-25X in good
condition?
YES : Go to Step 3.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-113
STEP 3. Check of headlight relay (LOW).

Refer to P.54A-152.
Q: Is the headlight relay (LOW) in good condition?
YES : Go to Step 4.
NO : Replace the headlight relay (LOW). Verify that the
low-beam headlights illuminate normally.

headlight relay (LOW). Measure the voltage at headlight
relay (LOW) connector A-25X.
CAUTION
The top and bottom of the headlight relay (LOW) are diffi-
cult to identify. Prior to inspection, confirm the triangle
mark on the relay box.
(1) Disconnect headlight relay (LOW) connector A-25X and
measure the voltage available at the relay box side of the
connector.
OK: The voltage should measure approximately 12
volts (battery positive voltage).
positive voltage)?
YES : Go to Step 5.
NO : Go to Step 7.

in the connector.
YES : Go to Step 6.
STEP 6. Check the wiring harness between headlight relay

(LOW) connector A-25X (terminal 1) and ETACS-ECU
Q: Is the wiring harness between headlight relay (LOW)
connector A-25X (terminal 1) and ETACS-ECU
connector C-312 (terminal 6) in good condition?
YES : Go to Step 8.
the low-beam headlights illuminate normally.
TSB Revision
HEADLIGHT

(LOW) connector A-25X (terminal 4) and the fusible link
(36).
Check the power supply line for open circuit.
Q: Is the wiring harness between headlight relay (LOW)
connector A-25X (terminal 4) and fusible link (36) in
good condition?
YES : Go to Step 8.
the low-beam headlights illuminate normally.
STEP 8. Check the column switch (switch body).

Refer to Column switch, Inspection P.54A-231.
Q: Is the column switch (switch body) in good condition?
YES : Go to Step 9.
NO : Replace the column switch. Verify that the low-beam
headlights illuminate normally.

Q: Does the headlights (low-beam) do not illuminate in
good condition?
Troubleshooting/inspection Service Points, How to
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-115
Inspection Procedure 2: Headlights (high-beam) do not illuminate.
CAUTION
Headlight Relay (High-Beam) Circuit
FUSIBLE
LINK 36
RELAY BOX
ENGINE
COMPARTMENT
HEADLIGHT
RELAY (HIGH)
ETACS-ECU
Connector: A-17X TECHNICAL DESCRIPTION (COMMENT)

If both headlights (high-beam) do not illuminate nor-
mally, the headlight switch input circuit, headlight
relay (HIGH), or ETACS-ECU may have a problem.
.
Malfunction of column switch
Malfunction of headlight relay (HIGH)
AC609409AD
Damaged harness wires and connectors
Connector: C-312
Junction block
AC608152 AP
TSB Revision
HEADLIGHT
DIAGNOSIS

trouble code.
CAUTION
Q: Is the DTC set?
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Check headlight relay (HIGH) connector A-17X for

Q: Is headlight relay (HIGH) connector A-17X in good
condition?
YES : Go to Step 3.
STEP 3. Check of headlight relay (HIGH)

Refer toP.54A-152.
Q: Is the headlight relay (HIGH) in good condition?
YES : Go to Step 4.
NO : Replace the headlight relay (HIGH). Verify that the
high-beam headlights illuminate normally.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-117

headlight relay (HIGH). Measure the voltage at headlight
relay (HIGH) connector A-17X
CAUTION
The top and bottom of the headlight relay (HIGH) are diffi-
cult to identify. Prior to inspection, confirm the triangle
mark on the relay box.
(1) Disconnect headlight relay (HIGH) connector A-17X and
measure the voltage available at the relay box side of the
connector.
(2) Measure the voltage between terminal 2 or 4 and ground.
positive voltage)?
YES : Go to Step 5.
NO : Go to Step 7.

in the connector.
YES : Go to Step 6.

(HIGH) connector A-17X (terminal 1) and ETACS-ECU
Q: Is the wiring harness between headlight relay (HIGH)
connector A-17X (terminal 1) and ETACS-ECU
YES : Go to Step 8.
the high-beam headlights illuminate normally.
TSB Revision
HEADLIGHT

(HIGH) connector A-17X (terminal 4) and the fusible link
(36).
Q: Is the wiring harness between headlight relay (HIGH)
connector A-17X (terminal 4) and fusible link (36) in
good condition?
YES : Go to Step 8.
the high-beam headlights illuminate normally.
STEP 8. Check the column switch (switch body).

Refer to Column switch, Inspection P.54A-231.
Q: Is the column switch (switch body) in good condition?
YES : Go to Step 9.
NO : Replace the column switch. Verify that the high-beam
headlights illuminate normally.

Q: Does the headlights (high-beam) do not illuminate in
good condition?
Inspection Procedure 3: The headlights do not illuminate when the lighting switch is at the
"PASSING" position, but the low-beam illuminates (high-beam and low-beam cannot be changed)
with the switch at the "HEAD" position.
CAUTION
Whenever the ECU is replaced, ensure that the power sup-
ply circuit, the ground circuit and the communication cir-
cuit are normal.
.

If the headlights illuminate only at low-beam regardless of the
lighting switch position, the headlight fail-safe function may be
active.
.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-119
DIAGNOSIS

trouble code.
CAUTION
Q: Is the DTC set?
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

Q: Do the headlights illuminate normally?
TSB Revision
HEADLIGHT
Inspection Procedure 4: Headlights do not illuminate when the passing switch is operated.
CAUTION
Whenever the ECU is replaced, ensure that the power sup-
ply circuit, the ground circuit and the communication cir-
cuit are normal.
.

If both headlights (low-beam and high-beam) do not illuminate,
the passing switch input circuit or ETACS-ECU may have a
problem.
.
DIAGNOSIS
STEP 1. Check that the headlights operate.

Check that the low-beam and high-beam headlights illuminate
normally.
YES : Go to Step 2.
NO : Refer to Inspection Procedure 1 "Headlights
(low-beam) do not illuminate." P.54A-111 and
Inspection Procedure 2 "Headlights (high-beam) do
not illuminate." P.54A-115.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-121

CAUTION
Q: Is the DTC set?
NO : Go to Step 3.
MB991910
MB991824
MB991827 AC608435 AB

Q: Do the headlights (low-beam and high-beam) illuminate
normally when turning ON the passing switch?
TSB Revision
HEADLIGHT
Inspection Procedure 5: The headlight(s) do not illuminate.
Headlights Circuit
RELAY
BOX HEADLIGHT HEADLIGHT
RELAY (HIGH) RELAY (LOW)
HEADLIGHT HEADLIGHT
ASSEMBLY ASSEMBLY
(LH) (RH)
Connectors: A-17X, A-25X Connector: A-31
A-31 (B)
A-25X
A-17X
AC609409AE AC608142AG
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-123
.
Connector: A-47 TROUBLESHOOTING HINTS

Malfunction of the headlight bulbs
Malfunction of the headlight assembly
A-47 (B)
AC608141AJ
.

If any of the headlights do not illuminate, the wiring
harness, connector(s), or the bulb may have a prob-
lem, or the fuse may be burned out.
DIAGNOSIS
STEP 1. Check headlight assembly connector A-31 <LH>

or A-47 <RH>, for loose, corroded or damaged terminals,
or terminals pushed back in the connector.
Q: Is headlight assembly connector A-31 <LH> or A-47
<RH> in good condition?
YES : Go to Step 2.
P.00E-2.
STEP 2. Check bulb.

Check the bulb(s) of headlight that does not illuminate.
NOTE: If discharge-type lower beam headlights do not illumi-
nate, their bulbs cannot be inspected. In this case, assume the
bulbs to be normal and proceed with steps.
Q: Is the bulb in good condition?
YES : Go to Step 3.
illuminate.
TSB Revision
HEADLIGHT

assembly connector and headlight relay connector.
Check the wiring harness between headlight assembly (LH)
connector A-31 (terminal 2) and headlight relay (LOW) con-
nector A-25X (terminal 3). <LH-LOW>
connector A-31 (terminal 1) and headlight relay (HIGH) con-
nector A-17X (terminal 3). <LH-HIGH>
connector A-31 (terminal 6) and ground. <LH-LOW and
HIGH>
Check the wiring harness between headlight assembly (RH)
connector A-47 (terminal 2) and headlight relay (LOW) con-
nector A-25X (terminal 3). <RH-LOW>
connector A-47 (terminal 1) and headlight relay (HIGH) con-
nector A-17X (terminal 3). <RH-HIGH>
connector A-47 (terminal 6) and ground. <RH-LOW and
HIGH>
Q: Is the wiring harness between headlight assembly
connector and headlight relay connector in good
condition?
YES : Replace the headlight assembly that does not
illuminate.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-125
Inspection Procedure 6: High-beam indicator light does not illuminate normally.
CAUTION
High-Beam Indicator Light Circuit
CAN COMMUNICATION LINE COMBINATION

(CAN_H LINE) METER
ETACS-ECU CAN COMMUNICATION LINE
(CAN_L LINE)
INPUT SIGNAL
DIMMER SWITCH

If the high-beam indicator does not illuminate normally, the har-
ness in the CAN bus lines, connector(s), ETACS-ECU, or com-
bination meter may have a problem.
.
Malfunction of combination meter
DIAGNOSIS
STEP 1. Check of headlight (high-beam).

Check that the headlights (high-beam) illuminate/extinguish
normally when the lighting switch is operated.
YES : Go to Step 2.
(high-beam) do not illuminate P.54A-115."
TSB Revision
HEADLIGHT

line.
CAUTION
position.
MB991910 Q: Is the CAN bus line found to be normal?
MB991824
YES : Go to Step 3.
NO : Repair the CAN bus line. (Refer to GROUP 54C,
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 4.

(2) Perform the actuator test for the combination meter, and
check that the high-beam indicator light illuminates (Refer
to combination meter P.54A-74).
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-127
Inspection Procedure 7: The headlight automatic shutdown function does not work normally.
CAUTION TECHNICAL DESCRIPTION (COMMENT)

Whenever the ECU is replaced, ensure that the If the headlight automatic shutdown function does
power supply circuit, the ground circuit and the not work normally, the above described input circuits
communication circuit are normal. or ETACS-ECU may have a problem. Also, it may be
.
possible that the headlight automatic shutdown func-
OPERATION tion is set to "Disable" through configuration function.
The ETACS-ECU operates this function in accor-
dance with the input signals from column switch
.
(lighting switch), ignition switch (IG1), and front door
Malfunction of front door switch (LH)
switch (LH).
.
DIAGNOSIS
TSB Revision
HEADLIGHT
STEP 1. Using scan tool MB991958, Check the

configuration function.
Use the ETACS-ECU configuration function to check that the
"Head light auto cut customize" is set to "A-spec." or "D-spec."
CAUTION
scan tool (M.U.T.-III) P.54A-94."
(3) Use the ETACS-ECU configuration function to check that
the "Headlight auto cut customize" is set to "A-spec." or
"D-spec".
YES : Go to Step 2.
MB991910 NO : Use the ETACS-ECU configuration function to set the
MB991824
"Headlight auto cut customize" to "A-spec." or
"D-spec." (Refer to P.54A-561).
MB991827 AC608435 AB

trouble code.
Q: Is the DTC set?
YES : Diagnose the ETACS-ECU (Refer to ETACS,
NO : Go to Step 3.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-129

Use the ETACS-ECU service data to check the signals related
to the operation of headlight automatic shutdown function.
Turn the ignition switch to the LOCK (OFF) position.
Illuminate the headlights.
condition
Item 206 Head light LO ON 100%
duty
Item 254 IG voltage Battery
voltage
Open the driver's door.

condition
Q: Does scan tool MB991958 display the items "Head light

LO ON duty", "IG voltage" and "Dr door ajar switch" as
normal condition?
YES : Go to Step 4.
NO : Troubleshoot the ETACS-ECU. Refer to ETACS,

Check that the headlight automatic shutdown function works
normally.
TSB Revision
HEADLIGHT
Inspection Procedure 8: Daytime running light function does not work normally.
CAUTION
Whenever the ECU is replaced, ensure that the
input and output signal circuits are normal.
Daytime Running Light Circuit
FUSIBLE
LINK 36
RELAY BOX
ENGINE
COMPARTMENT
HEADLIGHT
RELAY (LOW)
FEELD EFFECT
TRANSISTOR
ETACS-ECU
HEADLIGHT HEADLIGHT
ASSEMBLY ASSEMBLY
(LH) (RH)
. .

If the daytime running light function does not work, Trouble in input signal system
connector(s), wiring harness in the CAN bus lines, Malfunction of the ETACS-ECU
the engine control module, the combination meter, Damaged harness wires and connectors
the ETACS-ECU or the input signal circuit may be
defective.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-131
DIAGNOSIS
MB991824: V.C.I.
STEP 1. Verify the headlight (low-beam) operation.

Check to see that the headlight (low-beam) lights up properly
when operating the dimmer switch while the headlight switch is
ON.
Q: Do the headlights (low-beam) illuminate normally?
YES : Go to Step 2.
(low-beam) do not illuminate normally P.54A-111."

line.
CAUTION
YES : Go to Step 3.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
HEADLIGHT

Check whether ETACS-ECU DTCs are set.
(2) Check for ETACS-ECU DTCs.
Q: Is the DTC set?
NO : Go to Step 4.
STEP 4. Using scan tool MB991958, read the MFI system

Check whether engine control module DTCs are set or not.
(2) Check for engine control module DTCs.
Q: Is the DTC set?
YES : Diagnose the MFI system. Refer to GROUP 13A,
Diagnosis P.13A-46.
NO : Go to Step 5.
STEP 5. Check the parking brake switch.

Check the input signals from the parking brake switch.
(2) Check that the brake warning light on the combination
meter goes off when the parking brake lever is released.
Q: Does the brake warning light go off?
YES : Replace the ETACS-ECU. Verify that the daytime
running light function does not work normally.
NO : Refer to GROUP 36, Diagnosis, Inspection Procedure
3 P.36-7. Verify that the daytime running light function
does not work normally.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-133
Inspection Procedure 9: Any of position light, side marker lights or the license plate light do not
illuminate.
Position Lights, License Plate Lights and Rear Side Marker Lights Circuit
TAILLIGHT CONTROL CIRCUIT ETACS-

ECU
JOINT
CONNECTOR
REAR LICENCE HEADLIGHT HEADLIGHT

COMBINATION PLATE ASSEMBLY ASSEMBLY
LIGHT LIGHT (LH) (RH)
(LH) (RH) (LH) (RH)
REAR SIDE
MARKER LIGHT
(LH) (RH)
TSB Revision
HEADLIGHT
Connector: A-31 Connector: D-14
A-31 (B)
D-14 (BR)
AC608142AG AC608166AH
Connector: A-47 Connectors: F-07, F-11, F-13, F-15, F-18, F-23
F-07
A-47 (B)
F-23 F-11 (GR)
F-18
F-13 (GR)
AC608141AJ F-15 (B) AC608171AM

.
Connector: C-38 TECHNICAL DESCRIPTION (COMMENT)

If any position light, side marker light or license plate
light do not illuminate normally, the harness, connec-
tor(s), or bulb(s) may have a problem, or the fuse
may be burned out.
.
Malfunction of bulbs
AC608145BT Malfunction of rear combination light
Malfunction of rear combination light harness
Connectors: C-304, C-311 Malfunction of license plate light
Junction block Malfunction of headlight
C-304 Malfunction of rear side maker light
C-311 AC608152 AR
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-135
STEP 1. Rear combination light (taillight) check.

Q: Does the rear combination light (taillight) illuminate
normally?
YES : Go to Step 2.
NO : Refer to P.54A-165.
STEP 2. Check headlight assembly connector A-31

(position light-LH) or A-47 (position light-RH), rear side
marker light connector F-18 (LH) or F-07 (RH) or license
plate light connector F-13 (LH) or F-11 (RH) for loose,
in the connector.
Q: Is headlight assembly connector A-31 (position
light-LH) or A-47 (position light-RH), rear side marker
light connector F-18 (LH) or F-07 (RH) or license plate
light connector F-13 (LH) or F-11 (RH) in good
condition?
YES : Go to Step 3.
P.00E-2.
STEP 3. Bulb check.

Check the bulb(s) of the light that does not illuminate.
YES : Go to Step 4.
illuminate.
TSB Revision
HEADLIGHT

connector A-31 (position light-LH) or A-47 (position
light-RH), rear side marker light connector F-18 (LH) or
F-07 (RH) or license plate light connector F-13 (LH) or F-11
(RH) .
harness side.
(2) Measure the resistance between the connector of light
which does not illuminate and the body ground.
Measure the resistance between headlight assembly
connector A-31 (LH) or A-47 (RH) (terminal 6) and body
ground.
Measure the resistance between rear side marker light
connector F-18 (LH) or F-07 (RH) (terminal 1) and body
ground.
Measure the resistance between license plate light con-
nector F-13 (LH) or F-11 (RH) (terminal 1) and body
ground.
OK: The measured value should be continuity
exists (2 or less).
this range?
YES : Go to Step 6.
NO : Go to Step 5.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-137

assembly connector, rear side marker light connector or
license plate light connector and the body ground.
Check the ground line for open circuit.
connector A-31 (terminal 6) and the body ground. <position
light-LH>
connector A-47 (terminal 6) and the body ground. <position
light-RH>
Check the wiring harness between rear side marker light
(LH) connector F-18 (terminal 1) and the body ground.
<rear side marker light-LH>
NOTE: Also check intermediate connector F-23 for loose,
corroded, or damaged terminals, or terminals pushed back
in the connector. If intermediate connector F-23 is dam-
aged, repair or replace the connector as described in
GROUP 00E, Harness Connector Inspection P.00E-2.
(RH) connector F-07 (terminal 1) and the body ground.
<rear side marker light-RH>
Check the wiring harness between license plate light (LH)
connector F-13 (terminal 1) and the body ground. <license
plate light-LH>
Check the wiring harness between license plate light (RH)
connector F-11 (terminal 1) and the body ground. <license
plate light-RH>
connector, rear side marker light connector or license
plate light connector and the body ground in good
condition?
YES : Go to Step 8.
TSB Revision
HEADLIGHT
STEP 6. Check ETACS-ECU connector C-304 <position

light> or C-311 <rear side marker light or license plate
light> for loose, corroded or damaged terminals, or
Q: Is ETACS-ECU connector C-304 <position light> or
C-311 <rear side marker light or license plate light> in
good condition?
YES : Go to Step 7.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-139
STEP 7. Check wiring harness between headlight

assembly connector, rear side marker light connector or
license plate light connector and ETACS-ECU connector.
Check the ground line for open circuit.
C-304 (terminal 3). <position light-LH>
C-304 (terminal 7). <position light-RH>
(LH) connector F-18 (terminal 2) and ETACS-ECU connec-
tor C-311 (terminal 10). <rear side marker light-LH>
NOTE: Also check intermediate connectors D-14 and F-23
for loose, corroded, or damaged terminals, or terminals
pushed back in the connector. If intermediate connector
D-14 or F-23 is damaged, repair or replace the connector
as described in GROUP 00E, Harness Connector Inspec-
tion P.00E-2.
(RH) connector F-07 (terminal 2) and ETACS-ECU connec-
tor C-311 (terminal 13). <rear side marker light-RH>
and joint connector C-38 for loose, corroded, or damaged
terminals, or terminals pushed back in the connector. If
intermediate connector D-14 or F-23 or joint connector C-38
is damaged, repair or replace the connector as described in
Check the wiring harness between license plate light (LH)
connector F-13 (terminal 2) and ETACS-ECU connector
C-311 (terminal 10). <license plate light-LH>
tion P.00E-2.
Check the wiring harness between license plate light (RH)
connector F-11 (terminal 2) and ETACS-ECU connector
C-311 (terminal 13). <license plate light-RH>
tion P.00E-2.
connector, rear side marker light connector or license
plate light connector and ETACS-ECU connector in
good condition?
YES : Go to Step 8.
TSB Revision
HEADLIGHT

Check that the position light, rear side marker light, or license
plate light illuminate normally.
Q: Do the position light, rear side marker light, or license
plate light work normally?
YES (The light illuminate normally at both high and low
beams.) : The trouble can be an intermittent malfunction
(Refer to GROUP 00 How to use
NO <When the position light does not illuminate> :
Replace the position light socket.
NO <When the license plate light does not illuminate> :
Replace the license plate light socket.
NO <When the rear side marker lights do not illuminate>
: Replace the rear side maker light socket.
Inspection Procedure 10: The turn-signal lights do not illuminate.
.

If all the turn-signal lights do not illuminate, the igni- Malfunction of column switch
tion switch (IG1), the turn-signal light switch input cir- Malfunction of the ETACS-ECU
cuit or the ETACS-ECU may have a problem. The wiring harness or connectors may have
.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-141

CAUTION
Q: Is the DTC set?
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

Using the ETACS-ECU service data, check the signals related
to the illumination of turn-signal light.
conditions
Item 254 IG voltage Battery voltage
Q: Does scan tool MB991958 display the item "IG voltage"

as normal condition?
YES : Go to Step 3.
Diagnosis - Inspection Procedure 2 "ETACS-ECU
does not receive any signal from the ignition switch
(IG1)" P.54A-528.
TSB Revision
HEADLIGHT

Check that turn-signal lights illuminate.
Q: Do turn-signal lights work normal?
Inspection Procedure 11: The comfort flashing function does not work normally.
.

If the comfort flashing function does not work nor- Malfunction of column switch
mally, the turn-signal light switch input circuit(s) and Malfunction of the ETACS-ECU
ETACS-ECU may have a problem. The wiring harness or connectors may have
.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-143

CAUTION
the "Comfort flasher" is set to "Enable".
Q: Is the "Comfort flasher" set to "Enable"?
YES : Go to Step 2.
NO : Use the ETACS-ECU customize function to set the
MB991910 "Comfort flasher" to "Enable" (Refer to P.54A-561).
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.
STEP 3. Check that the turn-signal light operate.

Check that the turn-signal light work normally when the ignition
switch is in the "ON" position.
Q: Do turn-signal lights work normally?
YES : Go to Step 4.
NO : Refer to Inspection Procedure 10 "The turn-signal
lights do not illuminate" P.54A-140.
TSB Revision
HEADLIGHT

Check that the comfort flashing function works normally.
Q: Does comfort flashing function works normally?
Inspection Procedure 12: The turn-signal indicator light do not illuminate.

.

Whenever the ECU is replaced, ensure that the Malfunction of the ETACS-ECU
power supply circuit, the ground circuit and the Malfunction of combination meter
communication circuit are normal. The wiring harness or connectors may have
.

If the turn-signal light indicator does not illuminate
normally, the harness in the CAN bus lines, connec-
tor(s), ETACS-ECU, or combination meter may have
a problem.
DIAGNOSIS
STEP 1. Check turn-signal light.

Check that the turn-signal light flashes normally when the
turn-signal switch is operated.
Q: Do Turn-signal light work normally?
YES : Go to Step 2.
NO : Refer to Inspection Procedure 10 "The turn-signal
lights do not illuminate" P.54A-140.
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-145

line.
CAUTION
YES : Go to Step 3.
MB991910
MB991824
MB991827 AC608435 AB

trouble code.
Check if diagnostic trouble code is set to the ETACS-ECU.
Q: Is the DTC set?
NO : Go to Step 4.

(1) Connect scan tool MB991958 to the data link connector.
(3) Set scan tool MB991958 to the actuator test mode.
Item 7: Indicator1
TSB Revision
HEADLIGHT
ON-VEHICLE SERVICE
HEADLIGHT AIMING
M1540100500155
PRE-AIMING INSTRUCTIONS (LOW-BEAM)

.
1. Inspect for rusted or faulty headlight assemblies.

2. These conditions must be corrected before a satisfactory
adjustment can be made.
3. Inspect tire inflation, and adjust if necessary.
4. If the fuel tank is not full, place a weight in the trunk of the
vehicle to simulate weight of a full tank [3 kg (6.6 pounds)
per gallon].
5. There should be no other load in the vehicle other than
driver or substituted weight of approximately 68 kg (150
pounds) placed in driver's position.
6. Thoroughly clean headlight lenses.
7. Place the vehicle on a level floor, perpendicular to a flat
screen 7.62 m (25.0 ft) away from the bulb center-marks on
the headlight lens.
8. Rock vehicle sideways to allow vehicle to assume its normal
position.
9. Bounce the front suspension through three (3) oscillations
by applying the body weight to hood or bumper.
(1)
10.Set the distance between the screen and the bulb center
Screen Headlight center marks of the headlight as shown in the illustration.
(2)
(3) 11.Four lines of adhesive tape (or equivalent markings) are
Vehicle center line required on screen or wall:
(3)
(1) Position a vertical tape or mark so that it is aligned with
the vehicle center line.
(2) Measure the distance from the center-marks on the
7.62 m (25.0 ft)
headlight lens to the floor [ reference value: 679.5 mm
(26.75 inches)]. Transfer the measurement to the screen.
Horizontal tape or mark on the screen is for reference of
vertical adjustment.
(3) Measure the distance from the center line of the vehicle
to the center of each headlight. Transfer the
measurement to the screen. Vertical tape or mark on the
screen with reference to the center line of each headlight
Headlight bulb.
center
AC611389AB
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-147
HEADLIGHT ADJUSTMENT (LOW-BEAM)
NOTE: When adjusting headlight, disconnect the other
headlight harness.
1. The low-beam headlight will project on the screen upper
edge of the beam (cut-off).
2. Turn the adjusting screw to achieve the specified low-beam
Phillips screwdriver
(Vertical direction cut-off location on the aiming screen.
adjustment)
Adjusting screw
(Vertical direction adjustment)
AC609988AB
(V) Standard value:

266.1 (10.5)
(Vertical direction) Horizontal line (H) 50.5 mm ( 2.0
inches) ( 0.38 degrees angle)
Hot zone Cutoff
line
(Horizontal direction): 126.4 mm ( 5.0 inches) (
0.95 degrees angle) from the axis, which is 266.1
(H) 50.5 (2.0) mm (10.5 inches) (2 degrees angle) rightward from
50.5 (2.0) the vertical line (V)
CAUTION
Do not cover a headlight for more than three minutes to
mm (in) 126.4 (5.0) 126.4 (5.0) AC407437 AC prevent the plastic headlight lens deformation.
NOTE: High-beam pattern should be correct when the
low-beams are adjusted properly.
TSB Revision
HEADLIGHT
LUMINOUS INTENSITY MEASUREMENT

M1540100600129
1. Set the headlights to high-beam.
2. Using a photometer, and following its manufacturer's
instruction manual, measure the headlight center intensity
and check to be sure that the limit value is satisfied.
Limit: 40,000 cd or more {When a screen is set 18.3m
(60 feet) ahead of the vehicle}
NOTE: When measuring the intensity, maintain an engine
speed of 2,000 r/min, with the battery fully charged.
There may be special local regulations pertaining to headlight
intensity. Be sure to make any adjustments necessary to satisfy
such regulations.
If an illuminometer is used to make the measurements, convert
its values to photometer values by using the following formula.
I =E r2
I = intensity (cd)
E = illumination (lux)
r = distance (m) from headlights to illuminometer
REPLACE THE BULB

M1540100700159
HEADLIGHT BULB (LOW-BEAM) REPLACEMENT

CAUTION
Do not touch the bulb surface with bare hands or dirty
gloves. If the bulb surface (glass part) gets dirty, immedi-
ately clean it with alcohol or thinner. After drying com-
pletely, install the bulb.
Disconnect the connector, and twist the headlight bulb
(low-beam) to remove.
Headlight bulb (Low-beam)
AC609613AB
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-149
HEADLIGHT BULB (HIGH-BEAM) REPLACEMENT
CAUTION
Do not touch the bulb surface with bare hands or dirty
gloves. If the bulb surface (glass part) gets dirty, immedi-
ately clean it with alcohol or thinner. After drying com-
pletely, install the bulb.
1. Twist the socket cover to remove.
2. Disconnect the connector, and twist the headlight bulb
(high-beam) to remove.
Socket cover (High-beam)

AC609613AC
POSITION LIGHT BULB REPLACEMENT

Disconnect the connector, and twist the position light socket to
remove it.
Position light
AC609613AD
FRONT TURN-SIGNAL LIGHT BULB

REPLACEMENT
Disconnect the connector, and twist the front turn-signal light
socket to remove it.
Front turn-signal light
AC609613AE
HEADLIGHT AUTOMATIC-SHUTDOWN
FUNCTION CHECK
M1540100800101
Confirm that the headlights turn OFF in one second if the
driver's door is opened when the ignition switch is OFF and the
lighting switch is ON (HEAD position). If there is a malfunction,
perform the troubleshooting (Refer to P.54A-150).
TSB Revision
HEADLIGHT
M1540103700158
Use scan tool MB991958 to adjust the following func-
tions. The programmed information is held even
when the battery is disconnected.
item (scan tool (scan tool display)
display)
ACC power Time to ACC power Disable No function (default)
auto cut cut-off when the 30 min 30 minutes
ignition switch is in
the ACC position 60 min 60 minutes
Turn power Adjustment of ACC or IG1 Operable with ACC or ON position

source turn-signal light IG1 Operable with ON position (default)
operation condition
Comfort flasher With/without Disable No function
comfort flasher Enable With function (default)
function
Comfort flasher Switch operation Normal 0.4 seconds (default)
switch time time to activate the Long 0.8 seconds
comfort flasher
function
answer back
Headlight auto Adjustment of Disable No function
cut customize headlight automatic Enable (C-spec.) With function (default)
shutdown function
TSB Revision
CHASSIS ELECTRICAL
HEADLIGHT
54A-151
M1540101000153
4.5 1.5 Nm
40 13 in-lb 3 1.5 0.3 Nm
4 14 2 in-lb
2
4.5 1.5 Nm
40 13 in-lb
5
A
1 6
4.5 1.5 Nm
40 13 in-lb
Section A - A
1 Grommet
AC610215AB

Front bumper assembly (Refer to 3. Headlight bulb (high-beam)
GROUP 51 Front Bumper 4. Front turn-signal light bulb
Assembly P.51-3). 5. Position light bulb
1. Headlight assembly 6. Grommet
2. Headlight bulb (low-beam)
TSB Revision
HEADLIGHT
INSPECTION
HEADLIGHT RELAY CHECK

M1540104000141
HEADLIGHT RELAY (LOW) CHECK
Battery voltage Terminal Normal

number conditions
Not energized 3 4 No
continuity
With current supply Continuity
[terminal 4 (+), terminal 1 exists (2
()] ohms or
Headlight relay (low) less)
4 3
Field effect
transistor
2 1
AC610040AB
HEADLIGHT RELAY (HIGH) CHECK

number conditions
continuity
()] ohms or
Headlight relay (high) less)
4
3
2 1
AC609148AD
TSB Revision
CHASSIS ELECTRICAL
REAR COMBINATION LIGHT
54A-153
GENERAL INFORMATION
M1542000100327
Taillight
Taillight assembly
Back-up light
Rear side-marker
light
Rear
Rear turn-signal combination light
light assembly
Stop/taillight
AC608727 AC
The rear combination light assembly are inte- The taillight assembly are integrated with the tail-
grated with the stop/taillight, rear turn-signal light light and back-up light.
and rear side-marker light.
TSB Revision
SPECIAL TOOLS
M1541400100087

name
MB990784 General service Removal of trunk lid trim, rear
Ornament remover tool combination light assembly, taillight
assembly
MB990784

a
f. MB991825
ENTER key. check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g
measurement
adapter
harness
MB991826
MB991958
TSB Revision
CHASSIS ELECTRICAL
54A-155
name
a
b
Harness set b. For checking power supply circuit
a. Check harness c. For checking power supply circuit
b. LED harness d. For connecting a locally sourced
c. LED harness tester
c adapter
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
DIAGNOSIS
M1541402500081
tents P.00-6.
DIAGNOSTIC FUNCTION
M1541400900038

.

.
TSB Revision
CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
.

.
CAUTION
display.
button.
TSB Revision
CHASSIS ELECTRICAL
54A-157
M1541400200028
CAUTION
On troubleshooting, if the ignition switch is
turned ON while disconnecting connector(s),
diagnostic trouble code(s) associated with other
system may be set. On completion, confirm all
systems for diagnostic trouble code(s). If diag-
nostic trouble code(s) are set, erase them all.
B16A0 Taillight (RH) circuit open P.54A-158
B16A7 Taillight (RH) circuit short
B16A1 Taillight (LH) circuit open P.54A-162
B16A8 Taillight (LH) circuit short
TSB Revision
DTC B16A0: Taillight (RH) circuit open

DTC B16A7: Taillight (RH) circuit short
Taillight (RH) Circuit
ETACS-ECU
TAILLIGHT
CONTROL CIRCUIT
JOINT CONNECTOR
REAR
COMBINATION
LIGHT (RH)

Junction block
AC608145BT AC608152 AK
TSB Revision
CHASSIS ELECTRICAL
54A-159
Connector: D-11 TROUBLE JUDGEMENT
When an open circuit is detected in the taillight cir-
cuit, the ETACS-ECU sets DTC B16A0. If a short cir-
cuit is detected, DTC B16A7 is set.
.

The problem detection of taillight is made based on
the digital feed back signal (input signal to
ETACS-ECU) which operates the taillight. When the
AC608166AM ignition switch is "ON", the ETACS-ECU determines
the taillight circuit state from the load placed on the
Connector: F-06
line. After 100 ms has elapsed since the start of the
check, the ETACS-ECU performs a sampling with
each 10 ms. If an abnormality is detected, it
increases the counter by 2, and when no abnormality
is detected, it decreases the counter by 1. Once the
counter reaches "10", the ETACS-ECU sets the DTC
B16A0 if the load is detected on the line, and sets the
DTC B16A7 if no load is detected.
AC608171AN .
.
DIAGNOSIS
STEP 1. Check rear combination light (RH) connector F-06

Q: Is combination light (RH) connector F-06 in good
condition?
YES : Go to Step 2.
P.00E-2.
TSB Revision
STEP 2. Resistance measurement at rear combination light

(RH) connector F-06.
harness side.
(2) Measure the resistance between rear combination light
(RH) connector F-06 (terminal 1) and the body ground.
Harness side: F-06 OK: The measured value should be continuity
exists (2 ohms or less).
this range?
YES : Go to Step 4.
NO : Go to Step 3.
AC608255 AW
STEP 3. Check the wiring harness between rear

combination light (RH) connector F-06 (terminal 1) and
ground.
Q: Is the wiring harness between rear combination light
(RH) connector F-06 (terminal 1) and ground in good
condition?
YES : Go to Step 6.
STEP 4. Check ETACS-ECU connectors C-311 for loose,

in the connector.
Q: Is ETACS-ECU connectors C-311 in good condition?
YES : Go to Step 5.
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
54A-161

combination light (RH) F-06 connector (terminal 3) and
ETACS-ECU connector C-311 (terminal 13).
nector D-11 for loose, corroded, or damaged terminals, or ter-
minals pushed back in the connector. If joint connector C-38 or
intermediate connector D-11 is damaged, repair or replace the
Inspection P.00E-2.
(RH) F-06 connector (terminal 3) and ETACS-ECU
connector C-311 (terminal No. 13) in good condition?
YES : Go to Step 6.

CAUTION
(3) Erase the DTC.
position.
Q: Is the DTC set?
MB991824
MB991827 AC608435 AB
TSB Revision
DTC B16A1: Taillight (LH) circuit open

DTC B16A8: Taillight (LH) circuit short
Taillight (LH) Circuit
ETACS-ECU
TAILLIGHT
CONTROL CIRCUIT
REAR
COMBINATION
LIGHT (LH)
Connector: C-311 Connector: F-20

Junction block
AC608152 AK AC608171AO
.

When an open circuit is detected in the taillight cir-
cuit, the ETACS-ECU sets DTC B16A1. If a short cir-
cuit is detected, DTC B16A8 is set.
.

The problem detection of taillight is made based on
D-14 (BR)
the digital feed back signal (input signal to
AC608166AH ETACS-ECU) which operates the taillight. When the
ignition switch is "ON", the ETACS-ECU determines
the taillight circuit state from the load placed on the
line. After 100 ms has elapsed since the start of the
check, the ETACS-ECU performs a sampling with
each 10 ms. If an abnormality is detected, it
TSB Revision
CHASSIS ELECTRICAL
54A-163
increases the counter by 2, and when no abnormality
.
is detected, it decreases the counter by 1. Once the

counter reaches "10", the ETACS-ECU sets the DTC The wiring harness or connectors may have
B16A1 if the load is detected on the line, and sets the loose, corroded, or damaged terminals, or termi-
DTC B16A8 if no load is detected. nals pushed back in the connector
DIAGNOSIS
STEP 1. Check rear combination light (LH) connector F-20

Q: Is combination light (RH) connector F-20 in good
condition?
YES : Go to Step 2.
P.00E-2.

(LH) connector F-20.
harness side.
(2) Measure the resistance between the rear combination light
(LH) connector F-20 (terminal 1) and the body ground.
this range?
YES : Go to Step 4.
NO : Go to Step 3.
AC608255 AT
TSB Revision

combination light (LH) connector F-20 (terminal 1) and
ground.
(LH) connector F-20 (terminal 1) and ground in good
condition?
YES : Go to Step 6.

in the connector.
YES : Go to Step 5.
P.00E-2.

combination light (LH) F-20 connector (terminal 3) and
(LH) F-20 connector (terminal 3) and ETACS-ECU
YES : Go to Step 6.
TSB Revision
CHASSIS ELECTRICAL
54A-165

CAUTION
(3) Erase the DTC.
position.
Q: Is the DTC set?
MB991824
MB991827 AC608435 AB

M1541401000072
Inspection Trouble symptom Reference page

Procedure No.
1 The taillights do not illuminate. P.54A-165
2 Any of the taillights does not illuminate. P.54A-168
SYMPTOM PROCEDURES
Inspection Procedure 1: The Taillights do not Illuminate.

.

Before replacing the ECU, ensure that the power Malfunction of column switch
supply circuit, the ground circuit and the com- Malfunction of the ETACS-ECU
munication circuit are normal. The wiring harness or connectors may have
.

If all the taillights do not illuminate normally, the tail-
light switch input circuit or ETACS-ECU may have a
problem.
TSB Revision
DIAGNOSIS
STEP 1. License plate light operation check

Check that the license plate light illuminates normally.
Q: Does license plate light work normally?
YES : Go to Step 2.

trouble code.
CAUTION
Q: Is the DTC set?
NO : Go to Step 3.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
54A-167

the taillight illumination.
Turn the ignition switch to the "ACC" position.
Turn the taillight switch to the "ON" position.
conditions
Item 218 Taillight ON
Q: Does scan tool MB991958 display the items "Taillight"

as normal condition?
YES : Go to Step 4.
NO : Troubleshoot the ETACS-ECU (Refer to P.54A-528).

Check that the taillight illuminates normally.
Q: Does the taillight work normally?
TSB Revision
Inspection Procedure 2: Any of the Taillights does not Illuminate.
Taillight Circuit
ETACS-ECU
TAILLIGHT CONTROL CIRCUIT
JOINT
CONNECTOR
REAR
COMBINATION
LIGHT
(LH) (RH)

Junction block
AC608145BT AC608152 AK
TSB Revision
CHASSIS ELECTRICAL
54A-169
.
Connector: D-11 TECHNICAL DESCRIPTION (COMMENT)

If any of the taillights do not illuminate, the wiring har-
ness, connector(s), or rear combination light unit
may have a problem, or the fuse may be burned out.
.
Malfunction of rear combination light unit
AC608166AM
Connectors: F-06, F-20
F-06
F-20
AC608171AP
DIAGNOSIS
STEP 1. Check rear combination light connector F-20 (LH)

or F-06 (RH) for loose, corroded or damaged terminals, or
Q: Is rear combination light connector F-20 (RH) or F-06
(LH) in good condition?
YES : Go to Step 2.
P.00E-2.
TSB Revision

connector F-20 (LH) or F-06 (RH).
harness side.
(2) Measure the resistance between the connector of light
which does not illuminate and body ground.
(LH) connector F-20 (terminal 1) and body ground.
Harness side: F-20
AC608255 AT

(RH) connector F-06 ( terminal 1) and body ground.
this range?
YES : Go to Step 4.
NO : Go to Step 3.
AC608255 AW

combination light connectors F-20 (LH) or F-06 (RH)
(terminal 1) and ground.
connectors F-20 (LH) or F-06 (RH) (terminal 1) and
ground in good condition?
YES : Go to Step 6.

in the connector.
YES : Go to Step 5.
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
54A-171

combination light connector and ETACS-ECU connector.
Check the wiring harness between rear combination light
(LH) connector F-20 (terminal 3) and ETACS-ECU connec-
tor C-311 (terminal 10). <LH>
Check the wiring harness between rear combination light
(RH) connector F-06 (terminal 3) and ETACS-ECU connec-
tor C-311 (terminal 13). <RH>
NOTE: Also check joint connector C-38 and intermediate
connector D-11 for loose, corroded, or damaged terminals,
or terminals pushed back in the connector. If joint connector
C-38 or intermediate connector D-11 is damaged, repair or
replace the connector as described in GROUP 00E, Har-
ness Connector Inspection P.00E-2.
connector and ETACS-ECU connector in good
condition?
YES : Go to Step 6.

Check that the taillight illuminates normally.
NO : Replace the rear combination light unit.
TSB Revision
REAR COMBINATION LIGHT REMOVAL AND INSTALLATION

M1541402200154
Section A - A
Grommet
2 7
1.2 0.7 Nm
11 6 in-lb
Section B - B
Grommet A
A
B
B
6 5 4 3
2
2 1
AC610314AB

1. Rear combination light assembly 5. Rear side-marker light bulb
2. Rear combination light unit 6. Socket
3. Stop/taillight bulb 7. Grommet
4. Rear turn-signal light bulb
TAILLIGHT REMOVAL AND INSTALLATION

M1541402600022
Section A - A
Grommet 2
Section B - B
Grommet A
4.5 1.5 Nm
2 40 13 in-lb A
B B
7 6 5 4 3 2
AC610486AB
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-173
Trunk lid trim 4. Socket
1. Taillight assembly 5. Taillight bulb
2. Taillight unit 6. Socket
3. Back-up light bulb 7. Gasket
8. Grommet
FOG LIGHT
M1540400900091

Fog light aiming (cutoff line direction) [at 7.62 The horizontal line 153.0
m (25.0 ft)] mm (6.02 inches) (1.15
degrees angle) below the
horizontal line (H)
Fog light aiming (vertical direction) [at 7.62 m Area from 53.2 mm (2.09
(25.0 ft)] inches) (0.4 degrees angle)
above the cutoff line to 99.8 mm
(3.93 inches) (0.75 degrees
angle) below the cutoff line
Fog light aiming (horizontal direction) [at 7.62 Vertical line (V) 599.7 mm (
m (25.0 ft)] 23.6 inches) ( 4.5 degrees
angle).
TSB Revision
FOG LIGHT
SPECIAL TOOLS
M1540401800075

name
MB990784 General service Removal of front fog light bezel
Ornament remover tool
MB990784

a
f. MB991825
ENTER key. check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g
measurement
adapter
harness
MB991826
MB991958
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-175
name
a
b
c adapter
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
DIAGNOSIS
M1540401700012
tents P.00-6.
M1540401000109

Procedure No.
1 Fog lights do not illuminate normally. P.54A-176
2 The right or left fog light does not illuminate. P.54A-183
3 Fog light indicator does not illuminate/go out normally. P.54A-187
TSB Revision
FOG LIGHT
SYMPTOM PROCEDURES
Inspection Procedure 1: The front fog lights do not illuminate normally.
CAUTION
Fog Light and ETACS-ECU Communication Circuit
FUSIBLE
LINK 36
RELAY BOX
ENGINE
COMPARTMENT
FOG LIGHT
RELAY
FOG
ETACS-ECU
LIGHT
Connector: A-11X Connectors: A-34, A-39
A-34 (B)
A-39 (B)
AC609409AG AC608142AI
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-177
.
Connector: A-44 CIRCUIT OPERATION

If the fog lights do not illuminate normally, the input
signal circuit(s) below or the ETACS-ECU may be
defective.
Tail light switch
Headlight switch
Fog light switch
Option coding information
A-44 (B)
.
AC608141AL
Connector: C-312 When the fog lights do not illuminate normally, the
Junction block mentioned input signal circuit(s) or ETACS-ECU may
be defective.
.
Malfunction of the column switch
AC608152 AP
DIAGNOSIS
MB991824: V.C.I.
TSB Revision
FOG LIGHT
STEP 1. ETACS-ECU coding data check.

CAUTION
(3) Read out the option coding information in ETACS-ECU
(Refer to GROUP 00, Precautions before service, Coding
Table P.00-35).
(4) Check that the "Front fog light" is set to "YES."
Q: Is the ETACS-ECU coding data normal?
MB991824
NO : Operate scan tool MB991958 to set the option coding
"Front fog light" to "Yes," and check the trouble
symptom.
MB991827 AC608435 AB
STEP 2. Check that the tail/stop lights and headlights

operate.
Check that the tail/stop lights and headlights illuminate nor-
mally.
Q: Do the tail/stop lights and headlights operate normally?
YES : Go to Step 3.
NO : Check the tail/stop lights and the headlights (Refer to
trouble symptom chart P.54A-110).
STEP 3. Using scan tool MB991958, read the other system

Q: Is the DTC set?
YES : Troubleshoot the ETACS-ECU (Refer to ETACS,
NO : Go to Step 4.
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-179

the fog light function.
Turn the fog light switch to ON.
condition
Item 212 Front fog light ON
Q: Does scan tool MB991958 display the items "Front fog

light" as normal condition?
YES : Go to Step 5.
does not receive any signal from the column switch
signal." P.54A-528.
STEP 5. Check fog light relay connector A-11X for loose,

in the connector.
Q: Is fog light relay connector A-11X in good condition?
YES : Go to Step 6.
P.00E-2.
STEP 6. Check the fog light relay.

Refer to P.54A-191.
Q: Is the fog light relay in good condition?
YES : Go to Step 7.
NO : Replace the fog light relay.
TSB Revision
FOG LIGHT
STEP 7. Check the battery power supply circuit to the fog

light relay. Measure the voltage at fog light relay connector
A-11X.
CAUTION
The top and bottom of the fog light relay are difficult to
identify. Prior to inspection, confirm the triangle mark on
the relay box.
(1) Disconnect fog light relay connector A-11X and measure
the voltage available at the relay box side of the connector.
(2) Measure the voltage between terminal 2 and ground, and
Relay box side: A-11X between terminal 4 and ground.
positive voltage)?
YES : Go to Step 9.
NO : Go to Step 8.
AC608254 BA
STEP 8. Check the wiring harness between fog light relay

connector A-11X (terminal 2 and 4) and fusible link (36).
Q: Is the wiring harness between fog light relay connector
A-11X (terminal 2 and 4) and fusible link (36) in good
condition?

in the connector.
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-181
connector A-11X (terminal 1) and ETACS-ECU connector
C-312 (terminal 4).
A-11X (terminal 1) and ETACS-ECU connector C-312
(terminal 4) in good condition?
connector A-11X (terminal 3) and fog light (LH) connector
A-34 or fog light (RH) connector A-44 (terminal 2).
NOTE: Also check intermediate connector A-39 for loose, cor-
connector. If intermediate connector A-39 is damaged, repair or
A-11X (terminal 3) and fog light (LH) connector A-28
(terminal 2) or fog light (RH) connector A-38 in good
condition?
STEP 12. Check the wiring harness between fog light (LH)
connector A-34 or fog light (RH) connector A-44 (terminal
1) and ground.
Q: Is the wiring harness between fog light (LH) connector
A-28 or fog light (RH) connector A-38 (terminal 1) and
TSB Revision
FOG LIGHT

Q: Does the fog lights illuminate in good condition?
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-183
Inspection Procedure 2: Any of the front fog lights does not illuminate normally.
Fog Light Circuit
RELAY BOX
ENGINE
COMPARTMENT
FOG LIGHT
RELAY
FOG LIGHT
(LH) (RH)
Connector: A-11X Connectors: A-34, A-39
A-34 (B)
A-39 (B)
AC609409AG AC608142AI
TSB Revision
FOG LIGHT
Connector: A-44
A-44 (B)
AC608141AL

If any of the fog lights do not illuminate, the wiring harness con-
nector(s), the bulb or the fuse may be defective or burned out.
.
Burned-out fog light bulb
DIAGNOSIS
STEP 1. Check fog light (LH) connector A-34 or fog light

(RH) A-44 for loose, corroded or damaged terminals, or
Q: Is fog light (LH) connector A-34 or fog light (RH) A-44 in
good condition?
YES : Go to Step 2.
P.00E-2.
STEP 2. Check the fog light bulb.

(1) Remove the fog light bulb.
(2) Verify that the fog light bulb is not damaged or burned out.
Q: Is the fog light bulb in good condition?
YES : Go to Step 3.
NO : Replace the fog light bulb.
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-185
Step 3. Check the ground circuit to the fog light (LH) or fog
light (RH). Measure the resistance at fog light (LH)
connector A-34 or fog light (RH) connector A-44.
harness side.
(2) Check the resistance between the fog light connector and
ground.
Resistance between A-34 fog light (LH) connector termi-
nal No.1 and ground
Harness side: A-34
AC608255 AX
Resistance between A-44 front fog light (RH) connector

terminal No.1 and ground
OK: The resistance should be 2 ohm or less.
Harness side: A-44
YES : Go to Step 5.
NO : Go to Step 4.
AC608255 AY
Step 4. Check the wiring harness between fog light (LH)

1) and ground.
TSB Revision
FOG LIGHT
STEP 5. Check fog light relay connector A-11X for loose,

in the connector.
Q: Is fog light relay connector A-11X in good condition?
YES : Go to Step 6.
P.00E-2.
STEP 6. Check the wiring harness between fog light (LH)

2) and fog light relay connector A-11X (terminal 3).
fog light relay connector A-11X (terminal 3) in good
condition?
YES : Go to Step 7.

Q: Does the right or left fog light does not illuminate in
good condition?
NO : Replace the fog light(s).
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-187
Inspection Procedure 3: The front fog light indicator does not illuminate normally.
CAUTION
Front Fog Light Indicator Light Circuit
CAN COMMUNICATION LINE COMBINATION

(CAN_H LINE) METER
ETACS-ECU CAN COMMUNICATION LINE
(CAN_L LINE)
INPUT SIGNAL
FRONT FOG LIGHT
SWITCH
. .

If the fog light indicator does not illuminate normally, The ETACS-ECU may be defective
connector(s), wiring harness in the CAN bus lines, The combination meter may be defective
the ETACS-ECU or the combination meter may be Damaged harness wires and connectors
defective.
DIAGNOSIS
MB991824: V.C.I.
STEP 1. Check the fog lights.

When the fog light switch is operated, check that the fog lights
illuminate and go off normally.
Q: Is the fog lights normal?
YES : Go to Step 2.
NO : First, repair the front fog lights. Refer to Inspection
Procedure 2 "The right or left fog light does not
illuminate P.54A-183."
TSB Revision
FOG LIGHT

line.
CAUTION
YES : Go to Step 3.
MB991910
MB991824
MB991827 AC608435 AB

(1) Check whether a combination meter-related DTC is set.
Check whether the combination meter-related DTC is set.
Q: Is the DTC set?
YES : Diagnose the combination meter (Refer to
combination meter, Diagnosis P.54A-23).
NO : Go to Step 4.

(2) Perform the actuator test for the combination meter, and
check that the fog light indicator illuminates (Refer to
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-189
ON-VEHICLE SERVICE
FRONT FOG LIGHT AIMING

M1540400300141
PRE-AIMING INSTRUCTIONS
1. Inspect for rusted or faulty front fog light assemblies.
2. These conditions must be corrected before a satisfactory
adjustment can be made.
3. Inspect tire inflation, and adjust if necessary.
4. If the fuel tank is not full, place a weight in the trunk of the
vehicle to simulate weight of a full tank [3 kg (6.5 pounds)
per gallon].
5. There should be no other load in the vehicle other than
driver or substituted weight of approximately 68 kg (150
pounds) placed in driver's position.
6. Thoroughly clean the front fog light lenses.
7. Place the vehicle on a level floor, perpendicular to a flat
screen 7.62 meters (25.0 ft) away from the bulb
center-marks on the fog light lens.
8. Rock the vehicle sideways to allow the vehicle to assume its
normal position.
9. Bounce the front suspension through three (3) oscillations
by applying the body weight to the hood or bumper.
10.Measure the center of the front fog lights as shown in the
illustration.
Front fog light

center
AC609594 AB
11.Four lines of adhesive tape (or equivalent markings) are

(1)
Screen Front fog light center required on screen or wall:
(3) (1) Position a vertical tape or mark so that it is aligned with
(2)
Vehicle center line
the vehicle center line.
(2) Measure the distance from the center of the front fog light
(3) lens to the floor. Transfer the measurement to the screen.
Horizontal tape or mark on the screen is for reference of
7.62 m (25.0 ft) vertical adjustment.
(3) Measure the distance from the center line of the vehicle
AC307983AD to the center of each front fog light. Transfer the
measurement to the screen. Vertical tape or mark on the
screen is for reference to the center line of each front fog
light.
TSB Revision
FOG LIGHT
FOG LIGHT ADJUSTMENT

(V) 1. Check if the beam shining onto the screen is at the standard
Cutoff line value.
(H)
Standard value:
153.0
(6.02) (Cutoff line direction): The horizontal line 153.0 mm
53.2 (2.09)
(6.02 inches) (1.15 degrees angle) below the hori-
Hot zone 99.8 (3.93) zontal line (H)
Limit:
(Vertical direction): Area from 53.2 mm (2.09 inches)
599.7 (23.6) 599.7 (23.6) (0.4 degrees angle) above the cutoff line to 99.8
mm (in) AC407086 AC mm (3.93 inches) (0.75 degrees angle) below the
cutoff line
(Horizontal direction): Vertical line (V) 599.7 mm (
23.6 inches) ( 4.5 degrees angle)
Phillips screwdriver
2. If it is not within the standard value range, adjust by turning
(Vertical direction adjustment) the adjusting screw.
NOTE: The horizontal direction is non-adjustable. If deviation of
the light beam axis exceeds the standard value, check that the
mounting location or some other points are not faulty.
AC609596 AB
BULB REPLACEMENT
M1540400400148
1. Remove the front fog light bezel and the front fog light
assembly. (Refer to P.54A-191.)
CAUTION
Don't touch the bulb surface with bare hands or dirty
gloves. If the bulb surface (glass part) gets dirty, clean it
with alcohol or thinner immediately and dry well, and then
install it.
2. Disconnect the connector and withdraw the bulb.
3. Replace the bulb, and connect securely the connector.
Front fog light bulb

AC609657AB
TSB Revision
CHASSIS ELECTRICAL
FOG LIGHT
54A-191
M1540400500093
1 3
1.2 0.7 Nm 2
11 6 in-lb 4 AC609818AB

1. Front fog light bezel 3. Front fog light bulb
2. Fog light assembly 4. Front fog light unit
INSPECTION
FRONT FOG LIGHT RELAY CHECK

M1540400700075
Front fog light relay Battery voltage Terminal Normal

number conditions
continuity
()] ohms or
less)
4
3
2 1
AC609148AH
TSB Revision
SIDE TURN-SIGNAL LIGHT
SIDE TURN-SIGNAL LIGHT

M1541800200145
AC609819 AB
Removal step
<<A>> >>A<< 1. Side turn-signal light assembly

.
<<A>> SIDE TURN-SIGNAL LIGHT REMOVAL

Push the side turn-signal light toward the vehicle rear to bend
the hook, and then remove by disengaging the tab from the
Side turn-signal light fender panel.
Push
Forward of vehicle
AC506856 AC

.
>>A<< SIDE TURN-SIGNAL LIGHT INSTALLATION

Engage the claw to the fender panel to install the side turn sig-
nal light.
Hook
Claw
Fender
panel
Forward of vehicle AC506857AC
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-193
DOME LIGHT
GENERAL INFORMATION
M1542000100338
Front dome light

(Front dome light / reading lights)
Luggage compartment light
Rear dome light
AC608728AB
A front dome light, installed to the front part of the The rear dome light, which illuminates the rear
roof, has been equipped with the lens-push type passenger's seat, is installed above the rear seat.
map and dome light which can be operated easily <Vehicle without sunroof>
from the driver's and front passenger's seat, The luggage compartment light is installed to the
offering excellent operability for turning on and off upper part of the luggage compartment.
the light. <ES, GTS>
TSB Revision
DOME LIGHT
SPECIAL TOOLS
M1541301600088

name
a
f. MB991825
ENTER key. check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles
communication
MB991914 system)
harness C (for
Daimler
Chrysler
MB991825
models only)
g
f. M.U.T.-III
measurement
adapter
harness
MB991826
MB991958
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-195
name
a
b
circuit
c. LED harness
tester
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
TSB Revision
DOME LIGHT
DIAGNOSIS
M1541301500081
tents P.00-6.
DIAGNOSTIC FUNCTION
M1541302100020

.

.
CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
.

.
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-197
CAUTION
display.
button.
M1541300200139

Procedure No.
1 The front dome light does not illuminate normally. P.54A-198
2 The rear dome light does not illuminate normally. P.54A-202
3 The luggage compartment light does not illuminate normally. P.54A-206
4 The interior light auto-cut function does not operate correctly. P.54A-209
TSB Revision
DOME LIGHT
SYMPTOM PROCEDURES
Inspection Procedure 1: The front dome light does not illuminate normally.
CAUTION
Front Dome Light Circuit
ETACS-ECU
FRONT
DOME
LIGHT
Connector: C-316 Connector: D-02

Junction block
AC608152 AM AC608165AX
.
TROUBLE JUDGEMENT
The ETACS-ECU illuminates and extinguishes the
front room light in accordance with the input signals
below.
Ignition switch (IG1)
Key reminder switch
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-199
Door switches TROUBLESHOOTING HINTS
Front door lock actuator Malfunction of the key reminder switch
.
Malfunction of door switch
TECHNICAL DESCRIPTION (COMMENT) Malfunction of the front door lock actuator switch
If this does not work normally, the above switch input Malfunction of front dome light
circuit(s), front dome light, or ETACS-ECU may have Malfunction of the ETACS-ECU
a problem. The wiring harness or connectors may have
.
DIAGNOSIS
STEP 1. Rear dome light operation check.

Check that the rear dome light illuminates and extinguishes
normally.
Q: Does rear dome light work normally?
YES : Go to Step 2.

trouble code.
CAUTION
Q: Is the DTC set?
NO : Go to Step 3.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
DOME LIGHT

the front dome light.
Open each door.
condition
Item 254 IG voltage Battery voltage
Item 257 As door ajar switch Open
Item 258 RR door ajar switch Open
Item 259 RL door ajar switch Open
out

unlock", "IG voltage", "Dr door ajar switch", "As door
ajar switch", "RR door ajar switch", "RL door ajar
switch" and "Handle lock switch" as normal condition?
YES : (Normal conditions are displayed for all items.) Go to
Step 4.
NO : (Normal condition is not displayed.) Troubleshoot the
ETACS-ECU. Refer to ETACS, Diagnosis, Input
signal chart P.54A-528.
STEP 4. Check front dome light connector D-02 for loose,

in the connector.
Q: Is front dome light connector D-02 in good condition?
YES : Go to Step 5.
P.00E-2.
STEP 5. Front dome light bulb check

Check that the front dome light bulb is normal.
Q: Is front dome light bulb normal?
YES : Go to Step 6.
NO : Replace the front dome light bulb.
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-201

in the connector.
YES : Go to Step 7.
P.00E-2.
STEP 7. Check the wiring harness between front dome

light connector D-02 (terminal 2, 3) and ETACS-ECU
connector C-316 (terminal 6, 5)
Q: Are wiring harness between front dome light connector
D-02 (terminal 2, 3) and ETACS-ECU connector C-316
(terminal 6, 5) in good condition?
YES : Go to Step 8.
STEP 8. Check front dome light connector D-02 for loose,

in the connector.
Q: Is front dome light connector D-02 in good condition?
YES : Go to Step 9.
P.00E-2.
STEP 9. Check the wiring harness between front dome

light connector D-02 (terminal 1) and body ground.
Q: Is wiring harness between front dome light connector
D-02 (terminal 1) and body ground in good condition?
YES : Replace the front dome light, and then go to Step 10.

Check that the front dome light illuminates and extinguishes
normally.
Q: Do the front dome light work normal?
TSB Revision
DOME LIGHT
Inspection Procedure 2: The rear dome light does not illuminate normally.
CAUTION
Rear Dome Light Circuit
ETACS-ECU
REAR
DOME
LIGHT

Junction block The ETACS-ECU illuminates and extinguishes the
rear dome light in accordance with the input signals
below.
Ignition switch (IG1)
Key reminder switch
Door switches
C-316 Front door lock actuator
.
C-311 AC608152 AS TECHNICAL DESCRIPTION (COMMENT)

If this does not work normally, the above switch input
Connector: D-06
circuit(s), rear dome light, or ETACS-ECU may have
D-06 (GR) a problem.
.
PROBABLE CAUSES
Malfunction of the key reminder switch
Malfunction of door switch
Malfunction of the front door lock actuator (RH)
Malfunction of rear dome light
AC608166AP Malfunction of the ETACS-ECU
.
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-203
DIAGNOSIS
STEP 1. Front dome light operation check

Check that the front dome light illuminates and extinguishes
normally.
Q: Does rear dome light work normally?
YES : Go to Step 2.

trouble code.
CAUTION
Q: Is the DTC set?
NO : Go to Step 3.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
DOME LIGHT

the rear dome light.
Open each door.
condition
voltage
out

unlock", "IG voltage", "Dr door ajar switch", "As door
ajar switch", "RR door ajar switch", "RL door ajar
switch" and "Handle lock switch" as normal condition?
Step 4.
STEP 4. Check rear dome light connector D-06 for loose,

in the connector.
Q: Is rear dome light connector D-06 in good condition?
YES : Go to Step 5.
P.00E-2.
STEP 5. Rear dome light bulb check

Check that the rear dome light bulb is normal.
Q: Is rear dome light bulb normal?
YES : Go to Step 6.
NO : Replace the rear dome light bulb.
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-205

in the connector.
YES : Go to Step 7.
P.00E-2.
STEP 7. Check the wiring harness between rear dome light

D-06 connector (terminal 1, 2) and ETACS-ECU connector
C-316 (terminal 6, 5)
Q: Is wiring harness between rear dome light D-06
connector (terminal 1, 2) and ETACS-ECU connector
C-316 (terminal 6, 5) in good condition?
YES : Go to Step 8.

Check that the rear dome light illuminates and extinguishes
normally.
Q: Does rear dome light work normal?
TSB Revision
DOME LIGHT
Inspection Procedure 3: The luggage compartment light does not illuminate normally.
CAUTION
Luggage Compartment Light Circuit
ETACS-ECU
LUGGAGE
COMPARTMENT
LIGHT
Connector: C-311 Connector: F-01

Junction block
AC608152 AK AC608171AQ
.

The ETACS-ECU illuminates and extinguishes the
luggage compartment light in accordance with the
input signals from trunk lid actuator and switch.
.

If this does not work normally, the trunk lid actuator
D-14 (BR)
and switch input circuit, luggage compartment light,
AC608166AH or ETACS-ECU may have a problem.
.
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-207
TROUBLESHOOTING HINTS The wiring harness or connectors may have
Malfunction of trunk lid actuator and switch loose, corroded, or damaged terminals, or termi-
Malfunction of luggage compartment light nals pushed back in the connector
DIAGNOSIS

trouble code.
CAUTION
Q: Is the DTC set?
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
DOME LIGHT

Use the ETACS-ECU service data to check the signal related to
the operation of luggage compartment light.
Open the trunk lid.
condition
Item 260 Trunk/gate trunk ajar switch Open
Q: Does scan tool MB991958 display the item "Trunk/gate

trunk ajar switch" as normal condition?
YES : (Normal condition is displayed.) Go to Step 3.
STEP 3. Check luggage compartment light connector F-01

Q: Is luggage compartment light connector F-01 in good
condition?
YES : Go to Step 4.
P.00E-2.
STEP 4. Luggage compartment light bulb check

Check that the luggage compartment light bulb is normal.
Q: Is luggage compartment light bulb normal?
YES : Go to Step 5.
NO : Replace the luggage compartment light bulb.

in the connector.
YES : Go to Step 6.
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-209
STEP 6. Check the wiring harness between luggage

compartment light connector F-01 (terminal 1, 2) and
ETACS-ECU connector C-311 (terminal 17, 3).
Q: Is wiring harness between luggage compartment light
connector F-01 (terminal 1, 2) and ETACS-ECU
connector C-311 (terminal 17, 3) in good condition?
YES : Go to Step 7.

Check that the luggage compartment light illuminates and
extinguishes normally.
Q: Do the trunk room work normal?
Inspection Procedure 4: The interior light auto-cut function does not operate correctly.
. .

The ETACS-ECU operates the interior light auto-cut Malfunction of door switch
function in accordance with the input signals below. Malfunction of the dome light
Ignition switch (ACC) Malfunction of the ETACS-ECU
Ignition switch (IG1) The wiring harness or connectors may have
Door switches loose, corroded, or damaged terminals, or termi-
If this function does not work normally, these input nals pushed back in the connector
signal circuit(s) or the ETACS-ECU may have a prob-
lem. Also, "Interior light auto cut timer" may be set to
"0min" through customization.
DIAGNOSIS
TSB Revision
DOME LIGHT

CAUTION
(3) Use the ETACS-ECU customize function to check to see
which of the followings other than "0min" the "Interior light
auto cut timer" is set.
YES : Go to Step 2.
MB991910 NO : Use the ETACS-ECU configuration function to set the
MB991824
"Interior light auto cut timer" to other than "0min"
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.
TSB Revision
CHASSIS ELECTRICAL
DOME LIGHT
54A-211

the interior light auto-cut function.
Open each door.
condition
voltage
Item 288 ACC switch OFF
Q: Does scan tool MB991958 display the items "IG

voltage", "ACC switch", "As door ajar switch", "RR door
ajar switch", and "RL door ajar switch" as normal
condition?
Step 4.

Check that the interior light automatic shutdown function works
normally.
TSB Revision
DOME LIGHT
ON-VEHICLE SERVICE
M1541301200132
display)
Dome light Adjustment of 0 sec 0 second (no delay shutdown time)
7.5 sec 7.5 seconds
15 sec 15 seconds
30 sec 30 seconds (default <Vehicles with central
60 sec 60 seconds
120 sec 120 seconds
180 sec 180 seconds
Interior light Adjustment of Disable No function
auto cut timer interior light 3 min 3 minutes
automatic shutdown
function operation 30 min 30 minutes (default)
time 60 min 60 minutes
DOME LIGHT REMOVAL AND INSTALLATION

M1541302700011
A 9
A 3
A
8
6
2
5 7
4
Section A - A
3 Clip
1
Note
: Clip positions
AC610643AB
TSB Revision
CHASSIS ELECTRICAL
HIGH-MOUNTED STOPLIGHT
54A-213
1. Front dome light lens 6. Sunroof switch <Vehicles with
2. Dome light bulb sunroof>
3. Front dome light 7. Rear dome light lens
4. Front dome light cover 8. Dome light bulb
5. Microphone unit <Vehicles with 9. Rear dome light
hands-free cellular phone system>
LUGGAGE COMPARTMENT LIGHT REMOVAL AND INSTALLATION

M1541302600014
Section A - A
2
1
1
A
A
AC610327AB
Removal Steps
1. Luggage compartment light lens
2. Luggage compartment light bulb
HIGH-MOUNTED STOPLIGHT
M1541700200159
4.5 1.5 Nm
40 13 in-lb
1
2
AC609978AB

Trunk lid trim 1. High-mounted stoplight assembly
2. Gasket
TSB Revision
LICENSE PLATE LIGHT
LICENSE PLATE LIGHT

M1541900200175
4 1
1.2 0.7 Nm
11 6 in-lb AC610326AB

1. License plate light assembly 4. Body
2. Lens 5. Bulb
3. Gasket 6. Socket
TSB Revision
CHASSIS ELECTRICAL
HAZARD WARNING LIGHT SWITCH
54A-215
SPECIAL TOOLS
M1541500100084

name
a
f. MB991825
ENTER key. check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g
measurement
adapter
harness
MB991826
MB991958
TSB Revision

name
a
b
c adapter
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
DIAGNOSIS
M1541501400088
tents P.00-6.
DIAGNOSTIC FUNCTION
M1541500600034

.

.
TSB Revision
CHASSIS ELECTRICAL
54A-217
CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
.

.
CAUTION
display.
button.
TSB Revision

M1541500200025
CAUTION
B16A6 Turn-signal fuse blown P.54A-218
DTC B16A6: Turn-signal fuse blown

. .

When the hazard warning light fuse is blown, the The wiring harness or connectors may have
ETACS-ECU sets the DTC B16A6. loose, corroded, or damaged terminals, or termi-
.
With the DTC not set, when the blown fuse of hazard
warning light is detected three times consecutively,
the ETACS-ECU sets the DTC B16A3.
DIAGNOSIS
STEP 1. Fuse check

Check if the turn-signal light fuse is normal.
YES : Go to Step 2.
NO : Replace the turn-signal light fuse.
TSB Revision
CHASSIS ELECTRICAL
54A-219

CAUTION
(3) Erase the DTC.
position.
Q: Is the DTC set?
MB991824
MB991827 AC608435 AB

M1541500700075

Procedure No.
1 The hazard warning lights do not illuminate. P.54A-219
SYMPTOM PROCEDURES
Inspection Procedure 1: The hazard warning lights do not illuminate.

.

Before replacing the ECU, ensure that the power Malfunction of center panel unit
supply circuit, the ground circuit and the com- Malfunction of the ETACS-ECU
munication circuit are normal. The wiring harness or connectors may have
.

If the hazard warning light does not illuminate, the
hazard warning light switch input circuit in center
panel unit or the ETACS-ECU may have a problem.
TSB Revision
DIAGNOSIS
STEP 1. Check that the turn-signal light operate.

Check that the turn-signal lights illuminate normally.
Q: Does turn-signal light work normally?
YES : Go to Step 2.
NO : Diagnose the headlights. Refer to Inspection
Procedure 10 "The turn-signal lights do not illuminate"
P.54A-140.

Using the ETACS-ECU service data, check the hazard warning
light signal.
CAUTION
1.Connect scan tool MB991958. Refer to "How to connect scan
tool (M.U.T.-III) P.54A-216."
Data link connector 2.Turn the ignition switch to the "ACC" position.
3.Turn "ON" the hazard light switch.
Item No. Item name Normal conditions
Item 265 Hazard switch ON
Q: Does scan tool MB991958 display the items "Hazard

MB991910 switch" as normal condition?
MB991824 YES : (Normal condition is displayed for item) Go to Step 3.
NO : (Normal condition is not displayed for item No. 265.)
Troubleshoot the ETACS-ECU. Refer to ETACS,
does not receive any signal from the hazard warning
light switch" P.54A-557.
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
54A-221

Check that the hazard warning light illuminate normally.
M1541501000154
Refer to GROUP 52A Instrument Center Panel
P.52A-6.
INSPECTION
HAZARD WARNING LIGHT SWITCH CHECK

M1541501100128
Switch position Terminal Normal

number conditions
OFF 5 9 No
continuity
ON Continuity
exists (2
ohms or
less)
AC609727AB
TSB Revision
HORN
HORN
M1542100200172
18 7 Nm
13 4 ft-lb
1
18 7 Nm
13 4 ft-lb
AC608781AB

Front bumper assembly (Refer to 1. Horn (HIGH)
GROUP 51 Front Bumper 2. Horn (LOW)
Assembly P.51-3).
INSPECTION
HORN RELAY CHECK

M1542100400143

number condition
At no energization 3 4 No
continuity
Horn relay [terminal 1 (+), terminal 2 exists (2
()] ohms or
less)
4
3
2 1
AC609148AB
TSB Revision
CHASSIS ELECTRICAL
ACCESSORY SOCKET
54A-223
ACCESSORY SOCKET
GENERAL INFORMATION
M1542300500047
The plug-in type accessory socket has been installed
for the convenient use of accessories.
Accessory socket
Accessory socket
AC608325 AC608326
AC608567
Accessory socket has been added to the front The maximum load is 120 W when a single
floor console. This accessory socket can be accessory socket is used. When two accessory
replaced to the cigar lighter as an option. sockets are used simultaneously, the combined
Accessory sockets have been added to the rear maximum load for two sockets is 120 W.
floor console. <Standard equipment: ES,GTS>
M1542300200176
3
7
6
4
5
2
AC608779
AC608778 AC609358AB
Removal Steps <Rear Floor Console> Removal Steps <Front Floor Console>
Floor console panel assembly 5. Floor console box cup holder
(Refer to GROUP 52A Floor (Refer to GROUP 52A Front Floor
Console Assembly P.52A-8). Console Assembly P.52A-8).
1. Positive terminal assembly 6. Accessory socket case
2. Negative terminal assembly 7. Accessory socket and cap
<<A>> 3. Accessory socket
4. Accessory socket cover

.
<<A>> REMOVAL OF ACCESSORY SOCKET

<REAR FLOOR CONSOLE>
Disassemble, and remove.
TSB Revision
CIGARETTE LIGHTER
CIGARETTE LIGHTER
INSPECTION
M1543019502979
CIGARETTE LIGHTER CHECK

Take out the plug, and check for a worn edge on the ele-
ment spot connection, and for shreds of tobacco or other
Element
Spot material on the element.
Using an ohmmeter, check that the element resistance
value is 1.7 ohms.
ACX01832AE
COLUMN SWITCH
GENERAL INFORMATION
M1543101800017
Column switch has a function to ensure the driver's
.
safety during frontal collision of vehicle.
Function
Front of vehicle
Collision load Collision load
Column switch Column switch
AC603959 AB
If the column switch is moved to the front of the vehi-

cle and hit on the instrument panel or meter bezel by
the frontal collision of vehicle, the steering wheel is
moved to the front of the vehicle because the right
and left levers fall down, ensuring the driver's safety.
In addition, the column switch secures the rigidity
that the levers do not fall down by the normal opera-
tion, however, it cannot be reused after the deforma-
tion.
TSB Revision
CHASSIS ELECTRICAL
COLUMN SWITCH
54A-225
SPECIAL TOOLS
M1543100200175

name
a
b key. Diagnostic code and service data
f. MB991825
check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE
CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g measurement
adapter
harness
MB991826
MB991958
TSB Revision
COLUMN SWITCH

name
MB991223 General service tool Continuity check and voltage
a
a. MB991219 (jumper) measurement at harness wire or
b
circuit
c c. LED harness
adapter d. For connecting a locally
sourced tester
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
TROUBLESHOOTING
M1543101200112
Refer to GROUP 00 Contents of troubleshooting
P.00-6.
DIAGNOSTIC FUNCTION
M1543101300090

TSB Revision
CHASSIS ELECTRICAL
COLUMN SWITCH
54A-227
CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
CAUTION
display.
button.
TSB Revision
COLUMN SWITCH
DIAGNOSTIC TROUBLE CODE TABLE

M1543100300105
Diagnostic trouble code Diagnostic item Reference page

No.
B2350 Malfunction of lighting switch P.54A-228
B2351 Malfunction of wiper/washer switch
DTC B2350: Malfunction of lighting switch,

DTC B2351: Malfunction of wiper/washer switch
. .
TROUBLE JUDGEMENT TECHNICAL DESCRIPTION (COMMENT)

The ETACS-ECU receives the signals related to The column switch or the ETACS-ECU may have a
lighting and wiper/washer from the column switch. If problem.
the fail information data is included in the signal from .
column switch, DTC B2350 (malfunction of lighting TROUBLESHOOTING HINTS

switch) or B2351 (malfunction of wiper/washer Column switch may be defective
switch) is stored. The ETACS-ECU may be defective
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
COLUMN SWITCH
54A-229

CAUTION
scan tool P.54A-226".
(3) Erase the DTC.
position.
(5) Check if the DTC B2350 or B2351 is set.
Q: Is the DTC set?
MB991910 DTC B2351 is set. : Go to Step 2.
MB991824
DTC B2350 is set. : Go to Step 3.
No DTC is set. : The trouble can be an intermittent
malfunction (GROUP 00 How to Cope with
Intermittent Malfunction P.00-13).
MB991827 AC608435 AB

(1) Replace the wiper/washer switch.
(3) Erase the DTC.
position.
Q: Is the DTC set?
YES : Go to Step 3.
TSB Revision
COLUMN SWITCH

(1) Replace the lighting switch.
(3) Erase the DTC.
position.
Q: Is the DTC set?
M1543100700158
CAUTION
To remove the driver airbag module, refer to GROUP 52B Service Precautions P.52B-24 and
Driver/Front Passenger's Air Bag Module and Clock Spring P.52B-367.
2
2.5 0.5 Nm
23 4 in-lb
1
AC609141AB

Lower, upper Steering column Steering wheel assembly (Refer to
cover (Refer to GROUP 37 GROUP 52B - Drivers Front
Steering Column shaft assembly Passenger's Air Bag Module and
P.37-25). Clock Spring P.52B-367).
1. Wiper/washer switch Clock spring (Refer to GROUP 52B
2. Lighting switch - Drivers Front Passenger's Air
Bag Module and Clock Spring
P.52B-367).
3. Column switch body
TSB Revision
CHASSIS ELECTRICAL
COLUMN SWITCH
54A-231
INSPECTION
WIPER/WASHER SWITCH CONTINUITY CHECK

M1543101700043
1 Switch position Tester Specified

2
3 connectio condition
4 n
5
6 OFF Open circuit
7
8 Windshield 6 3 Operating the
9 intermittent wiper adjusting knob
10
11
interval adjusting changes the
AC609144AB
knob resistance.
Windshield washer 6 7 Continuity exists
switch (2 ohms or less)
Windshield Hi 6 8 Continuity exists
wiper switch (2 ohms or less)
Lo 6 9 Continuity exists
(2 ohms or less)
Int 6 10 Continuity exists
(2 ohms or less)
Mist 6 11 Continuity exists
(2 ohms or less)
COLUMN SWITCH (SWITCH BODY PART)

CONTINUITY CHECK
M1543100800058
1. Remove the lighting switch and wiper/washer switch.
2. Check that the continuity is present for the same terminal
numbers of the column switch body connectors that remain
on the steering column.
Lighting Wiper/washer
switch side switch side Column switch Terminal Normal
1 1 body number condition
2 2
3 3 Lighting switch side 3 3 Continuity
4
5
4
5
connector 6 6 exists (2
6 6 Wiper/washer 7 7 ohms or less)
7
8
7
8 switch side 8 8
9 9 connector 9 9
10 10
11 11 10 10
AC502901AG 11 11
TSB Revision
RADIO AND CD PLAYER
RADIO AND CD PLAYER

GENERAL INFORMATION
M1544000100237
Two types of audio, CD player with radio or 6-disk CD
changer with radio, have been established. The audio has
designed to fit uniformally into the instrument panel. Also, a
new function automatically corrects the sound quality and
volume during driving.
AC608345AB
For the vehicles with Rockford Fosgate premium sound

system, the 8-ch high-power audio amplifier with integrated
DSP (total maximum output of 650 W) has been established
under the driver's seat. The clear treble without distortion is
available.
Driver's seat
Audio amplifier
Rear seat
AC608321AB
For the vehicles with Rockford Fosgate premium sound

system, the audio adapter has been established onto the
center tray. With this modification, portable music player
can be connected. <Vehicles without MMCS>
Audio adapter
AC608417AB
Item CD player with radio 6-disk CD changer with radio

<Option>
Electronic tuning radio Equipped Equipped
SIRIUS satellite radio <Option: ES, GTS> Equipped (Only the vehicles
with the satellite radio tuner)
CD player*1 (compatible with MP3*2) Equipped Equipped
6-disk CD autochanger*1 (compatible with MP3*2) Equipped

Audio integrated 4-ch power amplifier <vehicles General 140 W General 140 W
with 4 speakers, 6 speakers>
Audio amplifier-integrated 8-ch power amplifier and General 650 W (maximum)
digital signal processor (DSP) <Rockford
Fosgate premium sound system>
NOTE: . *2
: Some may not be played.
*1: CD-R/CD-RW may not be played.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-233
STEERING WHEEL AUDIO REMOTE CONTROL SWITCH
The concentrated switch has been established onto
the steering wheel spoke for allowing the remote
Steering wheel
audio remote control control of audio. <ES, GTS>
switch
AC606795AF
AUDIO OPERATION TONE ALARM

To prevent an audio operational error, the audio
operation tone alarm confirms the audio operation
which sounds a tone alarm in the combination meter
when the audio is operated. The details are as
described in the following table:
Usage category Confirmation tone alarm sounding condition (with conditions below, tone alarm
sounds for 0.08 seconds)
Radio use Press and hold "1", "2", "3", "4", "5" or "6" button.
Press and hold "SCAN" button.
CD use Press and hold the "LOAD" button.
Press and hold the "DISC" button.
Press and hold the "RPT" button.
Press and hold the "RDM" button.
Press and hold the CD eject button
Audio adjustment With "BASS", "MID", "TREBLE", "BALANCE", or "FADER" selected, adjust the
adjustment level to zero.
Select "NORMAL" of "SOUND FIELD".
Select "NORMAL" of "MUSIC TYPE".
Others Press and hold the "TUNE" knob.
Press and hold the "MODE" switch of steering remote control switch.
TSB Revision
RADIO AND CD PLAYER
SPECIAL TOOLS
M1542000602146

name
MB990784 General service Removal of center air outlet, center
Ornament remover tool panel and center cover
MB990784

a
b pushing V.C.I. DTC and data list.
f. MB991825
ENTER key.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g
measurement
adapter
harness
MB991826
MB991958
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-235
name
a
b
c adapter
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
TSB Revision
RADIO AND CD PLAYER
DIAGNOSIS

TROUBLESHOOTING
M1544004800409
Refer to GROUP 00, Troubleshooting contents P.00-6.
TROUBLESHOOTING FOR NOISE
M1544009800181
RADIO AND CD PLAYER OR CD CAUTION

CHANGER Check that no noise of external origin is present.
The noise is generated during the engine run. Because the signal reception becomes poor
indoors, check in the open air. If this check is
neglected, the source of noise cannot be deter-
mined, resulting in a false recognition. Therefore,
be sure to perform this check.
CAUTION
When implementing the noise prevention, start
the prevention from the object causing the stron-
gest noise.
CAUTION
Check that the audio main body and others are
securely grounded.
Noise types Situation Cause Countermeasure
( ) indicates the
sound type.
AM, FM: When the engine Radiation noise caused Check or replace the ground
(Crack, tapping, speed is increased, the mainly by the spark plug cable ground bolt. (Refer to
rattle, plash) scratch noise becomes Noise wraparound Figure 1).
faster and the sound
volume decreases.
When the ignition
switch is turned to
ACC, the noise
disappears.
AM, FM: Synchronized with the Caused by the sparks Replace the wiper motor.
Wiper motor noise wiper movement, and also generated by the wiper
(hum, distorted becomes faster when motor brush.
hum) wiper movement is sped
up. When the wiper is
stopped, the noise also
stops.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-237
Noise types Situation Cause Countermeasure
( ) indicates the
sound type.
Noise from other The noise may be Repair or replace the
electrical generated when the electrical equipment.
equipment electrical equipment
become old.
Static electricity No noise is generated The parts or wiring move for Return the parts and wiring
(cracking, popping) when the vehicle comes to some reason, and cause the to the normal positions.
a complete stop. noise by contacting against
the body metal parts.
Various types of noise are Caused by the looseness Securely tighten the
generated in various parts between the body and the mounting bolts of each part.
of the body. hood, liftgate, bumper,
exhaust pipe and muffler,
suspension, or others.
NOTE: For trouble symptoms other than the noise, perform the following troubleshooting procedures. Refer
to P.54A-267.
<Figure 1>
Power steering
oil pump
AC506598AB
DATA LIST REFERENCE TABLE

M1544014100047
Item No. Check item (scan tool display) Check condition Normal condition
01 RADIO remote SW (SEEK-) SEEK (-) switch: ON ON
02 RADIO remote SW (SEEK+) SEEK (+) switch: ON ON
03 RADIO remote SW (MODE) MODE switch: ON ON
04 RADIO remote SW (VOL-) VOL (-) switch: ON ON
05 RADIO remote SW (VOL+) VOL (+) switch: ON ON
DIAGNOSIS FUNCTION
M1544013200018

TSB Revision
RADIO AND CD PLAYER
CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
display.
button.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-239
DIAGNOSIS CODE CHART
M1544012900047
CAUTION
DTC No. Description Reference page
U0155 Combination meter CAN timeout P.54A-246
U0168 WCM or KOS-ECU CAN timeout P.54A-249
U0195 Satellite radio tuner CAN timeout P.54A-251
B2420 Power integrated circuit P.54A-256
B2421 Radio tuner P.54A-258
B2423 6-disc CD player error P.54A-260
B2424 CD player error P.54A-261
B2450 Switch panel communication P.54A-263
B2451 Audio panel type error P.54A-265
CAUTION TROUBLE JUDGEMENT

If there is any problem in the CAN bus lines, an When the radio and CD player or CD changer is
incorrect diagnostic trouble code may be set. returned from the bus off state, or when the bus error
Prior to this diagnosis, always diagnose the CAN is indicated to the radio and CD player or CD
bus lines. changer state, the DTC U0019 (CAN-B) is set.
CAUTION .
Before replacing the radio and CD player or CD COMMENTS ON TROUBLE SYMPTOM

changer, be sure to check that the power supply The radio and CD player or CD changer, power sup-
circuit, ground circuit, and communication cir- ply for the radio and CD player or CD changer,
cuit are normal. ground circuit, or CAN bus line may have a problem.
.
TSB Revision
RADIO AND CD PLAYER
PROBABLE CAUSES Malfunction of CAN bus line wiring harness and

Malfunctions of radio and CD player or CD connector
changer
DIAGNOSIS

line.
Use scan tool MB991958 to diagnose the CAN bus lines.
CAUTION
ZC501967 (1) Connect scan tool MB991958 to the data link connector.
AC404789
Data link (2) Turn the ignition switch to "ON" position.
connector (3) Diagnose the CAN bus line.
YES : Go to Step 2.
MB991910 Diagnosis P.54C-16.) On completion, go to Step 2.
MB991824
MB991827 AC606941AB
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-241

Check again if the DTC is set to the radio and CD player or CD
changer.
(1) Erase the DTC.
position.
(3) Check if the DTC is set.
Q: Is the DTC set?
YES : Replace the radio and CD player or CD changer.
TSB Revision
RADIO AND CD PLAYER
CAUTION JUDGMENT CRITERIA

If DTC U0141 is set, be sure to diagnose the CAN With the ignition switch in the ON position, system
bus line. voltage between 10 16 volts (data from
CAUTION ETACS-ECU), power supply fuse is OK, or odometer
When replacing the ECU, always check that the value is 80.5 km (50 miles) or more, and the commu-
communication circuit is normal. nication with ETACS-ECU cannot be established for
.
2,500 ms or more, the radio and CD player or CD
DIAGNOSTIC FUNCTION changer determines that a problem has occurred.
If the signal from ETACS-ECU cannot be received, .
the radio and CD player or CD changer sets the DTC TROUBLESHOOTING HINTS
U0141. The CAN bus line may be defective
.
defective
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-243

Q: Is the DTC set?
NO : Go to Step 3.

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?

.
DIAGNOSTIC FUNCTION 2,500 ms or more, the radio and CD player or CD
If the signal from SRS-ECU cannot be received, the changer determines that a problem has occurred.
radio and CD player or CD changer sets DTC .

.
defective
DIAGNOSIS
TSB Revision
RADIO AND CD PLAYER

line
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-245

communication circuit is normal. nications with occupant classification-ECU cannot be
.
established for 2,500 ms or more, the radio and CD
DIAGNOSTIC FUNCTION player or CD changer determines that a problem has
When the signals from occupant classification-ECU occurred.
cannot be received, the radio and CD player or CD .
changer sets DTC U0154. TROUBLESHOOTING HINTS

.
defective.
tive.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
RADIO AND CD PLAYER

Q: Is the DTC set?
NO : Go to Step 3.

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC U0155: Combination meter CAN timeout

If DTC U0155 is set in the radio and CD player or With the ignition switch in the ON position, system
CD changer, diagnose the CAN main bus line. voltage between 10 16 volts (data from
Whenever the ECU is replaced, ensure that the value is 80.5 km (50 miles) or more, and the commu-
.
When the signals from combination meter cannot be occurred.
received, the radio and CD player or CD changer .
sets DTC U0155. TROUBLESHOOTING HINTS

.
defective.
DIAGNOSIS
MB991824: V.C.I.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-247

line
CAUTION
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958 read the combination

Check whether a combination meter DTCs are set or not.
(2) Check for combination meter DTCs.
YES : Go to Step 3.
NO : Diagnose the combination meter (Refer to

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
RADIO AND CD PLAYER

.
DIAGNOSTIC FUNCTION 2,500 ms or more, the satellite radio tuner deter-
If the signal from A/C-ECU cannot be received, the mines that a problem has occurred.

.
defective.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-249

Q: Is the DTC set?
A/C Diagnosis P.55A-8 <vehicles with manual A/C>
or GROUP 55B, Automatic A/C Diagnosis P.55B-7
<vehicles with automatic A/C>).
NO : Go to Step 3.

Check again if the DTC is set to the satellite radio tuner.
(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC U0168: WCM or KOS-ECU CAN timeout

.
KOS-ECU <vehicles with KOS> or WCM <vehicles
DIAGNOSTIC FUNCTION with WCM> cannot be established for 2,500 ms or
If the signal from KOS-ECU <vehicles with KOS> or more, the radio and CD player or CD changer deter-
WCM <vehicles with WCM> cannot be received, the mines that a problem has occurred.

.
<vehicles with KOS>
Malfunction of the WCM may be defective. <vehi-
cles with WCM>
Malfunction of radio and CD player or CD
changer may be defective.
DIAGNOSIS
TSB Revision
RADIO AND CD PLAYER


line.
CAUTION
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958, read the KOS-ECU

<vehicles with KOS> or WCM <vehicles with WCM>
Check again if the DTC is set to the KOS-ECU <vehicles with
KOS> or WCM <vehicles with WCM>.
Q: Is the DTC set?
42B, Diagnosis P.42B-20 <KOS> or GROUP 42C,
Diagnosis P.42C-14 <WCM>).
NO : Go to Step 3.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-251

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC U0195: Satellite radio tuner CAN timeout

If DTC U0195 is set in the radio and CD player or With the ignition switch in the ON position, system
CD changer, diagnose the CAN main bus line. voltage between 10 16 volts (data from
.
When the signals from satellite radio tuner cannot be occurred.
received, the radio and CD player or CD changer .
sets DTC U0195. TROUBLESHOOTING HINTS

.
defective.
The satellite radio tuner may be defective.
DIAGNOSIS
MB991824: V.C.I.
TSB Revision
RADIO AND CD PLAYER

line
CAUTION
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958 read the satellite radio

tuner diagnostic trouble code.
Check whether a satellite radio tuner DTCs are set or not.
(2) Check for satellite radio tuner DTCs.
YES : Go to Step 3.
NO : Diagnose the satellite radio tuner.

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-253

.
DIAGNOSTIC FUNCTION lished for 2,500 ms or more, the radio and CD player
When the signals from hands free module cannot be or CD changer determines that a problem has
received, the radio and CD player or CD changer occurred.
sets DTC U0197. .
defective.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
RADIO AND CD PLAYER

Q: Is the DTC set?
NO : Go to Step 3.

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
CAUTION
If there is any problem in the CAN bus lines, an incorrect
diagnostic trouble code may be set. Prior to this diagno-
sis, always diagnose the CAN bus lines.
CAUTION
Before replacing the radio and CD player or CD changer,
be sure to check that the power supply circuit, ground cir-
cuit, and communication circuit are normal.
.
TROUBLE JUDGEMENT
When the vehicle information data is not registered to the audio
unit, the radio and CD player or CD changer sets the diagnosis
code No.U1415.
.
COMMENTS ON TROUBLE SYMPTOM

The audio unit, ETACS-ECU, or CAN bus line may have a
problem.
.
PROBABLE CAUSES
Malfunctions of audio unit
Malfunction of CAN bus line wiring harness and connector
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-255
DIAGNOSIS

line.
CAUTION
AC404789
YES : Go to Step 2.
MB991824
MB991827 AC606941AB

DTC.
Q: Is the DTC set?
YES : Diagnose the ETACS-ECU (Refer to GROUP 54A,
ETACS-ECU, Diagnosis P.54A-482).
NO : Go to Step 3.
TSB Revision
RADIO AND CD PLAYER

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC B2420: Power integrated circuit

If there is any problem in the CAN bus lines, an If the radio and CD player or CD changer continu-
incorrect diagnostic trouble code may be set. ously apply the voltage of two volts or more to the
Prior to this diagnosis, always diagnose the CAN speakers for one minute or more, it is determined
bus lines. that the offset voltage is exceeded, and then the
CAUTION diagnostic trouble code is set.
Before replacing the radio and CD player or CD .
changer, be sure to check that the power supply COMMENTS ON TROUBLE SYMPTOM
circuit, ground circuit, and communication cir- The radio and CD player or CD changer or CAN bus
cuit are normal. line may have a problem.
.
PROBABLE CAUSES
Malfunctions of radio and CD player or CD
changer
Malfunction of CAN bus line wiring harness and
connector
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-257

line.
CAUTION
AC404789
YES : Go to Step 2.
MB991824
MB991827 AC606941AB

changer.
(1) Erase the DTC.
position.
TSB Revision
RADIO AND CD PLAYER
DTC B2421: Radio tuner

If there is any problem in the CAN bus lines, an If the communication cannot be established consec-
incorrect diagnostic trouble code may be set. utively for 10 times between the incorporated tuner of
Prior to this diagnosis, always diagnose the CAN radio and CD player or CD changer and the micro-
bus lines. computer, the diagnostic trouble code is set.
CAUTION .
Before replacing the radio and CD player or CD COMMENTS ON TROUBLE SYMPTOM

changer, be sure to check that the power supply The radio and CD player or CD changer or CAN bus
circuit, ground circuit, and communication cir- line may have a problem.
cuit are normal. .
PROBABLE CAUSES
.

changer
connector
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-259

line.
CAUTION
AC404789
YES : Go to Step 2.
MB991824
MB991827 AC606941AB

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
RADIO AND CD PLAYER
DTC B2423: 6-disc CD player error

If there is any problem in the CAN bus lines, an During the use of the CD changer of radio and CD
incorrect diagnostic trouble code may be set. changer, if any of the ERROR01, ERROR02,
Prior to this diagnosis, always diagnose the CAN ERROR03, or ERROR HOT continues for 1 minute,
bus lines. the diagnostic trouble code is set.
CAUTION .
Before replacing the radio and CD changer, be COMMENTS ON TROUBLE SYMPTOM

sure to check that the power supply circuit, The radio and CD changer or CAN bus line may
ground circuit, and communication circuit are have a problem.
normal. .
PROBABLE CAUSES
.
Malfunctions of radio and CD changer

connector
DIAGNOSIS

line.
CAUTION
AC404789
YES : Go to Step 2.
MB991910 Diagnosis P.54C-16).
MB991824
MB991827 AC606941AB
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-261
STEP 2. CD check
Playback a clean and unscratched CD for one minute, and
recheck if the diagnostic trouble code is set to the radio and CD
changer.
(1) Erase the diagnostic trouble code.
position.
(3) Playback the clean, unscratched CD for one minute.
(4) Check if diagnostic trouble code is set.
YES : Go to Step 3.
NO : Clean the CD, use a CD without scratches and burrs,
or remove the CD burrs, and then reinsert the CD.

Check again if the DTC is set to the radio and CD changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the radio and CD changer.
DTC B2424: CD player error
CAUTION TROUBLE JUDGMENT

If there is any problem in the CAN bus lines, an During the use of the CD player of radio and CD
incorrect diagnostic trouble code may be set. player, if any of the ERROR01, ERROR02,
Prior to this diagnosis, always diagnose the CAN ERROR03, or ERROR HOT continues for 1 minute,
bus lines. the diagnostic trouble code is set.
CAUTION .
Before replacing the radio and CD changer, be COMMENTS ON TROUBLE SYMPTOM

sure to check that the power supply circuit, The radio and CD player or CAN bus line may have a
ground circuit, and communication circuit are problem.
normal. .
PROBABLE CAUSES
.
Malfunctions of radio and CD player

connector
TSB Revision
RADIO AND CD PLAYER
DIAGNOSIS

line.
CAUTION
AC404789
YES : Go to Step 2.
MB991824
MB991827 AC606941AB
STEP 2. CD check
Playback a clean and unscratched CD for one minute, and
recheck if the diagnostic trouble code is set to the radio and CD
player.
(1) Erase the diagnostic trouble code.
position.
(3) Playback the clean, unscratched CD for one minute.
(4) Check if diagnostic trouble code is set.
YES : Go to Step 3.
NO : Clean the CD, use a CD without scratches and burrs,
or remove the CD burrs, and then reinsert the CD.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-263

Check again if the DTC is set to the radio and CD player.
(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the radio and CD player.
DTC B2450: Switch panel communication

.
CAUTION COMMENTS ON TROUBLE SYMPTOM

If there is any problem in the CAN bus lines, an The radio and CD player or CD changer, center
incorrect diagnostic trouble code may be set. panel assembly, or CAN bus line may have a prob-
Prior to this diagnosis, always diagnose the CAN lem.
bus lines.
.
CAUTION PROBABLE CAUSES

Before replacing the radio and CD player or CD Malfunctions of radio and CD player or CD
changer, be sure to check that the power supply changer
circuit, ground circuit, and communication cir- Malfunction of center panel assembly
cuit are normal. Malfunction of CAN bus line wiring harness and
.
TROUBLE JUDGEMENT connector

If the radio and CD player or CD changer cannot
establish the communication with center panel
assembly for 1 minute or more, the diagnostic trouble
code is set.
TSB Revision
RADIO AND CD PLAYER
DIAGNOSIS

line.
CAUTION
AC404789
YES : Go to Step 2.
MB991824
MB991827 AC606941AB
STEP 2. Connection status check of radio and CD player or

CD changer with center panel assembly
Check that the radio and CD player or CD changer are con-
nected to the center panel assembly without any problem.
Q: Is the connection established?
YES : Go to Step 3.
NO : Securely connect the radio and CD player or CD
changer with the center panel assembly.

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-265
DTC B2451: Audio panel type error

.
CAUTION COMMENTS ON TROUBLE SYMPTOM

If there is any problem in the CAN bus lines, an The center panel assembly or CAN bus line may
incorrect diagnostic trouble code may be set. have a problem.
Prior to this diagnosis, always diagnose the CAN
bus lines. .
.
PROBABLE CAUSES
TROUBLE JUDGEMENT Malfunction of center panel assembly
If the radio and CD player or CD changer consecu- Malfunction of CAN bus line wiring harness and
tively receive the display trouble signal from the cen- connector
ter panel assembly for 1 minute, the diagnostic
trouble code is set.
DIAGNOSIS

line.
CAUTION
AC404789
YES : Go to Step 2.
MB991824
MB991827 AC606941AB
TSB Revision
RADIO AND CD PLAYER

changer.
(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-267
M1544004900815

Procedure No. page
1 Power is not turned ON when the power switch is turned ON. P.54A-268
2 No sound is heard. <Vehicles with audio amplifier> P.54A-274
3 No sound is heard from one <Vehicles without audio amplifier> P.54A-279
of the speakers. <Vehicles with audio amplifier> P.54A-285
4 Noise Noise is present while moving (AM). P.54A-292
5 Noise is present while moving (FM). P.54A-293
6 Sound mixed with noise, only at night (AM). P.54A-294
7 Noise is overpowering both AM and FM. P.54A-294
8 Excessive noise on AM and FM. P.54A-295
9 Noise is detected with engine running. P.54A-296
10 Noise appears during vibration or shocks. P.54A-297
11 Noise is present while moving (FM). P.54A-299
12 Constant noise. P.54A-300
13 Radio No reception (AM). P.54A-300
14 Poor reception. P.54A-301
15 Distortion on AM and/or FM. P.54A-302
16 Distortion on FM only. P.54A-302
17 Auto select function inoperative, too few P.54A-303
automatic stations are selected.
18 Preset stations are erased. P.54A-304
19 CD player, CD changer CD cannot be Inserted. P.54A-304
20 No sound. (CD only). P.54A-305
21 CD sound skips. P.54A-305
22 Sound quality is poor. P.54A-306
23 CD cannot be ejected. P.54A-306
TSB Revision
RADIO AND CD PLAYER
SYMPTOM PROCEDURES
Inspection Procedure 1: Power is not turned ON when the power switch is turned ON.
CAUTION
Before replacing the ECU, ensure that the power supply circuit, the ground circuit and the communi-
cation circuit are normal.
Radio and CD Player or CD Changer Power Supply Circuit
FUSIBLE FUSIBLE
LINK 36 LINK 37
RELAY BOX
ENGINE
COMPARTMENT
ETACS-
ECU
ACC
RELAY 2
JOINT
CONNECTOR
RADIO AND CD PLAYER OR CD CHANGER
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-269
.
Connector: C-07 OPERATION

When the ignition switch is in the ON or ACC posi-
tion, the radio and CD player or CD changer power
can be turned ON. With the radio and CD player or
CD changer power ON, when the ignition switch is
turned to the OFF position, the power for radio and
CD player or CD changer is also turned OFF.
.

AC608145AP
Provided that the audio diagnostic trouble code is not
Connector: C-104 set, if the power for radio and CD player or CD
changer cannot be turned ON, the radio and CD
player or CD changer, or power supply circuit for
radio and CD player or CD changer may have a
problem, or the option coding information may be
inconsistent.
.
PROBABLE CAUSES
AC608146AC changer
Connectors: C-309, C-315, C-317
Junction block Option coding information inconsistency
C-317
C-309 (B)
C-315
AC608152 AC
DIAGNOSIS

(1) Operate scan tool MB991958 to read the ETACS-ECU
option coding information (Refer to GROUP 00, Coding
Table P.00-35).
(2) Check that the "AUDIO" is set to "enabled."
YES : Go to Step 2.
"AUDIO" to "enabled," and check the trouble
symptom.
TSB Revision
RADIO AND CD PLAYER

Check if the diagnostic trouble code is set to the ETACS-ECU.
YES : Troubleshoot the ETACS-ECU (Refer to GROUP
54A, ETACS, Diagnosis P.54A-482).
NO : Go to Step 3.
STEP 3. Check ETACS-ECU connector C-317 and radio and

CD player or CD changer connector C-104 for loose,
in the connector.
Q: Are ETACS-ECU connector C-317 and radio and CD
player or CD changer connector C-104 in good
condition?
YES : Go to Step 4.
NO : Repair or replace the damaged component(s) (Refer
P.00E-2). The steering remote control switch should
work normally.

connector C-317 (terminal 1) and radio and CD player or
CD changer connector C-104 (terminal 30).
Check the power supply lines (battery power supply) for
open circuit.
C-317 (terminal 1) and radio and CD player or CD
changer connector C-104 (terminal 30) in good
condition?
YES : Go to Step 5.

Check the input signal of ACC relay.
Turn the ignition switch to the ACC position.
conditions

YES : Go to Step 6.
NO : Refer to GROUP 54A, ETACS, Diagnosis Inspection
Procedure 1 "The ignition switch (ACC) signal is not
received" P.54A-529.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-271
STEP 6. Check the power supply circuit to the ETACS-ECU.

Measure the voltage at ETACS-ECU connector C-309.
harness-side connector.
OK: Battery voltage
Harness side: C-309 Q: Is the measured voltage battery voltage?
YES : Go to Step 8.
NO : Go to Step 7.
AC608254 AB

connector C-309 (terminal 2) and fusible link (37)
Check the power supply line for open circuit and short cir-
cuit.
C-309 (terminal 2) and fusible link (37) in good
condition?
YES : Go to Step 8.

in the connector.
YES : Go to Step 9.
NO : Repair or replace the damaged component (Refer to
GROUP 00E, Harness Connector Inspection
work normally.
TSB Revision
RADIO AND CD PLAYER

Measure the voltage at ETACS-ECU connector C-315.
(1) Disconnect the connector, and measure at the ETACS-ECU
side connector.
(3) Measure voltage between terminal 9 and ground.
OK: Battery voltage
Q: Is the measured voltage battery voltage?
Harness side: C-315

AC608254 AC
STEP 10. Check the wiring harness between radio and CD

player or CD changer connector C-104 (terminal 21) and
NOTE: Also check joint connector C-07 for loose, corroded, or
damaged terminals, or terminals pushed back in the connector.
If joint connector C-07 is damaged, repair or replace the con-
nector as described in GROUP 00E, Harness Connector
Inspection P.00E-2.
Q: Is the wiring harness between radio and CD player or
CD changer connector C-104 (terminal 21) and
ETACS-ECU connector C-315 (terminal 9) in good
condition?
STEP 11. Check the ground circuit to the radio and CD

player or CD changer. Measure the resistance at radio and
CD player or CD changer connector C-104.
harness side.
(2) Measure resistance between terminal 40 and ground.
OK: The resistance should be 2 ohm or less.
Harness side: C-104
NO : Go to Step 12.
AC608255 AB
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-273

player or CD changer connector C-104 (terminal 40) and
ground.
CD changer connector C-104 (terminal 40) and ground
in good condition?
YES : Check the trouble symptom.

Check if the radio and CD player or CD changer power is
turned ON.
NO : Replace the radio and CD player or CD changer.
TSB Revision
RADIO AND CD PLAYER
Inspection Procedure 2: No sound is heard. <Vehicles with audio amplifier>
CAUTION
Audio System Circuit
FUSIBLE
LINK 36
RELAY
BOX
AUDIO AMPLIFIER
RADIO AND CD PLAYER

OR CD CHANGER
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-275
.
Connectors: C-22, C-106 COMMENTS ON TROUBLE SYMPTOM

C-106
If the audio sound is not output, the radio and CD
changer, audio amplifier, or power supply circuit of
audio amplifier may have a problem, or the option
C-22 coding information may be inconsistent.
.
PROBABLE CAUSES
Malfunction of audio amplifier
AC608146AH
Option coding information inconsistency
Connectors: D-25, D-26 Damaged harness wires and connectors
D-26
D-25
AC608165AD
DIAGNOSIS
STEP 1. Check the ETACS-ECU coding data.

(1) Operate the scan tool MB991958 to read the ETACS-ECU
Table P.00-35).
(2) Check that the "Speaker" is set to "Premium."
YES : Go to Step 2.
"Speaker" to "Premium," and check the trouble
symptom.
STEP 2. Check audio amplifier connector D-25 for loose,

in the connector.
Q: Is audio amplifier connector D-25 in good condition?
YES : Go to Step 3.
P.00E-2).
TSB Revision
RADIO AND CD PLAYER
STEP 3. Check the ground circuit to the rear monitor.

Measure the resistance at audio amplifier connector D-25.
(1) Disconnect audio amplifier connector D-25, and measure
the resistance available at the wiring harness side of the
connector.
(2) Measure the resistance between terminal 24 and ground.
Harness side: D-25 OK: The resistance should be 2 ohms or less
AC608255 AC

OK: The resistance should be 2 ohms or less
Harness side: D-25
AC608255 AD

Harness side: D-25 Q: Is the measured resistance 2 ohms or less?
YES : Go to Step 5.
NO : Go to Step 4.
AC608255 AE
STEP 4. Check the wiring harness between audio amplifier

connector D-25 (terminal 24, 31, 32) and ground.
Q: Is the wiring harness between audio amplifier connector
D-25 (terminal 24, 31, 32) and ground in good condition?
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-277

Measure the voltage at audio amplifier connector D-25.
the voltage available at the wiring harness-side connector.
Harness side: D-25
AC608254 AD

Harness side: D-25
AC608254 AE

Harness side: D-25
positive voltage)?
YES : Go to Step 7.
NO : Go to Step 6.
AC608254 AF

connector D-25 (terminal 25, 35, 36) and fusible link (36).
cuit.
D-25 (terminal 25, 35, 36) and fusible link (36) in good
condition?
YES : Go to Step 7.
TSB Revision
RADIO AND CD PLAYER
STEP 7. Check radio and CD changer connector C-106 and

audio amplifier connector D-26 for loose, corroded or
connector.
Q: Are radio and CD changer connector C-106 and audio
amplifier D-26 in good condition?
YES : Go to Step 8.
P.00E-2).

changer connector C-106 (terminal 17) and audio amplifier
connector D-26 (terminal 3)
Check the communication lines for open circuit.
NOTE: Also check intermediate connector C-22 for loose, cor-
connector. If intermediate connector C-22 is damaged, repair or
Q: Is the wiring harness between radio and CD changer
connector C-106 (terminal 17) and audio amplifier
connector D-26 (terminal 3) in good condition?
YES : Go to Step 9.

Replace the audio amplifier, then check that the audio sound is
output.
NO : Replace the radio and CD changer.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-279
Inspection Procedure 3: No sound is heard from one of the speakers. <Vehicles without audio
amplifier>
CAUTION
Speaker System Circuit
TWEETER FRONT DOOR FRONT DOOR TWEETER

(LH) SPEAKER (LH) SPEAKER (RH) (RH)
JOINT
CONNECTOR
RADIO AND CD PLAYER

OR CD CHANGER
REAR DOOR REAR DOOR

SPEAKER (LH) SPEAKER (RH)
TSB Revision
RADIO AND CD PLAYER
Connectors: C-03, C-36, C-125, C-126 Connectors: E-03, E-11
C-03 E-03 (B)
C-125
C-36
C-126 (BR) E-11
AC608145AQ AC608168 AB
Connectors: C-21, C-104, C-114, C-115 Connector: E-23

C-104
C-114
C-21
C-115 (BR)
AC608146AI AC608170AB
Connector: D-01 Connector: E-24
AC608165AE AC608169AB
.
Connector: D-20 COMMENTS ON TROUBLE SYMPTOM

If the sound is not output from one of the speakers,
the speaker, AM/FM radio and CD player, communi-
cation line from the AM/FM radio and CD player to
the speakers may have a problem.
.
PROBABLE CAUSES
Malfunction of speaker
AC608166AB Malfunctions of radio and CD player or CD
changer
Connectors: E-02, E-13 Damaged harness wires and connectors
E-02 (B)
E-13 AC608167 AB
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-281
DIAGNOSIS

(1) Operate the scan tool to read the ETACS-ECU option
coding information (Refer to GROUP 00, Coding Table
P.00-35).
(2) Check that the "Speaker" is set to "6 speakers" or "4
speakers."
YES : Go to Step 2.
NO : Operate the scan tool to set the option coding
"Speaker" to "6 speakers" or "4 speakers," and check
the trouble symptom.
STEP 2. Checking with audio speaker check

Perform the audio speaker check, and check which speaker
does not output the sound (Refer to P.54A-441).
NOTE: In the following procedure, check the speaker or
tweeter that is abnormal.
YES (normal for all) : The trouble can be an intermittent
malfunction (Refer to GROUP 00 How to use
NO (abnormal for all) : Check the radio and CD player or
CD changer power supply and ground circuit, and
repair if necessary. If the radio and CD player or CD
changer power supply and ground circuit is normal,
replace the audiovisual navigation unit.
NO (Either a speaker is abnormal) : Go to Step 3.
STEP 3. Check door speaker connector E-13 <front-LH>,

E-11 <front-RH>, E-23 <rear-LH> or E-24 <rear-RH>, or
tweeter connector E-02 <LH> or E-03 <RH> for loose,
in the connector.
Q: Is door speaker connector E-13 <front-LH>, E-11
<front-RH>, E-23 <rear-LH> or E-24 <rear-RH>, or
tweeter connector E-02 <LH> or E-03 <RH> in good
condition?
YES : Go to Step 4.
P.00E-2).
TSB Revision
RADIO AND CD PLAYER
STEP 4. Check the speaker or tweeter.

(1) Remove the speaker or tweeter (Refer to P.54A-443).
(2) Check that the speaker or tweeter outputs the noise when
the voltage of 5 V is applied to the speaker or tweeter
connector terminal.
Q: Does the speaker or tweeter output the noise?
YES : Go to Step 5.
NO : Replace the speaker or tweeter.
STEP 5. Check radio and CD player or CD changer

connector C-104 for loose, corroded or damaged
Q: Is radio and CD player or CD changer connector C-104
in good condition?
YES : Go to Step 6.
P.00E-2).
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-283
STEP 6. Check the wiring harness between the speaker or

tweeter connector terminal and the radio and CD player or
CD changer connector terminal.
<Front door speaker (LH)> Check the wiring harness
between front door speaker (LH) connector E-13 (terminal
1, 2) and radio and CD player or CD changer connector
C-104 (terminal 28, 38).
connector C-125 for loose, corroded, or damaged terminals,
C-03 or intermediate connector C-125 is damaged, repair or
<Front door speaker (RH)> Check the wiring harness
between front door speaker (RH) connector E-11 (terminal
C-104 (terminal 26, 36).
<Rear door speaker (LH)> Check the wiring harness
between rear door speaker (LH) connector E-23 (terminal 1,
2) and radio and CD player or CD changer connector C-104
(terminal 27, 37).
NOTE: Also check intermediate connectors C-36 and D-20
C-36 or D-20 is damaged, repair or replace the connector
tion P.00E-2.
<Rear door speaker (RH)> Check the wiring harness
between rear door speaker (RH) connector E-24 (terminal
C-104 (terminal 25, 35).
NOTE: Also check intermediate connectors C-21 and D-01
C-21 or D-01 is damaged, repair or replace the connector
tion P.00E-2.
<Tweeter (LH)> Check the wiring harness between tweeter
(LH) connector E-02 (terminal 1, 2) and radio and CD player
or CD changer connector C-104 (terminal 38, 28).
TSB Revision
RADIO AND CD PLAYER

<Tweeter (RH)> Check the wiring harness between tweeter
(RH) connector E-03 (terminal 1, 2) and radio and CD
player or CD changer connector C-104 (terminal 36, 26).
Q: Is the wiring harness between the speaker or tweeter
connector terminal and the radio and CD player or CD
changer connector terminal in good condition?
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-285
Inspection Procedure 3: No sound is heard from one of the speakers. <Vehicles with audio amplifier>
CAUTION
FRONT DOOR FRONT DOOR

SPEAKER (LH) SPEAKER (RH) SUB WOOFER
AUDIO AMPLIFIER
TWEETER TWEETER REAR DOOR REAR DOOR

(LH) (RH) SPEAKER SPEAKER
(LH) (RH)
TSB Revision
RADIO AND CD PLAYER
AUDIO AMPLIFIER
RADIO AND CD CHANGER
Connectors: C-22, C-104, C-114, C-115 Connectors: D-15, D-20

C-104
C-114
C-22
C-115 (BR) D-15
D-20
AC608146AJ AC608166AC
Connectors: C-125, C-126 Connectors: E-02, E-13
E-02 (B)
C-125
C-126 (BR) E-13
AC608145AR AC608167 AB
Connectors: D-01, D-25, D-26 Connectors: E-03, E-11
E-03 (B)
D-01
D-26
D-25
E-11 AC608168 AB
AC608165AF
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-287
Connector: E-23 Connector: F-22
F-22 (B)
AC608170AB AC608171AB
.
Connector: E-24 COMMENTS ON TROUBLE SYMPTOM

If the sound is not heard from one of the speakers,
the speaker, radio and CD changer, audio amplifier,
communication line from the radio and CD changer
to the audio amplifier, or communication line from the
audio amplifier to the speaker may have a problem.
Also, the option coding information may be inconsis-
tent.
.
AC608169AB
PROBABLE CAUSES
DIAGNOSIS

Table P.00-35).
YES : Go to Step 2.
symptom.
TSB Revision
RADIO AND CD PLAYER

malfunction (Refer to GROUP 00 How to use
NO (abnormal for all) : Check the radio and CD changer
power supply and ground circuit, and repair if
necessary. If the radio and CD changer power supply
and ground circuit is normal, replace the audiovisual
navigation unit.

tweeter connector E-02 <LH> or E-03 <RH>, or sub woofer
connector F-22 for loose, corroded or damaged terminals,
tweeter connector E-02 <LH> or E-03 <RH>, or sub
woofer connector F-22 in good condition?
YES : Go to Step 4.
P.00E-2).
STEP 4. Check the speaker, tweeter or subwoofer.

(1) Remove the speaker, tweeter or subwoofer (Refer to
P.54A-443).
connector terminal. <speaker or tweeter>
(3) Check that the subwoofer outputs the noise when the
voltage of 5 V is applied to the subwoofer connector
terminal. <subwoofer>
YES : Go to Step 5.
NO : Replace the speaker, tweeter or subwoofer.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-289
STEP 5. Check audio amplifier connector D-25 <front door

speaker or sub woofer> or D-26 <rear door speaker or
tweeter> for loose, corroded or damaged terminals, or
Q: Is audio amplifier connector D-25 <front door speaker or
sub woofer> or D-26 <rear door speaker or tweeter> in
good condition?
YES : Go to Step 6.
P.00E-2).
TSB Revision
RADIO AND CD PLAYER
STEP 6. Check the wiring harness between the speaker,

tweeter or sub woofer connector terminal and the audio
amplifier connector terminal.
1, 2) and audio amplifier connector D-25 (terminal 28, 38).
NOTE: Also check intermediate connectors C-22 and
C-125 for loose, corroded, or damaged terminals, or termi-
nals pushed back in the connector. If intermediate connec-
tor C-22 or C-125 is damaged, repair or replace the
connector as described in GROUP 00E, Harness Connec-
tor Inspection P.00E-2.
NOTE: Also check intermediate connectors C-22 and C-114
C-22 or C-114 is damaged, repair or replace the connector
tion P.00E-2.
2) and audio amplifier connector D-26 (terminal 1, 7).
NOTE: Also check intermediate connector D-20 for loose,
in the connector. If intermediate connector D-20 is dam-
(LH) connector E-02 (terminal 1, 2) and audio amplifier con-
nector D-26 (terminal 14, 6).
(RH) connector E-02 (terminal 1, 2) and audio amplifier con-
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-291
tion P.00E-2.
<Subwoofer> Check the wiring harness between subwoofer
connector F-22 (terminal 1, 2, 3, 4) and audio amplifier con-
nector D-25 (terminal No.30, 22, 29, 21).
Q: Is the wiring harness between the speaker, tweeter or
sub woofer connector terminal and the audio amplifier
connector terminal in good condition?
YES <front door speaker> : Go to Step 7.
YES <except front door speaker> : Go to Step 9.
NO (harness wire is abnormal) : Repair or replace the
damaged component (Refer to GROUP 00E, Harness
Connector Inspection P.00E-2).
STEP 7. Check radio and CD changer connector C-104 for

Q: Is radio and CD changer connector C-104 in good
condition?
YES : Go to Step 8.
P.00E-2).
STEP 8. Check the harness wire between radio and CD

changer connector C-104 (terminal 26, 28, 36, 38) and
audio amplifier connector D-26 (terminal 10, 4, 11, 12).
Q: Is the wiring harness between radio and CD changer
connector C-104 (terminal 26, 28, 36, 38) and audio
amplifier connector D-26 (terminal 10, 4, 11, 12) in good
condition?
YES : Check the trouble symptom, go to Step 9.
P.00E-2).
TSB Revision
RADIO AND CD PLAYER
STEP 9. Replace the audio amplifier temporarily, and

check the trouble symptom.
Replace the audio amplifier temporarily, and check that the
sound is output from the speaker.
YES : Replace the audio amplifier.
NO : Replace the radio and CD changer.
INSPECTION PROCEDURE 8: Noise is Present while Moving (AM).
DIAGNOSIS STEP 3. Check if the noise can be eliminated by

adjusting the radio.
STEP 1. Ask the driver about the noise. (1) Adjust the radio as follows.
(1) Find out the following information from the owner. (2) Change to a different station with a stronger
(2) Place where the noise occurs. signal. This will boost the systems resistance to
(3) Locality conditions (valley, mountain, etc.) outside interference.
(4) Name and frequency of stations affected by noise (3) Suppress high tones to reduce noise.
Q: What type of noise is detected, vehicle noise or Q: Has the noise been eliminated?
external noise? YES : The noise has now been eliminated. Inform
Vehicle noise : It may not be possible to prevent the customer that it is normal to hear noise
noise if the signal is weak. Go to step 2. while receiving a weak station.
External noise : In almost all cases, prevention on NO : Go to Step 4.
the receiver side is next to impossible when
the signal is weak. Go to Step 4. STEP 4. Check for the noise.
Q: Does noise still exist?
STEP 2. Ask the driver about the location where YES : If there is still more noise than on other
the noise occurs similar radios find out the type of noise. Ask
Q: Does the noise occur when entering or near a the owner for the name and frequency of the
particular structure (building, tunnel, mountain, affected stations, and consult with the radio
etc.)? manufacturer service center.
YES : Go to Step 3. NO : System is operating normally.
NO : Go to Step 4.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-293
INSPECTION PROCEDURE 9: Noise is Present while Moving (FM).
FIRST FADING
INTERFERENCE
MALTIPATH INTERFERENCE
FOR STEREO:
20 - 25 km
10kW (12 - 16 miles)
OUTPUT FM
BROAD CAST FOR MONAURAL:
30 - 40 km (19 - 25 miles)
FOR HOME STEREO: ACX01869 AC

80 - 90 km (50 - 56 miles)
4. Since FM stereo transmission and reception has a

.
DIAGNOSIS
weaker field than monaural, it is often
NOTE: FM waves have the same properties as light, accompanied by a hissing noise.
and can be deflected and blocked. FM signal recep- After taking measures to prevent the noise, check
tion is severely degraded in the shadow of obstruc- that no noise occurs.
tions such as buildings or mountains. An FM receiver 5. Change to a different station with a stronger wave
will then only receive a reflected signal. to boost resistance to interference.
1. The signal becomes weak as the distance from
6. Suppress high tones to reduce noise.
the station's transmission antenna increases. The
signal strength received depends on the signal 7. Does vehicle have an antenna which extends? If
strength of the transmitting station and intervening not eliminate this step.
obstructions such as buildings and hills. Generally If there is noise, the following causes can be consid-
speaking, the area of good reception is ered.
approximately 20 25 km (12 16 miles) for stereo 8. If due to vehicle noise: It may not be possible to
reception, and 30 40 km (19 25 miles) for prevent noise if the signal is weak.
monaural reception. 9. If due to external noise: In almost all cases,
2. The signal will becomes weak when an area of prevention on the receiver side is not possible.
shadow from the transmitting antenna (places Weak signals especially are susceptible to
where there are obstructions such as mountains interference.
or buildings between the station transmitter and If there is more noise than on radios in other vehi-
the vehicle), and noise will appear. <This is called cles, find out the noise condition and the name and
first fading, and gives a steady buzzing noise.> frequency of the receiving stations from the owner,
and consult with the radio manufacturer's service
3. If a direct signal hits the antenna at the same time
center.
as a signal reflected by obstructions such as
mountains or buildings, interference of the two
signals will generate noise. When moving, noise
will appear each time the vehicle's antenna
passes through this kind of obstructed area. The
strength and interval of the noise varies according
to the signal strength and the conditions of
deflection. <This is called multipath noise, and is a
repetitive buzzing.>
TSB Revision
RADIO AND CD PLAYER
INSPECTION PROCEDURE 10: Sound mixed with Noise, Only at Night (AM).
The following can be considered as possible causes STEP 2. Check that the following actions
of noise appearing only at night. disappear the noise.
1. It is significantly easier to receive long-distance Tune to a station with a stronger signal.
signals at night. This means that even stations
that are received without a problem during the day Q: Is there more noise than on radio in other
may experience problems at night. Remember vehicles?
YES : Consult the radio manufacturer's service
that the weaker station is more susceptible to
center.
interference. The appearance of a beat sound
NO : Check that there is no noise.
may occur in the evening. A beat sound is created
when two signals close in frequency interfere with
each other. A common sign of this type of STEP 3. Check that the noise fades away when
interference is a repetitious high-pitched sound the vehicle harness is moved away from the
that may over power the desired radio station. radio (if the harness is not in the proper
This sound is generated not only by sound signals position).
but electrical waves as well. Q: Does the noise fade away when the vehicle
2. The changing system may also be a source of harness is moved any from the radio (If the
noise. When diagnosing radio noise, do not over harness is not in the proper position)?
look the possibility of a problem with the vehicles YES : Consult the radio manufacturer's service
generator. center.
NO : If there is more noise than other radios,
DIAGNOSIS consult the radio manufacturer's service
center.
STEP 1. Check the vehicles lighting system.

Q: Does the noise disappear when the vehicles
headlights are turned "OFF"?
YES : Go to Step 2.
NO : Go to Step 3.
INSPECTION PROCEDURE 11: Noise is Overpowering both AM and FM.
DIAGNOSIS STEP 3. Verify that the following actions

disappear the noise.
STEP 1. Check the state of the antenna. (1) Tune to a station with a stronger wave.
(2) Extend the antenna completely (Mast antenna).
Q: Is the mast antenna assembled? (3) Adjust the sound quality to suppress high tones.
YES : Go to Step 2.
NO : Assemble the mast antenna. Check to see Q: Is the noise eliminated?
that the noise is gone. YES : Consult the radio manufacturer's service
center.
NO : Go to Step 4.
STEP 2. Verify that the noise occur when the
engine is stopped or the engine is running.
Q: Does noise occur when the engine is stopped or
the engine is running?
When the engine is stopped : Go to Step 3.
When the engine is running : Check the vehicle's
noise suppressor. (Refer to Inspection
Procedure 11 P.54A-296).
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-295
STEP 4. Verify that the radio is correctly STEP 6. Verify that the noise is eliminated when
grounded the antenna plug is properly attached.
The radio is connected to the ground with an assem- Q: Is the noise eliminated?
bling screw. YES : Consult the radio manufacturer's service
Q: Is the radio correctly grounded? center.
YES : Go to Step 5. NO : Go to Step 7.
NO : Consult the radio manufacturer's service
center. STEP 7. Verify that the antenna is in good
condition and is it properly mounted.
STEP 5. Check the connection of the antenna Q: Is the antenna in good condition and is it properly
plug and radio and CD player. mounted?
Q: Is the antenna plug thoroughly connected to the YES : Consult the radio manufacturer's service
radio and CD player? center.
YES : Go to Step 7. NO : Either repair or replace the antenna
NO : Go to Step 6. assembly. Check to see that the noise is
gone.
INSPECTION PROCEDURE 12: Excessive Noise on AM and FM.

.
DIAGNOSIS STEP 2. Compare the customers radio to another

Radio reception can be affected by Radio Frequency identical model.
(RF) emissions from a variety of sources. The distur- Operate the radio in a vehicle with a known good
bance is even greater if the station is weak or poorly audio system of the same type as the customer's.
tuned. FM reception is not as sensitive to distur- Q: Is there more noise on the customers radio?
bances as AM. AM reception is sensitive to electrical YES : Check all power and ground connections. If
disturbances such as power lines, lightening and all connections are in good condition,
other types of similar electrical phenomena. consult the radio manufacturers service
center.
STEP 1. Check if the customer heard the noise NO : The observed noise is normal.
under any of the following conditions.
A motorcycle was passing.
Lighting was flashing.
Passed beneath a power line.
Passed beneath a telephone line.
Passed by a signal generator.
Passed by any other sources of electrical noise.
Passed under a bridge or through a tunnel.
Q: Did the noise occur during any of the
circumstances listed above?
YES : The observed noise is normal.
NO : Go to Step 2.
TSB Revision
RADIO AND CD PLAYER
INSPECTION PROCEDURE 13: Noise is Detected with Engine Running.
audio unit. In the case of the compressor clutch a

.
DIAGNOSIS "pop" will be heard through the speakers. The capac-

CAUTION itor, installed on this vehicle, will store the excess
Never connect a noise filter to the high ten- voltage and prevent the production of RF noise. This
sion cable (spark plug wire). Spark plug wires is because the capacitor will charge and discharge
incorporate resistors which have the effect of as the voltage fluctuates. This has the effect of
suppressing noise. If a spark plug wire is "attracting" noise and bleeding it to ground without
found to be causing noise, it must be interfering with the normal flow of current through the
replaced. system.
Confirm that the noise is not from an external
source.
Noise prevention should be performed by
suppressing strong sources of noise first.
NOTE: Voltage surges can be induced in the electri-
cal system by the collapse of a field (i.e. When power
is removed from the coil in an A/C compressor
clutch). This induced voltage surge will radiate a
Radio Frequency (RF) signal that is picked up by the
Description of noise Condition Cause Solution
AM, FM: ignition noise Increasing the engine Electrical interference Check or replace the
(popping, snapping, speed causes the from the spark plugs. ground cable.
cracking, buzzing) generator whine to Engine noise. Check or replace
speed up and the spark plug wires.
volume to decrease. Check or replace the
Disappears when the noise capacitor.
ignition switch turned
to "ACC", and engine
is off.
Other electrical - Noise may intensify Repair or replace the
components due to aging electrical electrical components.
components.
Static electricity (cracking, Noise disappears when Noise occurs when Return parts or wiring
crinkling) the vehicle is completely parts or wiring move to their proper
stopped. and contact vehicle position.
body.
Static electricity (cracking, Various noises are This may be due to Properly ground parts.
crinkling) produced depending the recent removal of Properly ground all
on the body part of the the front hood, body parts.
vehicle. bumpers, exhaust
pipe and muffler,
suspension, etc.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-297
Engine mount
Ground cable Noise capacitor
AC207027AC AC207588AC
Noise capacitor
AC207589AC
INSPECTION PROCEDURE 14: Noise Appears During Vibration or Shocks.
AC608146AC AC608165AG
DIAGNOSIS
STEP 1. Check the fit of the mast antenna.

Q: Is the mast antenna base fitted securely?
YES : Go to Step 2.
NO : Install the mast antenna, and tighten the mounting nut
(Refer to P.54A-447). Check that there is no noise.
STEP 2. Check the fit of antenna feeder cable.

Q: Is the antenna feeder cable fitted securely?
YES : Go to Step 3.
NO : Ensure that the antenna base and the radio and CD
player are fitted securely. Check that there is no
noise.
TSB Revision
RADIO AND CD PLAYER

connector C-104 and amplifier connector D-26 for loose,
in the connector.
Q: Are radio and CD player or CD changer connector C-
104 and amplifier connector D-26 in good condition?
YES : Go to Step 4.
P.00E-2. Check that there is no noise.
STEP 4. Check that noise appears when the radio switch is

turned on while the vehicle is stopped and the radio is
tapped while tuned away from a station.
NOTE: Body static electricity from the shock absorber rubber
bushings used to prevent vibration, tires, etc. occurs because
of separation from the ground, causing a buzzing noise. Since
no measures can be taken to discharge the static electricity of
the vehicle body. Check that there is no noise.
Q: Does noise appear when the radio switch is turned on
while the vehicle is stopped and the radio is tapped
while tuned away from a station?
YES : Go to Step 5.
NO : It may be static electricity noise.
STEP 5. Verify that the radio is correctly grounded.

The radio is connected to the ground with an assembling
screw.
Q: Is the radio correctly grounded?
YES : Go to Step 6.
NO : Tighten the screw securely. Check that there is no
noise.
STEP 6. Check by replacing radio and CD player or radio,

CD player and CD changer.
Q: Do the other radio and CD player or radio, CD player
and CD changer work normally?
YES : Either repair or replace the original radio and CD
player or radio, CD player and CD changer. Check
that there is no noise.
NO : Either repair or replace the antenna assembly. Check
that there is no noise.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-299
INSPECTION PROCEDURE 15: Noise is Present While Moving (FM).
DIAGNOSIS STEP 4. Check that noise appears when the radio

switch is turned on while the vehicle is stopped.
STEP 1. Check the state of the antenna. NOTE: Body static electricity from the shock
Q: Is the mast antenna assembled?
absorber rubber bushings used to prevent vibration,
YES : Go to Step 2. tires, etc. occurs because of separation from the
NO : Assemble the mast antenna. Check that ground, causing a buzzing noise. There is no mea-
there is no noise. sures to discharge the static electricity of the vehicle
body. Check that there is no noise.
STEP 2. Check the radio after adjusting it. Q: Does noise appear when the radio switch is turned
on while the vehicle is stopped and the radio is
Q: Readjust the radio. Is the noise eliminated? tapped while tuned away from a station?
YES : Check that there is no noise. YES : Go to Step 5.
NO : Go to Step 3. NO : It may be static electricity noise.
STEP 3. Check with several broad casting. STEP 5. Verify that the radio is correctly
NOTE: Multipath noise and fading noise: Because of grounded.
the frequency of FM waves in extremely high, it is The radio is connected to the ground with an assem-
highly susceptible to effects from geological forma- bling screw.
tions and buildings. These effects disrupt the broad- Q: Is the radio correctly grounded?
cast signal and obstruct reception in several ways. YES : Go to Step 6.
. NO : Tighten the screw securely. Check that
Multipath noise there is no noise.
This describes the echo that occurs when the
broadcast signal is reflected by a large obstruc-
STEP 6. Check by replacing radio and CD player
tion and enters the receiver with a slight time
or radio, CD player and CD changer.
delay relative to the direct signal (repetitious
buzzing). Q: Do the other radio and CD player or radio, CD
Fading noise player and CD changer work normally?
This is a buzzing noise that occurs when the YES : Either repair or replace the original radio
broadcast signal is disrupted by obstructing and CD player or radio, CD player and CD
objects and the signal strength fluctuates intri- changer. Check that there is no noise.
cately within a narrow range. NO : Either repair or replace the antenna
assembly. Check that there is no noise.
Q: Is the problem station or location specific?
YES : The effect of an electrical field condition
(multipath noise, fading noise) could be the
cause. Check that there is not noise.
NO : Go to Step 4.
TSB Revision
RADIO AND CD PLAYER
INSPECTION PROCEDURE 16: Constant Noise.
DIAGNOSIS Time period

. If there are still problems with noise, even after per-
Use the Symptom Chart to diagnose the possible forming inspection procedures 8 to 15, obtain infor-
cause(s) of the noise. Noise is often created by the mation on the factors listed above. Determine
following factors: whether the problem occurs on AM or FM, the station
Traveling conditions of the vehicle names, frequencies, etc. and contact the radio man-
Terrain of area traveled through ufacturer's service center.
Surrounding buildings
Signal conditions
INSPECTION PROCEDURE 17: No Reception (AM).
DIAGNOSIS STEP 4. Tune the radio, and then check it.

Q: Did the sensitivity improve after tuning?
STEP 1. Check the state of the antenna. YES : There is no action to be taken.
Q: Is the mast antenna assembled? NO : Go to Step 5.
YES : Go to Step 2.
NO : Assemble the mast antenna. The radio STEP 5. Check the connection of the antenna
should sound normally. plug and radio and CD player or radio, CD player
and CD changer.
STEP 2. Check to see if inspections are taking Q: Is the antenna plug thoroughly connected to the
place is an area exposed to special electric radio and CD player or radio, CD player and CD
fields. changer?
YES : Go to Step 6.
Q: Are inspections taking place under special electric
NO : Thoroughly connect the antenna plug and
field conditions (underground garage, inside a
building, etc.)? the radio and CD player or radio, CD player
YES : Go to Step 3. and CD changer. The radio should sound
NO : Go to Step 4. normally.
STEP 3. Move the vehicle and check the radio. STEP 6. Check by replacing radio and CD player
Move the vehicle to a good reception area that is not or radio, CD player and CD changer.
exposed to special electric fields. Q: Do the other radio and CD player or radio, CD
Q: Is reception of the strongest radio frequency player and CD changer work normally?
possible within the area? YES : Either repair or replace the original radio
YES : There is no action to be taken. and CD player or radio, CD player and CD
NO : Go to Step 4. changer. The radio should sound normally.
NO : Either repair or replace the antenna
assembly. The radio should sound normally.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-301
INSPECTION PROCEDURE 18: Poor Reception.
DIAGNOSIS STEP 5. Check with several broadcasting

stations.
STEP 1. Check the state of the antenna. NOTE: Two types of noise are addressed in this pro-
Q: Is the mast antenna assembled?
cedure, multipath and fading noise. The frequency of
YES : Go to Step 2. FM waves is extremely high. This makes them sus-
NO : Assemble the mast antenna. Check that a ceptible to effects from geological formations and
poor reception is resolved. buildings. These effects disrupt the broadcast signal
and obstruct reception in many ways.
.
STEP 2. Check to see if inspections are taking Multipath noise is the echo that occurs when the
place is an area exposed to special electric broadcast signal is reflected by a large obstruc-
fields. tion and enters the receiver with a slight time
Q: Are inspections taking place under special electric delay relative to the direct signal (repetitious
field conditions (underground garage, inside a buzzing).
building, etc.)? A fading or buzzing noise may occur when the
YES : Go to Step 3. broadcast beam is disrupted by obstructing
NO : Go to Step 4. objects and the signal strength fluctuates within a
narrow range.
STEP 3. Move the vehicle and check the radio. Q: Is the abnormality in reception generated only
Move the vehicle to a good reception area that is not within a certain range?
exposed to special electric fields. YES : Check that a poor reception is resolved.
Q: Is reception of the strongest radio frequency NO : Go to Step 6.
possible within the area?
YES : Check that a poor reception is resolved. STEP 6. Check the connection of the antenna
NO : Go to Step 4. plug and radio and CD player or radio, CD player
and CD changer.
STEP 4. Tune the radio, and then check it. Q: Is the antenna plug thoroughly connected to the
Q: Did the sensitivity improve after tuning? radio and CD player or radio, CD player and CD
YES : Check that a poor reception is resolved. changer?
NO : Go to Step 5. YES : Go to Step 7.
NO : Thoroughly connect the antenna plug and
the radio and CD player or radio, CD player
and CD changer. Check that a poor
reception is resolved.
STEP 7. Check by replacing radio and CD player

or radio, CD player and CD changer.
Q: Do the other radio and CD player or radio, CD
player and CD changer work normally?
YES : Either repair or replace the original radio
and CD player or radio, CD player and CD
changer. Check that a poor reception is
resolved.
assembly. Check that a poor reception is
resolved.
TSB Revision
RADIO AND CD PLAYER
INSPECTION PROCEDURE 19: Distortion on AM and/or FM.
DIAGNOSIS STEP 4. Remove the speakers, and check the

paper cone for foreign material or damage.
STEP 1. Check the level of distortion. Q: Is there foreign material or damage on the paper
Q: How much distortion is there? cone of the speaker?
Occasional distortion : Go to Step 2. YES : Repair or replace the speakers. The
Constant distortion : Go to Step 3. speaker should now be free of distortion.
NO : Go to Step 5.
STEP 2. Check the location of the distortion.

STEP 5. Check for distortion with the speaker
Q: Is there distortion when the vehicle is near the installed.
radio station?
YES : The antenna is receiving too strong a signal. Q: Does a distortion occur?
NO : Go to Step 3. YES : Install the speaker securely. The speaker
should now be free of distortion.
NO : Repair or replace the radio and CD player.
STEP 3. Check the wires at each speaker. The speaker should now be free of
Q: Are the speaker wires contacting the paper distortion.
speaker cone?
YES : Move the speaker wires away from the
paper speaker cone. The speaker should
now be free of distortion.
NO : Go to Step 4.
INSPECTION PROCEDURE 20: Distortion on FM Only.
DIAGNOSIS STEP 2. Relocate the reception area and check

the radio.
STEP 1. Check that the distortion is present Q: When relocating the reception area does the
when the radio is tuned to another station. distortion increase or decrease?
YES : The cause may be multipath or fading
Q: Does the distortion persist when the radio is tuned
to another station? noise. Multipath noise is the echo that
YES : Go to Step 2. occurs when the broadcast signal is
NO : The signal from that station is too weak. reflected by a large obstruction and enters
the receiver with a slight time delay relative
to the direct signal (repetitious buzzing). A
fading or buzzing noise may occur when the
broadcast beam is disrupted by obstructing
objects and the signal strength fluctuates
within a narrow range.
NO : Replace the radio and CD player. Check
that a distortion is resolved.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-303
INSPECTION PROCEDURE 21: Auto Select Function Inoperative, too Few Automatic Stations are
Selected.
DIAGNOSIS STEP 5. Check to see if inspections are taking

place is an area exposed to special electric
STEP 1. Check the state of the antenna. fields.
Q: Is the mast antenna assembled? Q: Are inspections taking place under special electric
YES : Go to Step 2. field conditions (underground garage, inside a
NO : Assemble the mast antenna. The building, etc.)?
auto-select function should operate YES : Go to Step 6.
NO : Go to Step 7.
normally.
STEP 2. Check the number of radio stations. STEP 6. Relocate and check.
Automatically receive in a good reception area that is
Q: Are there sufficient numbers of radio stations not exposed to special electric fields.
within the area?
YES : Go to Step 3. Q: Is reception of the strongest radio frequency
NO : Go to Step 4. possible within the area?
NO : Go to Step 7.
STEP 3. Check the distance from the
transmission antenna.
STEP 7. Check the connection of the antenna
Q: Is there a transmission antenna within a range of 2 feeder cable and radio and CD player or radio,
miles? CD player and CD changer.
YES : Go to Step 5.
NO : Go to Step 4. Q: Is the antenna feeder cable thoroughly connected
to the radio and CD player or radio, CD player and
CD changer?
STEP 4. The check if there are not that many YES : Repair or replace the radio and CD player
radio stations and when there is no transmission or radio, CD player and CD changer. The
antenna in the vicinity. auto-select function should operate
Execute automatic selection and check to see that normally.
the strongest radio frequency is receivable within the NO : Thoroughly connect the antenna feeder
area. cable and the radio and CD player or radio,
Q: Is reception of the strongest radio frequency CD player and CD changer. The auto-select
possible within the area? function should operate normally.
NO : Go to Step 5.
TSB Revision
RADIO AND CD PLAYER
INSPECTION PROCEDURE 22: Preset Stations are Erased.

. .
CIRCUIT OPERATION TROUBLESHOOTING HINTS

Power is continuously supplied to the radio and CD Damaged wiring harness or connector
player or CD changer. Malfunction of the radio and CD player or CD
.
changer
The cause is probably a faulty radio and CD player or DIAGNOSIS
CD changer memory backup power supply system Refer to Inspection Procedure 1P.54A-268.
circuit.
INSPECTION PROCEDURE 23: CD can not be Inserted.
DIAGNOSIS Q: Though the CD is inserted completely, is 'E01'

(vehicles with center display low type) or 'ERROR
01' (vehicles with center display middle type)
STEP 1. Check that a CD has been already displayed and the CD ejected?
loaded. YES : Go to Step 4.
Q: Has a CD been already loaded?
YES : Take out the CD (If the CD can not be
ejected, refer to INSPECTION STEP 4. Check the CD.
PROCEDURE 27 P.54A-306). Check that a Check the CD for the conditions below:
CD can be inserted. Is the CD loaded with its label facing down?
NO : Go to Step 2. Is the recorded face dirty or scratched?
Is there dew on the recorded face?
STEP 2. Check how a CD is inserted. Q: Is the CD in good condition?
Ensure that the ignition switch is at 'ACC' or 'ON'. YES : Go to Step 5.
NOTE: If you try to load a CD when the ignition NO : The original CD is defective. Check that a
switch is at the positions other than 'ACC' or 'ON,' the CD can be inserted.
CD will not be inserted completely and then rejected.
Q: If you try to load the CD, does the CD stops halfway STEP 5. Check again using a normal CD, which is
and then rejected? not dirty or scratched.
YES : Refer to INSPECTION PROCEDURE 27 Load another normal CD.
P.54A-306. Check that the CD player recognizes and play the
NO : Go to Step 3. CD.
Q: When you substitute another normal CD, is the CD
STEP 3. Check after the CD is loaded. loaded correctly?
YES : The original CD is defective. Check that a
NOTE: Even though the CD is loaded, 'E01' (vehi-
CD can be inserted.
cles with center display low type) or 'ERROR 01' NO : Replace or repair the CD player. Check that
(vehicles with center display middle type) sometimes a CD can be inserted.
displayed with the CD rejected because of vibra-
tion/shock or dew on the CD face or optical lens.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-305
INSPECTION PROCEDURE 24: No Sound. (CD Only)
DIAGNOSIS STEP 2. Check power supply to the CD player

when the ignition switch is at "ACC" or "ON"
STEP 1. Check again using another CD, which is position.
not dirty or scratched. Q: Is the radio and CD player energized when the
Q: When you substitute another normal CD, is the CD ignition switch is turned to the "ACC" or "ON"
played normally? position?
YES : The original CD is defective. The CD player YES : Replace the audio. The CD player should
should sound normally. sound normally.
NO : Go to Step 2. NO : Check the memory backup power supply
circuit. Refer to Inspection Procedure 1
P.54A-268.
INSPECTION PROCEDURE 25: CD Sound Skips.
DIAGNOSIS STEP 4. Check by tapping the radio and CD

player or radio, CD player and CD changer.
STEP 1. Check the state in which the sound on NOTE: Check by using a known-good CD which is
the CD jumps. free from scratches, dirt or any other abnormality.
Q: Does the sound jump when the car is parked? Q: Does the sound jump when tapping the radio and
YES : Go to Step 2. CD player or radio, CD player and CD changer?
NO : Go to Step 4. YES : Securely mount the audio. Check that a CD
sound skip is resolved.
NO : Either replace the audio system or take the
STEP 2. Check the surface of the CD.
following measures if a servicing shop is
Q: Are there any scratches or soiling on the CD? nearby.
YES : The CD is defective if there are any 1. Investigate in detail the conditions
scratches. Clean the CD surface if it is dirty. when the sound jumps while driving
Check that a CD sound skip is resolved. the car.
NO : Go to Step 3.
2. Describe these conditions to the
service shop for consultation.
STEP 3. Check when replacing with a CD that can 3. Either replace the audio according to
be played normally without any scratches or the instructions of the service shop.
soiling. Check that a CD sound skip is resolved.
Q: Does the CD play normally when replaced with a
CD that is not scratched or dirty and can play
normally?
YES : Defective CD used. Check that a CD sound
skip is resolved.
NO : Go to Step 4.
TSB Revision
RADIO AND CD PLAYER
INSPECTION PROCEDURE 26: Sound Quality is Poor.
DIAGNOSIS
Check to see that the CD can be played normally

and that it is free of any scratches or soiling.
Replace with better sound quality CD.
Q: Is the sound quality better replacing the CD with a
clean CD without any scratches that can be
played?
YES : The CD is defective. The sound quality
should return to normal.
NO : Replace the audio. The sound quality
should return to normal.
INSPECTION PROCEDURE 27: CD can not be Ejected.
DIAGNOSIS
Check the power of ignition switch "ACC".

Q: Does the radio and CD player or radio, CD player
and CD changer power turn ON when the ignition
switch is in the "ACC" or "ON" position?
YES : Either replace the audio. Check that a CD
can be ejected normally.
NO : Check the memory backup power supply
circuit. Refer to Inspection Procedure 1
P.54A-268.
TSB Revision
CHASSIS ELECTRICAL
RADIO AND CD PLAYER
54A-307
ON-VEHICLE SERVICE
ADJUSTMENT OF VOLUME AND SOUND

QUALITY AUTOMATIC CORRECTION FUNCTION
M1544014200055
When the following operations are performed with the audio
power ON, the sound volume during driving and the ON/OFF of
sound quality automatic correction function are switched.
1. Press and hold (approximately 2 seconds) the sound
adjustment switch.
2. "SCV" ON (when the automatic correction function is ON) or
"SCV" OFF (when the automatic correction function is OFF)
is displayed.
3. Turn the sound adjustment switch knob to switch between
"SCV" ON and OFF.
4. Press the sound adjustment switch or leave as it is for 10
seconds or more.
5. Go back to the audio normal screen.
Sound adjustment switch
AC506451AC

M1544010900126
1.0 0.5 Nm 1.0 0.5 Nm

9 4 in-lb 9 4 in-lb
3
4
3
AC609097AB
TSB Revision
RADIO AND CD PLAYER
Section A A
Claw
5
A A
5
A A
Claw
AC608893AB
Audio Unit Removal Steps Audio Adaptor Removal Steps

1. Instrument center panel (Refer to Instrument console box (Refer to
GROUP 52A Instrument Center GROUP 52A Instrument Center
Panel assembly P.52A-6). Panel assembly P.52A-6).
2. Audio unit assembly 5. Audio adaptor <Vehicles with audio
3. Audio unit bracket amplifier>
4. Audio unit
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-309
MMCS
GENERAL INFORMATION
M1546000100062
Mitsubishi multi-communication system (7-inch wide display
HDD navigation) with built-in hard disk drive (30 gigabyte) has
been installed. <Option> Also, a 7-inch liquid crystal display of
wide 2 DIN size has been adopted.
Audio visual navigation unit

AC608322AB
The audio and video adapter has been established to the cen-
ter lower tray in order to connect visual equipment such as
game machine and video player. <Vehicles with MMCS>
Audio and video adapter

AC608418AB
Operation part
MODE INFO
AUDIO NAVI
VOL SCALE
PWR MENU
SET
ENT
OPEN
Mitsubishi Multi Communication System
AC505475AB
Display (function) Contents

Navigation screen Displays the navigation functions including the map display, search, guidance,
information search.
Vehicle position information Displays the position information of current location. (Longitude and latitude,
screen altitude, GPS reception status)
CD screen Plays back the disc inserted to the CD drive (CD-R/CD-RW).
MP3/WMA screen Plays back the MP3/WMA.
DVD screen Plays back the disc inserted to the DVD drive.
Music server function Plays back the music data on hard disk drive, and records the music CD.
Radio screen Displays the receiving station information. Also, the operation of receiving
channel can be performed.
TSB Revision
MMCS
Navigation function Control by steering wheel audio remote control

The storage of very large map data is now possible, switch
and the following contents have been adopted. Integrated 4-ch power amplifier (MAX: 180 W)
Map type navigation Correspond to Rockford Fosgate premium
NAVTEQ map database sound system
Map data stored in hard disc drive Output of DVD video 5.1 channel data
U.S. English, French, and Spanish are available Connect with satellite radio tuner
to select.
Other function
Audio and visual function There are the following functions in addition to the
There are the following functions in addition to the navigation, audio and visual function.
navigation function. Clock display
Music server function Connect with hands free unit
DVD drive unit A/C information display
FM/AM radio Outside temperature display
MP3/WMA playback function Trip information display (Average fuel consump-
tion etc.)
Function customize
SYSTEM BLOCK DIAGRAM

ZC3050180000
A/C-ECU CAN AC505476
n
communication
Combination
ETACS-ECU
meter
Hands-free CAN box unit

module
Antenna
Voice Sound
Steering wheel
Audio visual navigation unit audio remote control
switch
Sound UART
communication Sound Picture
Audio and video

Audio amplifier adopter
Note:
Speaker *1: Controller Area Network
*2: Universal Asynchronous Receiver Transmitter
AC608750AB
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-311
SPECIAL TOOLS
M1540200300095

name
a
b key. CAN bus diagnostics or data list
f. MB991825
check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE
CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g measurement
adapter
harness
MB991826
MB991958
TSB Revision
MMCS

name
a
b
circuit
c c. LED harness
sourced tester
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
DIAGNOSIS

TROUBLESHOOTING
M1546001500085
Precautions on servicing MMCS
M1546003000105
Prior to disconnecting the vehicle battery 2. If an error is displayed, check that relevant wiring
The MMCS stores a lot of information which your harness connectors are engaged correctly. If a
customer registers in its memory. All of this informa- failure is found, repair the connectors and check
tion will be cleared when the battery terminals are the trouble symptom again.
disconnected. Therefore, the preset channels must 3. If the wiring harness connectors are engaged
be stored before the vehicle battery is disconnected. correctly, check the wiring harness. If the wiring
Vehicle's current position and destinations must be harness is in good condition, replace relevant
stored if the vehicle battery remains disconnected for component(s). Now the error code and the ser-
long periods. vice mode data must be stored.
NOTE: If a system communication related failure is
Diagnosis tips concerning the entire suspected, diagnose the system.
system
1. If at least two system functions are defective at Diagnosis tips concerning the navigation
the same time, it is possible that communication function
between the system components is abnormal. 1. The precision of the GPS positioning is limited
Check the system using the communication and due to its operation principles. So, some of cus-
wire connection check in the service mode. tomer reports do not mean that the system is
defective.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-313
Prior to troubleshooting, question your customer 2. If the system is not OK, diagnose the system
about how the navigation system is used and according to the trouble symptom chart.
where he/she drives. If you determine that the
system is OK, explain to your customer about
how the system works and how the customer
should operate it.
Service mode
M1546016600066
.
How to initiate the service mode

1. With the navigation system active, press and hold both the
"NAVI" and "SET" buttons for 3.5 seconds.
2. The service mode will be initiated. Then "Service" screen
will be displayed.
.
How to terminate the service mode

If the operations below are done, the service mode will be ter-
minated.
If "Back" button is selected on "Service" screen, the service
AC611541AB
mode will terminate and then return to the previous screen.
If "NAVI" button is pressed with the service mode active, the
service mode will terminate and change to the navigation
screen.
Versions Log Information
NOTE: If "NAVI" button is pressed, the following functions
of the service mode will terminate.
.
Vehicle Signal Check
Monitor Check
Network/Connect Line Check
AC611544AB Speaker Check
Versions Indication
Sensor Check
Touch Switch Confirmation
CAN communication Confirmation
Memory Initialization
.
VEHICLE SIGNAL CHECK

1. Select "Vehicle Signal Check" on "Service" screen.
AC611541AB
TSB Revision
MMCS
2. The check results will be displayed for the items below.

"Speed": "ON" when the vehicle speed is 6 km/h or more,
Vehicle Signal Check and "OFF" when the vehicle speed is 4 km/h or less.
Speed : OFF "ILL": "ON" when the lighting switch is on (headlight posi-
ILL : ON tion), and "OFF" when they are off (except headlight posi-
Shift Position R : OFF
Parking Brake : ON tion).
"Shift Position R": "ON" when the selector lever is at R posi-
tion, and "OFF" when it is at the other position.
"Parking Brake": "ON" when the parking brake is pulled,
Back
AC606320 and "OFF" when it is released.

.
MONITOR CHECK
1. Select "Monitor Check" on "Service" screen.
AC611541AB
2. Eight color bars will be displayed.
AC611390
3. When "Enter" is pressed on the navigation unit joystick while

the eight color bars are shown, gray scale will be displayed
with a 16-step gradation.
AC606321
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-315
4. When "Enter" is pressed while the gray scale is shown with
a 16-step gradation, a crosshatch pattern will be displayed
(Each cell should be square).
AC611391

the crosshatch pattern is shown, the screen will turn white.
AC611392

the screen is white, it will turn black.
AC611393

the screen is black, the screen will turn red.
AC606322

the screen is red, it will turn green.
AC606323
TSB Revision
MMCS

the screen is green, it will turn blue.
10.When "Enter" is pressed on the navigation unit joystick while
the screen is green, it will return to the "Service" screen.
AC606324
NETWORK AND CONNECT LINE CHECK

1. Select "Network/Connect Line Check" on "Service" screen.
AC611541AB
2. A network and connect line check will be initiated. The

"Network/Connect Line Check" screen will display how the
Network/Connect Line Check check is in progress.
Now checking the connection of the line.
Please wait.
AC606325
3. When the network and connect line check is finished, the

screen will change to "Network/Connect Line Result" to
Network/Connect Line Result show the check results.
DVD Drive NG Premium Audio N/A
HDD Drive OK Rear Seat Display N/A
SDRAM OK CAN BOX OK
Rear Camera N/A Video Input N/A
GPS Receiver OK
NG Code Back
AC608174
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-317
NOTE: If there is "NG" or "N/A" as the check results, select
"NG Code" on the "Network/Connect Line Result" screen.
NG Code Indication Then "NG code Indication" screen will show the NG code.
DVD Driver 0103
4. If "Back" is selected on "Network/Connect Line Result", the
screen will return to "Service" screen.
Back
AC606327
SPEAKER CHECK
1. Select "Speaker Check" on "Service" screen.
AC611541AB
2. Select a speaker to be checked, and play test tone through

the speaker.
Speaker Check
NOTE: .
The number of the speakers being displayed depends on
FL FR
how many speakers are connected.
RL RW RR
Volume cannot be adjusted while test tone is being
played.
Back During the test, only the selected speaker sounds. If
"Back" is selected during the test, the test tone will disap-
AC611716AB pear.
.
VERSIONS INDICATION
Displays versions indication (Loader, Application, Audio Micro-
computer, Navi Sub Microcomputer, Map Data, Monitor, and
CAN BOX).
1. Select "Versions Indication" on "Service" screen.
AC611541AB
TSB Revision
MMCS
2.3.Versions indication is displayed.

Version Information
Loader
Application
Navi Sub Microcomputer
Audio Microcomputer
Map Data
Monitor
CAN BOX
Back
AC610673AB
SENSOR CHECK
The speed sensor and gyro sensor will be checked, depending
on the vehicle conditions such as driving condition, stationary
condition and travel direction change.
1. Select "Sensor Check" on "Service" screen.
AC611541AB
2. The sensor check with the vehicle stationary will be

executed in accordance with the screen.
Sensor Check
You can check the sensors.

Please don't move your car until after 5 seconds. After this you
can move your car by changing the directions. lf you are ready.
please push Start
Start Back
AC606311
Sensor Check
Please don't move your car.
AC606332
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-319
3. The sensor check with the vehicle in motion will be executed
in accordance with the screen.
Sensor Check
Please move more than 10m

while changing direction of the car.
AC606334
4. When the sensor checks are complete, the screen will

display the check results.
Sensor Check
NOTE:
Speed Sensor OK
Gyro Sensor NG
NG Code Back
AC606335
If there is "NG" or "N/A" as the check results, select

"NG Code" on the "Sensor Check" screen. Then "NG code
NG Code Indication Indication" screen will show the NG code.
NG code reference table for Sensor Check
Gyro Sensor 5
Sensor NG Error items
classification code
No.
Back
Gyro sensor 1 Offset error while the vehicle is
AC606336 stationary (lower limit error)
2 Offset error while the vehicle is
stationary (upper limit error)
5 Output error during driving
Speed sensor 6 Output error while the vehicle is
stationary
TOUCH SWITCH CONFIRMATION

1. Select "Touch Switch Confirmation" on "Service" screen.
AC611541AB
TSB Revision
MMCS
2. If you touch the screen, the color of the dotted coordinate at

the touched area will be changed.
If you complete the touch switch confirmation.

please push [MENU]
AC606337
AC611394
MEMORY INITIALIZATION
1. Select "Memory Initialization" on "Service" screen.
AC611541AB
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-321
2. If you select "Start" on "Memory Initialization" screen, the
settings such as registered locations and music server will
Memory Initialization be erased (initialized) from the memory.
NOTE: If the ignition switch is turned to "LOCK" (OFF) posi-
You can erase all of the back up data.
After erasing the data, the system will reboot.
tion during the initialization, the initialization will be sus-
If you push Start, the data will be deleted. pended. If the ignition switch is turned to "ACC" or "ON"
position, the initialization will be resumed.
Start Back 3. After the memory initialization is complete, the navigation
system will restart automatically.
AC606338
ln Early Period Of Memory
Please do not switch off until rebooting is completed.
AC606339
CAN COMMUNICATION CONFIRMATION

1. Select "CAN Communication Confirmation" on "Service"
screen.
AC611541AB
TSB Revision
MMCS
2. If "List Of Connection Equipment" is selected on "CAN

Communication Confirmation" screen, the system will
CAN Communication Confirmation determine which equipment is installed according to the
List Of Connection Equipment connected equipment reference table. Then the equipment
Version Indication which are connected to the CAN box unit will be displayed.
CAN BOX Memory Data Indication
CAN box unit-connected equipment reference table
Screen indication Equipment
Back
HVAC A/C-ECU
AC606340 SATR Satellite radio tuner
HFM Hands free module
CAN List Of Connection Equipment FCM ETACS-ECU
HVAC OCM
ORC SRS-ECU
SATR CCN
HFM WCM OCM Occupant classification-ECU
FCM
ORC CNN Combination meter
Back WCM Wireless control module
AC608176
3. If "Version Indication" is selected on "CAN Communication

Confirmation" screen, the version for each item is displayed.
Version Indication
Hardware : 1.2 Software : 01.02.03
CAN MATRIX : 05.25 CAN DRIVER : 73.00
NM : 43.24 KWP2000 : 49.10
TPMC : 33.11 DBKOM : 49.17
DIAG : 00h
Back
AC606342
4. If "CAN BOX Memory Data Indication" is selected on "CAN

Communication Confirmation" screen, "CAN BOX Memory
CAN BOX Memory Data Indication Data Indication" will be displayed.
Various Data
5. If any item is selected on "CAN BOX Memory Data
Coding Data
Indication" screen, its relevant information is displayed.
VIN
Tell-Tale Stack
Chrono Stack
Back
AC606343
Various Data
Various Data
Origin : 04h Supplier : 85h

System ID : 08h Variation ID : 10h
Serial ID : 0000h
Back
AC611722AB
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-323
Coding Data
AC611723AB
VIN
VIN
current VIN
0123456 0123456 012
Original VIN
0123456 0123456 012
Back
AC606346
Tell-Tale Stack
Tell-Tale Stack 2/8
Historical
DTC : C197h
Odometer : 0132h
Interrogation
DTC Read Counter : 04h
Odometer : 01a5h
Previ Next Back
AC606347
Chrono Stack
Chrono Stack 2/8
DTC Value : 0197h

DTC Status : A0h
Odometer Mileage : 1B27h
Accumulation Timer : 06C4h
IG Counter : 15h
Previ Next Back
AC606348
TSB Revision
MMCS
VERSIONS LOG INFORMATION

Displays logs for drive and HDD.
Service Data Log
1. Select "Versions Log Information" on "Service" screen.
AC611544AB
2. Select "Service Data Log" on the "Versions Log Information"

screen.
Service Data Log
Time Adjustment Log
AC611719AB
Service Data Log 3. The logs are displayed from the latest one.
4. The log data is erased by pressing "Delete."
Time Item Factor
Delete
AC611721AB
Service Data Log
Time Item Factor
Delete
AC611721AB
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-325
1. Select "Time Adjustment Log" on the "Versions Log Infor-
mation" screen.
Service Data Log
Time Adjustment Log
AC611719AB
Time Adjustment Information 2. The time adjustment logs are displayed.

As for Factor, the following two types are displayed.
After Factor Before CT: Automatic adjustment
MAN: Manual adjustment
CT
CT
CT
CT
CT
CT
AC611720AB
TSB Revision
MMCS
DIAGNOSIS FUNCTION
M1546001600060

CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
display.
button.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-327

"OK" button.
TSB Revision
MMCS

M1546001700089
CAUTION
DTC No. Description Reference page
B2226 Navigation unit service data P.54A-329
B2240 Communication error between CAN box unit and navigation unit P.54A-329
B2477 VIN writing has never been completed P.54A-332
U0168 KOS-ECU or WCM CAN timeout P.54A-342
U1417 Implausible coding data P.54A-348
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-329
DTC B2226: Navigation unit service data

. .
TROUBLE JUDGEMENT TROUBLESHOOTING HINT

When the CAN box unit receives the signal from the The audio visual navigation unit may be defective
audio visual navigation unit to indicate an abnormal-
ity occurred in the navigation unit, the CAN box unit
sets DTC B2226.
DIAGNOSIS
Check that the audio visual navigation unit operate.

Check that the audio visual navigation unit work normally.
Q: Is audio visual navigation unit work normally?
YES : Intermittent malfunction is suspected. Refer to
GROUP 00, How to Use Troubleshooting/Inspection
Service Points How to Cope with Intermittent
Malfunction P.00-13.
NO : Diagnose the audio visual navigation unit (Refer to
Trouble symptom chart P.54A-350).
DTC B2240: Communication error between CAN box unit and navigation unit
CAN Box Unit Communication Circuit
CAN BOX UNIT
AUDIO VISUAL
NAVIGATION UNIT
TSB Revision
MMCS
Connectors: C-12, C-108 TROUBLE JUDGMENT

C-12 C-108 When the abnormality occurs in the transmis-
sion/reception data between the CAN box unit and
audio visual navigation unit, the CAN box unit sets
DTC B2240.
.
PROBABLE CAUSES
Audio visual navigation unit malfunction
CAN box unit malfunction
AC608146AR Damaged wiring harness and connectors
.
DIAGNOSIS
MB991958 Scan Tool (M.U.T.-III Sub Assembly)
MB991827 M.U.T.-III USB Cable
MB991910 M.U.T.-III Main Harness A (Vehicles with
STEP 1. Perform "Network/Connect Line Check" of the

MMCS service mode.
Perform "Network/Connect Line Check" of the MMCS service
mode, and check that the communication between the CAN
box unit and the audio visual navigation unit is normal. (Refer
to P.54A-313.)
NOTE: When the communication between the CAN box unit
and the audio visual navigation unit is normal, "CAN BOX" is
displayed on the check result screen. However, if the communi-
cation is not possible, "CAN BOX" is not displayed.
Q: Is "CAN BOX" displayed?
YES : Go to Step 2.
NO : Go to Step 3.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-331

line.
CAUTION
AC404789
Data link (2) Turn the ignition switch to the "ON" position.
YES : Intermittent malfunction is suspected. Refer to
MB991910 GROUP 00, How to Use Troubleshooting/Inspection
Malfunction P.00-13.
MB991827 AC606941AB
STEP 3. Check CAN box unit connector C-108 and audio

visual navigation unit connector C-12 for loose, corroded
or damaged terminals, or terminals pushed back in the
connector.
Q: Are CAN box unit connector C-108 and audio visual
navigation unit connector C-12 in good condition?
YES : Go to Step 4.
P.00E-2. The steering remote control switch should
work normally.
STEP 4. Check the wiring harness between CAN box unit

connector C-108 (terminal 4, 5, 6) and audio visual
navigation unit connector C-12 (terminal 43, 59, 58).
Q: Is the wiring harness between CAN box unit connector
C-108 (terminal 4, 5, 6) and audio visual navigation unit
connector C-12 (terminal 43, 59, 58) in good condition?
YES : Go to Step 5.
TSB Revision
MMCS
STEP 5. Substitute a known good CAN box unit, and check

Check whether scan tool MB991958 with CAN box unit nor-
mally.
YES : Replace the CAN box unit.
NO : Replace the audio visual navigation unit.
DTC B2477: VIN writing has never been completed.

. .

With the ignition switch at the ON position, if the VIN The CAN bus line may be defective.
code is not written to the CAN box unit, DTC B2477 The ETACS-ECU may be defective.
is stored. The CAN box unit may be defective.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-333

Q: Is the DTC set?
NO : Go to Step 3.

Check again if the DTC is set to the CAN box unit.
(1) Erase the DTC.
position.
Q: Is the DTC set?

.

If DTC U0019 is set, be sure to diagnose the CAN With the ignition switch at the ON position and the
bus line. system voltage at 10 16 volts (data from
CAUTION ETACS-ECU), if the CAN box unit becomes unable
When replacing the ECU, always check that the to transmit data normally due to the CAN-B bus cir-
communication circuit is normal. cuit malfunction, the CAN box unit determines that a
.
problem has occurred.
DIAGNOSTIC FUNCTION
If the CAN-B circuit malfunction occurs, the CAN box
.
unit sets DTC U0019.
DIAGNOSIS
TSB Revision
MMCS

CAUTION
position.
MB991824
YES : Go to Step 2.
MB991827 AC608435 AB

line.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-335

.
2,500 ms or more, the CAN box unit determines that
DIAGNOSTIC FUNCTION a problem has occurred.
the CAN box unit sets the DTC U0141. TROUBLESHOOTING HINTS
.
The CAN box unit may be defective
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
MMCS

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?

.
DIAGNOSTIC FUNCTION 2,500 ms or more, the CAN box unit determines that
If the signal from SRS-ECU cannot be received, the a problem has occurred.
CAN box unit sets DTC U0151. .
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-337

line
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
MMCS

.
established for 2,500 ms or more, the CAN box unit
DIAGNOSTIC FUNCTION determines that a problem has occurred.
When the signals from occupant classification-ECU .
cannot be received, the CAN box unit sets DTC TROUBLESHOOTING HINTS
U0154. The CAN bus line may be defective.
.
The CAN box unit may be defective.
tive.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-339

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?

If DTC U0155 is set in the CAN box unit, diagnose With the ignition switch in the ON position, system
the CAN main bus line. voltage between 10 16 volts (data from
.
When the signals from combination meter cannot be .
received, the CAN box unit sets DTC U0155. TROUBLESHOOTING HINTS
.
DIAGNOSIS
MB991824: V.C.I.
TSB Revision
MMCS

line
CAUTION
MB991824
MB991827 AC608435 AB

YES : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-341

.
DIAGNOSTIC FUNCTION 2,500 ms or more, the CAN box unit determines that
If the signal from A/C-ECU cannot be received, the a problem has occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
MMCS

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?

.
If the signal from KOS-ECU <vehicles with KOS> or more, the CAN box unit determines that a problem
WCM <vehicles with WCM> cannot be received, the has occurred.
<vehicles with KOS>
cles with WCM>
Malfunction of CAN box unit may be defective.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-343

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
MMCS

If DTC U0195 is set in the CAN box unit, diagnose With the ignition switch in the ON position, system
the CAN main bus line. voltage between 10 16 volts (data from
.
When the signals from satellite radio tuner cannot be .
received, the CAN box unit sets DTC U0195. TROUBLESHOOTING HINTS
.
DIAGNOSIS
MB991824: V.C.I.

line
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-345
STEP 2. Using scan tool MB991958 read the satellite radio

Check whether a satellite radio tuner DTCs are set or not.
(2) Check for satellite radio tuner DTCs.
YES : Go to Step 3.
NO : Diagnose the satellite radio tuner.

(1) Erase the DTC.
position.
Q: Is the DTC set?

.
DIAGNOSTIC FUNCTION lished for 2,500 ms or more, the CAN box unit
received, the CAN box unit sets DTC U0197. .
DIAGNOSIS
TSB Revision
MMCS

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-347

If DTC U1415 is set, diagnose the CAN bus lines. With the global coding counter value "0," if all the glo-
CAUTION bal coding data (vehicle information) are not stored,
When replacing the ECU, always check that the the CAN box unit determines that a problem has
communication circuit is normal. occurred.
.
DIAGNOSTIC FUNCTION
.
If the vehicle information data is not registered to the The CAN bus line may be defective.
CAN box unit, the CAN box unit sets DTC U1415. The CAN box unit may be defective.
.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
MMCS

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
Code No.U1417 Implausible coding data
CAUTION CIRCUIT OPERATION

If diagnostic trouble code U1417 is set in CAN CAN box unit receives the vehicle information stored
box unit, always diagnose the CAN bus lines. in the ETACS-ECU via CAN bus lines.
If there is any fault in the CAN bus lines, an .
incorrect diagnostic trouble code may be set. DTC SET CONDITIONS

In this case, the set diagnostic trouble code is CAN box unit communicates with ETACS-ECU via
not highly reliable. CAN bus lines. This diagnostic trouble code is set
Before replacing the ECU, ensure that the when the vehicle information received from the
communication circuit is normal. ETACS-ECU is invalid.
When the diagnostic trouble code U1417 is
set in CAN box unit, the diagnostic trouble
.
PROBABLE CAUSES
code may also be set in ETACS-ECU. When
Malfunction of ETACS-ECU
the diagnostic trouble code is set in
Engine control module malfunction
ETACS-ECU, carry out the diagnosis of the
ETACS-ECUs have been interchanged between
diagnostic trouble code for ETACS-ECU first.
.
two vehicles.
CAN box unit malfunction
External noise interference
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-349

line.
CAUTION
MB991824
MB991827 AC608435 AB

Check if DTC is set to the ETACS-ECU or engine control mod-
ule.
Q: Is the DTC set?
YES (DTC is set to ETACS-ECU.) : Troubleshoot the
ETACS (Refer to ETACS, Diagnosis P.54A-482).
YES (DTC is set to the engine control module.) :
Troubleshoot the MFI system (Refer to GROUP 13A,
NO : Go to Step 3.
STEP 3. Check part number of ETACS-ECU.

Check the part number of ETACS-ECU.
OK: 8637A313
YES : Go to Step 4.
NO : Replace ETACS-ECU.
STEP 4. Check part number of CAN box unit.

Check the part number of CAN box unit.
OK: 8750A090
YES : Go to Step 5.
NO : Replace CAN box unit.
TSB Revision
MMCS

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace CAN box unit.
M1546001800257

procedure page
No.
1 No navigation screen is displayed. P.54A-351
2 No sound is heard. <Vehicles with audio amplifier> P.54A-358
3 No sound is heard from one of the speakers. <vehicles without audio amplifier> P.54A-363
<vehicles with audio amplifier> P.54A-369
4 The navigation system can be operated while the vehicle is driven. P.54A-376
5 The screen is not normal in the navigation mode. P.54A-379
6 Poor reception. P.54A-381
7 GPS signal can not be received. P.54A-382
8 No DVD (video disk) cannot be played. P.54A-383
9 Image of a DVD (video disk) is played, but no sound is played. P.54A-384
10 Sound of a DVD (video disk) can be played, but no image is played. P.54A-385
11 The picture and sound of external input are not played. P.54A-386
12 Check the CAN box unit power supply circuit. P.54A-388
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-351
SYMPTOM PROCEDURES
Inspection Procedure 1: No Navigation Screen is Displayed.
CAUTION
Audio Visual Navigation Unit Power Supply Circuit
FUSIBLE FUSIBLE
LINK 36 LINK 37
RELAY BOX
ENGINE
COMPARTMENT
ETACS-
ECU
ACC
RELAY 2
JOINT
CONNECTOR
AUDIO VISUAL NAVIGATION UNIT
TSB Revision
MMCS
Connector: C-07 Connectors: C-309, C-315, C-317

Junction block
C-317
C-309 (B)
C-315
AC608145AP AC608152 AC
Connectors: C-13, C-14, C-103, C-105

C-13
C-14
C-103
C-105
AC608146AM
DIAGNOSIS
STEP 1. Check audio visual navigation unit connector C-14

Q: Is audio visual navigation unit connector C-14 in good
condition?
YES : Go to Step 2.
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-353
STEP 2. Check the ground circuit to the audio visual

navigation unit connector. Measure the resistance at audio
visual navigation unit connector C-14.
(1) Disconnect audio visual navigation unit connector C-14,
and measure the resistance available at the wiring harness
side of the connector.
YES : Go to Step 4.
NO : Go to Step 3.
Harness side: C-14
AC608255 AF
STEP 3. Check the wiring harness between audio visual

navigation unit connector C-14 (terminal 9) and ground.
connector. If intermediate connector C-105 is damaged, repair
or replace the connector as described in GROUP 00E, Harness
Q: Is the wiring harness between audio visual navigation
unit connector C-14 (terminal 9) and ground in good
condition?

Check if the diagnostic trouble code is set to the ETACS-ECU.
Q: Is the DTC set?
YES : Troubleshoot the ETACS-ECU. Refer to GROUP 54A,
NO : Go to Step 5.
TSB Revision
MMCS

in the connector.
YES : Go to Step 6.
P.00E-2.

connector C-317 (terminal 1) and audio visual navigation
unit connector C-14 (terminal 17).
Check the power supply lines (battery supply) for open cir-
cuit.
C-317 (terminal 1) and audio visual navigation unit
YES : Go to Step 7.

condition?
YES : Go to Step 8.
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-355

unit connector C-13 (terminal 21).
Check the power supply lines (battery supply) for open cir-
cuit.
C-317 (terminal 1) and audio visual navigation unit
YES : Go to Step 9.

Check the input signal of ACC relay.
Turn the ignition switch to the ACC position.
conditions

NO : Refer to GROUP 54A, ETACS, Diagnosis Inspection
Procedure 1 "The ignition switch (ACC) signal is not
received P.54A-529."

in the connector.
work normally.
TSB Revision
MMCS
STEP 11. Check the power supply circuit to the

ETACS-ECU. Measure the voltage at ETACS-ECU
connector C-309.
harness-side connector.
OK: Battery voltage
Harness side: C-309 Q: Is the measured voltage battery voltage?
NO : Go to Step 12.
AC608254 AH

connector C-309 (terminal 2) and fusible link (37)
cuit.
condition?

in the connector.
work normally.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-357

navigation unit connector C-14 (terminal 14) and
nector C-105 for loose, corroded, or damaged terminals, or ter-
intermediate connector C-105 is damaged, repair or replace
the connector as described in GROUP 00E, Harness Connec-
unit connector C-14 (terminal 14) and ETACS-ECU

Check if the audio visual navigation unit power is turned ON.
TSB Revision
MMCS
Inspection Procedure 2: No Sound is Heard. <Vehicles with Audio Amplifier>
Audio Visual Navigation System Circuit
FUSIBLE
LINK 36
RELAY
BOX
AUDIO AMPLIFIER
AUDIO VISUAL
NAVIGATION UNIT
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-359
Connectors: C-11, C-22, C-107 Connectors: D-25, D-26
C-107
C-11
C-22
D-26
D-25
AC608146AN AC608165AD
.
Connector: C-39 COMMENTS ON TROUBLE SYMPTOM

If the audio sound is not output, the audio visual nav-
igation unit, audio amplifier, or power supply circuit of
audio amplifier may have a problem, or the option
coding information may be inconsistent.
.
PROBABLE CAUSES
Malfunctions of audio visual navigation unit
AC608145AT Malfunction of audio amplifier
DIAGNOSIS
STEP 1. Check the ETACS-ECU coding data.

(1) Operate the scan tool MB991958 to read the ETACS-ECU
Table P.00-35).
YES : Go to Step 2.
symptom.
STEP 2. Check audio amplifier connector D-25 for loose,

in the connector.
Q: Is audio amplifier connector D-25 in good condition?
YES : Go to Step 3.
P.00E-2.
TSB Revision
MMCS

Measure the voltage at audio amplifier connector D-25.
the voltage available at the wiring harness-side connector.
Harness side: D-25
AC608254 AI

Harness side: D-25 volts (battery positive voltage).
AC608254 AJ

Harness side: D-25
positive voltage)?
YES : Go to Step 5.
NO : Go to Step 4.
AC608254 AK
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-361

connector D-25 (terminal 25, 35, 36) and fusible link (36).
cuit.
D-25 (terminal 25, 35, 36) and fusible link (36) in good
condition?
YES : Go to Step 7.

and audio amplifier connector D-26 for loose, corroded or
connector.
Q: Is audio visual navigation unit connector C-11 and audio
amplifier connector D-26 in good condition?
YES : Go to Step 6.
P.00E-2).

navigation unit connector C-11 (terminal 82) and audio
amplifier connector D-26 (terminal 3)
NOTE: Also check intermediate connectors C-22 and C-107 for
loose, corroded, or damaged terminals, or terminals pushed
back in the connector. If intermediate connector C-22 or C-107
unit connector C-11 (terminal 82) and audio amplifier
connector D-26 (terminal 3) in good condition?
YES : Go to Step 7.
TSB Revision
MMCS

Replace the audio amplifier, then check that the audio sound is
output.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-363
Inspection Procedure 3: No Sound is Heard from one of the Speakers. <Vehicles without Audio
Amplifier>
TWEETER FRONT DOOR FRONT DOOR TWEETER

(LH) SPEAKER (LH) SPEAKER (RH) (RH)
NOTE
: LHD
: RHD
REAR DOOR SPEAKER (LH) REAR DOOR SPEAKER (RH)
Wire color code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple
TSB Revision
MMCS
Connectors: C-14, C-22, C-105 Connector: E-23

C-14
C-105
C-22
AC608146AO AC608170AB
Connectors: E-02, E-13 Connector: E-24
E-02 (B)
E-13 AC608167 AB AC608169AB

.
Connectors: E-03, E-11 COMMENTS ON TROUBLE SYMPTOM

E-03 (B) the speaker, audio visual navigation unit, communi-
cation line from the audio visual navigation unit to the
speaker may have a problem. Also, the option coding
information may be inconsistent.
.
PROBABLE CAUSES
E-11 AC608168 AB Malfunction of speaker
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-365
STEP 1. ETACS-ECU coding data check

option coding information. (Refer to GROUP 00, Coding
Table P.00-35.)
(2) Check that the "Speaker" is set to "6 speakers".
YES : Go to Step 2.
symptom.

malfunction (Refer to GROUP 00, How to Cope with
NO (abnormal for all) : Check the audio visual navigation
unit power supply and ground circuit, and repair if
necessary. If the audio visual navigation unit power
supply and ground circuit is normal, replace the
audiovisual navigation unit.

tweeter connector E-02 <LH> or E-03 <RH> for loose,
in the connector.
tweeter connector E-02 <LH> or E-03 <RH> in good
condition?
YES : Go to Step 4.
P.00E-2).
STEP 4. Check the speaker or tweeter.

(1) Remove the speaker or tweeter (Refer to P.54A-443).
connector terminal.
Q: Does the speaker or tweeter output the noise?
YES : Go to Step 5.
NO : Replace the speaker or tweeter.
TSB Revision
MMCS

condition?
YES : Go to Step 6.
P.00E-2).
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-367

tweeter connector terminal and the audio visual navigation
unit connector terminal.
1, 2) and audio visual navigation unit connector C-14 (termi-
nal 12, 3).
nal 15, 7).
2) and audio visual navigation unit connector C-14 (terminal
11, 2).
nal 16, 8).
(LH) connector E-02 (terminal 2, 1) and audio visual naviga-
tion unit connector C-14 (terminal 12, 3).
TSB Revision
MMCS

(RH) connector E-03 (terminal 2, 1) and audio visual navi-
gation unit connector C-14 (terminal 15, 7).
Q: Is the wiring harness between the speaker or tweeter
connector terminal and the audio amplifier connector
terminal in good condition?
YES : Replace the audio visual navigation unit.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-369
Inspection Procedure 3: No Sound is Heard from one of the Speakers. <Vehicles with Audio
Amplifier>

SPEAKER (LH) SPEAKER (RH) SUB WOOFER
AUDIO AMPLIFIER
NOTE
: LHD
: RHD
TWEETER TWEETER REAR DOOR REAR DOOR

(LH) (RH) SPEAKER SPEAKER
(LH) (RH)
Wire color code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple
TSB Revision
MMCS
AUDIO AMPLIFIER
Connectors: C-14, C-22, C-105, C-114, C-115 Connectors: D-01, D-25, D-26
C-105 C-14
C-114 D-01
C-115 (BR)
C-22
D-26
D-25
AC608146AP AC608165AF
Connectors: C-125, C-126 Connectors: D-15, D-17, D-20
D-15
C-125
D-17 (B)
C-126 (BR) D-20
AC608145AR AC608166AD
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-371
Connectors: E-02, E-13 Connector: E-24
E-02 (B)
E-13 AC608167 AB AC608169AB
Connectors: E-03, E-11 Connector: F-22
E-03 (B)
F-22 (B)
E-11 AC608168 AB AC608171AB

.
Connector: E-23 COMMENTS ON TROUBLE SYMPTOM

the speaker, audio visual navigation unit, audio
amplifier, communication line from the audio visual
navigation unit to the audio amplifier, or communica-
tion line from the audio amplifier to the speaker may
have a problem. Also, the option coding information
may be inconsistent.
.
AC608170AB
PROBABLE CAUSES
DIAGNOSIS
TSB Revision
MMCS
STEP 1. ETACS-ECU coding data check

Table P.00-35).
YES : Go to Step 2.
symptom.

NOTE: In the following procedure, check the speaker, tweeter
or subwoofer that is abnormal.
malfunction (Refer to GROUP 00, How to Cope with
NO (abnormal for all) : Refer to Inspection Procedure 2
"No sound is heard" P.54A-358.
NO (Either a speaker, a tweeter or a subwoofer is
abnormal) : Go to Step 3.

tweeter connector E-02 <LH> or E-03 <RH>, or subwoofer
connector F-22 for loose, corroded or damaged terminals,
tweeter connector E-02 <LH> or E-03 <RH>, or
subwoofer connector F-22 in good condition?
YES : Go to Step 4.
P.00E-2).
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-373
STEP 4. Check the speaker, tweeter or subwoofer.

(1) Remove the speaker, tweeter or subwoofer (Refer to
P.54A-443).
connector terminal. <speaker or tweeter>
(3) Check that the subwoofer outputs the noise when the
voltage of 5 V is applied to the subwoofer connector
terminal. <subwoofer>
Q: Does the speaker, tweeter or subwoofer output the
noise?
YES : Go to Step 5.
NO : Replace the speaker, tweeter or subwoofer.
STEP 5. Check audio amplifier connector D-125 <front

door speaker or sub woofer> or D-126 <tweeter or rear
door speaker> for loose, corroded or damaged terminals,
Q: Is audio amplifier connector D-125 <front door speaker
or sub woofer> or D-126 <tweeter or rear door speaker>
in good condition?
YES : Go to Step 6.
P.00E-2).
TSB Revision
MMCS

tweeter connector terminal and the audio amplifier
connector terminal.
tion P.00E-2.
2) and audio amplifier connector D-26 (terminal 1, 7).
(LH) connector E-02 (terminal 1, 2) and audio amplifier con-
(RH) connector E-03 (terminal 1, 2) and audio amplifier con-
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-375
tion P.00E-2.
<Subwoofer> Check the wiring harness between subwoofer
connector F-22 (terminal 1, 2, 3, 4) and audio amplifier con-
nector D-25 (terminal 30, 22, 29, 21).
Q: Is the wiring harness between the speaker, tweeter or
subwoofer connector terminal and the audio amplifier
connector terminal in good condition?
YES <front door speaker> : Go to Step 7.
YES <except front door speaker> : Go to Step 9.
NO (harness wire is abnormal) : The wiring harness may
be damaged or the connector(s) may have loose,
corroded or damaged terminals, or terminals pushed
back in the connector. Repair the wiring harness as
necessary.
STEP 7. Check audio visual navigation unit connector D-26

Q: Is audio visual navigation unit connector D-26 in good
condition?
YES : Go to Step 8.
P.00E-2).

navigation unit connector C-14 (terminal 3, 7, 12, 15) and
audio amplifier connector D-26 (terminal 12, 11, 4, 15).
NOTE: Also check intermediate connectors C-22 and C-105 for
back in the connector. If intermediate connector C-22 or C-105
unit connector C-14 (terminal 3, 7, 12, 15) and audio
amplifier connector D-26 (terminal 12, 11, 4, 15) in good
condition?
YES : Check the trouble symptom, go to Step 9.
TSB Revision
MMCS
STEP 9. Replace the audio amplifier temporarily, and

Replace the audio amplifier temporarily, and check that the
sound is output from the speaker.
YES : Replace the audio amplifier.
Inspection Procedure 4: The Navigation System can be Operated while the Vehicle is Driven.
CAUTION
Audio Visual Navigation Unit Communication Circuit
COMBINATION
METER
INTERFACE
CIRCUIT
AUDIO VISUAL
NAVIGATION UNIT
Connectors: C-03, C-04 Connectors: C-14, C-105

C-14
C-04 C-03
C-105
AC608145AV AC608146AQ
.

There is a failure in the wiring harness between the
combination meter and the audio visual navigation
unit, the respective connector(s), the combination
meter or the audio visual navigation unit.
.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-377
PROBABLE CAUSES Malfunctions of audio visual navigation unit
Malfunctions of combination meter Damaged harness wires and connectors
DIAGNOSIS
STEP 1. Perform "Vehicle Signal Check" in the MMCS

service mode.
Perform "Vehicle Signal Check" in the MMCS service mode to
check whether vehicle speed signal is normal (Refer to
P.54A-313).
Q: Is the vehicle speed signal transmitted normally?
NO : Go to Step 2.
STEP 2. Check the speedometer.

Check whether the speedometer works normally.
Q: Does the speedometer work normally?
YES : Go to Step 3.
Combination meter Troubleshooting P.54A-53).
STEP 3. Check combination meter connector C-04 and

audio visual navigation unit connector C-14 for loose,
in the connector.
Q: Is combination meter connector C-04 and audio visual
YES : Go to Step 4.
P.00E-2).
TSB Revision
MMCS

meter connector C-04 (terminal 20) and audio visual
navigation unit connector C-14 (terminal 13).
connector C-04 (terminal 20) and audio visual
navigation unit connector C-14 (terminal 13) in good
condition?
YES : Go to Step 5.
STEP 5. Substitute a known good audio visual navigation

unit, and check the trouble symptom.
Check that no menus are active during driving.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-379
Inspection Procedure 5: The Screen is not Normal in the Navigation Mode.
CAUTION
Audio Visual Navigation Unit Communication Circuit
COMBINATION
METER
INTERFACE
CIRCUIT
AUDIO VISUAL
NAVIGATION UNIT
Connectors: C-03, C-04 COMMENTS ON TROUBLE SYMPTOM

There is a failure in the wiring harness between the
C-04 C-03 combination meter and the audio visual navigation
unit, the GPS antenna, the respective connector(s),
the combination meter or the audio visual navigation
unit.
.
PROBABLE CAUSES
AC608145AV
Malfunctions of GPS antenna
Malfunctions of combination meter
Connectors: C-14, C-105 Malfunctions of audio visual navigation unit
C-14
C-105
AC608146AQ
DIAGNOSIS
TSB Revision
MMCS
STEP 1. Confirmation in MMCS service mode

Check the items below in the MMCS service mode. (Refer to
P.54A-313.)
Perform "Network/Connect Line Check" in the MMCS ser-
vice mode to check that the communication and wire con-
nection with the GPS are in good condition.
Perform "Vehicle Signal Check", and then check the status
of the vehicle speed signal.
Perform "Sensor Check", and then check the status of the
vehicle speed sensor and the gyro sensor.
YES (OK for all) : Go to Step 7.
NO <GPS is not OK> : Go to Step 2.
NO <The vehicle speed sensor is not OK, or vehicle
speed pulse does not increase after starting from a
standstill> : Go to Step 4.
NO <Gyro sensor is not OK> : Go to Step 7.
STEP 2. Check the fit of the GPS antenna cable.

Check whether the GPS antenna cable is connected properly.
Q: Is the GPS antenna cable connected properly?
NO : Go to Step 3.
STEP 3. Substitute a known good GPS antenna, and then

check whether it works normally.
YES : Replace the GPS antenna.
NO : Go to Step 7.
STEP 4. Check the speedometer.

Check whether the speedometer works normally.
Q: Does the speedometer work normally?
YES : Go to Step 5.
Combination meter Diagnosis P.54A-53).
STEP 5. Check combination meter connector C-04 and

in the connector.
Q: Is combination meter connector C-04 and audio visual
YES : Go to Step 6.
P.00E-2).
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-381

meter connector C-04 (terminal 20) and audio visual
navigation unit connector C-14 (terminal 13).
connector C-04 (terminal 20) and audio visual
navigation unit connector C-14 (terminal 13) in good
condition?
YES : Go to Step 7.

Check whether the navigation screen is normal.
Q: Is the navigation screen normal?
Inspection Procedure 6: Poor Reception.
DIAGNOSIS STEP 3. Move the vehicle and check the radio.

Move the vehicle to a good reception area that is not
STEP 1. Check the state of the antenna. exposed to special electric fields.
Q: Is the mast antenna assembled? Q: Is reception of the strongest radio frequency
YES : Go to Step 2. possible within the area?
NO : Assemble the mast antenna. Check that a YES : Check that a poor reception is resolved.
poor reception is resolved. NO : Go to Step 4.
STEP 2. Check to see if inspections are taking STEP 4. Tune the radio, and then check it.
place is an area exposed to special electric Q: Did the sensitivity improve after tuning?
fields. YES : Check that a poor reception is resolved.
NO : Go to Step 5.
Q: Are inspections taking place under special electric
field conditions (underground garage, inside a
building, etc.)?
YES : Go to Step 3.
NO : Go to Step 4.
TSB Revision
MMCS
STEP 5. Check with several broadcasting STEP 6. Check the connection of the antenna
stations. plug and radio and CD player or CD changer.
NOTE: Two types of noise are addressed in this pro- Q: Is the antenna plug thoroughly connected to the
cedure, multipath and fading noise. The frequency of radio and CD player or CD changer?
FM waves is extremely high. This makes them sus- YES : Go to Step 7.
ceptible to effects from geological formations and NO : Thoroughly connect the antenna plug and
buildings. These effects disrupt the broadcast signal the radio and CD player or CD changer.
and obstruct reception in many ways. Check that a poor reception is resolved.
.
Multipath noise is the echo that occurs when the STEP 7. Check by replacing radio and CD player
broadcast signal is reflected by a large obstruc- or CD changer.
tion and enters the receiver with a slight time
delay relative to the direct signal (repetitious Q: Do the other radio and CD player or CD changer
work normally?
buzzing).
YES : Either repair or replace the original radio
A fading or buzzing noise may occur when the
and CD player or CD changer. Check that a
broadcast beam is disrupted by obstructing
poor reception is resolved.
objects and the signal strength fluctuates within a
narrow range.
assembly. Check that a poor reception is
Q: Is the abnormality in reception generated only resolved.
within a certain range?
YES : Check that a poor reception is resolved.
NO : Go to Step 6.
Inspection Procedure 7: GPS Signal can not be Received.

. .
COMMENTS ON TROUBLE SYMPTOM PROBABLE CAUSES

The GPS antenna or the audio visual navigation unit Malfunctions of GPS antenna
may be defective. Malfunctions of audio visual navigation unit
DIAGNOSIS

Perform "Network/Connect Line Check" in the MMCS service
mode to check that the communication and wire connection
with the GPS antenna are OK. (Refer to P.54A-313.)
YES : Go to Step 2.
NO : Go to Step 4.
STEP 2. Check for the vehicle's current position.

Check that the vehicle is parked on a well-ventilated place.
Q: Is the vehicle parked on a well-ventilated place?
YES : Go to Step 3.
NO : Move the vehicle to a well-ventilated area.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-383
STEP 3. Confirming GPS signal reception

(2) Wait for 15 minutes, and then check whether GPS signal
can be received.
Q: Can GPS signal be received?
YES : The procedure is complete. (There is no failure)
NO : Go to Step 4.
STEP 4. Substitute a known good GPS antenna, and check

When a known good GPS antenna is substituted, check
whether GPS signal can be received.
YES : Replace the GPS antenna.
Inspection Procedure 8: No DVD (Video Disk) cannot be Played.

. .

The DVD (video disk) or the audio visual navigation Defective DVD (video disk)
unit may be defective. Malfunctions of audio visual navigation unit
DIAGNOSIS

mode, and check whether "OK" is displayed under "DVD drive".
(Refer to P.54A-313.)
Q: Is "OK" displayed under "DVD drive" item?
YES : Go to Step 2.
STEP 2. Check that a DVD's recorded surface faces down.

Check that a DVD's recorded surface faces down.
Q: Is the DVD inserted with its recorded surface facing
down?
YES : Go to Step 3.
NO : Check the DVD's recorded surface, and insert the
DVD again. (For a one-sided disk, its recorded
surface should face down)
STEP 3. Check a DVD (video disk) to be inserted.

Check whether the DVD (video disk) is an authorized one.
Q: Is the DVD (video disk) an authorized one?
YES : Go to Step 4.
NO : Use an authorized DVD (video disk).
TSB Revision
MMCS

Check that there are no stains or scratches on the DVD (video
disk).
Q: Are there any stains or scratches on the DVD (video
disk)?
YES : Clean or deburr the disk, or use a scratch and
burr-free disk. Then insert the disk again.
NO : Go to Step 5.
STEP 5. Substitute a known good DVD (video disk), and

When a known good DVD (video disk) is loaded, check
whether it is played normally.
YES : Replace the DVD (video disk).
NO : Go to Step 6.
STEP 6. Check the trouble symptom.

When a DVD (video disk) is loaded, check whether it is played
normally.
Q: Is the DVD (video disk) played normally?
Inspection Procedure 9: Image of a DVD (Video Disk) is Played, but no Sound is Played.
. .

DIAGNOSIS
STEP 1. Check whether other sounds are emitted.

Check whether sound other than DVD (video disk) is emitted.
Q: Is sound other than DVD (video disk) emitted?
YES : Go to Step 2.
NO : Refer to "Inspection Procedure 2: No Sound is Head
P.54A-358."

Check whether sound data is recorded in the DVD (video disk).
Q: Is sound data recorded in the DVD (video disk)?
YES : Go to Step 3.
NO : Use a DVD (video disk) containing sound data.
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-385

mode, and check whether "OK" is displayed under "DVD drive".
(Refer to P.54A-313.)
YES : Go to Step 4.
STEP 4. Check a scene to be played.

Check whether the scene accompanies sound.
Q: Does the scene accompany sound?
YES : Go to Step 5.
NO : Confirm by playing a sound-free scene.
STEP 5. Check how the DVD is played.

Check whether the disk was played at normal speed (not
rewinded, fast-forwarded, slow, or pause).
Q: Was the disk played at normal speed (not rewind,
fast-forward, slow, or pause)?
NO : Play the disk at normal speed.
Inspection Procedure 10: Sound of a DVD (Video Disk) can be Played, but no Image is Played.
. .

DIAGNOSIS

mode, and check whether "OK" is displayed under "DVD drive"
YES : Go to Step 2.
STEP 2. Check DVD (video disk) to be inserted.

Check that there are no stains or scratches on the DVD (video
disk).
Q: Are there any stains or scratches on the DVD (video
disk)?
YES : Clean or deburr the disk, or use a scratch and
burr-free disk. Then insert the disk again.
NO : Go to Step 3.
TSB Revision
MMCS
STEP 3. Substitute a known good DVD (video disk), and

When a known good DVD (video disk) is loaded, check
whether it is played normally.
YES : Replace the DVD (video disk).
Inspection Procedure 11: The picture and sound of external input are not played.
Audio and Video Adapter Communication Circuit
AUDIO VISUAL
NAVIGATION UNIT
AUDIO AND
VIDEO ADAPTER
Connectors: C-12, C-103, C-107, C-121

C-12 C-107
C-103
C-121 (B)
AC608146AS
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-387
STEP 1. Check of DVD picture

Check that the DVD picture is displayed normally.
YES : Go to Step 2.
NO : Perform the troubleshooting related to the MMCS
STEP 2. Check audio navigation unit connector C-12 and

audio and video adaptor connector C-121 for loose,
in the connector.
Q: Are audio navigation unit connector C-12 and audio and
video adaptor connector C-121 in good condition?
YES : Go to Step 3.
NO : Repair the connector concerned.

navigation unit connector C-12 (terminal 47, 48, 49, 63, 64)
and audio and video adaptor connector C-121 (terminal 1,
6, 5, 4, 2).
back in the connector. If intermediate connector C-103 or
C-107 is damaged, repair or replace the connector as
P.00E-2.
unit connector C-12 (terminal 47, 48, 49, 63, 64) and
audio and video adaptor connector C-121 (terminal 1, 6,
5, 4, 2) in good condition?
YES : Replace the audio and video adapter.
Repair the wiring harness as necessary. The system
should communicate with the CAN box unit normally.

Check that the external input is normal.
NO : Replace the rear display unit.
TSB Revision
MMCS
Inspection Procedure 12: Check the CAN box unit power supply circuit.
CAUTION
CAN Box Unit Power Supply Circuit
FUSIBLE FUSIBLE
LINK 36 LINK 37
RELAY BOX
ENGINE
COMPARTMENT
ETACS-
ECU
ACC
RELAY 2
JOINT CONNECTOR
CAN BOX UNIT
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-389
Connector: C-07 Connectors: C-307, C-309, C-315, C-317
Junction block
C-317
C-307 (B)
C-309 (B)
C-315
AC608145AP AC608152 AD
.

C-105 C-108
If the CAN box unit functions do not work at all, the
CAN box unit power supply system, ground system,
or CAN box unit may have a problem.
.
AC608146AD
DIAGNOSIS
STEP 1. Check CAN box unit connectors C-108 for loose,

in the connector.
Q: Is CAN box unit connectors C-108 in good condition?
YES : Go to Step 2.
P.00E-2.
STEP 2. Check the ground circuit to the CAN box unit.

Measure the resistance at CAN box unit connector C-108.
(1) Disconnect CAN box unit connector C-108 and measure
the resistance available at the wiring harness side of the
connector.
(2) Measure the resistance value between CAN box unit
connector C-108 terminal 1 and ground.
OK: The resistance should be 2 ohms or less.
Harness side: C-108
YES : Go to Step 4.
NO : Go to Step 3.
AC608255 AG
TSB Revision
MMCS

connector C-108 (terminal 1) and the ground.
C-108 (terminal 1) and the ground in good condition?
STEP 4. Check the battery power supply circuit to the CAN

box unit. Measure the voltage at CAN box unit connectors
C-108.
(1) Disconnect CAN box unit connectors C-108 measure the
voltage available at the wiring harness side of the
connector.
(2) Measure the voltage between CAN box unit connector
C-108 terminal 2 and ground.
Harness side: C-108 volts (battery positive voltage).
positive voltage)?
YES : Go to Step 6.
NO : Go to Step 5.
AC608254 AL

connector C-108 (terminal 2) and fusible link (36).
NOTE: Also check intermediate connector C-105 and
ETACS-ECU connectors C-307 and C-317 for loose, corroded,
or damaged terminals, or terminals pushed back in the connec-
tor. If intermediate connector C-105 or ETACS-ECU connector
C-307 or C-317 is damaged, repair or replace the connector as
P.00E-2.
condition?
TSB Revision
CHASSIS ELECTRICAL
MMCS
54A-391

connector C-108 (terminal 10) and fusible link (37).
NOTE: Also check joint connector C-07, intermediate connec-
tor C-105 and ETACS-ECU connectors C-309 and C-315 for
back in the connector. If joint connector C-07, intermediate con-
nector C-105 or ETACS-ECU connectors C-309 or C-315 is
damaged, repair or replace the connector as described in
condition?
M1546001000121
8
1.5 0.5 Nm
14 4 in-lb
2
3.0 1.0 Nm
27 8 in-lb 1.5 0.5 Nm
6 14 4 in-lb
1
3.0 1.0 Nm
1.5 0.5 Nm
27 8 in-lb
14 4 in-lb
3.0 1.0 Nm
5 4
27 8 in-lb
3
7
AC609098AB
TSB Revision
MMCS
Section A A
Claw
9
A A
9
A A
Claw
AC608892AB
Audio Visual Navigation Unit GPS Antenna Removal Steps

Removal Steps Instrument panel assembly (Refer
Instrument center panel (Refer to to GROUP 52A Instrument Panel
GROUP 52A Instrument Center assembly P.52A-2).
Panel assembly P.52A-6). 8. GPS antenna
1. Audio visual navigation unit Audio and Video Adaptor
assembly Removal Steps
2. Audio visual navigation unit Instrument console box (Refer to
3. CAN box unit assembly GROUP 52A Instrument Center
4. CAN box unit Panel assembly P.52A-6).
5. CAN box unit bracket 9. Audio and video adaptor
6. Audio visual navigation unit bracket
7. Navigation harness
TSB Revision
CHASSIS ELECTRICAL
54A-393
DIAGNOSIS

TROUBLESHOOTING
M1544004800584
M1544004900826

Procedure No. page
1 Steering wheel audio remote control <vehicles without MMCS> P.54A-394
2 switch does not function <vehicles with MMCS> P.54A-398
3 Steering wheel audio remote control switch illumination does not come on. P.54A-402
TSB Revision
SYMPTOM PROCEDURES
Inspection Procedure 1: Steering Wheel Audo Remote Control Switch does not Function. <Vehicles
without MMCS>
CAUTION
Before replacing the ECU, ensure that the power
supply circuit, the ground circuit and the com-
Steering Wheel Audio Remote Control Switch Circuit
STEERING WHEEL AUDIO

REMOTE CONTROL
SWITCH
CLOCK
SPRING
RADIO AND CD PLAYER

OR CD CHANGER
TSB Revision
CHASSIS ELECTRICAL
54A-395
.

The power supply circuit to the steering remote con-
trol switch, the steering remote control switch, the
radio and CD player or CD changer, or the clock
spring may be defective.
.
Malfunction of steering remote control switch
AC608146AC
changer
Connectors: C-202, C-204, C-205 Malfunction of the clock spring
C-202 (R)
C-204
C-205
AC608147AB
DIAGNOSIS

Check whether the service data below are normal.
(1) Turn the ignition switch to "ON" position.
(2) Operate each switch of the steering remote control. Check
whether the normal conditions listed below are displayed.
Item Item name Normal
No. condition
Item 1 RADIO remoto SW (SEEK-) ON
Item 2 RADIO remoto SW (SEEK+) ON
Item 3 RADIO remoto SW (MODE) ON
Item 4 RADIO remoto SW (VOL-) ON
Item 5 RADIO remoto SW (VOL+) ON

NO : Go to Step 2.
TSB Revision
STEP 2. Check the remote controlled radio switch.

Remove the remote controlled radio switch. Then check conti-
nuity between the switch terminals.
Switch Tester Measurement Value
Position Connection
No push 2 3 Approximately 3.1 k
2 4 Approximately 71 k
Mode Approximately 270
CH up Approximately 740
CH down Approximately 1.3 k
VOL up Approximately 2.1 k
VOL down Approximately 3.1 k
Q: Is the remote controlled radio switch in good condition?

YES : Go to Step 3.
NO : Replace the remote controlled radio switch.
STEP 3. Check clock spring connector C-204 and C-205 for

Q: Are clock spring connector C-204 and C-205 in good
condition?
YES : Go to Step 4.
work normally.
STEP 4. Check the clock spring.

Check whether the clock spring is in good condition (Refer to
GROUP 52B, Air bag module and clock spring P.52B-375).
YES : Go to Step 5.
NO : Replace the clock spring.

in good condition?
YES : Go to Step 6.
work normally.
TSB Revision
CHASSIS ELECTRICAL
54A-397

player or CD changer connector C-104 (terminal 22, 32)
and clock spring connector C-205 (terminal 2, 3).
Check the communication lines for open or short circuit.
CD changer connector C-104 (terminal 22, 32) and clock
spring connector C-205 (terminal 2, 3) in good
condition?
YES : Go to Step 7.
STEP 7. Check steering remote control switch connector

C-202 for loose, corroded or damaged terminals, or
Q: Is steering remote control switch connector C-202 in
good condition?
YES : Go to Step 8.
work normally.
STEP 8. Check the wiring harness between steering

remote control switch connector C-202 (terminal 2, 4) and
clock spring connector C-204 (terminal 5, 4).
Q: Is the wiring harness between steering remote control
switch connector C-202 (terminal 2, 4) and clock spring
YES : Go to Step 9.

Check whether you can operate the radio and CD player or the
CD changer by using the steering remote control.
Cope with Intermittent Malfunction P.00E-2).
NO : Replace the radio and CD player or CD changer.
TSB Revision
Inspection Procedure 2: Steering Wheel Audio Remote Control Switch does not Function. <Vehicles
with MMCS>
CAUTION
Steering Wheel Audio Remote Control Switch Circuit
STEERING WHEEL AUDIO

REMOTE CONTROL
SWITCH
CLOCK
SPRING
AUDIO VISUAL
NAVIGATION UNIT
TSB Revision
CHASSIS ELECTRICAL
54A-399
.

C-12 C-105
audio visual navigation unit, or the clock spring may
be defective.
.
AC608146AT
Malfunction of the clock spring
Connectors: C-202, C-204, C-205 Damaged harness wires and connectors
C-202 (R)
C-204
C-205
AC608147AB
DIAGNOSIS

Check whether the service data below are normal.
(2) Operate each switch of the steering remote control. Check
whether the normal conditions listed below are displayed.
Item Item name Normal
No. condition
Item 1 RADIO remoto SW (SEEK-) ON
Item 2 RADIO remoto SW (SEEK+) ON
Item 3 RADIO remoto SW (MODE) ON
Item 4 RADIO remoto SW (VOL-) ON
Item 5 RADIO remoto SW (VOL+) ON

NO : Go to Step 2.
TSB Revision
STEP 2. Check the remote controlled radio switch.

Remove the remote controlled radio switch. Then check conti-
nuity between the switch terminals.
CH up
VOL up switch
switch Switch Tester Measurement Value
Position Connection
VOL down CH down
switch switch No push 2 3 Approximately 3.1 k
2 4 Approximately 71 k
Mode switch Mode Approximately 270
AC605242AC CH up Approximately 740
CH down Approximately 1.3 k
VOL up Approximately 2.1 k
VOL down Approximately 3.1 k
Q: Is the remote controlled radio switch in good condition?

YES : Go to Step 3.
NO : Replace the remote controlled radio switch.
AC600711AC
STEP 3. Check clock spring connector C-204 and C-205 for

Q: Are clock spring connector C-204 and C-205 in good
condition?
YES : Go to Step 4.
work normally.

YES : Go to Step 5.

condition?
YES : Go to Step 6.
work normally.
TSB Revision
CHASSIS ELECTRICAL
54A-401

navigation unit connector C-12 (terminal 53, 69) and clock
spring connector C-205 (terminal 2, 3).
unit connector C-12 (terminal 53, 69) and clock spring
YES : Go to Step 7.

good condition?
YES : Go to Step 8.
work normally.

remote control switch connector C-202 (terminal 2, 4) and
clock spring connector C-204 (terminal 5, 4).
switch connector C-202 (terminal 2, 4) and clock spring
YES : Go to Step 9.

Check whether you can operate the audio visual navigation unit
by using the steering remote control.
TSB Revision
Inspection Procedure 3: Steering wheel audio remote control switch illumination does not come on.
Steering Wheel Audio Remote Control Switch Illumination Circuit
STEERING WHEEL
AUDIO REMOTE
CONTROL SWITCH
COMBINATION
METER
INTERFACE
CIRCUIT CLOCK
SPRING

combination meter, or the clock spring may be defec-
tive.
.
AC608145AW
Malfunctions of combination meter
Malfunction of the clock spring
Connectors: C-202, C-204, C-205 Damaged harness wires and connectors
C-202 (R)
C-204
C-205
AC608147AB
TSB Revision
CHASSIS ELECTRICAL
54A-403
DIAGNOSIS
STEP 1. Check the combination metre.

Check whether the combination meter works normally.
Q: Does the combination meter operate normally?
YES : Go to Step 2.
NO : Diagnose the combination meter (Refer to P.54A-23).

good condition?
YES : Go to Step 3.
work normally.

remote control switch connector C-202 (terminal 5) and
ground.
Check the ground wire.
switch connector C-202 (terminal 5) and ground in good
condition?
YES : Go to Step 4.
STEP 4. Check clock spring connectors C-204 and C-205

Q: Are clock spring connectors C-204 and C-205 in good
condition?
YES : Go to Step 5.
work normally.
TSB Revision

YES : Go to Step 6.

remote control switch connector C-202 (terminal 1) and
clock spring connector C-204 (terminal 1).
Check the power supply lines.
switch connector C-202 (terminal 1) and clock spring
YES : Go to Step 7.

condition?
YES : Go to Step 8.
work normally.

meter connector C-04 (terminal 23) and clock spring
connector C-04 (terminal 23) and clock spring
YES : Go to Step 9.
TSB Revision
CHASSIS ELECTRICAL
54A-405

Check whether the illumination of the steering remote control
switch comes on normally.
Q: Doe the illumination of the steering remote control
switch comes on normally?
NO : Replace the steering remote control switch.
M1544015600023
WARNING
Before removing the air bag module, refer to GROUP 52B, Service Precautions P.52B-24 and
Drivers Front Passenger's Air Bag Module and Clock Spring P.52B-367.
WARNING
When removing and installing the steering wheel, do not let it bump against the air bag mod-
ule.
2
1
AC605239AC
Removal Steps
1. Air bag module (Refer to GROUP
52B, Drivers Front Passenger's Air
Bag Module and Clock Spring
P.52B-367).
2. Steering wheel audio remote
control switch
TSB Revision
STREERING WHEEL AUDIO REMOTE CONTROL

SWITCH INSPECTION
M1544015700020
Use an ohmmeter to measure the resistance value between the
terminal.
CH up
VOL up switch
switch Switch Position Tester Measurement
Connection Value
VOL down CH down
switch switch No push 2 3 Approximately
3.1 k
2 4 Approximately
Mode switch
71 k
AC605242AC
"Mode" switch Approximately
270
"CH up" switch Approximately
740
"CH down" switch Approximately
1.3 k
"VOL up" switch Approximately
2.1 k
AC600711AC
"VOL down" switch Approximately
3.1 k
TSB Revision
CHASSIS ELECTRICAL
HANDS-FREE CELLULAR PHONE SYSTEM
54A-407
GENERAL INFORMATION
M1544401200019
With the hands-free cellular phone system <GTS: NOTE: *: Bluetooth is the short-distance digital
Standard, DE, ES: Option> by registering a cellular wireless communication technology using 2.45 GHz
phone for Bluetooth* with voice recognition to the frequency band. The communication effective area is
hands free module, the telephone function becomes within 10 m, and the feature is that the communica-
available without operating the cellular phone tion can be achieved even when an obstacle is
directly. The hands-free cellular phone system can present between the communicating devices.
be used without connecting the cellular phone to the
.
vehicle via wiring cable.
Construction diagram
Microphone unit
(built in front dome light)
Speech
switch
OFF hook
switch
Steering
ON hook voice-control
switch switch
AC609223 AC609223
AC609228AB
When the registered cellular phone is inside the vehi- The communication directly via a cellular phone
cle, the hands-free cellular phone system operates can be switched to the communication via a
as follows. handsfree device. Also, the communication via a
NOTE: The owners manual contains details on pair- handsfree device can be switched to the commu-
ing a cellular phone with the Bluetooth system, nication directly via a cellular phone.
speaker enrollment, and other functions. The voice input mode corresponds to the follow-
When the cellular phone receives a call, the ing languages: English, American Spanish,
occupant can start conversation by pressing Canadian French.
"OFF hook" in the steering voice-control switches The voice of occupant is picked up by the micro-
on the steering wheel. When the conversation phone unit incorporated in the front dome light,
ends, the occupant can finish the call by pressing and then transmitted to the cellular phone via
"ON hook" in the steering voice-control switches. hands-free module. Also, the receiver's voice is
To make a call, press "Speech" in the steering transmitted from the cellular phone to radio with
voice-control switches on the steering wheel, call CD player, radio with CD changer <vehicles with-
up the registered receiver's information in the out MMCS> or audio visual navigation unit <vehi-
voice input mode, press "OFF hook". Then, the cles with MMCS> via hands-free module, and
transmission starts to call the receiver. Also, then output from the vehicle-mounted speaker.
when the conversation ends, the occupant can Using the steering audio remote control switch,
finish the call by pressing "ON hook" in the steer- the volume can be adjusted.
ing voice-control switches. The reception state of the cellular phone is indi-
cated on the display section of radio with CD
player, radio with CD changer <vehicles without
MMCS> or audio visual navigation unit <vehicles
with MMCS>.
.
TSB Revision
System block diagram
*1
Steering voice-control
Audio display
switch
CAN Radio with CD changer*1 or

radio with CD player*1 or Speaker
audio visual navigation unit*2
Phone voice
BluetoothTM
CAN Cellular phone
Hands-free module
Microphone power Voice *1: Vehicles without MMCS

CAN bus line *2: Vehicles with MMCS
Microphone unit
(built in front dome light)
AC609355AB
TSB Revision
CHASSIS ELECTRICAL
54A-409
DIAGNOSIS

TROUBLESHOOTING
M1540203800011
Refer to GROUP 00 Contents of troubleshooting P.00-6.
M1546001800202

Procedure No. page
1 Hands-free cellular phone system does not work normally. P.54A-410
2 During the conversation with the hands-free system, the speakers voice P.54A-418
cannot be heard by the other party.
3 During the conversation with the hands-free system, the voice of other party P.54A-421
cannot be heard.
4 Even when the steering wheel voice-control switch is operated, the P.54A-422
conversation is not possible.
5 The cellular phone is not recognized or the connection cannot be established. P.54A-427
6 Steering wheel voice-control switch illumination does not come on. P.54A-429
7 Check the hands-free-ECU power supply circuit. P.54A-433
TSB Revision
SYMPTOM PROCEDURES
Inspection Procedure 1: Hands-free cellular phone system does not work normally.
CAUTION
Hands Free Module Power Supply Circuit
FUSIBLE
LINK 36
RELAY BOX
ENGINE
COMPARTMENT
HANDS FREE
MODULE
Connectors: C-12, C-106, C-107, C-110 Connector: C-130

C-12 C-106, C-107
C-110
AC608146AU AC608145AX
TSB Revision
CHASSIS ELECTRICAL
54A-411
Connector: C-317
mitted from the cellular phone to the hands-free mod-
Junction block ule. Then, the voice is transmitted from the
hands-free module to the radio and CD player or CD
changer <vehicles without MMCS> or audio visual
navigation unit <vehicles with MMCS>, and output
from the speaker.
.
TROUBLE JUDGEMENT CONDITIONS

If the hands-free system cannot be used normally,
AC608152 AE the hands-free module, microphone unit, steering
wheel voice-control switch, or radio and CD player or
Connector: D-03 CD changer <vehicles without MMCS> or audio
visual navigation unit <vehicles with MMCS> may be
defective.
.
Malfunction of the hands-free module
Malfunction of the microphone unit
Malfunction of the steering wheel voice-control
AC608165AH
switch
.
Malfunction of the radio and CD player or CD
FUNCTION changer <vehicles without MMCS> or audio
visual navigation unit <vehicles with MMCS>
During the conversation with the hands-free system,
the signal of speaker's voice is transmitted from the
microphone unit to the hands-free module. Then the
signal is transmitted from the hands-free module to
the cellular phone. The voice of other party is trans-
DIAGNOSIS
STEP 1. Check the cellular phone.

Check that the cellular phone can be used normally as a unit.
Q: Is it possible to use the cellular phone normally?
YES : Go to Step 2.
NO : Repair or replace the cellular phone.
TSB Revision
STEP 2. Temporarily replace the cellular phone, and check

Temporarily register a separate Bluetooth-supported cellular
phone, and check that the hands-free cellular phone system
operates normally.
Q: Is the normal conversation possible with the hands-free
system?
YES : Ask the customer to have the cellular phone repaired
or replaced. Then, delete the temporarily registered
cellular phone. Once the customer prepares the
normally-working cellular phone, register the cellular
phone to the hands-free module.
NO : Go to Step 3.

line.
CAUTION
AC404789
(4) Turn the ignition switch to "LOCK" (OFF) position.
YES : Go to Step 4.
MB991910 NO : Repair the CAN bus line (Refer to GROUP 54C,
MB991824
MB991827 AC606941AB
STEP 4. Check hands-free module connector C-110 for

Q: Are hands-free module connector C-110 in good
condition?
YES : Go to Step 5.
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
54A-413
STEP 5. Check the ground circuit to the hands-free

module. Measure the resistance at hands-free module
connector C-110.
(1) Disconnect hands-free module connector C-110, and
(2) Measure resistance between terminal 15 and ground.
Harness side: C-110 OK: The resistance should be 2 ohm or less.
YES : Go to Step 7.
NO : Go to Step 6.
AC608255AH
STEP 6. Check the wiring harness between hands-free

module connector C-110 (terminal 15) and ground.
Q: Is the wiring harness between hands-free module
condition?
STEP 7. Check the power supply circuit to the hands-free

module. Measure the voltage at hands-free module
connector C-110.
measure the voltage available at the hands-free module
Harness side: C-110
positive voltage)?
YES : Go to Step 9.
NO : Go to Step 8.
AC608254AM
TSB Revision

module connector C-110 (terminal 13) and ETACS-ECU
connector C-110 (terminal 13) and ETACS-ECU
STEP 9. Check microphone unit connector D-03 for loose,

in the connector.
Q: Is microphone unit connector D-03 in good condition?
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
54A-415

module connector C-110 and microphone unit connector
D-03.
(1) Disconnect hands-free module connector C-110 and
microphone unit connector D-03, and check the wiring
harness.
NOTE: Also check intermediate connector C-130 for loose,
in the connector. If intermediate connector C-130 is dam-
(2) Check the wiring harness between hands-free module
connector C-110 (terminal 1) and microphone unit
connector C-110 and microphone unit connector D-03 in
good condition?

connector C-106 <vehicles without MMCS> or audio visual
navigation unit connector C-12 <vehicles with MMCS> for
<vehicles without MMCS> or audio visual navigation
unit connector C-12 <vehicles with MMCS> in good
condition?
P.00E-2.
TSB Revision

module connector C-110 and radio and CD player or CD
changer connector C-106 <vehicles without MMCS> or
audio visual navigation unit connector C-12 <vehicles with
MMCS>.
(1) Disconnect hands-free module connector C-110 and radio
and CD player or CD changer connector C-106 <vehicles
without MMCS> or audio visual navigation unit connector
C-12 <vehicles with MMCS>, and check the wiring harness.
<vehicles with MMCS>
CD changer connector C-106 (terminal 3) <vehicles without
MMCS>
MMCS>
MMCS>
unit connector C-12 (terminal 45) <vehicles without MMCS>
connector C-110 and radio and CD player or CD changer
connector C-106 <vehicles without MMCS> or audio
visual navigation unit connector C-12 <vehicles with
MMCS> in good condition?
TSB Revision
CHASSIS ELECTRICAL
54A-417
STEP 13. Temporarily replace the microphone unit, and

Check that the normal conversation is possible with the
hands-free system.
system?
YES : Replace the microphone unit.
NO : Go to Step 14.
STEP 14. Temporarily replace the hands-free module, and

hands-free system.
system?
YES : Replace the hands-free module.
NO : Replace the radio and CD player or CD changer
unit <vehicles with MMCS>.
TSB Revision
Inspection Procedure 2: During the conversation with the hands-free system, the speakers voice
cannot be heard by the other party.
Hands Free Cellular Phone System Circuit
MICROPHONE
UNIT
HANDS
FREE
MODULE
RADIO AND CD PLAYER AUDIO VISUAL

OR CD CHANGER NAVIGATION UNIT
<VEHICLES WITHOUT <VEHICLES WITH

MITSUBISHI MITSUBISHI
MULTI-COMMUNICATION MULTI-COMMUNICATION
SYSTEM (MMCS)> SYSTEM (MMCS)>
TSB Revision
CHASSIS ELECTRICAL
54A-419
AC608145AY AC608165AH
.
Connector: C-110 FUNCTION

the signal of speaker's voice is transmitted from the
microphone unit to the hands-free module. Then the
signal is transmitted from the hands-free module to
the cellular phone.
.

AC608146AG
if the speaker's voice cannot be heard by the other
party, the hands-free module or microphone unit may
be defective.
.
Malfunction of the microphone unit
DIAGNOSIS

YES : Go to Step 2.
STEP 2. Check hands-free module connector C-110 and

microphone unit connector D-03 for loose, corroded or
connector.
Q: Are hands-free module connector C-110 and
microphone unit connector D-03 in good condition?
YES : Go to Step 3.
P.00E-2.
TSB Revision

module connector C-110 and microphone unit connector
D-03.
(1) Disconnect hands-free module connector C-110 and
microphone unit connector D-03, and check the wiring
harness.
connector C-110 and microphone unit connector D-03 in
good condition?
YES : Go to Step 4.
STEP 4. Temporarily replace the microphone unit, and

hands-free system.
system?
YES : Replace the microphone unit.
NO : Replace the hands-free module.
TSB Revision
CHASSIS ELECTRICAL
54A-421
Inspection Procedure 3: During the conversation with the hands-free system, the voice of other party
cannot be heard.

.
FUNCTION
During the conversation with the hands-free system, During the conversation with the hands-free system,
the voice signal of other party is transmitted from the if the voice of other party cannot be heard, the
cellular phone to the hands-free module. Then, the hands-free module, or the radio and CD player or CD
signal is transmitted from the hands-free module to changer <vehicles without MMCS> or audio visual
the radio and CD player or CD changer <vehicles navigation unit <vehicles with MMCS> may be defec-
without MMCS> or audio visual navigation unit tive.
<vehicles with MMCS>, and then output from the .
speaker. TROUBLESHOOTING HINTS

.
Malfunction of the radio and CD player or CD
changer <vehicles without MMCS> or audio
visual navigation unit <vehicles with MMCS>
DIAGNOSIS

YES : Go to Step 2.
STEP 2. Check the radio and CD player or CD changer

<vehicles without MMCS> or audio visual navigation unit
<vehicles with MMCS>.
Check that the sound of radio and CD player or CD changer
<vehicles without MMCS> or audio visual navigation unit <vehi-
cles with MMCS> is output normally from the speaker.
Q: Is the sound of radio and CD player or CD changer
unit <vehicles with MMCS> output normally from the
speaker?
YES : Replace the hands-free module.
NO : Diagnose the radio and CD player or CD changer
unit <vehicles with MMCS> (Refer to P.54A-393
<vehicles without MMCS> or P.54A-393 <vehicles
with MMCS>).
TSB Revision
Inspection Procedure 4: Even when the steering wheel voice-control switch is operated, the
conversation is not possible.
Steering Wheel Voice Control Switch Circuit
STEERING WHEEL STEERING WHEEL

AUDIO REMOTE VOICE CONTROL
CONTROL SWITCH SWITCH
CLOCK
SPRING
RADIO AND CD PLAYER

OR CD CHANGER
TSB Revision
CHASSIS ELECTRICAL
54A-423
Steering Wheel Voice Control Switch Circuit
STEERING WHEEL STEERING WHEEL

AUDIO REMOTE VOICE CONTROL
CONTROL SWITCH SWITCH
CLOCK
SPRING
AUDIO VISUAL
NAVIGATION UNIT
Connectors: C-202, C-204, C-209 FUNCTION

When the steering wheel voice-control switch is
operated, the switch signal is transmitted to the radio
and CD player or CD changer <vehicles without
C-202 (R) MMCS> or audio visual navigation unit <vehicles
with MMCS>. Then, via the CAN communication, the
C-204 signal is transmitted from the radio and CD player or
CD changer <vehicles without MMCS> or audio
C-209 visual navigation unit <vehicles with MMCS> to the
AC608147AD hands-free module.
.
.
TSB Revision
TROUBLE JUDGEMENT CONDITIONS TROUBLESHOOTING HINTS

If the conversation is not possible even when the Malfunction of the steering wheel voice-control
steering wheel voice-control switch is operated, the switch
steering wheel voice-control switch or radio and CD Malfunction of the hands-free module
player or CD changer <vehicles without MMCS> or Malfunction of the radio and CD player or CD
the audio visual navigation unit <vehicles with changer <vehicles without MMCS> or audio
MMCS> may be defective. visual navigation unit <vehicles with MMCS>
.
DIAGNOSIS
STEP 1. Check the steering wheel audio remote control

switch.
Check that the radio and CD player or CD changer <vehicles
without MMCS> or audio visual navigation unit <vehicles with
MMCS> can be operated normally using the steering wheel
audio remote control switch.
Q: Is it possible to normally operate the radio and CD
player or CD changer <vehicles without MMCS> or
audio visual navigation unit <vehicles with MMCS>
using the steering wheel audio remote control switch?
YES : Go to Step 2.
NO : Diagnose the steering wheel audio remote control
switch (Refer to P.54A-393 <vehicles without MMCS>
or P.54A-393 <vehicles with MMCS>.)
TSB Revision
CHASSIS ELECTRICAL
54A-425

line.
CAUTION
AC404789
(4) Turn the ignition switch to "LOCK" (OFF) position.
YES : Go to Step 3.
MB991910 NO : Repair the CAN bus line (Refer to GROUP 54C,
MB991824
MB991827 AC606941AB
STEP 3. Check the steering wheel voice-control switch.

Remove the steering wheel voice-control switch. Then check
continuity between the switch terminals.
Speech" switch Switch Position Tester Measurement
Connection Value
Pick-up" switch
No push 2 3 Approximately
74 k
Hang-up" switch
"Speech" switch Approximately
1.5 k
AC606271AB
"Pick-up" switch Approximately
ZC6016190000 3.3 k
"Hang-up" switch Approximately
5.0 k
Q: Is the steering wheel voice-control switch in good

condition?
YES : Go to Step 4.
NO : Replace the steering wheel voice-control switch.
AC606272
TSB Revision
STEP 4. Check the steering wheel audio remote control

switch.
Remove the steering wheel audio remote control switch. Then
check continuity between the switch terminals.
Switch Position Tester Measurement
Connection Value
3.1 k
Q: Is the steering wheel audio remote control switch in

AC600711AC good condition?
YES : Go to Step 5.
NO : Replace the steering wheel audio remote control
switch.
STEP 5. Check steering wheel voice-control switch

connector C-209 and steering wheel audio remote control
switch connector C-202 for loose, corroded or damaged
Q: Are steering wheel voice-control switch connector
C-209 and steering wheel audio remote control switch
YES : Go to Step 6.
work normally.
STEP 6. Check the wiring harness between steering wheel

voice-control switch connector C-209 (terminal 3) and
steering wheel audio remote control switch connector
C-202 (terminal 3).
Check the communication lines for open circuit and short
circuit.
Q: Is the wiring harness between steering wheel
steering wheel audio remote control switch connector
C-202 (terminal 3) in good condition?
YES : Go to Step 7.
TSB Revision
CHASSIS ELECTRICAL
54A-427

Check the communication lines for open circuit and short
circuit.
clock spring connector C-204 (terminal 4) in good
condition?
YES : Go to Step 8.

Check that the hands-free cellular phone system works nor-
mally when the steering wheel voice-control switch is operated.
Q: Check that the hands-free cellular phone system works
normally when the steering wheel voice-control switch
is operated.
NO : Replace the radio and CD player or CD changer
unit <vehicles with MMCS>.
Inspection Procedure 5: The cellular phone is not recognized or the connection cannot be
established.
.
FUNCTION
With the hands-free cellular phone system, the cellu- Malfunction of the cellular phone
lar phone and hands-free module communicate with Malfunction of the hands-free module
each other by using Bluetooth.
DIAGNOSIS
.

When the cellular phone cannot be recognized or the STEP 1. Check the cellular phone.
communication cannot be established, the cellular Check that the cellular phone can be used normally
phone or hands-free module may be defective. as a unit.
.
YES : Go to Step 2.
TSB Revision
STEP 2. Check the position of cellular phone. STEP 4. Temporarily replace the cellular phone,
Check that the function becomes normal when the and check the trouble symptom.
cellular phone is moved closer to the hands-free Temporarily register a separate Bluetooth-sup-
module. ported cellular phone, and check that the hands-free
Q: Does the function become normal when the
cellular phone system operates normally.
cellular phone is moved closer to the hands-free Q: Is the normal conversation possible with the
module? hands-free system?
YES : No action is necessary and testing is YES : Ask the customer to have the cellular phone
complete. repaired or replaced. Then, delete the
NO : Go to Step 3. temporarily registered cellular phone. Once
the customer prepares the normally-working
STEP 3. Check the registration method of cellular cellular phone, register the cellular phone to
phone. the hands-free module.
By referring to the operation manuals, check that the NO : Replace the hands-free module.
cellular phone was registered to the hands-free mod-
ule by following the normal procedure.
Q: Was the cellular phone registered by following the
normal procedure?
YES : Check the trouble symptom, and finish
when it is normal. When the abnormality is
present, go to Step 4.
NO : Register a cellular phone according to a
regular procedure.
TSB Revision
CHASSIS ELECTRICAL
54A-429
Inspection Procedure 6: Steering wheel voice-control switch illumination does not come on.
CAUTION
Steering Wheel Voice Control Switch Illumination Circuit
STEERING
WHEEL
VOICE
CONTROL
SWITCH
COMBINATION
METER
INTERFACE
CIRCUIT CLOCK
SPRING
Connector: C-04 Connectors: C-204, C-205, C-209
C-204
C-209 (Y) C-205

AC608145AW AC608147AC
.

The power supply circuit to the steering wheel
voice-control switch, the steering wheel voice-control
switch, the combination meter, or the clock spring
may be defective.
.
TSB Revision
TROUBLESHOOTING HINTS Malfunctions of combination meter

Malfunction of steering wheel voice-control Malfunction of the clock spring
switch Damaged harness wires and connectors
DIAGNOSIS
STEP 1. Check the combination meter.

Check whether the combination meter works normally.
YES : Go to Step 2.
NO : Diagnose the combination meter (Refer to P.54A-23).
STEP 2. Check steering wheel voice-control switch

Q: Is steering wheel voice-control switch connector C-209
in good condition?
YES : Go to Step 3.
work normally.

voice-control switch connector C-209 (terminal 1) and the
ground.
Check the ground wire.
the ground in good condition?
YES : Go to Step 4.
TSB Revision
CHASSIS ELECTRICAL
54A-431
STEP 4. Check clock spring connectors C-204 and C-205

Q: Are clock spring connectors C-204 and C-205 in good
condition?
YES : Go to Step 5.
work normally.

GROUP 52B Air bag module and clock spring P.52B-375).
YES : Go to Step 6.

clock spring connector C-204 (terminal 1) in good
condition?
YES : Go to Step 7.

condition?
YES : Go to Step 8.
work normally.
TSB Revision

meter connector C-04 (terminal 23) and clock spring
connector C-04 (terminal 23) and clock spring
YES : Go to Step 9.

Check whether the illumination of the steering remote control
switch comes on normally.
Q: Doe the illumination of the steering remote control
switch comes on normally?
NO : Replace the steering wheel voice-control switch.
TSB Revision
CHASSIS ELECTRICAL
54A-433
Inspection Procedure 7: Check the hands-free-ECU power supply circuit.
CAUTION
Hands Free Module Power Supply Circuit
FUSIBLE
LINK 36
RELAY BOX
ENGINE
COMPARTMENT
HANDS FREE
MODULE
Connector: C-110 Connectors: C-307, C-317

Junction block
C-317
C-307 (B)
AC608146AG AC608152 AF
.
CIRCUIT OPERATION
The power supply to the hands-free module is
provided by the fusible link (36).
If the power supply system from the battery is
defective, the system operates by the power sup-
ply from the ignition switch (IG1).
.
TSB Revision

.
If the hands-free cellular phone system don't work, The wiring harness or connectors may have
power supply and ground system to the hands-free loose, corroded, or damaged terminals, or termi-
module, or the hands-free module itself may be nals pushed back in the connector
defective. The hands-free module may be defective
DIAGNOSIS
STEP 1. Check hands-free module connector C-110 for

Q: Is hands-free module connector C-110 in good
condition?
YES : Go to Step 2.
P.00E-2).
STEP 2. Check the ground circuit to the hands-free

module. Measure the resistance at hands-free module
connector C-110.
Harness side: C-110
ground.
OK: The resistance should be 2 ohms or less.
YES : Go to Step 4.
NO : Go to Step 3.
AC608255 AZ

module connector C-110 (terminal 15) and ground.
condition?
YES : Replace the hands-free module. The system should
communicate with the hands-free module normally.
TSB Revision
CHASSIS ELECTRICAL
54A-435

module connector C-110 (terminal 13) and fusible link (36).
C-317 is damaged, repair or replace the damaged compo-
nent(s) as described in GROUP 00E, Harness Connector
Inspection P.00E-2.
connector C-110 (terminal 13) and fusible link (36) in
good condition?
YES : Replace the hands-free module. The system should
communicate with the hands-free module normally.
M1544401000015
HANDS FREE MODULE
AC608894AB
Hands Free Module Removal

Steps
Grove box cover (Refer to GROUP
52A Grovebox Assembly
P.52A-5).
1. Hands free module
TSB Revision
MICROPHONE UNIT
ZC6027270000
AC606269AB
Microphone Unit Removal Steps

Front dome light assembly (Refer
to GROUP 52A Headlining
P.52A-15).
1. Microphone unit
STEERING VOICE CONTROL SWITCH
2.5 0.5 Nm
23 4 in-lb
1
AC609419AB
Steering Voice Control Switch

Removal Step
<<A>> 1. Steering voice control switch

.
<<A>> STEERING VOICE CONTROL SWITCH

REMOVAL
Remove the cover first, and then remove the screw that is used
to fix the switch body part.
TSB Revision
CHASSIS ELECTRICAL
54A-437
STEERING WHEEL VOICE-CONTROL SWITCH
CONTINUITY CHECK
M1544401100012
Use an ohmmeter to measure the resistance value between the
terminal.
Speech" switch Switch position Tester Measurement
connection value
Pick-up" switch
74 k
Hang-up" switch
"Speech" switch Approximately
1.5 k
AC606271AB
"Pick-up" switch Approximately
ZC6016190000 3.3 k
"Hang-up" switch Approximately
5.0 k
AC606272
TSB Revision
AMPLIFIER
AMPLIFIER
M1544004100422
CAUTION
To remove the front seat assembly of vehicle with side air bag, refer to GROUP 52B Service Precau-
tions P.52B-24 and Air Bag Module(S) And Clock Spring P.52B-367.
1 1.5 0.5 Nm
14 4 in-lb 1.5 0.5 Nm
2 14 4 in-lb
3
5.0 1.0 Nm
5.0 1.0 Nm
44 9 in-lb
44 9 in-lb
5.0 1.0 Nm
44 9 in-lb
AC608802 AB

Front (drivers) seat assembly 2. Audio amplifier cover
(Refer to GROUP 52A Front Seat 3. Audio amplifier
Assembly P.52A-17). <<A>> 4. Audio amplifier box bracket
1. Audio amplifier assembly

.
<<A>> REMOVAL OF AUDIO AMPLIFIER BOX

BRACKET
Turn up and remove the carpet.
TSB Revision
CHASSIS ELECTRICAL
SPEAKER
54A-439
SPEAKER
GENERAL INFORMATION
M1544101000014
<4 speakers> <6 speakers> <9 speakers>

Tweeter
Tweeter
Front door Front door
Front door speaker
speaker speaker
Rear door
Rear door speaker
speaker Rear door
speaker
Subwoofer
AC608693AB
The following three types of speakers are available. 9 speakers (tweeter: 3.5 cm, front door: 16 cm,
4 speakers (Front door: 16 cm, rear door: 16 cm) rear door: 2-way coaxial 16 cm, subwoofer: 25
6 speakers (tweeter: 3.5 cm, front door: 16 cm, cm) <Rockford Fosgate premium sound sys-
rear door: 16 cm) tem>
TWEETER
For the front sash trim, two types of tweeters, the bal-
Front door sash trim ance dome tweeter <Vehicles with 6 speakers> and
soft dome tweeter <Vehicles with 9 speakers (Rock-
ford Fosgate premium sound system)>, have been
established. The soft dome tweeter can play clearer
treble with less distortion compared to the balance
dome tweeter. For better treble, two types of front
sash garnish, resin type <Vehicles with 6 speakers>
and punching metal type <Rockford Fosgate pre-
Tweeter mium sound system>, has been established. With
AC608346AB
the punching metal type, the metal has been adopted
for the punching part to enlarge the punching open-
ing, enabling the playback of cleaner treble.
TSB Revision
SPEAKER
DOOR SPEAKER
Resin cover*
Sheet metal
cover*
Urethane integrated Resin cover*

resin sheet*
Rear door water

proof film
Front door speaker
Rear door speaker
Front door water

Urethane integrated proof film
resin sheet*
AC608347AB
*
NOTE: The parts with " " are installed exclusively to tage of the sheet metal cover, the rigidity of the areas
the vehicles with Rockford Fosgate premium sound around the speaker has been increased, and the
system. higher sound pressure, suppression of high har-
For the front door speaker, two types of speakers, 16 monic, and suppression of dumping are achieved to
cm paper cone speaker <vehicles with 4 speakers, 6 improve sound quality.
speakers> and PP (polypropylene) cone speaker
<Rockford Fosgate premium sound system>, are
available. For the rear door speaker, two types of
speakers, 16 cm paper cone speaker <Vehicles with
4 speakers, 6 speakers> and PP (polypropylene)
cone 2-way coaxial speaker <Vehicles with 9 speak-
ers (Rockford Fosgate premium sound system)>,
are available. Compared to the paper cone speakers,
the PP (polypropylene) cone speakers can playback
crisper bass. The door opening of the vehicles with 9
AC507245AB
speaker (Rockford Fosgate premium sound sys-
tem) is blocked by using the sheet metal cover and The one-touch installable speaker (with 3 tabs, fixed
the urethane integrated resin sheet (resin cover and by rotating) has been adopted to improve service-
water proof film) to make the door into a speaker ability.
box, thus improving the sound quality. As an advan-
TSB Revision
CHASSIS ELECTRICAL
SPEAKER
54A-441
SUBWOOFER <VEHICLES WITH Rockford
Fosgate PREMIUM SOUND SYSTEM>
Trunk room
The 25 cm dual voice coil subwoofer has been installed to the
trunk room, enabling the playback of dynamic deep bass.
Subwoofer
AC608344AB
ON-VEHICLE SERVICE
SPEAKER TEST
M1544100500049
HOW TO START SPEAKER CHECK MODE

With the ignition switch at the ACC position and the audio
power OFF, press the button in the following order.
1. Press the [CH1] button.
Rewind button Fast-forward button
2. Press the fast rewind button.
3. Press the fast forward button.
4. Press the [CH6] button.
NOTE: To start the speaker check mode, perform the button
operations above within 60 seconds since turning OFF the
audio power.
[CH1] button [CH6] button
AC609154AB
SPEAKER CONNECTION CHECK MODE

With the speaker connection check mode, the connection sta-
tus of each speaker can be checked based on the sound output
from each speaker. The procedure is as follows.
TSB Revision
SPEAKER
1. At the same time with the start of speaker check mode, the
<Display>
sound for speaker connection check is output from the front
door speaker (LH). Check the speaker connection of front
Front door speaker (LH)
and tweeter (LH) door speaker (LH) based on this sound output.
2. Press the [CH6] button to switch the sound output for
speaker check from the front door speaker (LH) to the front
Front door speaker (RH) door speaker (RH). Check the speaker connection of front
and tweeter (RH)
door speaker (RH) based on the output of speaker
connection check sound from the front door speaker (RH).
3. Press the [CH6] button again to switch the sound output for
Rear door speaker (RH)
speaker check from the front door speaker (RH) to the rear
door speaker (LH). Check the speaker connection of rear
door speaker (LH) based on the output of speaker
Rear door speaker (LH) connection check sound from the rear door speaker (LH).
4. Press the [CH6] button again to switch the sound output for
speaker check from the rear door speaker (LH) to the rear
: Off door speaker (RH). Check the speaker connection of rear
: Illuminates door speaker (RH) based on the output of speaker
connection check sound from the rear door speaker (RH).
: Flash
ACX01941AL
CHATTERING CHECK MODE

Inserting a CD during the speaker connection check mode
shifts the mode to the chattering check mode, and the chatter-
ing sound of each speaker can be checked.
As with the speaker connection check mode, press the [CH6]
button to switch the output speaker of the chattering check
sound.
Check that the chattering sound is output from the output
speaker of chattering check sound.
TSB Revision
CHASSIS ELECTRICAL
SPEAKER
54A-443
M1544100300119
DOOR SPEAKER
Pre-removal Operation
Learning of the power window fully closed position (Refer to
GROUP 42A Door, On-vehicle service P.42A-144).
1 2
AC506846 AC506847
AC507216 AB
Front Door Speaker Removal Rear Door Speaker Removal

Steps Steps
Front door trim (Refer to GROUP Rear door trim (Refer to GROUP
52A Door Trim P.52A-13). 52A Door Trim P.52A-13).
<<A>> 1. Front door speaker <<A>> 2. Rear door speaker

.
<<A>> REMOVAL OF FRONT DOOR SPEAKER

AND REAR DOOR SPEAKER
Disconnect the connector, and remove by twisting as shown in
the figure.
AC507244
TSB Revision
SPEAKER
TWEETER
Section A A
1
1 Clip
A
AC608780AB
5
4
2
3
AC608782AB

1. Front door sash trim assembly 4. Tweeter
2. Tweeter bracket and Tweeter 5. Front door sash trim
3. Tweeter bracket
TSB Revision
CHASSIS ELECTRICAL
SPEAKER
54A-445
SUBWOOFER
4.0 2.0 Nm
1 44 9 in-lb
4.0 2.0 Nm
44 9 in-lb
AC608803AB

1. Rear speaker box assembly 3. Rear speaker
2. Rear speaker garnish 4. Rear speaker box
TSB Revision
ANTENNA
ANTENNA
GENERAL INFORMATION
M1544200500013
The pole antenna has been adopted for the radio.
The antenna base incorporates the radio amplifier.
When the satellite radio tuner is installed, the
antenna base that also corresponds to the satellite
radio is installed.
Satellite radio tuner (Vehicles with satellite radio)
Pole antenna (for radio)
Antenna base
AC608360AB
TSB Revision
CHASSIS ELECTRICAL
ANTENNA
54A-447
M1544200200120
1
2
3 3.0 1.0 Nm
27 8 in-lb
<Vehicles with
satellite radio tuner>
1
2
3.0 1.0 Nm
27 8 in-lb
AC608844AB

1. Antenna rod Grove box cover (Refer to GROUP
Headlining (Refer to GROUP 52A 52A Grove box P.52A-5).
Headlining P.52A-15). Rear side roof energy absorption
2. Antenna base box (RH) <Vehicle with
Audio unit (Refer to P.54A-307). sunroof>(Refer to GROUP 52A
<Vehicles with Audio unit> Headlining P.52A-15).
Audio visual navigation unit <<A>> 3. Antenna feeder
assembly (Refer to P.54A-307).
<Vehicles with MMCS>
TSB Revision
ANTENNA

.
<<A>> REMOVAL OF ANTENNA FEEDER

Remove a part of the curtain airbag module, and remove the
Clip* clip* of antenna feeder. <Vehicles with sun roof>
Antenna feeder cable
AC608853AB
TSB Revision
CHASSIS ELECTRICAL
SATELLITE RADIO TUNER
54A-449
DIAGNOSIS

TROUBLESHOOTING
M1544016500018
DIAGNOSIS FUNCTION
M1544013200052

CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
TSB Revision

display.
button.

"OK" button.
TSB Revision
CHASSIS ELECTRICAL
54A-451
M1544012900058
Diagnostic trouble Trouble content Reference page

code number
B2222 Radio receiver internal fail P.54A-452
TSB Revision
DTC B2222: Radio receiver internal fail

If there is any problem in the CAN bus lines, an When the ignition switch is ON and the system volt-
incorrect diagnostic trouble code may be set. age is from 10 V to 16 V (data from ETACS-ECU), if
Prior to this diagnosis, always diagnose the CAN the satellite radio tuner receives abnormal status by
bus lines. signal conditioning 10 times consecutively, DTC
CAUTION B2222 is stored.
Before replacing the satellite radio tuner, be sure .
to check that the power supply circuit, ground COMMENTS ON TROUBLE SYMPTOM
circuit, and communication circuit are normal. The satellite radio tuner or CAN bus line may have a
.
problem.
.
PROBABLE CAUSES
Malfunctions of satellite radio tuner
connector
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
54A-453

line.
CAUTION
AC404789
YES : Go to Step 2.
MB991824
MB991827 AC606941AB

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the satellite radio tuner.
TSB Revision

.

If DTC U0019 is set, be sure to diagnose the CAN With the ignition switch at the ON position and the
bus line. system voltage at 10 16 volts (data from
CAUTION ETACS-ECU), if the Satellite radio tuner becomes
When replacing the ECU, always check that the unable to transmit data normally due to the CAN-B
communication circuit is normal. bus circuit malfunction, the satellite radio tuner deter-
.
mines that a problem has occurred.
DIAGNOSTIC FUNCTION
If the CAN-B circuit malfunction occurs, the satellite
.
radio tuner sets DTC U0019.
The satellite radio tuner may be defective
DIAGNOSIS

CAUTION
position.
MB991824
YES : Go to Step 2.
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
54A-455

line.

.
2,500 ms or more, the satellite radio tuner deter-
DIAGNOSTIC FUNCTION mines that a problem has occurred.
the satellite radio tuner sets the DTC U0141. TROUBLESHOOTING HINTS
.
DIAGNOSIS
TSB Revision

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
54A-457

.
If the signal from SRS-ECU cannot be received, the mines that a problem has occurred.
satellite radio tuner sets DTC U0151. .
DIAGNOSIS

line
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?

.
established for 2,500 ms or more, the satellite radio
DIAGNOSTIC FUNCTION tuner determines that a problem has occurred.
When the signals from occupant classification-ECU .
cannot be received, the satellite radio tuner sets DTC TROUBLESHOOTING HINTS
U0154. The CAN bus line may be defective.
.
tive.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
54A-459

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision

If DTC U0155 is set in the satellite radio tuner, With the ignition switch in the ON position, system
diagnose the CAN main bus line. voltage between 10 16 volts (data from
.
established for 2,500 ms or more, the satellite radio
DIAGNOSTIC FUNCTION tuner determines that a problem has occurred.
When the signals from combination meter cannot be .
received, the satellite radio tuner sets DTC U0155. TROUBLESHOOTING HINTS
.
DIAGNOSIS
MB991824: V.C.I.

line
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
54A-461

YES : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?

.
If the signal from A/C-ECU cannot be received, the mines that a problem has occurred.
DIAGNOSIS
TSB Revision

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
54A-463

.
If the signal from KOS-ECU <vehicles with KOS> or more, the satellite radio tuner determines that a prob-
WCM <vehicles with WCM> cannot be received, the lem has occurred.
<vehicles with KOS>
cles with WCM>
Malfunction of satellite radio tuner may be defec-
tive.
DIAGNOSIS
TSB Revision

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
54A-465
CAUTION No abnormality is present to the network.

If DTC U0184 is set to the ETACS-ECU, always Ignition switch is in the ON position.
diagnose the CAN bus line. No abnormality is present to the power supply
fuse, or the odometer value is at 80.5 km (50.0
Before replacing the ECU, ensure that the
miles) or more.
communication circuit is normal.
.
ETACS-ECU system voltage is at 1016 volts.
TROUBLE JUDGMENT .
If the signal from radio and CD player or CD changer TROUBLESHOOTING HINTS

cannot be received, the satellite radio tuner sets DTC The radio and CD player or CD changer may be
U0184. defective.
.
JUDGMENT CRITERIA The CAN bus may be defective.
After the following statuses continue to be true for 5
seconds, if the communication with the radio and CD
player or CD changer cannot be established for 0.6
second or more, the satellite radio tuner determines
that a problem has occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision

Check if DTC is set to the audio.
Q: Is the DTC set?
YES : Troubleshoot the audio (Refer to P.54A-239).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?

.
DIAGNOSTIC FUNCTION lished for 2,500 ms or more, the satellite radio tuner
received, the satellite radio tuner sets DTC U0197. .
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
54A-467

line.
CAUTION
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision

M1544016400011

Procedure No.
1 A satellite radio cannot be received. P.54A-468
2 Check the satellite radio tuner power supply circuit. P.54A-472
SYMPTOM PROCEDURES
Inspection Procedure 1: A satellite radio cannot be received.
CAUTION
Before replacing the satellite radio tuner, antenna
feeder cable, radio and CD changer <vehicles
with radio and CD changer> or audio visual navi-
gation unit <vehicles with MMCS>, ensure that
the power supply circuit, the ground circuit and
the communication circuit are normal.
Satellite Radio Tuner Communication Circuit <Vehicles with Radio and CD Changer>
RADIO AND CD CHANGER
TSB Revision
CHASSIS ELECTRICAL
54A-469
Satellite Radio Tuner Communication Circuit <Vehicles with MMCS>
AUDIO VISUAL
NAVIGATION UNIT
Connectors: C-11, C-17, C-106, C-107 COMMENTS ON TROUBLE SYMPTOM

C-106, C-107 There may be a failure in the wiring harness from the
C-11 satellite radio tuner to the radio and CD changer
C-17
<vehicles with radio and CD changer> or audio
visual navigation unit <vehicles with MMCS>, its
respective connector(s), the satellite radio tuner, the
CD changer <vehicles with radio and CD changer>
or the audio visual navigation unit <vehicles with
MMCS>.
AC608146BR .
. PROBABLE CAUSES
Malfunctions of satellite radio tuner
Malfunctions of changer <vehicles with radio and
CD changer> or audio visual navigation unit
<vehicles with MMCS>
DIAGNOSIS
TSB Revision
STEP 1. Check whether AM or FM broadcast frequency is

received.
Check whether AM or FM broadcast frequency is received.
Q: Is AM or FM broadcast frequency received?
YES : Go to Step 2.
NO : Diagnose the radio <vehicles with radio and CD
changer> or the audio visual navigation unit <vehicles
with MMCS> (Refer to P.54A-267 <vehicles with radio
and CD changer> or P.54A-350 <vehicles with
MMCS>).

line.
CAUTION
AC404789
YES <vehicles with radio and CD changer> : Go to Step
MB991910 3.
YES <vehicles with MMCS> : Go to Step 6.
NO <vehicles with radio and CD changer or MMCS> :
Repair the CAN bus line. (Refer to GROUP 54C,
MB991827 AC606941AB
STEP 3. Check satellite radio tuner connector C-17 and

radio and CD changer connector C-106 for loose, corroded
connector.
Q: Is satellite radio tuner connector C-17 or radio and CD
changer connector C-106 in good condition?
YES : Go to Step 4.
P.00E-2.
TSB Revision
CHASSIS ELECTRICAL
54A-471
STEP 4. Check the wiring harness between satellite radio

tuner connector C-17 (terminal 6, 7, 14) and radio and CD
changer connector C-106 (terminal 15, 5, 16).
Q: Is the wiring harness between satellite radio tuner
connector C-17 (terminal 6, 7, 14) and radio and CD
changer connector C-106 (terminal 15, 5, 16) in good
condition?
YES : Go to Step 5.
STEP 5. Substitute a known good radio and CD changer,

and check the trouble symptom.
Check whether satellite radio broadcast can be received.
Q: Can a satellite radio be received?
YES : Replace the radio and CD changer.
NO : Replace the satellite radio tuner.
STEP 6. Check satellite radio tuner connector C-17 and

in the connector.
Q: Is satellite radio tuner connector C-17 or audio visual
YES : Go to Step 7.
P.00E-2.

tuner connector C-17 (terminal 6, 7, 14) and audio visual
navigation unit connector C-11 (terminal 85, 86, 87).
connector C-17 (terminal 6, 7, 14) and audio visual
navigation unit connector C-11 (terminal 85, 86, 87) in
good condition?
YES : Go to Step 8.
TSB Revision

Check whether satellite radio broadcast can be received.
Q: Can a satellite radio be received?
NO : Replace the satellite radio tuner.
Inspection Procedure 2: Check the satellite radio tuner power supply circuit.
Satellite Radio Tuner Power Supply Circuit
FUSIBLE
LINK 36
RELAY BOX
ENGINE
COMPARTMENT
SATELLITE
RADIO
TUNER
TSB Revision
CHASSIS ELECTRICAL
54A-473
.

If the satellite radio tuner functions do not work at all,
the satellite radio tuner power supply system, ground
system, or satellite radio tuner may have a problem.
.
AC608146AF
Connectors: C-307, C-317
Junction block
C-317
C-307 (B)
AC608152 AF
DIAGNOSIS
STEP 1. Check satellite radio tuner connectors C-17 for

Q: Is satellite radio tuner connectors C-17 in good
condition?
YES : Go to Step 2.
P.00E-2.
TSB Revision
STEP 2. Check the ground circuit to the satellite radio

tuner. Measure the resistance at satellite radio tuner
connectors C-17.
(1) Disconnect satellite radio tuner connector C-17 and
of the connector.
(2) Measure the resistance value between satellite radio tuner
YES : Go to Step 4.
NO : Go to Step 3.
AC608255 BA

tuner connector C-17 (terminal 8) and ground.
condition?

tuner connector C-17 (terminal 1) and fusible link (36).
C-317 is damaged, repair or replace the connector as
P.00E-2.
connector C-17 (terminal 1) and fusible link (36) in good
condition?
should communicate with the satellite radio tuner
normally.
TSB Revision
CHASSIS ELECTRICAL
54A-475
M1544016100010
1.0 0.5 Nm
9 4 in-lb 13 2 Nm
111 22 in-lb
5
1 2
13 2 Nm
1.0 0.5 Nm
111 22 in-lb
9 4 in-lb AC608845AB

Bottom cover (passenger side) 1. Satellite radio tuner connector
(Refer to GROUP 52A Grove box 2. Satellite radio tuner assembly
P.52A-5). 3. Satellite radio tuner bracket (upper)
Grove box (Refer to GROUP 52A 4. Satellite radio tuner bracket (lower)
Grove box P.52A-5). 5. Satellite radio tuner
TSB Revision
DEFOGGER
DEFOGGER
TROUBLESHOOTING
M1540500200152
Refer to GROUP 55 Troubleshooting P.55B-12.
ON-VEHICLE SERVICE
PRINTED HEATER CHECK

M1540500500131
Normal characteristics of print heater

1. Let the engine run (2,000 r/min), and check the printed
Voltage (V) heater with the battery fully charged.
12 2. With the rear window defogger switch "ON," use the circuit
tester to measure the voltage of each printed heater at the
A (middle point) rear window glass center A point. If approximately 6 V is
6 Approximately 6 V indicated, it is judged good.
3. If the voltage of 12 V is indicated at the A point, there is an
0 open circuit between the A point and negative terminal.
(+) terminal (-) terminal
Therefore, by moving the test bar slowly to the negative
Length of print heater
side, search and determine the location where the voltage
Abnormal characteristics of print heater
changes suddenly (0 V). The location of voltage change
indicates the open circuit position.
Voltage (V)
12 Disconnection 4. Also, if the voltage indicates 0 V at the A point, there is an
location open circuit between the A point and positive terminal.
Therefore, search and determine the location of voltage
6 change (12 V) using the above mentioned method.
0
AC407247AD
TSB Revision
CHASSIS ELECTRICAL
DEFOGGER
54A-477
REAR WINDOW DEFOGGER RELAY CHECK
M1540500600149

number condition
At no energization 3 4 No
Rear window continuity
defogger relay
()] ohms or
less)
4
3
1 2
AC609147AB
TSB Revision
DEFOGGER SWITCH
DEFOGGER SWITCH
M1540600200148
Refer to GROUP 55 Heater control unit P.55A-118.
ETACS
SPECIAL TOOL
M1545000600105

name
a
b key. ETACS-ECU check (Diagnostic
f. MB991825
trouble code, service data)
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE
CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g measurement
adapter
harness
MB991826
MB991958
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-479
name
a
b d. MB991222
pressure inspection
a. Test harness
b. LED harness
c c. LED harness
d. Probe
d
DO NOT USE
MB991223BA
MB992006 Making voltage and resistance

troubleshooting
MB992006
TROUBLESHOOTING

TROUBLESHOOTING
M1545000900076
Refer to GROUP 00, Contents of troubleshooting P.00-6.
DIAGNOSTIC FUNCTION
M1545001000087

TSB Revision
ETACS
CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
display.
button.

TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-481
"OK" button.
CHECK OF FREEZE FRAME DATA When detecting fault and storing the DTC, the ECU
The freeze frame data can be checked by using the connected to CAN bus line obtains the data before
scan tool (GROUP 00, How to Cope with Intermittent the determination of the DTC and the data when the
Malfunction P.00-13). DTC is determined, and then stores the ECU status
. of that time. By analyzing the data from scan tool, the
troubleshooting can be performed more efficiently.
The displayed items are as shown in the table below.
Display item list
Item No. Item name Data item Unit
01 Odometer Total driving distance after the diagnostic trouble km*1
code is generated
02 Ignition cycle Number of times the ignition switch is turned "ON" or Number of
"LOCK (OFF)" after the past failure transition counts is
displayed.
03 Elapsed time after Total elapsed time after a diagnostic trouble code is min*2
failure generated
04 Current trouble Cumulative time for current malfunction of min
accumulative time diagnostic trouble code
NOTE: . erly. Thus, 65,535 minutes (null value) is dis-
*1: If a failure occurs to both the ABS-ECU and played. Because it is calculated based on the
ETACS-ECU, 0000 km or FFFF km is displayed ETACS-ECU information, the correct display may
to the scan tool MB991958. not be shown if the ETACS-ECU has had a time-
out.
*2: Total elapsed time can be stored up to 65,534
minutes (45.5 days). The display of scan tool is
fixed to 65,534 minutes after 65,534 minutes
have elapsed. Or, if the battery is disconnected,
the total elapsed time cannot be measured prop-
TSB Revision
ETACS

M1545001100211

code number
U0001 Bus off (CAN-C) P.54A-483
U0019 Bus off (CAN-B)
U0100 Engine control module CAN timeout P.54A-485
U0101 CVT-ECU CAN timeout P.54A-487
U0121 ABS-ECU CAN timeout P.54A-489
U0245 Audio visual navigation unit CAN timeout P.54A-507
U1108 Excess CAN-B ECU detection P.54A-509
U1120 Bus line (CAN-C) low input P.54A-510
U1121 Bus line (CAN-C) high input
U0169 Sunroof-ECU timeout Refer to GROUP 54B,
U0215 Power window main switch timeout Diagnosis P.54B-5.
U1109 Column switch timeout
U150B Column switch checksum error
U150C Power window main switch checksum error
U1511 Sunroof-ECU checksum error
U1514 Bit error (LIN)
U1515 Bus error (LIN)
U0331* ECU internal error P.54A-512
B1034 Temperature sensor (low input) Refer to GROUP 55A,
B1035 Temperature sensor (high input) Manual A/C Diagnosis
P.55A-8.
B16A0 Taillight (right) open circuit P.54A-157
B16A1 Taillight (left) open circuit
B16A2 Blown turn-signal light (left) bulb P.54A-96
B16A3 Turn-signal light (left) short circuit
B16A4 Blown turn-signal light (right) bulb
B16A5 Turn-signal light (right) short circuit
B16A6 Blown turn-signal light fuse P.54A-218
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-483
code number
B16A7 Taillight (right) short circuit P.54A-157
B16A8 Taillight (left) short circuit
B1761* VIN not recorded P.54A-513
B210A +B power supply (low input) P.54A-514
B210B +B power supply (high input)
B222C* Coding incomplete P.54A-517
B2206* Chassis number does not match P.54A-518
B2215* ECU internal error P.54A-519
B2350 Malfunction of lighting switch P.54A-228
B2351 Malfunction of the wiper switch
B2353 Ignition power supply (low input) P.54A-519
B2354 Ignition power supply (high input)
NOTE: *: If diagnostic trouble codes No. U0331,
B1761, B222C, B2206, or B2215 is set, there may be
an error with the coding data stored in the
ETACS-ECU.
DIAGNOSIS TROUBLE CODE PROCEDURES
DTC U0001: Bus off (CAN-C)

.

If DTC U0001 or U0019 is set to the The ETACS-ECU may have a malfunction, or the
ETACS-ECU, always diagnose the CAN bus ETACS-ECU power supply or earth circuit may have
line. a problem.
.
.
TROUBLE JUDGEMENT The ETACS-ECU may be defective.
When the ETACS-ECU is returned from the bus off The wiring harness or connectors may have
state, or when the bus off error is indicated to the loose, corroded, or damaged terminals, or termi-
ETACS-ECU state, the DTC U0001 (CAN-C) or nals pushed back in the connector
U0019 (CAN-B) is stored.
DIAGNOSIS
TSB Revision
ETACS

line.
CAUTION
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-485
DTC U0100: Engine control module CAN timeout

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from engine control module cannot be TROUBLESHOOTING HINTS

received, the ETACS-ECU sets DTC U0100. The Engine control module may be defective.
.
JUDGMENT CRITERIA The CAN bus may be defective.
seconds, if the communication with the engine con-
trol module cannot be established for 0.6 second or
more, the ETACS-ECU determines that a problem
has occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS
STEP 2. Using scan tool MB991958, read the engine

control module diagnostic trouble code.
Q: Is the DTC set?
YES : Troubleshoot the engine (Refer to GROUP 13A,
Diagnostic Trouble Code Chart P.13A-46).
NO : Go to Step 3.

Check if DTC U0100 is set to the CVT-ECU.
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the engine control module.
NO : The trouble can be an intermittent malfunction such
as a poor connection or open circuit in the CAN bus
lines between the engine control module and the
ETACS-ECU (Refer to GROUP 00, How to Cope with

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the engine control module and the
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-487
DTC U0101: CVT-ECU CAN timeout

miles) or more.
.
TROUBLE JUDGMENT .
If the signal from CVT-ECU cannot be received, the TROUBLESHOOTING HINTS

ETACS-ECU sets the DTC U0101. The CVT-ECU may be defective.
.
JUDGEMENT CRITERIA The CAN bus may be defective.
seconds, if the communication with the CVT-ECU
cannot be established for 0.6 second or more, the
ETACS-ECU determines that a problem has
occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS

Check if DTC is set to the CVT.
Q: Is the DTC set?
YES : Troubleshoot the CVT (Refer to GROUP 23A,
NO : Go to Step 3.

Check if the DTC U0101 is set to the engine control module.
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the CVT-ECU.
lines between the CVT-ECU and the ETACS-ECU
(Refer to GROUP 00, How to Cope with Intermittent

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the CVT-ECU and the ETACS-ECU
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-489
DTC U0121: ABS-ECU CAN timeout

miles) or more.
.
TROUBLE JUDGMENT .
If the signal from ABS-ECU cannot be received, the TROUBLESHOOTING HINTS

ETACS-ECU sets DTC U0121. The ABS-ECU may be defective.
.
The ASC-ECU may be defective.
JUDGEMENT CRITERIA The ETACS-ECU may be defective.
After the following statuses continue to be true for 5 The CAN bus may be defective.
seconds, if the communication with the ABS-ECU
occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS
STEP 2. Using scan tool MB991958, read the ABS

Check if DTC is set to the ABS-ECU.
Q: Is the DTC set?
YES : Troubleshoot the ABS (Refer to GROUP 35B,
Diagnosis P.35B-8).
NO : Go to Step 3.

Check if the DTC U0121 is set to the CVT-ECU.
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the ABS-ECU.
lines between the ABS-ECU and the ETACS-ECU

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the ABS-ECU and the ETACS-ECU
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-491

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from SRS-ECU cannot be received, the TROUBLESHOOTING HINTS

ETACS-ECU sets DTC U0151. The SRS-ECU may be defective.
.
seconds, if the communication with the SRS-ECU
occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS

Check if DTC is set to the SRS-ECU.
Q: Is the DTC set?
NO : Go to Step 3.
STEP 3. Using scan tool MB991958, read the A/C-ECU

Check if the DTC U0151 is set to the A/C-ECU.
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the SRS-ECU.
lines between the SRS-ECU and the ETACS-ECU

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the SRS-ECU and the ETACS-ECU
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-493

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from occupant classification-ECU cannot TROUBLESHOOTING HINTS

be received, the ETACS-ECU sets DTC U0154. The occupant classification-ECU may be defec-
.
tive.
seconds, if the communication with the occupant
classification-ECU cannot be established for 0.6 sec-
ond or more, the ETACS-ECU determines that a
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS

Q: Is the DTC set?
YES : Troubleshoot the occupant classification-ECU (Refer
to GROUP 52B, Diagnosis P.52B-280).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the occupant classification-ECU, then go to
Step 4.
lines between the occupant classification-ECU and
the ETACS-ECU (Refer to GROUP 00, How to Cope
with Intermittent Malfunction P.00-13).

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the occupant classification-ECU and
the ETACS-ECU (Refer to GROUP 00, How to Cope
with Intermittent Malfunction P.00-13).
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-495

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from combination meter cannot be TROUBLESHOOTING HINTS

received, the ETACS-ECU sets DTC U0155. The combination meter may be defective.
.
seconds, if the communication with the combination
meter cannot be established for 0.6 second or more,
the ETACS-ECU determines that a problem has
occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS

Q: Is the DTC set?
P.54A-23).
NO : Go to Step 3.

Check if the DTC U0155 is set to the A/C-ECU.
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the combination meter and the

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the combination meter and the
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-497

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from A/C-ECU cannot be received, the TROUBLESHOOTING HINTS

ETACS-ECU sets DTC U0164. The A/C-ECU may be defective.
.
seconds, if the communication with the A/C-ECU
occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS

Q: Is the DTC set?
A/C Diagnosis P.55A-8 or GROUP 55B, Auto A/C
Diagnosis P.55B-7).
NO : Go to Step 3.

Check if the DTC U0164 is set to the combination meter.
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the A/C-ECU.
lines between the A/C-ECU and the ETACS-ECU

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the A/C-ECU and the ETACS-ECU
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-499
DTC U0168: WCM or KOS-ECU CAN timeout

miles) or more.
.
TROUBLE JUDGMENT .
If the signal from WCM or KOS-ECU cannot be TROUBLESHOOTING HINTS

received, the ETACS-ECU sets DTC U0168. The WCM may be defective.
.
The KOS-ECU may be defective.
seconds, if the communication with the WCM or
KOS-ECU cannot be established for 0.6 second or
has occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS
STEP 2. Using scan tool MB991958, read the WCM or

KOS-ECU diagnostic trouble code.
Check if DTC is set to the WCM or KOS-ECU.
Q: Is the DTC set?
YES : Troubleshoot the WCM or KOS (Refer to GROUP
NO : Go to Step 3.

trouble code.
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the WCM or KOS-ECU.
lines between the WCM or KOS-ECU and the

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the WCM or KOS-ECU and the
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-501

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from radio and CD player or CD changer TROUBLESHOOTING HINTS

cannot be received, the ETACS-ECU sets DTC The radio and CD player or CD changer may be
U0184. defective.
.
seconds, if the communication with the radio and CD
player or CD changer cannot be established for 0.6
second or more, the ETACS-ECU determines that a
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS

Check if DTC is set to the audio.
Q: Is the DTC set?
YES : Troubleshoot the audio (Refer to P.54A-239).
NO : Go to Step 3.

Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the radio and CD player or CD changer
and the ETACS-ECU (Refer to GROUP 00, How to

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the radio and CD player or CD changer
and the ETACS-ECU (Refer to GROUP 00, How to
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-503

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from satellite radio tuner cannot be TROUBLESHOOTING HINTS

received, the ETACS-ECU sets DTC U0195. The satellite radio tuner may be defective.
.
seconds, if the communication with the satellite radio
tuner cannot be established for 0.6 second or more,
occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS
STEP 2. Using scan tool MB991958, read the satellite radio

Check if DTC is set to the satellite radio tuner.
Q: Is the DTC set?
YES : Troubleshoot the satellite radio (Refer to P.54A-468).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the satellite radio tuner, then go to Step 4.
lines between the satellite radio tuner and the

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the satellite radio tuner and the
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-505

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from hands free module cannot be TROUBLESHOOTING HINTS

received, the ETACS-ECU sets DTC U0197. The hands free module may be defective.
.
seconds, if the communication with the hands free
module cannot be established for 0.6 second or
has occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS

Check if DTC is set to the hands free module.
Q: Is the DTC set?
YES : Troubleshoot the hands free telephone system (Refer
to P.54A-409).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the hands free module, then go to Step 4.
lines between the hands free module and the

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the hands free module and the
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-507
DTC U0245: Audio visual navigation unit CAN timeout

miles) or more.
.
TROUBLE JUDGEMENT .
If the signal from CAN box unit (audio visual naviga- TROUBLESHOOTING HINTS
tion unit) cannot be received, the ETACS-ECU sets The CAN box unit may be defective.
DTC U0245. The ETACS-ECU may be defective.
.
The CAN bus may be defective.
JUDGEMENT CRITERIA
seconds, if the communication with the CAN box unit
(audio visual navigation unit) cannot be established
for 0.6 second or more, the ETACS-ECU determines
that a problem has occurred.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS
STEP 2. Using scan tool MB991958, read the audio visual

navigation unit diagnostic trouble code.
Check if DTC is set to the audio visual navigation unit.
Q: Is the DTC set?
YES : Troubleshoot the MMCS (Refer to P.54A-328).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
YES : Replace the CAN box unit (audio visual navigation
unit), then go to Step 4.
lines between the CAN box unit (audio visual
navigation unit) and the ETACS-ECU (Refer to
GROUP 00, How to Cope with Intermittent

(1) Erase the DTC.
position.
Q: Is the DTC set?
lines between the CAN box unit (audio visual
navigation unit) and the ETACS-ECU (Refer to
GROUP 00, How to Cope with Intermittent
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-509
DTC U1108: Excess CAN-B ECU Detection

.

If the DTC U1108 is set to the ETACS-ECU, always The ETACS-ECU may be defective.
diagnose the CAN bus line. The CAN bus may be defective.
.
TROUBLE JUDGEMENT
If the ETACS-ECU receives the signal from the
CAN-B line ECU which does not exist in the written
variant code information, the ETACS-ECU sets DTC
U1108.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
ETACS
STEP 2. Variant code check.

Check the variant code written to the ETACS-ECU, and check
whether it matches the ECU connected to the CAN-B line.
YES : Go to Step 3.
NO : Make a correction so that the ECU connected to the
CAN-B line matches with the variant code
information, and then go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
NO : This diagnosis is complete.
DTC U1120: Bus line (CAN-C) low input

DTC U1121: Bus line (CAN-C) high input
If the CAN bus line voltage is 4.7 volts or more,

.
TROUBLE JUDGEMENT DTC U1121 is set.

When the CAN bus line voltage is in the following
states, the ETACS-ECU set the DTC. .
If the CAN bus line voltage is 0.3 volt or less, TROUBLESHOOTING HINTS
DTC U1120 is set. The CAN bus line may be defective.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-511

line.
CAUTION
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
position.
Q: Is the DTC set?
NO : The diagnosis is complete.
TSB Revision
ETACS
DTC U0331: ECU internal error

. .

If the ETACS-ECU error counter value is detected to The ETACS-ECU may be defective.
be "255," DTC U0331 is set, and the ETACS-ECU is
reset. The DTC U0331 exists only as past trouble.
DIAGNOSIS

CAUTION
(3) Erase the DTC.
position.
MB991824
Q: Is the DTC set?
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-513
DTC B1761: VIN not recorded

. .

If the VIN is not written to the ETACS-ECU, the Chassis number not recorded
ETACS-ECU sets DTC B1761. The ETACS-ECU may be defective.
DIAGNOSIS

CAUTION
(3) Erase the DTC.
position.
MB991824
Q: Is the DTC set?
YES : Replace with the coded ETACS-ECU.
MB991827 AC608435 AB
TSB Revision
ETACS
DTC B210A: +B power supply (low input)

DTC B210B: +B power supply (high input)
CAUTION
Before replacing the ECU, ensure that the input
and output signal circuits are normal.
ETACS-ECU Power Supply Circuit
FUSIBLE
LINK 36
RELAY
BOX
ETACS-ECU

Junction block
The power supply fuse or the ETACS-ECU may have
a problem.
C-307 (B) .
The power supply fuse may be defective.
The battery may be defective.
AC608152 BB
The alternator may be defective.
.
TROUBLE JUDGEMENT
The ETACS-ECU sets DTC B210A if the power sup-
ply fuse voltage decreases to the specified value or
less, and sets DTC B210B if the power supply fuse
voltage increases to the specified value or more.
However, when the status returns to normal, the
ETACS-ECU automatically erases DTCs B210A and
B210B.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-515
DIAGNOSIS
STEP 1. Power supply fuse check.

Q: Is the fuse in good condition?
YES : Go to Step 2.
NO : Replace the power supply fuse, and then go to Step
2.

in the connector.
YES : Go to Step 3.
NO : Repair or replace the component(s). Refer to GROUP

connector C-307.
connector.
Harness side: C-307 The voltage should measure approximately 12 volts
positive voltage)?
YES : Go to Step 5.
NO : Go to Step 4.
AC608254 BF

connector C-307 (terminal 2) and the fusible link (36).
C-307 (terminal 2) and the fusible link (36) in good
condition?
TSB Revision
ETACS

Check the power supply fuse voltage.
CAUTION
MB991910 condition
MB991824 Item 253 Voltage sensing Approximately
of IOD Line 12 volts (battery
positive voltage)

Q: Do the scan tool MB991958 display the item "voltage
sensing of IOD Line" is normal condition?
YES : Go to Step 6.
MB991827 AC608435 AB NO : Replace the ETACS-ECU.

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-517
DTC B222C: Coding incomplete

. .

If the ETACS-ECU is in the initial state or the variant Variant code not written
coding is incomplete, the ETACS-ECU sets DTC The ETACS-ECU may be defective.
B222C.
DIAGNOSIS

CAUTION
(3) Perform the variant coding to the ETACS-ECU.
(4) Erase the DTC.
MB991910 position.
MB991824 (7) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the DTC set?
MB991827 AC608435 AB
TSB Revision
ETACS
DTC B2206: Chassis number does not match

If DTC B2206 is set, always diagnose the CAN If the chassis number registered to ETACS-ECU and
bus line. the chassis number on CAN bus lines do not match,
.
TROUBLE JUDGEMENT occurred.
If the registered chassis number is different from the
chassis number transmitted on the CAN bus lines,
.
the ETACS-ECU sets DTC B2206.
Chassis number not written
.
The engine control module may be defective.
DIAGNOSIS

line.
CAUTION
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-519

Q: Is the DTC set?
YES : Troubleshoot the engine (Refer to GROUP 13A,
Diagnostic Trouble Code Chart P.13A-46).
NO : Go to Step 3.

(1) Erase the DTC.
position.
Q: Is the DTC set?
DTC B2215: ECU internal error
.
TROUBLE JUDGEMENT
When the ETACS-ECU internal error count reaches The ETACS-ECU may be defective.
"255," DTC B2215 is set.
DIAGNOSIS
.
Replace the ETACS-ECU.
DTC B2353: Ignition power supply (low input)

DTC B2354: Ignition power supply (high input)
CAUTION
Before replacing the ECU, ensure that the input
and output signal circuits are normal.
Ignition Switch (IG1) Input Circuit
IGNITION
SWITCH (IG1)
ETACS-ECU
TSB Revision
ETACS
.

Junction block
The power supply circuit or the ETACS-ECU may
have a problem.
.
The power supply circuit may be defective.
The battery may be defective.
The alternator may be defective.
AC608152 AE
The ignition switch may be defective.
.
TROUBLE JUDGMENT
These DTCs are set when the ignition power supply
voltage decreases to the specified value or less
(DTC B2353) or increases to the specified value or
more (DTC B2354). However, when the status
returns to normal, the DTCs B2353 and B2354 are
automatically erased.
DIAGNOSIS

Check the ignition power supply voltage.
CAUTION
MB991910 condition
MB991824 Item 254 IG voltage Approximately 12
volts (battery
positive voltage)

Q: Do the scan tool MB991958 display the item "IG voltage"
is normal condition?
YES : Go to Step 2.
MB991827 AC608435 AB NO : Replace the ETACS-ECU.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-521

in the connector.
YES : Go to Step 3.
NO : Repair or replace the component(s). Refer to GROUP
STEP 3. Check the ignition switch (IG1) circuit to the

connector C-317.
connector.
positive voltage)?
YES : Go to Step 5.
NO : Go to Step 4.
Harness side: C-317
AC608254 BG

connector C-317 (terminal 6) and the ignition switch (IG1).
C-317 (terminal 6) and the ignition switch (IG1) in good
condition?
STEP 5. Recheck for diagnostic trouble .

(1) Erase the DTC.
position.
Q: Is the DTC set?
TSB Revision
ETACS

M1545001300118
NOTE: Some items are not displayed on scan tool
MB991958 according to the information in the ECU.
Item No. Scan tool display Condition
1 CAN-H voltage 04 V
2 CAN-L voltage 15 V
200 Original VIN writing status Comp/Unperformed or ECU internal Err or
Comp and locked
201 Current VIN writing status Comp/Unperformed or ECU internal Err or
Comp and locked
202 Internal error No error or EEPROM error or Boot loader
Err or EEPROM/Boot or ADC Error or
ADC/EEPROM error or ADC/Boot error or
ADC/Boot/EEPROM or PLL Error or
PLL/EEPROM error or PLL/EEPROM error
or PLL/Boot/EEPROM or PLL/ADC error or
PLL/ADC/EEPROM or PLL/ADC/Boot or
PLL/ADC/Boot/ROM
203 Process error No error or Interrupt error or Switch error or
Sequence error or Stck pointer Err or
Dispatch call Er or Other error
204 Coding counter times
205 Coding counter Option times
206 Headlight LO ON duty 0100%
207 Fan control relay ON duty 0100%
208 Dome light ON duty 0100%
209 Gate light ON duty 0100%
210 IG key illumination 0100%
211 Headlight Hi ON or OFF
212 Front fog light ON or OFF
213 Horn theft horn ON or OFF
214 Headlight washer ON or OFF
215 Security indicator ON or OFF
216 IG1-2 fuel pump ON or OFF
218 Taillight ON or OFF
219 Turn RH/LH light ON or OFF
220 Blower fan ON or OFF
221 Defogger ON or OFF
222 Interior light cut ON or OFF
224 Door lock ON or OFF
227 Door unlock ON or OFF
228 Dr door unlock ON or OFF
230 Trunk/gate opener ON or OFF
231 Rear fog light ON or OFF
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-523
232 ACC Relay ON or OFF
233 Fan Lo ON or OFF
234 Fan Hi ON or OFF
235 Front wiper ACT ON or OFF
236 Front wiper Lo/Hi ON or OFF
237 Front washer ON or OFF
238 Rear washer ON or OFF
239 Rear wiper ON or OFF
240 Power window ON or OFF
241 Hold mirror open ON or OFF
242 Hold mirror close ON or OFF
243 Dead lock ON or OFF
244 Independent DRL ON or OFF
251 Auto light sensor Voltage
252 Ambient temperature sensor Voltage
253 Voltage sensing of IOD Line Voltage
254 IG voltage Voltage
255 Theft sensor ON or OFF
256 Dr door ajar switch Open or Close
257 As door ajar switch Open or Close
258 RR door ajar switch Open or Close
259 RL door ajar switch Open or Close
260 Trunk/gate trunk ajar switch Open or Close
262 dome light center ON switch ON or OFF
263 dome light center OFF switch ON or OFF
264 Handle lock switch Key out or Key in
265 Hazard switch ON or OFF
266 Hood switch ON or OFF
267 Mirror switch ON or OFF
268 Trunk/gate opener switch ON or OFF
270 Dr door lock switch Lock or Not lock
271 Dr door unlock switch Unlock or Not Unlock
272 As door unlock switch Unlock or Not Unlock
273 Except Dr/As door unlock switch Unlock or Not Unlock
274 Door key lock switch ON or OFF
275 Dr door key unlock switch ON or OFF
276 Door key unlock switch ON or OFF
277 Power lock switch ON or OFF
278 Power unlock switch ON or OFF
279 Brake fluid switch ON or OFF
TSB Revision
ETACS

280 Washer fluid switch ON or OFF
281 ASC/TCL OFF switch ON or OFF
287 Starter switch ON or OFF
288 ACC switch ON or OFF
289 Backup light or shift reveres SW ON or OFF
290 Brake switch ON or OFF
291 Front wiper auto stop switch ON or OFF
292 Rear wiper auto stop switch ON or OFF
293 Process error information
294 Process error times
295 Rear sunroof unlock ON or OFF
340 Headlight switch(tail) ON or OFF
341 Headlight switch ON or OFF
342 Headlight switch(Dimmer) ON or OFF
343 Turn switch left ON or OFF
344 Turn switch right ON or OFF
345 Fog light ON ON or OFF
346 Fog light OFF ON or OFF
347 Switch type LHD or RHD
348 Headlight switch(auto) ON or OFF
349 Headlight cleaner ON or OFF
350 Headlight switch(flasher) ON or OFF
351 Column ECU sleep OK or NG
352 Front wiper(INT) ON or OFF
353 Front wiper(LO) ON or OFF
354 Front wiper(HI) ON or OFF
355 Front wiper(washer) ON or OFF
356 Rear wiper ON or OFF
357 Rear wiper(washer) ON or OFF
358 Front wiper(MIST) ON or OFF
359 Front wiper(interval volume)
360 Wiper switch lever fail No fail or Fail
361 Turn/Light switch lever fail No fail or Fail
M1545001200111
Trouble symptom Reference page

Malfunction of ETACS-ECU power supply circuit P.54A-525
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-525
SYMPTOM PROCEDURES
Malfunction of ETACS-ECU power supply circuit
ETACS-ECU Power Supply Circuit
FUSIBLE FUSIBLE
LINK 34 LINK 36
RELAY BOX
ENGINE
COMPARTMENT
ETACS-ECU
Connectors: C-307, C-309, C-315, C-317 TECHNICAL DESCRIPTION (COMMENT)

Junction block If the ETACS-ECU functions do not work at all, the
C-317
ETACS-ECU power supply system, earth system, or
ETACS-ECU may have a problem.
C-307 (B)
.
C-309 (B) loose, corroded, or damaged terminals, or termi-
C-315
AC608152 AD The ETACS-ECU may be defective
.
DIAGNOSIS
TSB Revision
ETACS

Q: Is ETACS-ECU connectors C-315 and C-317 in good
condition?
YES : Go to Step 2.
P.00E-2).
STEP 2. Check the ground circuit to the ETACS-ECU.

Measure the resistance at ETACS-ECU connectors C-315
and C-317.
(1) Disconnect ETACS-ECU connector C-315 and C-317 and
of the connector.
(2) Measure the resistance value between ETACS-ECU
Harness side: C-315 connector C-315 terminal 17 and ground.
AC608255 BG
(3) Measure the resistance value between ETACS-ECU

YES : Go to Step 4.
NO : Go to Step 3.
AC608255 BH

connector C-315 (terminal 17) or C-317 (terminal 15) and
the ground.
C-315 (terminal 17) or C-317 (terminal 15) and the
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-527

Q: Is ETACS-ECU connectors C-307 and C-309 in good
condition?
YES : Go to Step 5.
P.00E-2).

connectors C-307 and C-309.
(1) Disconnect ETACS-ECU connectors C-307 and C-309
measure the voltage available at the wiring harness side of
the connector.
(2) Measure the voltage between ETACS-ECU connector
Harness side: C-307 C-307 terminal 2 and ground.
AC608254 BF

C-309 terminal 1 and ground.
Harness side: C-309
positive voltage)?
YES : Go to Step 7.
NO : Go to Step 6.
AC608254 BI

connectors C-307 (terminal 2) or C-309 (terminal 1) and the
fusible link (36) or (34).
Q: Is the wiring harness between ETACS-ECU connectors
C-307 (terminal 2) or C-309 (terminal 1) and the fusible
link (36) or (34) in good condition?
should communicate with the ETACS-ECU normally.
TSB Revision
ETACS

Check that the ETACS-ECU functions work normally.
YES : The procedure is complete (If no malfunctions are
found in all steps, an intermittent malfunction is
suspected. Refer to GROUP 00, How to Use
TROUBLE SYMPTOM CHART FOR INPUT SIGNAL
M1545004900090

Procedure page
No.
ETACS-ECU does not receive any signal from the ignition switch (ACC). 1 P.54A-529
ETACS-ECU does not receive any signal from the ignition switch (IG1). 2 P.54A-531
ETACS-ECU does not receive any signal from the key reminder switch. 3 P.54A-533
ETACS-ECU does not receive any signal from the front door lock actuator. 4 P.54A-536
ETACS-ECU does not receive any signal from the front door switch (LH). 5 P.54A-543
ETACS-ECU does not receive any signal from the front door switch (RH). 6 P.54A-545
ETACS-ECU does not receive any signal from the rear door switch (LH). 7 P.54A-548
ETACS-ECU does not receive any signal from the rear door switch (RH). 8 P.54A-550
ETACS-ECU does not receive any signal from the trunk lid actuator and switch. 9 P.54A-553
ETACS-ECU does not receive any signal from the hazard warning light switch. 10 P.54A-557
ETACS-ECU does not receive any signal from the column switch signal. 11 P.54A-559
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-529
INPUT SIGNAL PROCEDURES
Inspection Procedure 1: ETACS-ECU does not receive any signal from the ignition switch (ACC).
Ignition Switch (ACC) Input Circuit
IGNITION
SWITCH (ACC)
ETACS-ECU

Junction block If there is an error to the ignition switch (ACC) input
signal, or the ACC relay inside the ETACS-ECU does
not operate, the ignition switch (ACC) signal is no
longer output to the communication line.
.
The ignition switch may be defective
AC608152 AE The wiring harness or connectors may have
.
DIAGNOSIS

in the connector.
YES : Go to Step 2.
P.00E-2). Check that the input signal of ignition switch
(ACC) is normal.
TSB Revision
ETACS
STEP 2. Check the ignition switch (ACC) line of the power

supply circuit to the ETACS-ECU. Measure the voltage at
ETACS-ECU connector C-317.
voltage available at the junction block side of the connector.
positive voltage)?
YES : Replace the ETACS-ECU. Check that the input signal
of ignition switch (ACC) is normal.
Harness side: C-317 NO : Go to Step 3.
AC608254 BK

connector C-317 (terminal 7) and the ignition switch (ACC).
C-317 (terminal 7) and ignition switch (ACC) in good
condition?
Repair the wiring harness as necessary. Check that
the input signal of ignition switch (ACC) is normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-531
Inspection Procedure 2: ETACS-ECU does not receive any signal from the ignition switch (IG1).
Ignition Switch (IG1) Input Circuit
IGNITION
SWITCH (IG1)
ETACS-ECU

Junction block If there is an error to the ignition switch (IG1) input
signal, or the IG1 relay inside the ETACS-ECU does
not operate, the ignition switch (IG1) signal is no
longer output to the communication line.
.
The ignition switch may be defective
AC608152 AE The fuse may be defective
.
DIAGNOSIS

in the connector.
YES : Go to Step 2.
P.00E-2). Check that the input signal of ignition switch
(IG1) is normal.
TSB Revision
ETACS
STEP 2. Check the ignition switch (IG1) line of the power

supply circuit to the ETACS-ECU. Measure the voltage at
ETACS-ECU connector C-317.
voltage available at the junction block side of the connector.
positive voltage)?
Harness side: C-317
of ignition switch (IG1) is normal.
NO : Go to Step 3.
AC608254 BJ

connector C-317 (terminal 6) and the ignition switch (IG1).
C-317 (terminal 6) and ignition switch (IG1) in good
condition?
the input signal of ignition switch (IG1) is normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-533
Inspection Procedure 3: ETACS-ECU does not receive any signal from the key reminder switch.
Key Reminder Switch Input Circuit
ETACS-
ECU
KEY REMINDER
SWITCH
WHEN KEY IS
REMOVED: ON
Connector: C-213 COMMENTS ON TROUBLE SYMPTOM

The key reminder switch input signal is used for the
operation judgement of the functions below. If the
signal is abnormal, these functions will not work.
Ignition key reminder function
Central door locking
Keyless entry system
KOS
Ignition key cylinder illumination light
AC608147AF Interior light
Connector: C-315 .
Junction block TROUBLESHOOTING HINTS

The key reminder switch may be defective
AC608152 AL
DIAGNOSIS
TSB Revision
ETACS
STEP 1. Check key reminder switch connector C-213 for

Q: Is key reminder switch connector C-213 in good
condition?
YES : Go to Step 2.
P.00E-2). Check that the input signal of key reminder
switch is normal.
STEP 2. Check the key reminder switch.

Disconnect key reminder switch connector C-213. Then check
continuity between terminals.
Ignition key Tester connection Specified
condition
Removed 2 3 Open circuit
Inserted 2 3 Continuity exists (2
ohms or less)
Q: Is the key reminder switch in good condition?

YES : Go to Step 3.
NO : Replace the key reminder switch. Check that the input
signal of key reminder switch is normal.
STEP 3. Check the ground circuit to the key reminder

switch. Measure the resistance at key reminder switch
connector C-213.
(1) Disconnect key reminder switch connector C-213 and
of the connector.
ground.
Harness side: C-213
YES : Go to Step 5.
NO : Go to Step 4.
AC608255 BK
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-535
STEP 4. Check the wiring harness between key reminder

switch connector C-213 (terminal 2) and ground.
Q: Is the wiring harness between key reminder switch
condition?
the input signal of key reminder switch is normal.

in the connector.
YES : Go to Step 6.
P.00E-2). Check that the input signal of key reminder
switch is normal.
STEP 6. Check the wiring harness between key reminder

switch connector C-213 (terminal 3) and ETACS-ECU
Q: Is the wiring harness between key reminder switch
connector C-213 (terminal 3) and ETACS-ECU connector
YES : Go to Step 7.
the input signal of key reminder switch is normal.
STEP 7. Check for continuity between key reminder switch

connector C-213 terminal 2 and each of the other terminals
as well as terminal 3 and each of the other terminals.
(1) Disconnect key reminder switch connector C-213 and
measure the resistance available at the equipment side of
the connector.
(2) Check for continuity between key reminder switch
connector C-213 terminal 2 and each of the other terminals
as well as terminal 3 and each of the other terminals.
Q: Does continuity exist between the terminals?
NO : Replace the ETACS-ECU. Check that the input signal
of key reminder switch is normal.
YES : Replace the key reminder switch. Check that the input
signal of key reminder switch is normal.
TSB Revision
ETACS
Inspection Procedure 4: ETACS-ECU does not receive any signal from the front door lock actuator.
Door Look Actuator Input Circuit
ETACS-ECU

LOCK ACTUATOR (LH) LOCK ACTUATOR (RH)
Connectors: C-114, C-115 Connector: C-301

Junction block
C-114
C-115 (BR)
AC608146AY AC608152 AB
Connectors: C-125, C-126 Connector: E-07
E-07 (B)
C-125
C-126 (BR)
AC608145AR AC608168 AF
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-537
Connector: E-17
Key reminder function
Central door locking
KOS
Keyless entry system
Interior light
E-17 (B) .
PROBABLE CAUSES
The front door lock actuator (LH) may be defec-
tive
AC608167AH The front door lock actuator (RH) may be defec-
. tive <vehicles with KOS>
COMMENTS ON TROUBLE SYMPTOM The ETACS-ECU may be defective
The front door lock actuator (LH) or front door lock The wiring harness or connectors may have
actuator (RH) <vehicles with KOS> input signal is loose, corroded, or damaged terminals, or termi-
used for the operation judgement of the functions nals pushed back in the connector
below. If the signal is abnormal, these functions will
not work normally.
DIAGNOSIS
TSB Revision
ETACS

Check the input signals from the front door lock actuators.
CAUTION
Set the driver's door to "UNLOCK."
MB991910 condition
MB991824 Item 271 Dr door unlock Unlock
switch
Set the front passenger's door to "UNLOCK." <vehicles

with KOS>
condition
MB991827 AC608435 AB
Item 272 As door unlock Unlock
switch

Q: Are normal conditions displayed on the "Dr door unlock
switch" and "As door unlock switch"?
YES <Normal conditions are displayed for all the items>
: No action is necessary and testing is complete.
NO <Normal condition is not displayed for item No.271>
: Go to Step 2.
NO <Normal condition is not displayed for item No.272>
: Go to Step 8.
STEP 2. Check front door lock actuator (LH) connector

E-17 for loose, corroded or damaged terminals, or
Q: Is front door lock actuator (LH) connector E-17 in good
condition?
YES : Go to Step 3.
P.00E-2). Check that the input signal of front door
lock actuator (LH) is normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-539
STEP 3. Check the front door lock actuator (LH).

Disconnect front door lock actuator (LH) connector E-17. Then
check continuity between the terminals.
Lever position Tester connection Specified
condition
UNLOCK 1 3 Continuity exists (2
ohms or less)
LOCK 1 3 Open circuit
Q: Is the front door lock actuator (LH) in good condition?

YES : Go to Step 4.
NO : Replace the front door lock actuator (LH). Check that
the input signal of front door lock actuator (LH) is
normal.
STEP 4. Check the ground circuit to the front door lock

actuator (LH). Measure the resistance at front door lock
actuator (LH) connector E-17.
(1) Disconnect front door lock actuator (LH) connector E-17
ground.
YES : Go to Step 6.
NO : Go to Step 5.
Harness side: E-17
AC608255 BI
STEP 5. Check the wiring harness between front door lock

actuator (LH) connector E-17 (terminal 1) and ground.
Q: Is the wiring harness between front door lock actuator
(LH) connector E-17 (terminal 1) and ground in good
condition?
normal.
TSB Revision
ETACS

in the connector.
YES : Go to Step 7.
lock actuator (LH) is normal.
STEP 7. Check the wiring harness between front door lock

actuator (LH) connector E-17 (terminal 3) and ETACS-ECU
(LH) connector E-17 (terminal 3) and ETACS-ECU
of front door lock actuator (LH) is normal.
normal.
STEP 8. Check front door lock actuator (RH) connector

E-07 for loose, corroded or damaged terminals, or
Q: Is front door lock actuator (RH) connector E-07 in good
condition?
YES : Go to Step 9.
lock actuator (RH) is normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-541
STEP 9. Check the front door lock actuator (RH).

Disconnect front door lock actuator (RH) connector E-07. Then
check continuity between the terminals.
Lever position Tester connection Specified
condition
UNLOCK 1 3 Continuity exists (2
ohms or less)
LOCK 1 3 Open circuit
Q: Is the front door lock actuator (RH) in good condition?

NO : Replace the front door lock actuator (RH). Check that
the input signal of front door lock actuator (RH) is
normal.
STEP 10. Check the ground circuit to the front door lock
actuator (RH). Measure the resistance at front door lock
actuator (RH) connector E-07.
(1) Disconnect front door lock actuator (RH) connector E-07
ground.
NO : Go to Step 11.
Harness side: E-07
AC608255 BJ
STEP 11. Check the wiring harness between front door

lock actuator (RH) connector E-07 (terminal 3) and ground.
(RH) connector E-07 (terminal 3) and ground in good
condition?
normal.
TSB Revision
ETACS

in the connector.
lock actuator (RH) is normal.

lock actuator (RH) connector E-07 (terminal 1) and
(RH) connector E-07 (terminal 1) and ETACS-ECU
of front door lock actuator (RH) is normal.
normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-543
Inspection Procedure 5: ETACS-ECU does not receive any signal from the front door switch (LH).
Front Door Switch (LH) Input Circuit
ETACS-
ECU
FRONT DOOR
SWITCH (LH)

Junction block
If there is an error to the front door switch (LH) input
signal, the front door switch (LH) signal is no longer
output to the communication line.
.
The front door switch (LH) may be defective
C-313 (BR)
AC608152 AW
Connector: D-24 nals pushed back in the connector
AC608166AS
DIAGNOSIS
TSB Revision
ETACS
STEP 1. Check front door switch (LH) connector D-24 for

Q: Is front door switch (LH) connector D-24 in good
condition?
YES : Go to Step 2.
switch (LH) is normal.
STEP 2. Check the front door switch (LH).

Remove the front door switch (LH). Then check the continuity
between the switch terminals and the switch body.
connection
Released 3 switch body Continuity exists (2
ohms or less)
Pressed 3 switch body Open circuit
Q: Is the driver's door switch in good condition?

YES : Go to Step 3.
NO : Replace the front door switch (LH). Check that the
input signal of front door switch (LH) is normal.
STEP 3. Measure at the lower metal part of the front door

switch (LH) in order to check the ground circuit to the front
door switch (LH).
NOTE: Check that the front door switch (LH) is grounded to the
vehicle body by means of its mounting screw.
Remove the cap, and measure the resistance value between
the lower metal part and the ground.
The resistance should equal 2 ohms or less.
YES : Go to Step 4.
NO : Check the fit of the switch, and repair if necessary.
Check that the input signal of front door switch (LH) is
normal.

in the connector.
YES : Go to Step 5.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-545
STEP 5. Check the wiring harness between driver's door

switch connector D-24 (terminal 3) and ETACS-ECU
Q: Is the wiring harness between driver's door switch
connector D-24 (terminal 3) and ETACS-ECU connector
of front door switch (LH) is normal.
the input signal of front door switch (LH) is normal.
Inspection Procedure 6: ETACS-ECU does not receive any signal from the front door switch (RH).
Front Door Switch (RH) Input Circuit
ETACS-
ECU
FRONT DOOR
SWITCH (RH)

Junction block
C-313 (BR)
AC608152 AW AC608165BA
.

If there is an error to the front door switch (RH) input
signal, the front door switch (RH) signal is no longer
TSB Revision
ETACS

.
TROUBLESHOOTING HINTS loose, corroded, or damaged terminals, or termi-

The front door switch (RH) may be defective nals pushed back in the connector
DIAGNOSIS
STEP 1. Check front door switch (RH) connector D-35 for

Q: Is front door switch (RH) connector D-35 in good
condition?
YES : Go to Step 2.
P.00E-2. Check that the input signal of front door
switch (RH) is normal.
STEP 2. Check the front door switch (RH).

Remove the front door switch (RH). Then check the continuity
connection
ohms or less)
Q: Is the front door switch (RH) in good condition?

YES : Go to Step 3.
NO : Replace the front door switch (RH). Check that the
input signal of front door switch (RH) is normal.
STEP 3. Measure at the lower metal part of the front door

switch (RH) in order to check the ground circuit to the front
door switch (RH).
NOTE: Check that the front door switch (RH) is grounded to the
YES : Go to Step 4.
Check that the input signal of front door switch (RH) is
normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-547

in the connector.
YES : Go to Step 5.
P.00E-2. Check that the input signal of front door

switch (RH) connector D-39 (terminal 3) and ETACS-ECU
Q: Is the wiring harness between driver's door switch
of front door switch (RH) is normal.
the input signal of front door switch (RH) is normal.
TSB Revision
ETACS
Inspection Procedure 7: ETACS-ECU does not receive any signal from the rear door switch (LH).
Rear Door Switch (LH) Input Circuit
ETACS-
ECU
REAR DOOR
SWITCH (LH)

Junction block
If there is an error to the rear door switch (LH) input
signal, the rear door switch (LH) signal is no longer
.
The rear door switch (LH) may be defective
C-313 (BR)
AC608152 AW
Connector: D-16 nals pushed back in the connector
AC608166AU
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-549
STEP 1. Check rear door switch (LH) connector D-16 for

Q: Is rear door switch (LH) connector D-16 in good
condition?
YES : Go to Step 2.
P.00E-2). Check that the input signal of rear door
STEP 2. Check the rear door switch (LH).

Remove the rear door switch (LH). Then check the continuity
connection
ohms or less)
Q: Is the rear door switch in good condition?

YES : Go to Step 3.
NO : Replace the rear door switch (LH). Check that the
input signal of rear door switch (LH) is normal.
STEP 3. Measure at the lower metal part of the rear door

switch (LH) in order to check the ground circuit to the rear
door switch (LH).
NOTE: Check that the rear door switch (LH) is grounded to the
YES : Go to Step 4.
Check that the input signal of rear door switch (LH) is
normal.

in the connector.
YES : Go to Step 5.
TSB Revision
ETACS

Q: Is the wiring harness between rear door switch
of rear door switch (LH) is normal.
the input signal of rear door switch (LH) is normal.
Inspection Procedure 8: ETACS-ECU does not receive any signal from the rear door switch (RH).
Rear Door Switch (RH) Input Circuit
ETACS-
ECU
REAR DOOR
SWITCH (RH)

Junction block
C-313 (BR)
AC608152 AW AC608166AT
.

If there is an error to the rear door switch (RH) input
signal, the rear door switch (RH) signal is no longer
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-551
.
TROUBLESHOOTING HINTS loose, corroded, or damaged terminals, or termi-

The rear door switch (RH) may be defective nals pushed back in the connector
DIAGNOSIS
STEP 1. Check rear door switch (RH) connector D-07 for

Q: Is rear door switch (RH) connector D-07 in good
condition?
YES : Go to Step 2.
STEP 2. Check the rear door switch (RH).

Remove the rear door switch (RH). Then check the continuity
connection
ohms or less)
Q: Is the rear door switch in good condition?

YES : Go to Step 3.
NO : Replace the rear door switch (RH). Check that the
input signal of rear door switch (RH) is normal.
STEP 3. Measure at the lower metal part of the rear door

switch (RH) in order to check the ground circuit to the rear
door switch (RH).
NOTE: Check that the rear door switch (RH) is grounded to the
YES : Go to Step 4.
Check that the input signal of rear door switch (RH) is
normal.
TSB Revision
ETACS

in the connector.
YES : Go to Step 5.

Q: Is the wiring harness between rear door switch
of rear door switch (RH) is normal.
the input signal of rear door switch (RH) is normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-553
Inspection Procedure 9: ETACS-ECU does not receive any signal from the trunk lid actuator and
switch.
Trunk Lid Actuator and Switch Input Circuit
ETACS-
ECU
TRUNK LID
ACTUATOR
AND SWITCH
Connector: C-313 Connectors: F-12, F-23

Junction block
F-23 F-12
C-313 (BR)
AC608152 AW AC608171AE
.
Connector: D-15 TECHNICAL DESCRIPTION (COMMENT)

If there is an error to the trunk lid actuator and switch
input signal, the trunk lid actuator and switch signal is
no longer output to the communication line.
.
The trunk lid actuator and switch may be defec-
tive
AC608166AL The ETACS-ECU may be defective
TSB Revision
ETACS

DIAGNOSIS
STEP 1. Check trunk lid actuator and switch connector

F-12 for loose, corroded or damaged terminals, or
Q: Is trunk lid actuator and switch connector F-12 in good
condition?
YES : Go to Step 2.
P.00E-2). Check that the input signal of trunk lid
actuator and switch is normal.
STEP 2. Check the trunk lid actuator and switch.

Disconnect trunk lid actuator and switch connector F-12. Then
check continuity between terminals.
Ignition key Tester connection Specified
condition
Released 1 2 Continuity exists (2
ohms or less)
Pressed 1 2 Open circuit
Q: Is the trunk lid actuator and switch in good condition?

YES : Go to Step 3.
NO : Replace the trunk lid actuator and switch. Check that
the input signal of trunk lid actuator and switch is
normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-555
STEP 3. Check the ground circuit to the trunk lid actuator

and switch. Measure the resistance at trunk lid actuator
and switch connector F-12.
(1) Disconnect trunk lid actuator and switch connector F-12
ground.
Harness side: F-12 Q: Is the measured resistance 2 ohms or less?
YES : Go to Step 5.
NO : Go to Step 4.
AC608255 BL
STEP 4. Check the wiring harness between trunk lid

actuator and switch connector F-12 (terminal 2) and
ground.
NOTE: Also check intermediate connector F-23 for loose, cor-
connector. If intermediate connector F-23 is damaged, repair or
Q: Is the wiring harness between trunk lid actuator and
switch connector F-12 (terminal 2) and ground in good
condition?
normal.

in the connector.
YES : Go to Step 6.
P.00E-2). Check that the input signal of trunk lid
actuator and switch is normal.
TSB Revision
ETACS
STEP 6. Check the wiring harness between trunk lid

actuator and switch connector F-12 (terminal 1) and
NOTE: Also check intermediate connectors F-23 and D-15 for
back in the connector. If intermediate connector F-23 or D-15 is
damaged, repair or replace the connector as described in
Q: Is the wiring harness between trunk lid actuator and
switch connector F-12 (terminal 1) and ETACS-ECU
of trunk lid actuator and switch is normal.
normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-557
Inspection Procedure 10: ETACS-ECU does not receive any signal from the hazard warning light
switch.
Hazard Warning Switch Input Circuit
ETACS-
ECU
CENTER
PANEL
UNIT
HAZARD
WARNING
SWITCH

If there is an error to the hazard warning light switch
input signal, the hazard warning light switch signal is
C-18 (B) no longer output to the communication line.
.
The center panel unit may be defective
AC608146BS
Connector: C-301 nals pushed back in the connector
Junction block
AC608152 AB
DIAGNOSIS
TSB Revision
ETACS
STEP 1. Check center panel unit connector C-18 for loose,

in the connector.
Q: Is center panel unit connector C-18 in good condition?
YES : Go to Step 2.
P.00E-2). Check that the input signal of hazard
warning light switch is normal.
STEP 2. Check the hazard warning light switch.

Remove the center panel unit. Then check continuity between
the switch terminal and switch body.
Switch position Tester Specified
connection condition
Released 5 switch body Continuity exists
(2 ohms or less)
Q: Is the hazard warning light switch in good condition?

YES : Go to Step 3.
NO : Replace the center panel unit. Check that the input
signal of hazard warning light switch is normal.

in the connector.
YES : Go to Step 4.
P.00E-2). Check that the input signal of hazard
warning light switch is normal.
STEP 4. Check the wiring harness between center panel

unit connector C-18 (terminal 5) and ETACS-ECU
Q: Is the wiring harness between center panel unit
of hazard warning light switch is normal.
the input signal of hazard warning light switch is
normal.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-559
Inspection Procedure 11: ETACS-ECU does not receive any signal from the column switch signal.
. .

The ETACS-ECU receives the column switch signal The column switch may be defective
via the LIN communication. If there is an abnormality The LIN bus line may be defective
to column switch or LIN bus line, the lights and
wiper/washer do not work normally.
DIAGNOSIS
STEP 1. Using scan tool MB991958, read the ETACS

Check the DTC is set to the ETACS-ECU.
CAUTION
position.
MB991824
NO : Go to Step 2.
MB991827 AC608435 AB
TSB Revision
ETACS
STEP 2. Column switch check

Check the continuity for windshield wiper and windshield
washer switch (Refer to P.54A-231).
Check the continuity for column switch (switch body part)
to GROUP 00, How to Use
NO : Replace the column switch.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-561
ON-VEHICLE SERVICE
M1545002500104
display)
ACC power Time to ACC power Disable No function (default)
auto cut cut-off when the 30 min 30 minutes
ignition switch is in
the ACC position 60 min 60 minutes
Turn power Adjustment of ACC or IG1 Operable with ACC or ON position

source turn-signal light IG1 Operable with ON position (default)
operation condition
Comfort flasher With/without Disable No function
comfort flasher Enable With function (default)
function
Comfort flasher Switch operation Normal 0.4 seconds (default)
switch time time to activate the Long 0.8 seconds
comfort flasher
function
answer back
operation by the wiper volume control.
according to the intermittent wiper volume
washer-linked wiper
function
TSB Revision
ETACS

display)
Dome light Adjustment of 0 sec 0 second (no delay shutdown time)
7.5 sec 7.5 seconds
15 sec 15 seconds
30 sec 30 seconds (default <Vehicles with central
60 sec 60 seconds
120 sec 120 seconds
180 sec 180 seconds
Headlight auto Adjustment of Disable No function
cut customize headlight automatic Enable (C-spec.) With function (default)
shutdown function
Interior light Adjustment of Disable No function
auto cut timer interior light 3 min 3 minutes
automatic shutdown
function operation 30 min 30 minutes (default)
time 60 min 60 minutes
mode <Vehicles with driver's side door is unlocked.
central door locking Dr door unlock Only the driver's side door is unlocked
system> when the driver's side door is unlocked.
(default)
system>
back
(default)
Buzzer answer Adjusts the tone Not sound buzzer No function
back <Vehicles alarm answer back At keyless Sounds when the keyless entry system is
with KOS> function. activated.
At F.A.S.T. Sounds when KOS is activated (default).
KOS is activated.
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-563
display)
Timer lock timer Timer lock period 30 sec 30 seconds (default)
adjustment 60 sec 60 seconds
120 sec 120 seconds
180 sec 180 seconds
F.A.S.T. key out With/without KOS Enable No function
of car key exterior Disable With function (default)
detection function
F.A.S.T. feature KOS function Both enable All KOS functions are enabled (default).
adjustment DoorEntry enable Only door entry function is enabled.
ENG strt enable Only engine starting function is enabled.
Both disabled All KOS functions are disabled.
F.A.S.T. unlock Adjusts the door 0 sec 0 seconds
disable time unlock inhibition 3 sec 3 seconds (default)
period after door
lock is activated. 5 sec 5 seconds
TSB Revision
ETACS
ETACS-ECU
M1545004700030
WARNING
Before removing the ETACS-ECU and knee air bag module, refer to GROUP 52B, Service
Precautions P.52B-24 and Knee Air Bag Module P.52B-378.
When removing and installing the ETACS-ECU, do not let it bump against the knee air bag
module.
CAUTION
When replacing the ETACS-ECU, use the ETACS-ECU to which the chassis number is written and the
coding is implemented. Also, if diagnosis code No. B1761 "VIN not programmed" or No. B222C "Cod-
ing not completed" is set to the ETACS-ECU, replace with the ETACS-ECU to which the chassis num-
ber same as that of vehicle is written and the coding is implemented.
4.0 2.0 Nm
36 17 in-lb
AC610001AB

Side lower panel assembly (Refer Knee air bag module (Refer to
to GROUP 52A, Instrument Lower GROUP 52B, Knee Air Bag Module
Panel P.52A-7). P.52B-378).
1. ETACS-ECU
CHECK WITH TERMINAL VOLTAGE

M1545004800060
C-301
C-317 C-304
C-316
C-307
C-315
C-309
C-314
C-313
C-311
C-312 AC507027AB
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-565
CONNECTOR: C-301
AC507030AB
Terminal Check item Check condition Normal

No. condition
1
2 Input from power window main Power window main switch or front 0 volt
switch or front power window sub power window sub switch: Locked
switch (lock)
39
10 Input from front passenger's door Front passenger's door lock: Unlocked 0 volt
lock actuator (unlock)
11
12 Output to defogger switch Defogger switch: ON 0 volt
1315
16 Input from door lock key cylinder Door lock key cylinder switch: Locked 0 volt
switch (lock)
17 Input from door lock key cylinder Door lock key cylinder switch: Unlocked 0 volt
switch (unlock)
18
19 Input from hazard warning light Hazard warning light switch: ON 0 volt
switch
20
21 Input from windshield wiper backup Windshield low-speed wiper switch or 0 volt
switch windshield high-speed wiper switch: ON
22 Input from driver's door lock Driver's door lock: Unlocked 0 volt
actuator (unlock)
23, 24
TSB Revision
ETACS
CONNECTOR: C-304
AC507031AB

No. condition
1 Stop light switch power supply Stop light switch: ON Battery voltage
2
3 Output to position light (LH) When position light is illuminated Battery voltage
4
5 Output to windshield wiper (HI) When windshield wipers are operating Battery voltage
at high speed
6 Output to windshield wiper (LO) When windshield wipers are operating Battery voltage
at low speed
7 Output position light (RH) When position light illuminated Battery voltage
8 Input from windshield wiper auto When windshield wipers are operating Battery voltage
stop switch
9 Output to front and side turn-signal When front and side turn-signal light Battery voltage
light (LH) (LH) is illuminated
10 Output to engine control module Ignition switch: ON Battery voltage
(IG1)
11 Input from engine control module Engine: Started 0 volt
(fuel control)
12 Output to windshield wiper (ACC) Ignition switch: ACC Battery voltage
13 Output to windshield washer When windshield washer is operating Battery voltage
14
15 Output to engine control module Ignition switch: START Battery voltage
(START)
16 Output to front and side turn-signal When front and side turn-signal light Battery voltage
light (RH) (RH) is illuminated
CONNECTOR: C-307
AC507032AB

No. condition
1 Fuel pump power supply Ignition switch: ON Battery voltage
2 Battery power supply Always Battery voltage
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-567
CONNECTOR: C-309
AC507033AB

No. condition
CONNECTOR: C-311
AC507035AB

No. condition
1 Output to trunk lid lock actuator When trunk is locked Battery voltage
2 Backup light power supply When backup light is illuminated Battery voltage
3 Input from luggage compartment When luggage compartment light is 0 volt
light illuminated
4, 5
6 Output to rear door lock actuator When rear door is unlocked Battery voltage
(unlock)
7, 8
9 Output to rear door lock actuator When rear door is locked Battery voltage
(lock)
10 Output to taillight (LH) and side When taillight (LH) and side maker light Battery voltage
maker light (LH) and license plate (LH) and license plate light are
light illuminated
11
12 Rear power window motor power Ignition switch: ON Battery voltage
supply
13 Output to taillight (RH) and side When taillight (RH) and side maker light Battery voltage
maker light (RH) and glove box light (RH) and glove box light are illuminated
14, 15
16 Output to accessory socket 1 Ignition switch: ACC Battery voltage
17 Output to luggage compartment When luggage compartment light is 2 volts or less
light illuminated
18 Output to rear turn-signal light (LH) When rear turn-signal light (LH) is Battery voltage
illuminated
19 Output to rear turn-signal light (RH) When rear turn-signal light (RH) is Battery voltage
illuminated
20
TSB Revision
ETACS
CONNECTOR: C-312
AC507034AB

No. condition
1 Input from brake fluid level switch Brake fluid level switch: ON 0 volt
2 Output to radiator fan relay When radiator fan is operating 0 volt
3
4 Output to fog lights Fog light switch: ON 0 volt
5
6 Output to headlight (LO) Headlight switch: ON 0 volt
7 Input from ambient temperature Always 0.2 2.72 volts
sensor
8 Output to condenser fan relay When condenser fan is operating 0 volt
9 Output to fan control relay When fan control is operating 0 volt
10 Output to daytime running light Ignition switch: ON 0 volt
11 Output to horn When horn sounds 0 volt
12
13 Output to Headlight (HI) Dimmer switch: ON 0 volt
14 Ground (ambient temperature Always 0 volt
sensor)
15
16 Input from stoplight switch Stoplight switch: ON 12 volts
CONNECTOR: C-313
AC610017

No. condition
1
2 Ignition switch (IG1) power supply Ignition switch: ON Battery voltage
3
5 Input from trunk lid actuator and Trunk lid actuator and switch: ON (trunk 0 volt
switch lid open)
6
7 Input from rear door switch (LH) Rear door switch (LH): ON (door open) 0 volt
8 Input from rear door switch (RH) Rear door switch (RH): ON (door open) 0 volt
911
TSB Revision
CHASSIS ELECTRICAL
ETACS
54A-569
No. condition
12 Input from front door switch (RH) Front door switch (LH): ON (door open) 0 volt
1315
16 Input from front door switch (LH) Front door switch (RH): ON (door open) 0 volt
CONNECTOR: C-314
AC507037AB

No. condition
1 Output to fuel pump Engine: Started Battery voltage
2
CONNECTOR: C-315
AC507029AB

No. condition
1
2 Output to front door lock actuator When front door (LH) is unlocked Battery voltage
(LH) (unlock)
3
5 Output to front door lock actuator When front door (RH) is unlocked Battery voltage
(RH) (unlock)
6 Output to central door locking (for When the door lock actuators lock the Battery voltage
locking the doors) doors
7 Ignition switch (START) power Ignition switch: START Battery voltage
supply
8 Power window motor power supply Ignition switch: ON Battery voltage
9 Ignition switch (ACC) power supply Ignition switch: ACC Battery voltage
10 Power window main switch power Ignition switch: ON Battery voltage
supply
13 Input from key reminder switch Key reminder switch: ON (ignition key 0 volt
removed)
14
TSB Revision
ETACS

No. condition
2 Input from power window main Power window main switch or front 0 volt
switch or front power window sub power window sub switch: Unlocked
switch (unlock)
16 Output to blower motor Blower motor in operation Battery voltage
17 Ground (signal) Always 0 volt
18 Output to ignition key cylinder When ignition key cylinder illumination is 12 volts
illumination light ON
19 Input from horn switch Horn switch: ON 0 volt
CONNECTOR: C-316
AC507038AB

No. condition
1
2 Sunroof motor assembly power Always Battery voltage
supply
3, 4
5 Input from dome light When dome light is illuminated 0 volt
6 Output to dome light output When dome light is illuminated 2 volts or less
CONNECTOR: C-317
AC507028AB

No. condition
3, 4
6 Input from ignition switch (IG1) Ignition switch: ON Battery voltage
7 Input from ignition switch (ACC) Ignition switch: ACC Battery voltage
8
9 Output to theft-alarm indicator light When theft-alarm indicator light is 0 volt
illuminated
1114
15 Ground Always 0 volt
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-571
THEFT ALARM
GENERAL INFORMATION
M1547000100098
When the doors are locked using the keyless By pressing the panic button of transmitter, the
entry or KOS (except when locked by using the flashing of headlights and the intermittent sound-
key cylinder or door lock switch), the improper ing of horns can be performed by remote control
opening of door or trunk causes the ETACS-ECU operation. < ES,GTS: Standard, DE (Except for
function and control to give off an alarm with the California and Canada):Option>
flashing of headlights and the intermittent sound- .
ing of horns. Also, the ETACS-ECU warns that

the theft-alarm system is being set by flashing the
theft-alarm indicator. < ES,GTS: Standard, DE
(Except for California and Canada): Option>
<Vehicles with KOS>
Theft-alarm indicator
AC608323
C608323
Panic button
<Vehicles with WCM>
Headlight
Horn (HIGH)
Horn (LOW) ETACS-ECU

Panic button
AC608752AB
TSB Revision
THEFT ALARM
SPECIAL TOOLS
M1547000600145

name
a
b key. Reading diagnostic trouble code.
f. MB991825
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE
CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g measurement
adapter
harness
MB991826
MB991958
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-573
name
a
b
circuit
c c. LED harness
sourced tester
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
TSB Revision
THEFT ALARM
DIAGNOSIS
M1547001200106
Refer to GROUP 00 Contents of troubleshooting
P.00-6.
DIAGNOSTIC FUNCTION
M1547001300028

CAUTION
position.
MB991910
position.
color.
MB991827
AC608435 AB

TROUBLE CODES
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-575
CAUTION
display.
button.

"OK" button.
M1547001500152
TSB Revision
THEFT ALARM

Procedure page
No.
The theft-alarm is not armed (the theft-alarm indicator does not illuminate). 1 P.54A-577
The interior alarm does not work normally while the theft-alarm is triggered. 2 P.54A-583
Horns do not sound while the theft-alarm system is triggered. 3 P.54A-587
Panic alarm function does not work normally. 4 P.54A-592
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-577
SYMPTOM PROCEDURES
Inspection Procedure 1: The theft-alarm is not armed (the theft-alarm indicator does not illuminate).
CAUTION
Theft-alarm Indicator Circuit
FUSIBLE
LINK 36
RELAY
BOX
ETACS-
ECU
CENTER
PANEL
UNIT
TSB Revision
THEFT ALARM

C-104 If this function does not work normally, the input sig-
nal circuits to the components below, the theft-alarm
C-18 (B)
indicator, the ETACS-ECU or the CAN bus line may
have a problem.
Keyless entry transmitter
Key reminder switch
Ignition switch (ACC)
Hood switch
AC608146BA Door switches
Trunk latch switch
Junction block .
C-317 CAN bus line may be defective
C-307 (B) Theft-alarm indicator may be defective
Keyless entry transmitter may be defective
The key reminder switch may be defective
Door switch may be defective
Trunk latch switch may be defective
Hood switch may be defective
AC608152 AF
The KOS-ECU may be defective
The WCM may be defective
.

DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-579

line.
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958, check for any

Check if DTC is set to the KOS-ECU <vehicles with KOS> or
WCM <vehicles with WCM>.
(2) Check whether the KOS or WCM related DTC is set.
Q: Is the DTC set?
YES <vehicles with KOS> : Troubleshoot the KOS (Refer
to GROUP 42B, KOS P.42B-20).
YES <vehicles with WCM> : Troubleshoot the WCM (Refer
to GROUP 42C, WCM P.42C-14).
NO : Go to Step 3.
STEP 3. Check the keyless operation key <KOS> or

keyless entry transmitter <WCM>.
Q: is the keyless operation key <KOS> or keyless entry
transmitter <WCM> normally?
YES : Go to Step 4.
NO <vehicles with KOS> : Troubleshoot the KOS (Refer to
GROUP 42B, KOS P.42B-20).
NO <vehicles with WCM> : Troubleshoot the WCM (Refer
TSB Revision
THEFT ALARM

the theft-alarm function.
Close the hood.
Turn the ignition switch to the "LOCK" (OFF) position (with
ignition key <vehicles with WCM> or emergency key <vehi-
cles with KOS> inserted).
Open each door.
Open the Trunk.
condition
Item 260 Trunk/gate trunk ajar Open
switch
Item 264 Handle lock switch Key in

ajar switch", "As door ajar switch", "RR door ajar
switch", "RL door ajar switch", "Trunk/gate trunk ajar
switch" , "Handle lock switch", "Hood switch" and "ACC
switch" as normal condition?
YES <Normal conditions are displayed for all items.> :
Go to Step 5.
256.> : Troubleshoot the ETACS-ECU. Refer to diagnosis -
Inspection Procedure 5 "ETACS-ECU does not
receive any signal from the front door switch (LH)"
P.54A-543.
receive any signal from the front door switch (RH)"
P.54A-545.
receive any signal from the rear door switch (LH)"
P.54A-548.
receive any signal from the rear door switch (RH)"
P.54A-550.
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-581
receive any signal from the trunk lid actuator and
switch P.54A-553.
receive any signal from key reminder switch"
P.54A-533.
receive any signal from the ignition switch (ACC)
signal" P.54A-529.
STEP 5. Check center panel unit connector C-18 for loose,

in the connector.
Q: Is center panel unit connector C-104 in good condition?
YES : Go to Step 6.
STEP 6. Check the theft-alarm indicator.

Q: Is the theft-alarm indicator in good condition?
YES : Go to Step 7.
NO : Replace the center panel unit.
AC609727AB

in the connector.
Q: Is the ETACS-ECU connector C-307 in good condition?
YES : Go to Step 8.
TSB Revision
THEFT ALARM
STEP 8. Measure the voltage at ETACS-ECU connector

C-307.
(1) Disconnect ETACS-ECU connector C-307, and measure
the voltage wiring harness side.
(2) Measure the voltage between ETACS-ECU connector-307
(terminal No. 2) and the body ground.
positive voltage)?
NO : Go to Step 9.
Harness side: C-307
AC402679 FH
STEP 9. Check the Wiring harness between ETACS-ECU

connector C-307 (terminal No. 2) and fusible link (36).
NO : Repair the wiring harness between ETACS-ECU
connector C-307 and fusible link (36).

in the connector.
STEP 11. Check the Wiring harness between ETACS-ECU

connector C-317 (terminal No. 2,9) and center panel unit
connector C-104 (terminal No. 15,12).
Check the input/output lines for open circuit and short cir-
cuit.
NO : Repair the wiring harness between ETACS-ECU
connector C-317 and center panel unit connector
C-104.
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-583

Q: Does the theft-alarm work normally?
Inspection Procedure 2: The interior alarm does not work normally while the theft-alarm is triggered.
CAUTION Trunk latch switch

Before replacing the ECU, ensure that the power .
supply circuit, the ground circuit and the com- TROUBLESHOOTING HINTS
munication circuit are normal. Hood switch may be defective
.
All the door switch may be defective

TECHNICAL DESCRIPTION (COMMENT) Trunk latch switch may be defective
If the interior alarm does not work normally, the input The ETACS-ECU may be defective
signal circuits to the components below, Combination meter may be defective
ETACS-ECU, or combination meter built-in tone The wiring harness or connectors may have
alarm may have a problem. loose, corroded, or damaged terminals, or termi-
Hood switch nals pushed back in the connector
All of the door switches
DIAGNOSIS
TSB Revision
THEFT ALARM

CAUTION
Q: Is the DTC set?
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-585

the theft-alarm function.
Close the hood.
Turn the ignition switch to the "LOCK" (OFF) position (with
ignition key <vehicles with WCM> or emergency key <vehi-
cles with KOS> inserted).
Open each door.
Hood is opened
Open the trunk.
condition
Item 260 Trunk/gate trunk ajar Open
switch

ajar switch", "As door ajar switch", "RR door ajar
switch", "RL door ajar switch", "Trunk/gate trunk ajar
switch" and "Hood switch" as normal condition?
YES <Normal conditions are displayed for all items.> :
Go to Step 3.
receive any signal from the front door switch (LH)"
P.54A-543.
receive any signal from the front door switch (RH)"
P.54A-545.
receive any signal from the rear door switch (LH)"
P.54A-548.
receive any signal from the rear door switch (RH)"
P.54A-550.
receive any signal from the trunk lid actuator and
TSB Revision
THEFT ALARM
switch" P.54A-553.

(3) Set scan tool MB991958 to the actuator test mode.
Item 12: Buzzer
YES : Go to Step 4.

Check that the theft-alarm works normally.
Q: Does the theft-alarm work normally?
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-587
Inspection Procedure 3: Horns do not sound while the theft-alarm system is triggered.
CAUTION
Horn Circuit
FUSIBLE
LINK 36
RELAYBOX
ENGINE
COMPARTMENT
HORN
RELAY
HORN HORN ETACS-ECU

(LOW) (HIGH)
Connector: A-12X Connector: A-37
A-37 (B)
AC609409AB AC608142AO
TSB Revision
THEFT ALARM
.
Connector: A-43 TECHNICAL DESCRIPTION (COMMENT)

If horns do not sound, the horn input signal circuit or
the ETACS-ECU may be defective.
.
A-43 (B)
Horns may be defective
Horn relay may be defective
AC608141AO
Connector: C-312 nals pushed back in the connector
Junction block
AC608152 AP
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-589

trouble code.
CAUTION
Q: Is the DTC set?
YES : Diagnose the ETACS-ECU. Refer to P.54A-482.
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Check horn relay connector A-12X for loose,

in the connector.
Q: Is horn relay connector A-12X in good condition?
YES : Go to Step 3.
STEP 3. Check the horn relay.

Refer to P.54A-594.
Q: Is the horn relay in good condition
YES : Go to Step 4.
NO : Replace the theft-alarm horn relay.
TSB Revision
THEFT ALARM
STEP 4. Measure the voltage at horn relay A-12X.

(1) Remove the relay, and measure at the relay box side.
(2) Measure the voltage between horn relay connector A-12X
(terminal No. 2,4) and the body ground.
positive voltage)?
YES : Go to Step 6.
NO : Go to Step 5.
Relay box side: A-12X
AC402679 FE
STEP 5. Check the Wiring harness between theft-alarm

horn relay connector A-12X (terminal No. 2,4) and fusible
link (36).
Check the power supply line for open circuit and short circuit.
NO : Repair the wiring harness between horn relay
connector A-12X and fusible link (36).

in the connector.
YES : Go to Step 7.
STEP 7. Check the Wiring harness between theft-alarm

horn relay connector A-12X (terminal No. 1) and
ETACS-ECU connector C-312 (terminal No. 11).
Check the output lines for open circuit and short circuit.
YES : Go to Step 8.
NO : Repair the wiring harness between horn relay
connector A-12X and ETACS-ECU connector C-312.
STEP 8. Check horn (HIGH) connector A-43 for loose,

in the connector.
Q: Is Horn (HIGH) connector A-43 in good condition?
YES : Go to Step 9.
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-591
STEP 9. Check the Wiring harness between horn (HIGH)

connector A-43 (terminal No. 1) and horn relay connector
A-12X (terminal No. 3).
NO : Repair the wiring harness between horn (HIGH)
connector A-43 and horn relay connector A-12X.
STEP 10. Check the horn (HIGH) work normally.

Connect the battery as shown, and verify that the horn sounds.
NO : Replace the horn (HIGH). go to step 11.
AC607630AC
STEP 11. Check horn (LOW) connector A-37 for loose,

in the connector.
Q: Is Horn (LOW) connector A-37 in good condition?
STEP 12. Check the Wiring harness between horn (LOW)

connector A-37 (terminal No. 1) and horn relay connector
A-12X (terminal No. 3).
NO : Repair the wiring harness between horn (LOW)
connector A-37 and horn relay connector A-12X.
STEP 13. Check the horn (LOW) work normally.

Connect the battery as shown, and verify that the horn sounds.
NO : Replace the horn (LOW). go to step 14.
AC607630AC
TSB Revision
THEFT ALARM
STEP 14.Retest the theft-alarm system.

Q: Does the theft-alarm system work normally?
YES : he trouble can be an intermittent malfunction (Refer to
GROUP 00, How to use Troubleshooting/inspection
Inspection Procedure 4: Panic alarm does not work normally.
.

If keyless operation system <KOS> or keyless entry Keyless operation system <KOS> or keyless
system <WCM> is normal, the ETACS-ECU may be entry system <WCM> may be defective
defective. The ETACS-ECU may be defective
Function is not set with the customization.
.
DIAGNOSIS
TSB Revision
CHASSIS ELECTRICAL
THEFT ALARM
54A-593

trouble code.
Check if DTC is set to the KOS-ECU <Vehicles with KOS> or
WCM <Vehicles with WCM>.
CAUTION
(3) Check whether the KOS or WCM related DTC is set.
Q: Is the DTC set?
YES <vehicles with KOS> : Troubleshoot the KOS (Refer
to GROUP 42B, KOS P.42B-20).
YES <vehicles with WCM> : Troubleshoot the WCM (Refer
MB991910 to GROUP 42C, WCM P.42C-14).
MB991824
NO : Go to Step 2.
MB991827 AC608435 AB
STEP 2. Check keyless operation system <KOS> or

keyless entry system <WCM>.
Q: Do keyless operation system <KOS> or keyless entry
system <WCM> work normally?
YES : Go to Step 3.
NO <vehicles with KOS> : Troubleshoot the KOS (Refer to
GROUP 42B, KOS P.42B-120).
NO <vehicles with WCM> : Troubleshoot the WCM (Refer
STEP 3. Using scan tool MB991958, check the

the "Panic alarm switch" is set to "Enable".
Q: Is the "Panic alarm switch" set to "Enable"?
NO : Use the ETACS-ECU configuration function to set the
"Panic alarm switch" to "Enable"(Refer to P.54A-594).
TSB Revision
THEFT ALARM
ON-VEHICLE SERVICE
M1547003400098
Adjustment item Adjustment item Adjustment contents (scan tool Adjusting contents
(scan tool display)
display)
Panic alarm switch With/without panic Disable Without function
alarm function Enable With function (default)

M1547001000339
Theft-alarm system component parts Trunk lid latch assembly (Refer to GROUP 42A
Headlight assembly (Refer to P.54A-151). Trunk Lid P.42A-174).
Horn (Refer to P.54A-222). Key reminder switch (Refer to P.52A-6).
Door switch (Refer to GROUP 42A Door, Door Theft-alarm indicator (Refer to GROUP 52A
Assembly P.42A-148). Instrument Center Panel P.52A-2).
Front and rear door lock actuator (Refer to
Panic alarm system component parts
GROUP 42A Door, Door Handle and Latch
Headlight assembly (Refer to P.54A-151).
P.42A-157). Horn (Refer to P.54A-222).
INSPECTION
THEFT-ALARM INDICATOR CHECK

M1547001100187
1. Remove the center panel.
2. Connect the battery (+) terminal with the center panel
connector (terminal No. 15). Then, check if the theft-alarm
indicator is illuminated when the battery () terminal and the
center panel connector (terminal No. 12) are connected.
3. If the theft-alarm indicator is illuminated, it is judged good.
AC609727AB
TSB Revision
54B-1
GROUP 54B
LOCAL
INTERCONNECT
NETWORK (LIN)
CONTENTS
GENERAL INFORMATION . . . . . . . . 54B-2 SYSTEM OPERATION . . . . . . . . . . . . 54B-3
STRUCTURE . . . . . . . . . . . . . . . . . . . 54B-2
54B-2 LOCAL INTERCONNECT NETWORK (LIN)
GENERAL INFORMATION
GENERAL INFORMATION
M2545600100064
LIN refers to "Local Interconnect Network," which is a NOTE: *: The regulations that have been decided in
serial multiplex communication protocol* adminis- detail, from software matters such as the necessary
trated by LIN consortium. A communication circuit transmission rate for communication, the system,
employing the LIN protocol connects each ECU, and data format, and communication timing control
switch and sensor data can be shared among ECUs, method to hardware matters such as the harness
which enables more reduction in wiring. type and length and the resistance values.
STRUCTURE
M2545600200083
Master ECU Slave ECU
Column switch
ETACS-ECU (column-ECU)
LIN bus line
<Vehicles with auto down

and auto up mechanism>
Sunroof motor
Power window
assembly
main switch
(Sunroof-ECU)
Slave ECU Slave ECU

AC608956AB
*1
Master and slave ECUs are connected to the LIN NOTE: : ETACS (Electronic Time and Alarm Con-
bus lines. The master ECU is the ETACS*1-ECU, trol System)
and the slave ECUs are the column switch (col- NOTE: *2: Vehicles with auto down and auto up
umn-ECU), the sunroof-ECU and the power window mechanism.
main switch*2. The master ECU requests these slave
ECUs to communicate each other via communication
lines.
LOCAL INTERCONNECT NETWORK (LIN)
SYSTEM OPERATION
54B-3
SYSTEM OPERATION
M2545600300068
Master ECU LIN bus line Slave ECU

Master task Slave task C
Slave task A
Slave task B Slave ECU

Slave task D
State of message on LIN bus line Byte area
1 byte
1
Theory value:
<Master task> 0
Start bit Data bit Stop bit
Transmits the header
at regular intervals.
Header Response Header Response Header Response Header Response Time

Slave task D Slave task A Slave task C Slave task B
Transmits the response

to suit the header
<Slave task>
AC506324 AB
A header and response collectively are called as

.
LIN communication system is described below:

The master ECU performs the master tasks and a message frame, and the communication
slave tasks, and the slave ECUs perform the method that uses the message frame is called as
slave tasks. the frame communication.
When the master ECU performs a master task, Basically, the communication data is used with
the header frame which stores information to call some blocks of 10-bit data group which includes
certain slave tasks (ECU) is transmitted at regular one start bit and one stop bit (byte region)
intervals. arranged in order.
When the master ECU and slave ECU perform a .
slave task, the ECU called by the header frame

transmits the response frame which stores data
used for control.
54B-4 LOCAL INTERCONNECT NETWORK (LIN)
SYSTEM OPERATION
VOLTAGE VARIATION OF LIN BUS LINE
Battery voltage
Voltage variation of
LIN bus line:
GND
(Ground level)
Recessive Dominant Recessive

State:
1
Theoretical value:
0
AC309813 AD
When each ECU sends or receives signals, LIN bus When no communication is established, the LIN
line voltage varies as follows: bus line remains recessive (battery voltage).
The voltage variation of LIN bus line (0 and 1 .
combination as a theoretical value) ranging

between battery voltage (recessive) and 0 V
(dominant) is output (transmitted) as a control
signal.
MESSAGE FRAME
Message frame
Header Response
1 (Recessive)
Theoretical value:
0 (Dominant)
a b c d d d e
a: Synchronization start region c: Identifier region e: Checksum region

b: Synchronization region d: Data region AC506907 AB
A message frame consists of regions that include a

synchronization start region, identifier region, data
region, and checksum region. A few bits of recessive
data is used to separate the frame from each region.
LOCAL INTERCONNECT NETWORK (LIN)
SYSTEM OPERATION
54B-5
Frame Region name Description

Header Synchronization A region that informs each ECU of the starting of header transmission
start region by sending dominant signals for a given period of time.
Synchronization A region that synchronizes the transmission cycle of each ECU
region connected to the LIN bus line (the slave ECU matches its
communication speed to that of the master ECU).
Identifier region A region that stores an ID to call the slave ECU defined by the LIN
protocol. The number of bytes for the data region is also defined in this
region.
Response Data region A region to store the control data used by ECU that is called by the
header
Checksum region A region for checking errors in data content The sending-end ECU
calculates data region value according to the specified computing
equation, and the result is stored in this filed. The receiving-end ECU
detects the transmission error based on the checksum filed value.
NOTES
54C-1
GROUP 54C
CONTROLLER
AREA NETWORK
(CAN)
CONTENTS
GENERAL INFORMATION . . . . . . . . 54C-2 EXPLANATION ABOUT THE SCAN

TOOL (M.U.T.-III) CAN BUS
SPECIAL TOOL . . . . . . . . . . . . . . . . . 54C-5 DIAGNOSTICS . . . . . . . . . . . . . . . . . . 54C-9
TEST EQUIPMENT . . . . . . . . . . . . . . 54C-6 DIAGNOSTIC TROUBLE CODE

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 54C-15
SERVICE PRECAUTIONS. . . . . . . . . 54C-7
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 54C-16
PRECAUTIONS ON HOW TO REPAIR CAN BUS DIAGNOSTICS TABLE . . . . . . . 54C-16
THE CAN BUS LINES . . . . . . . . . . . . 54C-8 CAN BUS DIAGNOSTICS . . . . . . . . . . . . . . 54C-22
CAN COMMUNICATION-RELATED DTC
(U-CODE) TABLE. . . . . . . . . . . . . . . . . . . . 54C-189
54C-2 CONTROLLER AREA NETWORK (CAN)
GENERAL INFORMATION
GENERAL INFORMATION
M1548310000308
CAN, an abbreviation for Controller Area Network, is CAN offers the following advantages.
an ISO-certified international standard for a serial Transmission rates are much faster than those in
multiplex communication protocol*. A communication conventional communication (up to 1 Mbps),
circuit employing the CAN protocol connects each allowing much more data to be sent.
electric control module (ECU), and sensor data can It is exceptionally immune to noise, and the data
be shared among, which enables more reduction in obtained from each error detection device is more
wiring. reliable.
Each ECU connected via the CAN communicates
NOTE: *: The regulations have been decided in
independently, therefore if the ECU enters dam-
detail, from software matters such as the necessary
aged mode, communications can be continued in
transmission rate for communication, the system,
some cases.
data format, and communication timing control
method to hardware matters such as the harness
type and length and the resistance values.
TSB Revision
GENERAL INFORMATION
54C-3
STRUCTURE
TERMINAL RESISTOR
ETACS-ECU
CAN_L CAN_H
WCM OR
SRS-ECU
KOS-ECU
DATA LINK
ABS-ECU CONNECTOR
OCCUPANT
CLASSIFICATION- A/C-ECU
ECU M.U.T.-III
DIAGNOSIS CAN-C
HANDS-FREE RADIO AND
TCM MODULE CD PLAYER OR
CD CHANGER
SATELLITE
CAN BOX
RADIO
UNIT
TUNER
MAIN BUS LINE
CAN_L CAN_H
CAN_L CAN_H
MAIN BUS LINE
COMBINATION
TERMINAL ECM METER
RESISTOR
: INDICATES MAIN BUS LINE
: INDICATES SUB BUS LINE
CAN-C CAN-B
AC608015AB
A gateway function has been integrated to The CAN bus line connecting two dominant
ETACS-ECU as the network central ECU. ECUs is the main bus line, and the CAN bus line
The CAN system consists of the following three connecting each ECU is the sub-bus line.
networks: CAN-B (middle-speed body network), With CAN-C, the terminal resistors are incorpo-
CAN-C (high-speed power train network), and the rated in ECU. Resistors with approximately 120
diagnosis CAN-C (diagnosis exclusive network). ohms is used for the dominant ECU, and that with
Each ECU is connected to one of the networks 4.7 kilo ohms is used for the non-dominant ECU.
depending on its functions. NOTE: .
The CAN bus line consists of two lines, CAN_L Dominant ECU: ETACS-ECU and engine
and CAN_H (CAN Low and CAN High, respec- ECU
tively), as well as two terminal resistors (A Non-dominant ECU: ECU and sensor on
twisted-pair cable, highly resistant to noise, is CAN-C network, excluding ETACS-ECU and
used for the communications line). engine ECU
TSB Revision
GENERAL INFORMATION
To the CAN bus line, ECU, sensor, and data link CAN box unit <vehicles with Mitsubishi
connector are connected as follows for each net- Multi-Communication System (MMCS)>
work. Hands-free module <vehicles with hands-free
CAN-B system>
Wireless control module (WCM) <vehicles Satellite radio tuner <vehicles with satellite
without KOS> radio>
KOS-ECU <vehicles with KOS> Combination meter
SRS-ECU CAN-C
Occupant classification-ECU ABS-ECU <vehicles with ABS>
A/C-ECU Transaxle control module (TCM)
Radio and CD player or CD changer <vehi- Engine control module (ECM)
cles without Mitsubishi Multi-Communication DIAGNOSIS CAN-C
System (MMCS)> Data link connector
TSB Revision
SPECIAL TOOL
54C-5
SPECIAL TOOL
M1548304200392

name
a
b key. CAN bus diagnostics
f. MB991825
g. MB991826
M.U.T.-III sub
assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles without
DO NOT USE
CAN
communication
MB991914 system)
harness C (for
Daimler Chrysler
models only)
g measurement
adapter
harness
MB991826
MB991958
TSB Revision
TEST EQUIPMENT

name
a
b d. MB991222
pressure inspection
a. Test harness
b. LED harness
c c. LED harness
d. Probe
d
DO NOT USE
MB991223BA

connector for loose, corroded or
damaged terminals, or terminals
MB992006
MB991970 Measure the voltage and

ABS check harness resistance at the ABS-ECU
MB991970
TEST EQUIPMENT
M1548304300258
Test equipment Name Use

Digital multimeter Checking CAN bus circuit (for resistance and voltage
measurements)
AC000019
TSB Revision
SERVICE PRECAUTIONS
54C-7
SERVICE PRECAUTIONS
M1548302100258
Warnings in diagnosis section Details regarding warnings

CAUTION
When servicing a CAN bus line, ground yourself
by touching a metal object such as an unpainted
water pipe. If you fail to do, a component
connected to the CAN bus line may be broken.
CAUTION When measuring resistance value or voltage in
A digital multimeter should be used. CAN bus lines, use a digital multimeter. If not
using a digital multimeter, the equipments, which
are connected through the CAN communication
lines, may be damaged.
CAUTION Disconnect the negative battery terminal when
When measuring the resistance, disconnect the measuring the resistance value in the CAN bus
negative battery terminal. line. If you fail to do so, the equipments, which
are connected through the CAN communication
lines, may be damaged.
CAUTION Always use the test harness when measuring the
The test wiring harness should be used. voltage or resistance value at the female
connector. If you fail to do so, connectors may be
damaged.
CAUTION
10 cm Connector
The strand end of the twist wire should be within Twisted wire (4.0 inches)
10 cm from the connector.
AC203824 AF
If you repair the wire due to a defective

connector or its terminal or harness wire, you
should cut the wire so that the strand end of the
twist wire should be within 10 cm (4 inches) from
the connector as shown. If it exceeds 10 cm (4
inches), twist the wiring harness just like the
original twisted wire. If the strand end exceeds
10 cm (4 inches), a communication error may be
caused.
CAUTION When you repair a CAN bus line, observe the
Strictly observe the specified wiring harness precautions on how to repair the CAN bus line
repair procedure. strictly. Refer to P.54C-8. If a new wire is added
or a splice point is modified for the CAN_L or
CAN_H line, an error in the CAN communication
may be caused.
TSB Revision
PRECAUTIONS ON HOW TO REPAIR THE CAN BUS LINES
PRECAUTIONS ON HOW TO REPAIR THE CAN BUS LINES

M1548301900251
.
PRECAUTIONS ON HOW TO REPAIR THE CAN

BUS LINES
No good
If the CAN bus line(s) are repaired, renew all the twisted
wires between the end connectors. If the wiring harness is
Added wire partially repaired, or only CAN_L or CAN_H line is repaired,
noise suppression is deteriorated, causing a communica-
tion error.
AC204696 AD
If the connector or wire on the main bus line or the sub-bus

10 cm Connector wire is replaced, the frayed end of the twisted wire should
Twisted wire (4.0 inches) be within 10 cm (4 inches) from the connector. If it exceeds
10 cm (4 inches), twist the wiring harness just like the origi-
nal twisted wire. If the frayed end exceeds 10 cm (4 inches),
noise suppression is deteriorated, causing a communica-
tion error.
AC203824 AF
No good If a sub-bus line is repaired, splice a new wire directly into

Terminator resistor
the main bus line. If a new wire is spliced into the sub-bus
line, which is connected to another device, the CAN com-
munication will be disabled.
Open
circuit
ECU ECU point
Good
Terminator resistor
Open
circuit
ECU ECU point
AC202856 AE
TSB Revision
EXPLANATION ABOUT THE SCAN TOOL (M.U.T.-III) CAN BUS DIAGNOSTICS
54C-9
PRECAUTIONS ON HOW TO REPAIR THE
TERMINATOR RESISTOR
If one-side terminator resistor is broken, the CAN
communication will continue although noise suppres-
sion is deteriorated. No diagnostic trouble code may
be set even if the terminator resistor was broken. If a
damage is found, replace the ECU which incorpo-
rates the defective terminator resistor.
EXPLANATION ABOUT THE SCAN TOOL (M.U.T.-III) CAN

BUS DIAGNOSTICS
M1548300100412
Scan tool MB991958 CAN bus diagnostics carries
out the two checks below automatically, and then dis-
plays current condition of the CAN bus lines accord-
ing to the check results.
CAN BUS LINE DIAGNOSTIC FLOW
From other diagnosis
1. Scan tool MB991958

(M.U.T.-III) CAN bus
diagnostics
YES Short in CAN bus line to power

(1) Check that the etacs-ecu sets a diagnosis code.
supply or ground
NO
NG
(2) Checking the communication condition of ecus.
OK for (2) OK for (2)

P code, B code, U code (past trouble)
C code or
U code (current trouble)
Open circuit in CAN bus line

Go to ordinary diagnosis 2. Pinpoint possible trouble spot Broken terminator resistor
according to diagnosis code Power supply to ecu poorly grounded
AC507612AB
1. Scan tool CAN bus diagnostics (1) Check that the ETACS-ECU sets a diagnostic
Scan tool MB991958 diagnoses CAN bus lines in trouble code.
accordance with the following strategy. You can narrow down the points to be
diagnosed by confirming an ETACS-ECU
NOTE: After you determine whether the CAN-C
lines are in good condition, then determine
whether the CAN-B lines are in good condition. (2) Checking the communication condition of
Then confirm each judgement result on the scan ECUs
tool screen. Scan tool MB991958 narrows down troubles in
circuit by itself. Its strategies are as follows.
TSB Revision
Reference circuit
(h)
ETACS-ECU Data link
(Gateway) connector
(b)
(a) (c) (d) (e)
ECU A ECU D
(f) (g)
ECU B ECU C
AC204741AD
TSB Revision
54C-11
ECU which Possible Logic for narrowing down trouble spot
cannot trouble spot
communicate
with the scan
tool
ETACS-ECU CAN bus line The ETACS-ECU and the other
(h)
and all ECUs (h) and power ECUs use the CAN bus line (h) ETACS-ECU Data link
supply system when they communicate with (Gateway) connector
to scan tool MB991958. Since (b)
ETACS-ECU none of the ETACS-ECU and (a) (c) (d) (e)

ECU A ECU D
the other ECUs can
communicate with scan tool (f) (g)
MB991958, CAN bus line (h) or
the power supply circuit to the ECU B ECU C
ETACS-ECU may be faulty. AC204742BO
ECU A CAN bus line ECU A communicates with the

(h)
(a) and power scan tool MB991958 via CAN ETACS-ECU Data link
supply system bus lines (a) and (b). Scan tool (Gateway) connector
to ECU A MB991958 judges that CAN (b)
bus line (b) is normal, because (a) (c) (d) (e)

ECU A ECU D
it can communicate with other
ECUs. Possible trouble may be (f) (g)
present in CAN bus line (a) or
the power supply system to ECU B ECU C
ECU A. AC204742BH
ECU C CAN bus line The ECU C communicates with

(h)
(g) and power scan tool MB991958 via CAN ETACS-ECU Data link
supply system bus lines (b), (c), (d) and (g). (Gateway) connector
to ECU C Scan tool MB991958 judges (b)
that CAN bus lines (b), (c) and (a) (c) (d) (e)
ECU A ECU D
(d) are normal, because it can
communicate with ECUs B and (f) (g)
D. Possible trouble may be
present in CAN bus line (g) or ECU B ECU C
the power supply system to AC204742BI
ECU C.
ECU C communicates with
scan tool MB991958 via CAN
bus lines (b), (c), (d) and (g).
Scan tool MB991958 judges
that CAN bus lines (b), (c) and
(d) are normal, because it can
communicate with ECUs B and
D. Possible trouble may be
present in CAN bus line (g) or
the power supply system to
ECU C.
TSB Revision
ECU which Possible Logic for narrowing down trouble spot

cannot trouble spot
communicate
with the scan
tool
ECU C and Trouble in ECUs C and D communicate
(h)
ECU D CAN bus line with scan tool MB991958 via ETACS-ECU Data link
(d) CAN bus lines (b), (c), (d), (e) (Gateway) connector
and (g). Scan tool MB991958 (b)

judges that CAN bus lines (b) (a) (c) (d) (e)
ECU A ECU D
and (c) are normal, because it
can communicate with ECU B. (f) (g)
Possible trouble may be
present in CAN bus line (d), (e) ECU B ECU C
or (g) or the power supply AC204742BJ
system to ECU C and ECU D.
CAN bus line (d) is shared by
ECUs C and D when they
communicate with scan tool
MB991958, so CAN bus line (d)
is suspected as ultimate cause.
CAN bus line (g) or (e) and
power supply systems to ECU
C or D are also suspected as
second cause.
ECU B and CAN bus line ECUs C and D communicate
(h)
ECU D (e) or (f) or with scan tool MB991958 via ETACS-ECU Data link
power supply CAN bus lines (b), (c), (d), (e) (Gateway) connector
system to and (f). Scan tool MB991958 (b)
ECU B or D judges that CAN bus lines (b), (a) (c) (d) (e)
ECU A ECU D
(c) and (f) are normal, because
it can communicate with ECU (f) (g)
C. Possible trouble may be
present in CAN bus line (f) or ECU B ECU C
(e) or the power supply system AC204742BK
to ECU D.
All ECU CAN bus line The other ECUs except the
(h)
(except (b) ETACS-ECU use CAN bus ETACS-ECU Data link
ETACS-ECU) lines (b) and (h) when they (Gateway) connector
communicate with scan tool (b)

MB991958. It must be (a) (c) (d) (e)
ECU A ECU D
assumed that CAN bus line (b)
is defective since the (f) (g)
ETACS-ECU can communicate
with scan tool MB991958. ECU B ECU C
AC204742BP
2. Pinpoint possible trouble spot according to NOTE: If you pinpoint trouble spot according to
diagnostic trouble code diagnostic trouble code, you should use time-out
diagnostic trouble code. Diagnostic trouble code
If diagnostic trouble code related to CAN
related to failure information is set when the data
communication is set as past trouble, isolate
to be set contains an error, so CAN bus line itself
opens as described below.
is probably normal.
TSB Revision
54C-13
NOTE: Time-out diagnostic trouble codes are
stored in each ECU memory individually. There-
fore, it is possible that these diagnostic trouble
codes have not been set simultaneously. If the
trouble spot cannot be found when you diagnose
by judging from multiple diagnostic trouble codes,
check the communication lines between each
ECU.
Diagnostic Possible Logic for narrowing down trouble spot
trouble code to trouble spot
be set
Time-out Trouble in When time-out diagnostic
(h)
diagnostic CAN bus line trouble code associated with ETACS-ECU Data link
trouble code (e) and power ECU D is stored in ECU A, B (Gateway) connector
associated with supply system and C, or time-out diagnostic (b)

(a) (c) (d) (e)
ECU D is stored to ECU D trouble code associated with
ECU A ECU D
in ECU A, ECU B ECUs A, B and C is stored in
and ECU C. ECU D, or "bus off" diagnostic (f) (g)
Time-out trouble code is stored in ECU

diagnostic D, CAN bus line (e) is ECU B ECU C
trouble code suspected. When diagnostic AC204742BL
associated with trouble code is not stored in

ECUs A, B and C ECU D, the power supply to
is stored in ECU ECU D is suspected.
D.
"Bus off"
diagnostic
trouble code is
stored in ECU D.
Time-out Trouble in When time-out diagnostic
(h)
diagnostic CAN bus line trouble code associated with ETACS-ECU Data link
trouble code (a) and power ECU A is stored in ECUs B, C (Gateway) connector
associated with supply system and D, or time-out diagnostic (b)

(a) (c) (d) (e)
ECU A is stored to ECU A. trouble code associated with
ECU A ECU D
in ECUs B, C and ECUs B, C and D is stored in
D. ECU A, or "bus off" diagnostic (f) (g)
Time-out trouble code is stored in ECU

diagnostic A, CAN bus line (a) or (c) is ECU B ECU C
trouble code suspected. When diagnostic AC204742BM
associated with trouble code is not stored in

ECUs B, C and D ECU A, the power supply to
is stored in ECU ECU A is suspected.
A.
"Bus off"
diagnostic
trouble code is
stored in ECU A.
TSB Revision
Diagnostic Possible Logic for narrowing down trouble spot

trouble code to trouble spot
be set
Time-out Trouble in If time-out diagnostic trouble
(h)
diagnostic CAN bus line codes associated with ECUs ETACS-ECU Data link
trouble codes (d) C and D are stored in ECUs A (Gateway) connector
associated with and B, or time-out codes (b)

(a) (c) (d) (e)
ECUs C and D associated with ECUs A and
ECU A ECU D
are stored in B are stored in ECUs C and
ECU A and ECU D, CAN bus line (d) is (f) (g)
B. suspected. CAN bus line (g)

Time-out or (e) and power supply ECU B ECU C
diagnostic systems to ECU C or D are AC204742BN
trouble codes also suspected as second

associated with cause.
ECUs A and B
are stored in
ECU C and ECU
D.
Time-out Trouble in It must be assumed that a
(h)
diagnostic CAN bus line fault was present in CAN bus ETACS-ECU Data link
trouble codes (b) line (b) when the (Gateway) connector
associated with ETACS-ECU has set a (b)

(a) (c) (d) (e)
ECUs A, B, C time-out diagnostic trouble
ECU A ECU D
and D are stored code for ECU A, B, C or D.
in ETACS-ECU. (f) (g)
Time-out
ECU B ECU C
diagnostic
trouble codes AC204742BP
associated with
ETACS-ECU is
stored in ECU A,
B, C and ECU D.
TSB Revision
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
54C-15
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
M1548304500111
ON-BOARD DIAGNOSTICS A/C-ECU

The CAN is a communication method which the SRS-ECU
ECUs use in order to communicate each other. The Occupant classification-ECU
CAN-related diagnostic trouble codes will be stored Hands free module <vehicles with hands free
in the following ECUs, which use the CAN communi- system>
cation. Radio and CD player or CD changer <vehicles
ETACS-ECU without Mitsubishi Multi-Communication System
ECM (MMCS)> or CAN box unit <vehicles with Mitsub-
TCM ishi Multi-Communication System (MMCS)>
ABS-ECU <vehicles without ASC> or ASC-ECU Satellite radio tuner <vehicles satellite radio>
<vehicles with ASC> WCM <vehicles without KOS> or KOS-ECU
AWD-ECU <vehicles with KOS>
Steering wheel sensor <vehicles with ASC> Combination meter

CAUTION
position.
MB991910
position.
color.
7. Start the scan tool system on the personal computer.
MB991827
AC608435 AB
HOW TO DIAGNOSE THE CAN BUS LINE

TSB Revision
DIAGNOSIS
CAUTION
3. Select "CAN Bus Diagnosis" from the start-up screen.
matches the vehicle whose CAN bus lines will be
diagnosed.
MB991910
MB991824 If not, go to step 5.
that it matches the vehicle whose CAN bus lines will be
diagnosed.
MB991827 AC608435 AB
"OK" button.
DIAGNOSIS
CAN BUS DIAGNOSTICS TABLE
M1548300200624
CAUTION
A diagnosis code may not also be set in the
CAN-B lines under the conditions below. If no
diagnosis code has been set due to electrical
noise, confirm diagnosis item 23 P.54C-143.
Open circuit at the CAN_H side of the CAN-B
bus lines
Open circuit at the CAN_L side of the CAN-B
bus line
Short to ground at the CAN_H side of the
CAN-B bus line
CAUTION
During diagnosis, a diagnosis code associated
with another system may be set when the igni-
tion switch is turned on with connector(s) dis-
connected. After completing the repair, confirm
all systems for diagnosis code(s). If diagnosis
code(s) are set, erase them all.
This diagnosis applies only to the CAN bus lines. If a
different system is defective, proceed to the applica-
ble diagnosis section for each system. Observe the
diagnosis procedure below only when the CAN bus
line is defective.
TSB Revision
DIAGNOSIS
54C-17
Scan tool screen Diagnosis detail Reference
(The ECUs that are not adopted are not Comment page
displayed.)
M.U.T.
Short circuit to Diagnosis Item 1 P.54C-22
: Red section on screen
battery in red Diagnose when the
ETACS displayed area is scan tool cannot receive
J/C (2)
estimated. the data sent by
ETACS-ECU.
J/C (3)
J/C (1) ABS CVT ENGINE
KOS/WCM SRS OCM A/C AUDIO MMCS Sat Radio HFM METER
AC608016AB
M.U.T.
Grounding in red Diagnosis Item 2 P.54C-27
displayed area is Malfunction of the
ETACS estimated. ETACS-ECU.
J/C (2)
J/C (3)
AC608016AC
M.U.T.
CAN-C: A bus-off Diagnosis Item 3 P.54C-28
failure is present in Abnormal short
ETACS the gateway ECU. between the CAN-C bus
J/C (2)
lines.
CAN-C: Grounding Diagnosis Item 4 P.54C-37
J/C (3)
in red displayed Diagnose shorts in the
area is estimated ground to CAN-C bus
line.
CAN-C: Short Diagnosis Item 5 P.54C-47
AC608016AD
circuit to battery in Diagnose shorts in the
red displayed area power supply to CAN-C
is estimated bus line.
M.U.T.
CAN-C: Diagnosis Item 6 P.54C-57
Disconnection in Diagnose when the
ETACS red displayed area scan tool cannot receive
J/C (2)
is estimated. the data sent by TCM.
J/C (3)
AC608016AE
TSB Revision
DIAGNOSIS

displayed.)
M.U.T.
J/C (2)
is estimated. the data sent by
ABS-ECU.
J/C (3)
AC608016AF
M.U.T.
J/C (2)
is estimated. the data sent by ECM.
J/C (3)
AC608016AG
M.U.T.
Disconnection in Diagnose the lines
ETACS red displayed area between the
J/C (2)
is estimated. ETACS-ECU and joint
connector (CAN2).
J/C (3)
AC608016AH
M.U.T.
Disconnection in Diagnose the lines
ETACS red displayed area between joint connector
J/C (2)
is estimated. (CAN2) and joint
connector (CAN3).
J/C (3)
AC608016AI
TSB Revision
DIAGNOSIS
54C-19
displayed.)
M.U.T.
CAN-B: Diagnosis Item 11 P.54C-72
J/C (2)
KOS-ECU.
J/C (3)
Diagnosis Item 12 P.54C-75
Diagnose when the
scan tool cannot receive
the data sent by WCM.
AC608016AJ
M.U.T.
J/C (2)
SRS-ECU.
J/C (3)
AC608016AK
M.U.T.
J/C (2)
occupant
J/C (3) classification-ECU.
AC608016AL
M.U.T.
J/C (2)
A/C-ECU.
J/C (3)
AC608016AM
TSB Revision
DIAGNOSIS

displayed.)
M.U.T.
J/C (2)
is estimated. the data sent by radio
and CD player or CD
J/C (3) changer.
AC608016AN
M.U.T.
J/C (2)
is estimated. the data sent by CAN
box unit.
J/C (3)
AC608016AO
M.U.T.
J/C (2)
is estimated. the data sent by satellite
radio tuner.
J/C (3)
AC608016AP
M.U.T.
J/C (2)
hands-free module.
J/C (3)
AC608016AQ
TSB Revision
DIAGNOSIS
54C-21
displayed.)
M.U.T.
J/C (2)
combination meter.
J/C (3)
AC608016AR
M.U.T.
CAN-B: A failure in Diagnosis Item 21 P.54C-102
the red section, or Short to power supply or
ETACS a bus-off failure is ground in both CAN_H
J/C (2)
present in the and CAN_L lines.
gateway ECU.
J/C (3)
AC608016AS
M.U.T.
Disconnection in Diagnose the
ETACS red displayed area ETACS-ECU, joint
J/C (2)
is estimated. connector (CAN1) or
lines between
J/C (3) ETACS-ECU and joint
connector (CAN1).
AC608016AT
M.U.T.
Disconnection in Short to power supply or
ETACS red displayed area ground, open circuit or
J/C (2)
is estimated. line-to-line short in the
CAN-B bus lines.
J/C (3)
AC608016AS
TSB Revision
DIAGNOSIS
CAN BUS DIAGNOSTICS
DIAGNOSTIC ITEM 1: Diagnose when the scan tool cannot receive the data sent by ETACS-ECU.
CAUTION
When servicing a CAN bus line, ground yourself by touching a metal object such as an unpainted
water pipe. If you fail to do so, a component connected to the CAN bus line may be damaged.
CAN Communication Circuit
ETACS-ECU
CAN DRIVE
CIRCUIT
INTERFACE
CIRCUIT
DATA LINK
CONNECTOR
FRONT SIDE

When the CAN bus diagnosis is carried out, the scan
tool communicates with the ETACS-ECU. If a com-
munication flag is not set for the ETACS-ECU, the
ETACS-ECU will be diagnosed as a communication
error.
.

C-34 (B) If a communication flag is not set for the
AC608145AB ETACS-ECU, the ETACS-ECU determines that there
is a failure.
Connector: C-301
Junction block .
Malfunction of the connector (data link connector
or ETACS-ECU connector improperly connected)
Malfunction of the wiring harness (open circuit,
short to ground, short to power supply between
the data link connector and the ETACS-ECU con-
nector, line-to-line short, or power supply to the
AC608152 AB ETACS-ECU)
.
Malfunction of ETACS-ECU
TSB Revision
DIAGNOSIS
54C-23
DIAGNOSIS
STEP 1. Check data link connector C-34 and ETACS-ECU

CAUTION
The strand end of the twisted wire should be within 10 cm
(4 inches) from the connector. For details refer to P.54C-7.
Q: Are data link connector C-34 and ETACS-ECU connector
C-301 in good condition?
YES : Go to Step 2.
STEP 2. Check the wiring harness between data link

connector C-34 and ETACS-ECU connector C-301.
CAUTION
Strictly observe the specified wiring harness repair proce-
dure. For details refer to P.54C-7.
(1) Disconnect the scan tool and ETACS-ECU connector
C-301, and check the wiring harness.
(2) Check the wiring harness between data link connector C-34
(terminal 6) and ETACS-ECU connector C-301 (terminal 5)
<CAN_H>
(3) Check the wiring harness between data link connector C-34
(terminal 14) and ETACS-ECU connector C-301 (terminal
4) <CAN_L>
Q: Is the wiring harness between data link connector C-34
and ETACS-ECU connector C-301 in good condition?
YES : Go to Step 3.
NO : Repair the wiring harness between data link
TSB Revision
DIAGNOSIS

connector C-34 and ETACS-ECU connector C-301 for a
short to ground. Measure the resistance at data link
connector C-34.
CAUTION
Disconnect the negative battery terminal. For details refer
to P.54C-7.
CAUTION
A digital multimeter should be used. For details refer to
P.54C-7.
CAUTION
The test wiring harness should be used. For details refer to
P.54C-7.
C-301, and measure the resistance at the wiring harness
side of data link connector C-34.
(2) Measure the resistance between data link connector
terminal 6 and body ground. <CAN_H>
TEST OK: 1 kilo ohm or more
HARNESS
Harness side: C-34
AC608179 AB

terminal 14 and body ground. <CAN_L>
Harness side: C-34 OK: 1 kilo ohm or more
Q: Do all the resistances measure 1 kilo ohm or more?
YES : Go to Step 4.
TEST connector C-34 and ETACS-ECU connector C-301.
HARNESS
AC608179 AC
TSB Revision
DIAGNOSIS
54C-25

connector C-34 and ETACS-ECU connector C-301 for a
short to the power supply. Measure the voltage at data link
connector C-34.
(3) Measure the voltage between data link connector terminal 6
and body ground. <CAN_H>
TEST OK: 5 volts or less
HARNESS
Harness side: C-34
AC608178 AB
(4) Measure the voltage between data link connector terminal

14 and body ground. <CAN_L>
Harness side: C-34 OK: 5 volts or less
Q: Do all the voltage measure 5 volts or less?
YES : Go to Step 5.
TEST connector C-34 and ETACS-ECU connector C-301.
HARNESS
AC608178 AC

connector C-34 and ETACS-ECU connector C-301 for
line-to-line short. Measure the resistance at data link
connector C-34.
Harness side: C-34
terminal 6 and 14.
TEST OK: Continuity exists (2 ohm or less)
HARNESS
Q: Do the resistance measure 2 ohm or less?
YES : Go to Step 6.
TEST
HARNESS AC608179 AD
TSB Revision
DIAGNOSIS

line.
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
(3) Diagnose CAN bus lines, and check if the scan tool screen
M.U.T. is as shown in the illustration.
ETACS Q: Does the scan tool screen correspond to the
J/C (2)
illustration?
J/C (3)

KOS/WCM SRS OCM A/C AUDIO MMCS Sat Radio HFM METER Cope with Intermittent Malfunction P.00-13).
AC608017AB
TSB Revision
DIAGNOSIS
54C-27
DIAGNOSTIC ITEM 2: Malfunction of the ETACS-ECU.

.
CAUTION TROUBLE JUDGEMENT CONDITIONS

When servicing a CAN bus line, ground yourself If no communication flags are set for the ECUs (on
by touching a metal object such as an unpainted the CAN-B or CAN-C lines) other than the
water pipe. If you fail to do, a component con- ETACS-ECU, the ETACS-ECU determines that there
nected to the CAN bus line may be broken. is a failure.
.
FUNCTION .
When the CAN bus diagnosis is carried out, the scan TROUBLESHOOTING HINT
tool sets communication "OK" flags in the patch Malfunction of the ETACS-ECU
between the ETACS-ECU and active other ECUs. If
a commutation "OK" flag is not set for the ECUs
other than the ETACS-ECU, this diagnosis result will
be set.
DIAGNOSIS
Recheck for other system diagnostic trouble code.

CAUTION
Check whether ETACS-ECU-related DTC is set.
Q: Is the DTC set?
MB991910 The DTC other than the U code is set. : Troubleshoot the
MB991824
ETACS-ECU. Refer to GROUP 54A, ETACS-ECU
P.54A-482.
Only U-code DTC is set. : Check the power supply circuit
of the ETACS-ECU. Refer to GROUP 54A,
ETACS-ECU P.54A-524.
The DTC is not set. : Check the power supply circuit of the
ETACS-ECU. Refer to GROUP 54A, ETACS-ECU
P.54A-524.
MB991827 AC608435 AB
TSB Revision
DIAGNOSIS
DIAGNOSTIC ITEM 3: Abnormal short between the CAN-C bus lines.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
JOINT CONNECTOR
(CAN2)
JOINT CONNECTOR
(CAN3)
ENGINE
CONTROL
MODULE
TRANSAXLE ABS-ECU
CONTROL
MODULE
TSB Revision
DIAGNOSIS
54C-29
Connector: A-01 A-01 (B) Connector: C-301
Junction block
AC608141AC AC608152 AB
.
Connector: B-109 FUNCTION

If a line-to-line short is present in the CAN-C lines,
B-109 (GR) this diagnosis result will be set.
.

If only diagnostic trouble code U0001 is set, the
ETACS-ECU determines that there is a failure.
.
AC608144AB TROUBLESHOOTING HINTS

Malfunction of the connector (joint connectors or
Connectors: C-05, C-41, C-124, C-128
ECU connectors improperly connected)
C-05 Malfunction of the wiring harness (line-to-line
short in the CAN-C main or sub bus lines)
Malfunction of the ECU (ECU on CAN-C lines
failed)
C-41
C-124
C-128
AC608145AC
DIAGNOSIS
MB991970: ABS Check Harness
TSB Revision
DIAGNOSIS
STEP 1. Check joint connector (CAN2) C-05 and joint

connector (CAN3) C-124 for loose, corroded or damaged
CAUTION
Q: Are joint connector (CAN2) C-05 and joint connector
(CAN3) C-124 in good condition?
YES : Go to Step 2.
STEP 2. Check the wiring harness between joint connector

(CAN3) C-124 and ECM connector B-109 for line-to-line
short. Measure the resistance at joint connector (CAN3)
C-124.
CAUTION
to P.54C-7.
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(1) Disconnect joint connector (CAN3), and check that there is
continuity at the harness side of joint connector (CAN3).
Harness side: C-124 (2) Check that there is continuity between joint connector
(CAN3) terminals 4 and 15.
TEST OK: No continuity
HARNESS
YES : Go to Step 3.
NO : Go to Step 6.
TEST
HARNESS
AC608179 AE
TSB Revision
DIAGNOSIS
54C-31

(CAN3) C-124 and ABS-ECU connector A-01 for line-to-line
C-124.
HARNESS
YES <M/T> : Go to Step 5.
NO (the check result is not normal.) : Go to Step 7.
TEST
HARNESS
AC608179 AF

(CAN3) C-124 and TCM connector C-41 for line-to-line
C-124.
HARNESS
YES : Go to Step 5.
NO : Go to Step 8.
TEST
HARNESS
AC608179 AG

(CAN2) C-05 and ETACS-ECU connector C-301 for
line-to-line short. Measure the resistance at joint
connector (CAN2) C-05.
HARNESS
YES : Check intermediate connector C-128, and repair if
necessary. If the intermediate connector is in good
condition, repair the wiring harness between joint
TEST connector (CAN2) C-05 and joint connector (CAN3)
HARNESS C-124.
AC608179 AH
NO : Go to Step 9.
TSB Revision
DIAGNOSIS

line. (checking the ECM for internal short)
CAUTION
CAUTION
(1) Disconnect ECM connector B-109.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
(4) Diagnose CAN bus lines, and check if the scan tool
M.U.T. MB991958 screen is as shown in the figure.
ETACS
OK: The display of the scan tool MB991958 is as
J/C (2)
J/C (3)
Q: Does scan tool MB991958 screen correspond to the
illustration?
YES : Repair the wiring harness between ECM connector
B-109 and joint connector (CAN3) C-124.
NO : Check ECM connector B-109, and repair if necessary.
AC608017AC
If the ECM connector is in good condition, replace the
ECM.
TSB Revision
DIAGNOSIS
54C-33

line. (checking the ABS-ECU for internal short)
CAUTION
CAUTION
(1) Disconnect ABS-ECU connector A-01.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
YES : Repair the wiring harness between ABS-ECU
connector A-01 and joint connector (CAN3) C-124.
NO : Check ABS-ECU connector A-01, and repair if
AC608017AC
necessary. If the ABS-ECU connector is in good
condition, replace the ABS-ECU.
TSB Revision
DIAGNOSIS

line. (checking the TCM for internal short)
CAUTION
CAUTION
(1) Disconnect TCM connector C-41.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
YES : Repair the wiring harness between TCM connector
C-41 and joint connector (CAN3) C-124.
NO : Check TCM connector C-41, and repair if necessary.
AC608017AC
If the TCM connector is in good condition, replace the
TCM.
TSB Revision
DIAGNOSIS
54C-35

(CAN2) C-05 and ETACS-ECU connector C-301 for
(1) Disconnect joint connector (CAN2) and ETACS-ECU
connector, and check that there is continuity at the harness
side of joint connector (CAN2).
(2) Check that there is continuity between joint connector
OK: No continuity
NO : Repair the wiring harness between joint connector
(CAN2) C-05 and ETACS-ECU connector C-301.
TSB Revision
DIAGNOSIS
STEP 10. Using scan tool MB991958, diagnose the CAN

bus line.
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
J/C (2)
illustration?
J/C (3)

AC608017AC
TSB Revision
DIAGNOSIS
54C-37
DIAGNOSTIC ITEM 4: Diagnose shorts in the ground to CAN-C bus line.
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
JOINT CONNECTOR
(CAN2)
JOINT CONNECTOR
(CAN3)
ENGINE
CONTROL
MODULE
TRANSAXLE ABS-ECU
CONTROL
MODULE
TSB Revision
DIAGNOSIS

Junction block
AC608141AC AC608152 AB
.

If a short to ground is present in the CAN-C lines, this
B-109 (GR) diagnosis result will be set.
.

If DTC U1120 is set, the ETACS-ECU determines
that there is a failure.
.

Malfunction of the connector (short to ground
Connectors: C-05, C-41, C-124, C-128
inside connector)
C-05 Malfunction of the wiring harness (short to ground
in the CAN-C main or sub bus lines)
Malfunction of the ECU (ETACS-ECU, or ECUs
on CAN-C lines failed)
C-41
C-124
C-128
AC608145AC
DIAGNOSIS
TSB Revision
DIAGNOSIS
54C-39

(CAN2) C-05 and ETACS-ECU connector C-301 for a short
to ground. Measure the resistance at joint connector
(CAN2) C-05.
CAUTION
to P.54C-7.
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(1) Disconnect joint connector (CAN2), and measure the
resistance at the wiring harness side of joint connector
(CAN2).
(2) Measure the resistance between joint connector (CAN2)
terminal 6 and body ground.
HARNESS
Harness side: C-05
AC608179 AJ

YES : Go to Step 2.
NO : Go to Step 5.
TEST
HARNESS
AC608179 AK
TSB Revision
DIAGNOSIS

(CAN3) C-124 and ECM connector B-109 for a short to
ground. Measure the resistance at joint connector (CAN3)
C-124.
(CAN3).
HARNESS
Harness side: C-124
AC608179 AL

YES : Go to Step 3.
NO : Go to Step 6.
TEST
HARNESS
AC608179 AM
TSB Revision
DIAGNOSIS
54C-41

(CAN3) C-124 and ABS-ECU connector A-01 for a short to
C-124.
(CAN3).
HARNESS
Harness side: C-124
AC608179 AN

YES <M/T> : Check intermediate connector C-128, and
repair if necessary. If the intermediate connector is in
TEST good condition, repair the wiring harness between
HARNESS joint connector (CAN2) C-05 and joint connector
(CAN3) C-124.
AC608179 AO
TSB Revision
DIAGNOSIS

(CAN3) C-124 and TCM connector C-41 for a short to
C-124.
(CAN3).
HARNESS
Harness side: C-124
AC608179 AP

TEST condition, repair the wiring harness between joint
HARNESS connector (CAN2) C-05 and joint connector (CAN3)
C-124.
AC608179 AQ
NO : Go to Step 8.
TSB Revision
DIAGNOSIS
54C-43

line. (checking the ETACS-ECU for internal short to
ground)
CAUTION
CAUTION
(1) Disconnect ETACS-ECU connector C-301.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
YES : Repair the wiring harness between ETACS-ECU
connector C-301 and joint connector (CAN2) C-05.
NO : Check ETACS-ECU connector C-128, and repair if
AC608017AC
necessary. If the ETACS-ECU connector is in good
condition, replace the ETACS-ECU.
TSB Revision
DIAGNOSIS

line. (checking the ECM for internal short to ground)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AC
ECM.
TSB Revision
DIAGNOSIS
54C-45

line. (checking the ABS-ECU for internal short to ground)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AC
TSB Revision
DIAGNOSIS

line. (checking the TCM for internal short to ground)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AC
TCM.
TSB Revision
DIAGNOSIS
54C-47
DIAGNOSTIC ITEM 5: Diagnose shorts in the power supply to CAN-C bus line.
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
JOINT CONNECTOR
(CAN2)
JOINT CONNECTOR
(CAN3)
ENGINE
CONTROL
MODULE
TRANSAXLE ABS-ECU
CONTROL
MODULE
TSB Revision
DIAGNOSIS

Junction block
AC608141AC AC608152 AB
.

If a short to power supply is present in the CAN-C
B-109 (GR) lines, this diagnosis result will be set.
.

The wiring harness wire or connectors may have
loose, corroded, or damage terminals, or terminals
pushed back in the connector, or an ECU may be
AC608144AB
defective.
.
Connectors: C-05, C-41, C-124, C-128

C-05 Malfunction of the connector (short to power sup-
ply in connector)
Malfunction of the wiring harness (short to power
supply in the CAN-C main or sub bus lines)
C-41 Malfunction of the ECU (ETACS-ECU, or ECUs
C-124 on CAN-C lines failed)
C-128
AC608145AC
DIAGNOSIS
TSB Revision
DIAGNOSIS
54C-49

(CAN2) C-05 and ETACS-ECU connector C-301 for a short
to power supply. Measure the voltage at joint connector
(CAN2) C-05.
voltage at the wiring harness side of joint connector
(CAN2).
(3) Measure the voltage between joint connector (CAN2)
TEST OK: 4.7 volts or less
HARNESS
Harness side: C-05
AC608178 AD

Harness side: C-124 OK: 4.7 volts or less
Q: Do all the voltages measure 4.7 volts or less?
YES : Go to Step 2.
NO : Go to Step 5.
TEST
HARNESS
AC608178 AE
TSB Revision
DIAGNOSIS

(CAN3) C-124 and ECM connector B-109 for a short to
power supply. Measure the voltage at joint connector
(CAN3) C-124.
(CAN3).
HARNESS
Harness side: C-124
AC608178 AF

YES : Go to Step 3.
NO : Go to Step 6.
TEST
HARNESS
AC608178 AG
TSB Revision
DIAGNOSIS
54C-51

(CAN3) C-124 and ABS-ECU connector A-01 for a short to
power supply. Measure the voltage at joint connector
(CAN3) C-124.
(CAN3).
HARNESS
Harness side: C-124
AC608178 AH

YES <M/T> : Check intermediate connector C-128, and
repair if necessary. If the intermediate connector is in
TEST good condition, repair the wiring harness between
HARNESS joint connector (CAN2) C-05 and joint connector
(CAN3) C-124.
AC608178 AI
TSB Revision
DIAGNOSIS

(CAN3) C-124 and TCM connector C-41 for a short to power
supply. Measure the voltage at joint connector (CAN3)
C-124.
(CAN3).
HARNESS
Harness side: C-124
AC608178 AJ

TEST condition, repair the wiring harness between joint
HARNESS connector (CAN2) C-05 and joint connector (CAN3)
C-124.
AC608178 AK
NO : Go to Step 8.
TSB Revision
DIAGNOSIS
54C-53

line. (checking the ETACS-ECU for internal short to
ground)
CAUTION
CAUTION
(1) Disconnect ETACS-ECU connector C-301.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
YES : Repair the wiring harness between ETACS-ECU
connector C-301 and joint connector (CAN2) C-05.
NO : Check ETACS-ECU connector C-128, and repair if
AC608017AC
necessary. If the ETACS-ECU connector is in good
TSB Revision
DIAGNOSIS

line. (checking the ECM for internal short to ground)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AC
ECM.
TSB Revision
DIAGNOSIS
54C-55

line. (checking the ABS-ECU for internal short to ground)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AC
TSB Revision
DIAGNOSIS

line. (checking the TCM for internal short to ground)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AC
TCM.
TSB Revision
DIAGNOSIS
54C-57
DIAGNOSTIC ITEM 6: Diagnose when the scan tool cannot receive the data sent by TCM.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
JOINT CONNECTOR
(CAN2)
JOINT CONNECTOR
(CAN3)
ENGINE
CONTROL
MODULE
TRANSAXLE ABS-ECU
CONTROL
MODULE
TSB Revision
DIAGNOSIS
.
Connectors: C-41, C-124 TROUBLE JUDGEMENT CONDITIONS

If a communication flag is not set for the TCM, the
.
C-41 Malfunction of the connector [joint connector
C-124
(CAN3) or TCM connector improperly connected]
Malfunction of the wiring harness [open circuit
AC608145AD
between the TCM and the joint connector
(CAN3), power supply circuit to the TCM]
Malfunction of the TCM
.
FUNCTION
If the scan tool MB991958 cannot communicate with
the TCM, this diagnosis result will be set.
DIAGNOSIS
STEP 1. Check joint connector (CAN3) C-124 and TCM

connector C-41 for loose, corroded or damaged terminals,
CAUTION
Q: Are joint connector (CAN3) C-124 and TCM connector
YES : Go to Step 2.

(CAN3) C-124 and TCM connector C-41.
CAUTION
(1) Disconnect joint connector (CAN3) C-124 and TCM
connector C-41, and check the wiring harness.
(2) Check the wiring harness between joint connector (CAN3)
C-124 (terminal 7) and TCM connector C-41 (terminal 4)
C-124 (terminal 20) and TCM connector C-41 (terminal 5)
Q: Is the wiring harness between joint connector (CAN3)
C-124 and TCM connector C-41 in good condition?
YES : Check the power supply circuit of the TCM. Refer to
GROUP 23A, Troubleshooting P.23A-30.
(CAN3) C-124 and TCM connector C-41.
TSB Revision
DIAGNOSIS
54C-59
DIAGNOSTIC ITEM 7: Diagnose when the scan tool cannot receive the data sent by ABS-ECU.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
JOINT CONNECTOR
(CAN2)
JOINT CONNECTOR
(CAN3)
ENGINE
CONTROL
MODULE
TRANSAXLE ABS-ECU
CONTROL
MODULE
TSB Revision
DIAGNOSIS
.
Connector: A-01 A-01 (B) FUNCTION

the ABS-ECU, this diagnosis result will be set.
.

If a communication flag is not set for the ABS-ECU,
the ETACS-ECU determines that there is a failure.
.
AC608141AC TROUBLESHOOTING HINTS

Malfunction of the connector [joint connector
Connector: C-124
(CAN3) or ABS-ECU connector improperly con-
nected]
between the ABS-ECU and the joint connector
(CAN3), power supply circuit to the ABS-ECU]
Malfunction of the ABS-ECU
AC608145AE
DIAGNOSIS
STEP 1. Check joint connector (CAN3) C-124 and ABS-ECU

connector A-01 for loose, corroded or damaged terminals,
CAUTION
Q: Are joint connector (CAN3) C-124 and ABS-ECU
connector A-01 in good condition?
YES : Go to Step 2.
TSB Revision
DIAGNOSIS
54C-61

(CAN3) C-124 and ABS-ECU connector A-01.
CAUTION
(1) Disconnect joint connector (CAN3) C-124 and ABS-ECU
connector A-01, and check the wiring harness.
C-124 (terminal 6) and ABS-ECU connector A-01 (terminal
4)
C-124 (terminal 19) and ABS-ECU connector A-01 (terminal
6)
C-124 and ABS-ECU connector A-01 in good condition?
YES : Check the power supply circuit of the ABS-ECU.
Refer to GROUP 35B, Troubleshooting P.35B-146.
(CAN3) C-124 and ABS-ECU connector A-01.
TSB Revision
DIAGNOSIS
DIAGNOSTIC ITEM 8: Diagnose when the scan tool cannot receive the data sent by ECM.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
JOINT CONNECTOR
(CAN2)
JOINT CONNECTOR
(CAN3)
ENGINE
CONTROL
MODULE
TRANSAXLE ABS-ECU
CONTROL
MODULE
TSB Revision
DIAGNOSIS
54C-63
.

B-109 (GR) the ECM, this diagnosis result will be set.
.

If a communication flag is not set for the ECM, the
.

Connector: C-124
(CAN3) or ECM connector improperly connected]
between the ECM and the joint connector
(CAN3), power supply circuit to the ECM]
Malfunction of the ECM
AC608145AE
DIAGNOSIS
STEP 1. Check joint connector (CAN3) C-124 and ECM

connector B-109 for loose, corroded or damaged
CAUTION
Q: Are joint connector (CAN3) C-124 and ECM connector
B-109 in good condition?
YES : Go to Step 2.
TSB Revision
DIAGNOSIS

(CAN3) C-124 and ECM connector B-109.
CAUTION
(1) Disconnect joint connector (CAN3) C-124 and ECM
connector B-109, and check the wiring harness.
C-124 (terminal 4) and ECM connector B-109 (terminal 90)
C-124 (terminal 15) and ECM connector B-109 (terminal
91)
C-124 and ECM connector B-109 in good condition?
YES : Check the power supply circuit of the ECM. Refer to
GROUP 13A, Troubleshooting P.13A-51.
(CAN3) C-124 and ECM connector B-109.
TSB Revision
DIAGNOSIS
54C-65
DIAGNOSTIC ITEM 9: Diagnose the lines between the ETACS-ECU and joint connector (CAN2).
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
JOINT CONNECTOR
(CAN2)
JOINT CONNECTOR
(CAN3)
ENGINE
CONTROL
MODULE
TRANSAXLE ABS-ECU
CONTROL
MODULE
TSB Revision
DIAGNOSIS
.

If a failure is present in the wiring harness between
the ETACS-ECU connector and the joint connector
(CAN2), this diagnosis result will be set.
.

If a communication flag is not set for some of the
ECUs on the CAN-C line, the ETACS-ECU deter-
AC608145AG
mines that there is a failure.
.
Connector: C-301 TROUBLESHOOTING HINTS

Junction block
(CAN2) or ETACS-ECU connector improperly
connected]
between the ETACS-ECU connector and the joint
connector (CAN2), power supply circuit to the
ECM]
AC608152 AB
DIAGNOSIS
STEP 1. Check joint connector (CAN2) C-05 and

ETACS-ECU connector C-301 for loose, corroded or
connector.
CAUTION
Q: Are joint connector (CAN2) C-05 and ETACS-ECU
YES : Go to Step 2.
TSB Revision
DIAGNOSIS
54C-67

CAUTION
(1) Disconnect joint connector (CAN2) C-05 and ETACS-ECU
C-05 (terminal 6) and ETACS-ECU connector C-301
(terminal 9)
(terminal 8)
C-05 and ETACS-ECU connector C-301 in good
condition?
YES : Go to Step 3.
TSB Revision
DIAGNOSIS

line.
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
J/C (2)
illustration?
J/C (3)

AC608017AB
TSB Revision
DIAGNOSIS
54C-69
DIAGNOSTIC ITEM 10: Diagnose the lines between joint connector (CAN2) and joint connector
(CAN3).
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
JOINT CONNECTOR
(CAN2)
JOINT CONNECTOR
(CAN3)
ENGINE
CONTROL
MODULE
TRANSAXLE ABS-ECU
CONTROL
MODULE
TSB Revision
DIAGNOSIS
.
Connectors: C-05, C-124, C-128 TROUBLE JUDGEMENT CONDITIONS

C-05 If a communication flag is not set for some of the
ECUs on the CAN-C line, the ETACS-ECU deter-
.
C-124
C-128 (CAN2), joint connector (CAN3) or intermediate
AC608145AH
connector failed]
between joint connector (CAN2) and joint con-
.
FUNCTION
nector (CAN3)]
If a failure is present in the wiring harness between
the joint connector (CAN2) and the joint connector
(CAN3), this diagnosis result will be set.
DIAGNOSIS
STEP 1. Check joint connector (CAN2) C-05, joint

connector (CAN3) C-124 and intermediate connector C-128
CAUTION
Q: Are joint connector (CAN2) C-05, joint connector (CAN3)
C-124 and intermediate connector C-128 in good
condition?
YES : Go to Step 2.
TSB Revision
DIAGNOSIS
54C-71

(CAN2) C-05 and joint connector (CAN3) C-124.
CAUTION
(1) Disconnect joint connector (CAN2) C-05 and joint connector
(CAN3) C-124, and check the wiring harness.
C-05 (terminal 5) and joint connector (CAN3) C-124
(terminal 5)
C-05 (terminal 16) and joint connector (CAN3) C-124
(terminal 16)
C-05 and joint connector (CAN3) C-124 in good
condition?
(CAN2) C-05 and joint connector (CAN3) C-124.
TSB Revision
DIAGNOSIS
DIAGNOSTIC ITEM 11: Diagnose when the scan tool cannot receive the data sent by KOS-ECU.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
KOS-ECU
A/C-ECU
CAN DRIVE
CIRCUIT
JOINT CONNECTOR
(CAN1)
CAN DRIVE CAN DRIVE NOTE

CIRCUIT CIRCUIT VEHICLES WITH WCM
SRS-ECU VEHICLES WITH KOS
COMBINATION WIRELESS
METER CONTROL
MODULE
TSB Revision
DIAGNOSIS
54C-73
.
Connectors: C-06, C-31 FUNCTION

C-06 If the scan tool MB991958 cannot communicate with
the KOS-ECU, this diagnosis result will be set.
.

C-31 If a communication flag is not set for the KOS-ECU,
.
AC608145AI TROUBLESHOOTING HINTS

Connector: C-301 (CAN1), KOS-ECU connector improperly con-
Junction block
nected]
between the KOS-ECU connector and the joint
KOS-ECU]
Malfunction of the KOS-ECU
AC608152 AB
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06 and KOS-ECU

CAUTION
Q: Are joint connector (CAN1) C-06 and KOS-ECU
YES : Go to Step 2.
TSB Revision
DIAGNOSIS

(CAN1) C-06 and KOS-ECU connector C-31.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and KOS-ECU
C-06 (terminal 9) and KOS-ECU connector C-31 (terminal
1)
2)
C-06 and KOS-ECU connector C-31 in good condition?
YES : Check the power supply circuit of the KOS-ECU.
Refer to GROUP 42B, KOS-ECU Diagnosis
P.42B-120.
TSB Revision
DIAGNOSIS
54C-75
DIAGNOSTIC ITEM 12: Diagnose when the scan tool cannot receive the data sent by WCM.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
KOS-ECU
A/C-ECU
CAN DRIVE
CIRCUIT
JOINT CONNECTOR
(CAN1)

METER CONTROL
MODULE
TSB Revision
DIAGNOSIS
.

the WCM, this diagnosis result will be set.
C-09 .

If a communication flag is not set for the WCM, the
.
AC608145AJ TROUBLESHOOTING HINTS

Connector: C-301 (CAN1), WCM connector improperly connected]
Junction block
between the WCM connector and the joint con-
nector (CAN1), power supply circuit to the WCM]
Malfunction of the WCM
AC608152 AB
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06 and WCM

CAUTION
Q: Are joint connector (CAN1) C-06 and WCM connector
YES : Go to Step 2.
TSB Revision
DIAGNOSIS
54C-77

(CAN1) C-06 and WCM connector C-09.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and WCM
C-06 (terminal 5) and WCM connector C-09 (terminal 11)
C-06 and WCM connector C-09 in good condition?
YES : Check the power supply circuit of the WCM. Refer to
GROUP 42C, WCM Diagnosis P.42C-74.
TSB Revision
DIAGNOSIS
DIAGNOSTIC ITEM 13: Diagnose when the scan tool cannot receive the data sent by SRS-ECU.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
KOS-ECU
A/C-ECU
CAN DRIVE
CIRCUIT
JOINT CONNECTOR
(CAN1)

METER CONTROL
MODULE
TSB Revision
DIAGNOSIS
54C-79
.

the SRS-ECU, this diagnosis result will be set.
.

If a communication flag is not set for the SRS-ECU,
C-122 (Y) the ETACS-ECU determines that there is a failure.
.
AC608145AK TROUBLESHOOTING HINTS

Connector: C-301 (CAN1), SRS-ECU connector improperly con-
Junction block
nected]
between the SRS-ECU connector and the joint
SRS-ECU]
Malfunction of the SRS-ECU
AC608152 AB
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06 and SRS-ECU

CAUTION
Q: Are joint connector (CAN1) C-06 and SRS-ECU
YES : Go to Step 2.
TSB Revision
DIAGNOSIS

(CAN1) C-06 and SRS-ECU connector C-122.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and SRS-ECU
C-06 (terminal 8) and SRS-ECU connector C-122 (terminal
10)
C-06 (terminal 21) and SRS-ECU connector C-122
(terminal 9)
C-06 and SRS-ECU connector C-122 in good condition?
YES : Check the power supply circuit of the SRS-ECU.
Refer to GROUP 52B, SRS Troubleshooting
P.52B-339.
TSB Revision
DIAGNOSIS
54C-81
DIAGNOSTIC ITEM 14: Diagnose when the scan tool cannot receive the data sent by occupant
classification-ECU.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
RADIO AND CD
HANDS FREE PLAYER OR CD
MODULE CHANGER
JOINT CONNECTOR
(CAN1)
FRONT SEAT
ASSEMBLY (LH)
INTERFACE
OCCUPANT SATELLITE CIRCUIT
CLASSIFICATION- RADIO
ECU TUNER
CAN
TRANSCEIVER
CIRCUIT
CAN BOX UNIT
NOTE
VEHICLES WITHOUT MITSUBISHI MULTI-COMMUNICATION SYSTEM (MMCS)
VEHICLES WITH MITSUBISHI MULTI-COMMUNICATION SYSTEM (MMCS)
TSB Revision
DIAGNOSIS
.

the occupant classification-ECU, this diagnosis result
will be set.
.

If a communication flag is not set for the occupant
classification-ECU, the ETACS-ECU determines that
C-35
AC608145AL
there is a failure.
.
Connectors: D-35, D-35-2 TROUBLESHOOTING HINTS

D-35,
(CAN1), occupant classification-ECU connector
D-35-2
improperly connected]
between the occupant classification-ECU con-
nector and the joint connector (CAN1), power
supply circuit to the occupant classification-ECU]
Malfunction of the occupant classification-ECU
AC608165AB
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06, occupant

classification-ECU connector D-35, D-35-2 and
intermediate connector C-35 for loose, corroded or
connector.
CAUTION
Q: Are joint connector (CAN1) C-06, occupant
classification-ECU connector D-35, D-35-2 and
intermediate connector C-35 in good condition?
YES : Go to Step 2.
TSB Revision
DIAGNOSIS
54C-83

(CAN1) C-06 and occupant classification-ECU connector
D-35-2.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and occupant
classification-ECU connector D-35-2, and check the wiring
harness.
C-06 (terminal 11) and occupant classification-ECU
connector D-35-2 (terminal 24)
C-06 and occupant classification-ECU connector D-35-2
in good condition?
YES : Check the power supply circuit of the occupant
classification-ECU. Refer to GROUP 52B, SRS air
bag Diagnosis P.52B-339.
(CAN1) C-06 and occupant classification-ECU
connector D-35-2.
TSB Revision
DIAGNOSIS
DIAGNOSTIC ITEM 15: Diagnose when the scan tool cannot receive the data sent by A/C-ECU.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
KOS-ECU
A/C-ECU
CAN DRIVE
CIRCUIT
JOINT CONNECTOR
(CAN1)

METER CONTROL
MODULE
TSB Revision
DIAGNOSIS
54C-85
.

the A/C-ECU, this diagnosis result will be set.
.

If a communication flag is not set for the A/C-ECU,
.
AC608145AM TROUBLESHOOTING HINTS

Connector: C-20 (CAN1), A/C-ECU connector improperly con-
nected]
between the A/C-ECU connector and the joint
C-20 (B)
A/C-ECU]
Malfunction of the A/C-ECU
AC608146AB
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06 and A/C-ECU

CAUTION
Q: Are joint connector (CAN1) C-06 and A/C-ECU
YES : Go to Step 2.
TSB Revision
DIAGNOSIS

(CAN1) C-06 and A/C-ECU connector C-20.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and A/C-ECU
C-06 (terminal 1) and A/C-ECU connector C-20 (terminal
11)
12)
C-06 and A/C-ECU connector C-20 in good condition?
YES : Check the power supply circuit of the A/C-ECU. Refer
to GROUP 55A, Diagnosis P.55A-64.
TSB Revision
DIAGNOSIS
54C-87
DIAGNOSTIC ITEM 16: Diagnose when the scan tool cannot receive the data sent by radio and CD
player or CD changer.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
RADIO AND CD
MODULE CHANGER
JOINT CONNECTOR
(CAN1)
FRONT SEAT
ASSEMBLY (LH)
INTERFACE
ECU TUNER
CAN
TRANSCEIVER
CIRCUIT
CAN BOX UNIT
NOTE
TSB Revision
DIAGNOSIS
.

the radio and CD player or CD changer, this diagno-
sis result will be set.
.

If a communication flag is not set for the radio and
CD player or CD changer, the ETACS-ECU deter-
AC608145AM
.

(CAN1), radio and CD player or CD changer con-
nector improperly connected]
between the radio and CD player or CD changer
connector and the joint connector (CAN1), power
supply circuit to the radio and CD player or CD
changer]
AC608146AC Malfunction of the radio and CD player or CD
Connector: C-301
changer
Junction block
AC608152 AB
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06 and radio and

CD player or CD changer connector C-104 for loose,
in the connector.
CAUTION
Q: Are joint connector (CAN1) C-06 and radio and CD
player or CD changer connector C-104 in good
condition?
YES : Go to Step 2.
TSB Revision
DIAGNOSIS
54C-89

(CAN1) C-06 and radio and CD player or CD changer
connector C-104.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and radio and CD
player or CD changer connector C-301, and check the
wiring harness.
C-06 (terminal 7) and radio and CD player or CD changer
connector C-104 (terminal 23)
C-06 and radio and CD player or CD changer connector
YES : Check the power supply circuit of the radio and CD
player or CD changer. Refer to GROUP 54A, radio
and CD player Diagnosis <radio and CD player>
P.54A-267.
connector C-104.
TSB Revision
DIAGNOSIS
DIAGNOSTIC ITEM 17: Diagnose when the scan tool cannot receive the data sent by CAN box unit.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
RADIO AND CD
MODULE CHANGER
JOINT CONNECTOR
(CAN1)
FRONT SEAT
ASSEMBLY (LH)
INTERFACE
ECU TUNER
CAN
TRANSCEIVER
CIRCUIT
CAN BOX UNIT
NOTE
TSB Revision
DIAGNOSIS
54C-91
.

the CAN box unit, this diagnosis result will be set.
.

If a communication flag is not set for the CAN box
unit, the ETACS-ECU determines that there is a fail-
ure.
AC608145AM .
Connectors: C-105, C-108 Malfunction of the connector [joint connector
C-105 C-108
(CAN1), CAN box unit connector improperly con-
nected]
between the CAN box unit connector and the joint
CAN box unit]
Malfunction of the CAN box unit
AC608146AD
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06, CAN box unit

connector C-108 and intermediate connector C-105 for
CAUTION
Q: Are joint connector (CAN1) C-06, CAN box unit
connector C-108 and intermediate connector C-105 in
good condition?
YES : Go to Step 2.
TSB Revision
DIAGNOSIS

(CAN1) C-06 and CAN box unit connector C-108.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and CAN box unit
C-06 (terminal 7) and CAN box unit connector C-108
(terminal 8)
(terminal 9)
C-06 and CAN box unit connector C-108 in good
condition?
YES : Check the power supply circuit of the CAN box unit.
Refer to GROUP 54A, Diagnosis <MMCS>
P.54A-350.
TSB Revision
DIAGNOSIS
54C-93
DIAGNOSTIC ITEM 18: Diagnose when the scan tool cannot receive the data sent by satellite radio
tuner.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
RADIO AND CD
MODULE CHANGER
JOINT CONNECTOR
(CAN1)
FRONT SEAT
ASSEMBLY (LH)
INTERFACE
ECU TUNER
CAN
TRANSCEIVER
CIRCUIT
CAN BOX UNIT
NOTE
TSB Revision
DIAGNOSIS
.

the satellite radio tuner, this diagnosis result will be
set.
.

If a communication flag is not set for the satellite
radio tuner, the ETACS-ECU determines that there is
AC608145AM
a failure.
.

(CAN1), satellite radio tuner connector improp-
erly connected]
between the satellite radio tuner connector and
the joint connector (CAN1), power supply circuit
to the satellite radio tuner]
Malfunction of the satellite radio tuner
AC608146AF
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06 and satellite

radio tuner connector C-17 for loose, corroded or
connector.
CAUTION
Q: Are joint connector (CAN1) C-06 and satellite radio
tuner connector C-17 in good condition?
YES : Go to Step 2.
TSB Revision
DIAGNOSIS
54C-95

(CAN1) C-06 and satellite radio tuner connector C-17.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and satellite radio
tuner connector C-17, and check the wiring harness.
C-06 (terminal 2) and satellite radio tuner connector C-17
(terminal 4)
(terminal 11)
C-06 and satellite radio tuner connector C-17 in good
condition?
YES : Check the power supply circuit of the satellite radio
tuner. Refer to GROUP 54A, Diagnosis <Satellite
radio tuner> P.54A-468.
TSB Revision
DIAGNOSIS
DIAGNOSTIC ITEM 19: Diagnose when the scan tool cannot receive the data sent by hands free
module.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
RADIO AND CD
MODULE CHANGER
JOINT CONNECTOR
(CAN1)
FRONT SEAT
ASSEMBLY (LH)
INTERFACE
ECU TUNER
CAN
TRANSCEIVER
CIRCUIT
CAN BOX UNIT
NOTE
TSB Revision
DIAGNOSIS
54C-97
Junction block
AC608145AM AC608152 AB
.

the hands free module, this diagnosis result will be
set.
.

If a communication flag is not set for the hands free
module, the ETACS-ECU determines that there is a
AC608146AG
failure.
.
(CAN1), hands free module connector improperly
connected]
between the hands free module connector and
to the hands free module]
Malfunction of the hands free module
DIAGNOSIS
STEP 1. Check joint connector (CAN1) C-06 and hands free

module connector C-110 for loose, corroded or damaged
CAUTION
Q: Are joint connector (CAN1) C-06 and hands free module
YES : Go to Step 2.
TSB Revision
DIAGNOSIS

(CAN1) C-06 and hands free module connector C-110.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and hands free
module connector C-301, and check the wiring harness.
C-06 (terminal 7) and hands free module connector C-110
(terminal 4)
(terminal 16)
C-06 and hands free module connector C-110 in good
condition?
YES : Check the power supply circuit of the hands free
module. Refer to GROUP 54A, Hands-free cellular
phone system Diagnosis <Hands-free cellular phone
system> P.54A-409.
(CAN1) C-06 and hands free module connector
C-110.
TSB Revision
DIAGNOSIS
54C-99
DIAGNOSTIC ITEM 20: Diagnose when the scan tool cannot receive the data sent by combination
meter.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
KOS-ECU
A/C-ECU
CAN DRIVE
CIRCUIT
JOINT CONNECTOR
(CAN1)

METER CONTROL
MODULE
TSB Revision
DIAGNOSIS
.
Connectors: C-04, C-06 TROUBLE JUDGEMENT CONDITIONS

C-06 If a communication flag is not set for the combination
C-04 meter, the ETACS-ECU determines that there is a
failure.
.
(CAN1), combination meter connector improperly
AC608145AU
connected]
between the combination meter connector and
.
FUNCTION
to the combination meter]
the combination meter, this diagnosis result will be
Malfunction of the combination meter
set.
DIAGNOSIS

combination meter connector C-04 for loose, corroded or
connector.
CAUTION
Q: Are joint connector (CAN1) C-06 and combination meter
YES : Go to Step 2.
TSB Revision
DIAGNOSIS
54C-101

(CAN1) C-06 and combination meter connector C-04.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and combination
meter connector C-301, and check the wiring harness.
C-06 (terminal 3) and combination meter connector C-04
(terminal 14)
(terminal 15)
C-06 and combination meter connector C-04 in good
condition?
YES : Check the power supply circuit of the combination
meter. Refer to GROUP 54A, combination meter
Diagnosis P.54A-53.
TSB Revision
DIAGNOSIS
DIAGNOSTIC ITEM 21: Short to power supply or ground in both CAN_H and CAN_L lines.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
KOS-ECU
A/C-ECU
CAN DRIVE
CIRCUIT
JOINT CONNECTOR
(CAN1)

METER CONTROL
MODULE
TSB Revision
DIAGNOSIS
54C-103
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
RADIO AND CD
MODULE CHANGER
JOINT CONNECTOR
(CAN1)
FRONT SEAT
ASSEMBLY (LH)
INTERFACE
ECU TUNER
CAN
TRANSCEIVER
CIRCUIT
CAN BOX UNIT
NOTE
TSB Revision
DIAGNOSIS
.
Connectors: C-04, C-06, C-31 FUNCTION

C-06 If a short to power supply or ground is present in both
C-04 CAN_H and CAN_L lines, this diagnosis result will be
set.
.
C-31
If a communication flag is set for the ETACS-ECU,
no communication is present through the CAN-B
AC608145AN
line, and diagnostic trouble code U0019 is set, the
Connector: C-301 .
Junction block
Malfunction of the connector (ETACS-ECU con-
nector improperly connected)
Malfunction of the wiring harness (CAN_H and
CAN_L lines are short to power supply or ground
on the CAN-B line.)
Malfunction of ECUs
AC608152 AB
DIAGNOSIS
TSB Revision
DIAGNOSIS
54C-105

connector C-301 and body ground for a short to power
supply. Measure the voltage at ETACS-ECU connector
C-301.
CAUTION
P.54C-7.
CAUTION
P.54C-7.
the voltage at the wiring harness side of ETACS-ECU
connector.
HARNESS
Harness side: C-301
AC608178 AL

HARNESS
YES : Go to Step 2.
NO : Go to Step 13.
Harness side: C-301
AC608178 AM
TSB Revision
DIAGNOSIS

(CAN1) C-06 and combination meter connector C-04 for a
short to ground. Measure the resistance at joint connector
(CAN1) C-06.
(CAN1).
HARNESS
Harness side: C-06
AC608179 AR

YES <vehicles with KOS> : Go to Step 3.
YES <vehicles with WCM> : Go to Step 4.
TEST NO (vehicles with KOS or WCM) : Go to Step 24.
HARNESS
AC608179 AS
TSB Revision
DIAGNOSIS
54C-107

(CAN1) C-06 and KOS-ECU connector C-31 for a short to
C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 AT

YES : Go to Step 5.
NO : Go to Step 25.
TEST
HARNESS
AC608179 AU
TSB Revision
DIAGNOSIS

(CAN1) C-06 and WCM connector C-09 for a short to
C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 AV

YES : Go to Step 5.
NO : Go to Step 26.
TEST
HARNESS
AC608179 AW
TSB Revision
DIAGNOSIS
54C-109

(CAN1) C-06 and SRS-ECU connector C-122 for a short to
C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 AX

YES : Go to Step 6.
NO : Go to Step 27.
TEST
HARNESS
AC608179 AY
TSB Revision
DIAGNOSIS

D-35-2 for a short to ground. Measure the resistance at
joint connector (CAN1) C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 AZ

OK: 1 kilo ohm or more
Harness side: C-06
YES (vehicles without hands free system) : Go to Step 8.
YES (vehicles with hands free system) : Go to Step 7.
TEST NO : Go to Step 28.
HARNESS
AC608179 BA
TSB Revision
DIAGNOSIS
54C-111

(CAN1) C-06 and hands free module connector C-110 for a
(CAN1) C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 BB

Harness side: C-06
YES : Go to Step 8.
NO : Go to Step 29.
TEST
HARNESS
AC608179 BC
TSB Revision
DIAGNOSIS

(CAN1) C-06 and A/C-ECU connector C-20 for a short to
C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 BD

YES (vehicles without MMCS) : Go to Step 9.
YES (vehicles with MMCS) : Go to Step 10.
HARNESS
AC608179 BE
TSB Revision
DIAGNOSIS
54C-113

connector C-104 for a short to ground. Measure the
resistance at joint connector (CAN1) C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 BF

YES <vehicles without satellite radio> : Go to Step 12.
YES <vehicles with satellite radio> : Go to Step 11.
HARNESS
AC608179 BG
TSB Revision
DIAGNOSIS
STEP 10. Check the wiring harness between joint

connector (CAN1) C-06 and CAN box unit connector C-108
for a short to ground. Measure the resistance at joint
(CAN1).
HARNESS
Harness side: C-06

AC608179 BF

YES (vehicles without satellite radio) : Go to Step 12.
YES (vehicles with satellite radio) : Go to Step 11.
HARNESS
AC608179 BG
TSB Revision
DIAGNOSIS
54C-115

connector (CAN1) C-06 and satellite radio tuner connector
C-17 for a short to ground. Measure the resistance at joint
(CAN1).
HARNESS
Harness side: C-06

AC608179 BH

NO : Go to Step 33.
TEST
HARNESS
AC608179 BI
TSB Revision
DIAGNOSIS

connector (CAN1) C-06 and ETACS-ECU connector C-301
connector C-301, and measure the resistance at the wiring
harness side of joint connector (CAN1).
HARNESS
Harness side: C-06

AC608179 BJ

TEST (CAN1) C-06 and ETACS-ECU connector C-301.
HARNESS
AC608179 BK
TSB Revision
DIAGNOSIS
54C-117

connector (CAN1) C-06 and combination meter connector
C-04 for a short to power supply. Measure the voltage at
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06
AC608178 AN

YES (vehicles with KOS) : Go to Step 14.
YES (vehicles with WCM) : Go to Step 15.
TEST NO (vehicles with KOS and WCM) : Go to Step 24.
HARNESS
AC608178 AO
TSB Revision
DIAGNOSIS

connector (CAN1) C-06 and KOS-ECU connector C-31 for a
short to power supply. Measure the voltage at joint
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 AP

NO : Go to Step 25.
TEST
HARNESS
AC608178 AQ
TSB Revision
DIAGNOSIS
54C-119

connector (CAN1) C-06 and WCM connector C-09 for a
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 AR

NO : Go to Step 26.
TEST
HARNESS
AC608178 AS
TSB Revision
DIAGNOSIS

connector (CAN1) C-06 and SRS-ECU connector C-122 for
a short to power supply. Measure the voltage at joint
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 AT

NO : Go to Step 27.
TEST
HARNESS
AC608178 AU
TSB Revision
DIAGNOSIS
54C-121

connector (CAN1) C-06 and occupant classification-ECU
connector D-35-2 for a short to power supply. Measure the
voltage at joint connector (CAN1) C-06.
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 AV

YES (vehicles without hands free system) : Go to Step
19.
TEST YES (vehicles with hands free system) : Go to Step 18.
HARNESS NO : Go to Step 28.
AC608178 AW
TSB Revision
DIAGNOSIS

connector (CAN1) C-06 and hands free module connector
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 AX

NO : Go to Step 29.
TEST
HARNESS
AC608178 AY
TSB Revision
DIAGNOSIS
54C-123

connector (CAN1) C-06 and A/C-ECU connector C-20 for a
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 AZ

HARNESS
AC608178 BA
TSB Revision
DIAGNOSIS

connector (CAN1) C-06 and radio and CD player or CD
changer connector C-104 for a short to power supply.
Measure the voltage at joint connector (CAN1) C-06.
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 BB

HARNESS
AC608178 BC
TSB Revision
DIAGNOSIS
54C-125

for a short to power supply. Measure the voltage at joint
CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 BB

HARNESS
AC608178 BC
TSB Revision
DIAGNOSIS

CAUTION
P.54C-7.
CAUTION
P.54C-7.
(CAN1).
HARNESS
Harness side: C-06

AC608178 BD

NO : Go to Step 33.
TEST
HARNESS
AC608178 BE
TSB Revision
DIAGNOSIS
54C-127

CAUTION
P.54C-7.
CAUTION
P.54C-7.
connector C-301, and measure the voltage at the wiring
HARNESS
Harness side: C-06

AC608178 BF

HARNESS
AC608178 BG
TSB Revision
DIAGNOSIS

bus line. (checking the combination meter for internal
failure)
CAUTION
CAUTION
(1) Disconnect combination meter connector C-04.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
YES : Repair the wiring harness between joint connector
NO : Check combination meter connector C-04, and repair
AC608017AD
if necessary. If the combination meter connector is in
good condition, replace the combination meter.
TSB Revision
DIAGNOSIS
54C-129

bus line. (checking the KOS-ECU for internal failure)
CAUTION
CAUTION
(1) Disconnect KOS-ECU connector C-31.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check KOS-ECU connector C-31, and repair if
AC608017AD
necessary. If the KOS-ECU connector is in good
condition, replace the KOS-ECU.
TSB Revision
DIAGNOSIS

bus line. (checking the WCM for internal failure)
CAUTION
CAUTION
(1) Disconnect WCM connector C-09.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check WCM connector C-09, and repair if necessary.
AC608017AD
If the WCM connector is in good condition, replace
the WCM.
TSB Revision
DIAGNOSIS
54C-131

bus line. (checking the SRS-ECU for internal failure)
CAUTION
CAUTION
(1) Disconnect SRS-ECU connector C-122.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check SRS-ECU connector C-122, and repair if
AC608017AD
necessary. If the SRS-ECU connector is in good
condition, replace the SRS-ECU.
TSB Revision
DIAGNOSIS

bus line. (checking the occupant classification-ECU for
internal failure)
CAUTION
CAUTION
(1) Disconnect occupant classification-ECU connector D-35-2.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
connector D-35-2.
AC608017AD
NO : Check occupant classification-ECU connector D-35-2,
and repair if necessary. If the occupant
classification-ECU connector is in good condition,
replace the occupant classification-ECU.
TSB Revision
DIAGNOSIS
54C-133

bus line. (checking the hands free module for internal
failure)
CAUTION
CAUTION
(1) Disconnect hands free module connector C-110.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
C-110.
AC608017AD
NO : Check hands free module connector C-110, and
repair if necessary. If the hands free module
connector is in good condition, replace the hands free
module.
TSB Revision
DIAGNOSIS

bus line. (checking the A/C-ECU for internal failure)
CAUTION
CAUTION
(1) Disconnect A/C-ECU connector C-20.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check A/C-ECU connector C-20, and repair if
AC608017AD
necessary. If the A/C-ECU connector is in good
condition, replace the A/C-ECU.
TSB Revision
DIAGNOSIS
54C-135

bus line. (checking the radio and CD player or CD changer
for internal failure)
CAUTION
CAUTION
(1) Disconnect radio and CD player or CD changer connector
C-104.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
connector C-104.
AC608017AD
NO : Check radio and CD player or CD changer connector
C-104, and repair if necessary. If the radio and CD
player or CD changer connector is in good condition,
replace the radio and CD player or CD changer.
TSB Revision
DIAGNOSIS

bus line. (checking the CAN box unit for internal failure)
CAUTION
CAUTION
(1) Disconnect CAN box unit connector C-108.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check CAN box unit connector C-108, and repair if
AC608017AD
necessary. If the CAN box unit connector is in good
condition, replace the CAN box unit.
TSB Revision
DIAGNOSIS
54C-137

bus line. (checking the satellite radio tuner for internal
failure)
CAUTION
CAUTION
(1) Disconnect satellite radio tuner connector C-17.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check satellite radio tuner connector C-17, and repair
AC608017AD
if necessary. If the satellite radio tuner connector is in
good condition, replace the satellite radio tuner.
TSB Revision
DIAGNOSIS

bus line. (trouble symptom check)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AB
NO : Check the ETACS-ECU connector C-301, and repair
if necessary. If the ETACS-ECU connector is in good
TSB Revision
DIAGNOSIS
54C-139
DIAGNOSTIC ITEM 22: Diagnose the ETACS-ECU, joint connector (CAN1) or lines between
ETACS-ECU and joint connector (CAN1).
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
RADIO AND CD
MODULE CHANGER
JOINT CONNECTOR
(CAN1)
FRONT SEAT
ASSEMBLY (LH)
INTERFACE
ECU TUNER
CAN
TRANSCEIVER
CIRCUIT
CAN BOX UNIT
NOTE
TSB Revision
DIAGNOSIS
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
KOS-ECU
A/C-ECU
CAN DRIVE
CIRCUIT
JOINT CONNECTOR
(CAN1)

METER CONTROL
MODULE

Junction block
AC608145AM AC608152 AB
.
TSB Revision
DIAGNOSIS
54C-141
FUNCTION
.
If a failure is present in the wiring harness wires Malfunction of the connector [joint connector
between the ETACS-ECU connector, the joint con- (CAN1) or ETACS-ECU connector improperly
nector (CAN1), the ETACS-ECU connector and the connected]
joint connector (CAN1), this diagnosis result will be Malfunction of the wiring harness [open circuit
set. between the ETACS-ECU connector and the joint
.
connector (CAN1)]
TROUBLE JUDGEMENT CONDITIONS Malfunction of the ETACS-ECU
If a communication flag is set for none of the ECUs
on the CAN-B line, the ETACS-ECU determines that
there is a failure.
DIAGNOSIS

EATCS-ECU connector C-301 for loose, corroded or
connector.
CAUTION
Q: Are joint connector (CAN1) C-06 and ETACS-ECU
YES : Go to Step 2.

CAUTION
(terminal 6)
(terminal 7)
condition?
YES : Go to Step 3.
TSB Revision
DIAGNOSIS

line. (trouble symptom check)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AB
TSB Revision
DIAGNOSIS
54C-143
DIAGNOSTIC ITEM 23: Short to power supply or ground, open circuit or line-to-line short in the
CAN-B bus lines.
CAUTION
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
RADIO AND CD
MODULE CHANGER
JOINT CONNECTOR
(CAN1)
FRONT SEAT
ASSEMBLY (LH)
INTERFACE
ECU TUNER
CAN
TRANSCEIVER
CIRCUIT
CAN BOX UNIT
NOTE
TSB Revision
DIAGNOSIS
ETACS-ECU
INTERFACE CAN DRIVE
CIRCUIT CIRCUIT
KOS-ECU
A/C-ECU
CAN DRIVE
CIRCUIT
JOINT CONNECTOR
(CAN1)

METER CONTROL
MODULE
Connectors: C-04, C-06, C-09, C-31, C-122 Connectors: C-17, C-20, C-104, C-108, C-110
C-104 C-108
C-06
C-04 C-110
C-17
C-31 C-09
C-20 (B)
C-122 (Y)
AC608145AO AC608146AE
TSB Revision
DIAGNOSIS
54C-145
.

Junction block
If a short to power supply or ground, open circuit or
line-to-line short is present at either CAN_H or
CAN_L side on the CAN-B lines, this diagnosis result
will be set.
.

When CAN-B lines communication is normal, and
AC608152 AB
diagnostic trouble code U0019 is set, the
Connector: D-35-2 .
Malfunction of the connector (short to power sup-
ply or ground in connector or improperly con-
nected)
Malfunction of the wiring harness (short to power
supply or ground, open circuit or line-to-line short
in CAN bus lines)
Faulty ECU(s) (internal short to power supply or
AC608165AC ground)
DIAGNOSIS
TSB Revision
DIAGNOSIS

connector C-301 and body ground for a short to ground.
Measure the resistance at ETACS-ECU connector C-301.
CAUTION
to P.54C-7.
CAUTION
P.54C-7.
CAUTION
P.54C-7.
connector.
(2) Measure the resistance between ETACS-ECU connector
HARNESS
Harness side: C-301

AC608179 BL
(3) Measure the resistance between ETACS-ECU connector

HARNESS
YES : Go to Step 2.
NO : Go to Step 13.
Harness side: C-301

AC608179 BM
TSB Revision
DIAGNOSIS
54C-147

(CAN1) C-06 and combination meter connector C-04 for a
(CAN1) C-06.
(CAN1).
HARNESS
Harness side: C-06
AC608179 AR

TEST NO (vehicles with KOS or WCM) : Go to Step 48.
HARNESS
AC608179 AS
TSB Revision
DIAGNOSIS

(CAN1) C-06 and KOS-ECU connector C-31 for a short to
C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 AT

YES : Go to Step 5.
NO : Go to Step 49.
TEST
HARNESS
AC608179 AU
TSB Revision
DIAGNOSIS
54C-149

(CAN1) C-06 and WCM connector C-09 for a short to
C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 AV

YES : Go to Step 5.
NO : Go to Step 50.
TEST
HARNESS
AC608179 AW
TSB Revision
DIAGNOSIS

(CAN1) C-06 and SRS-ECU connector C-122 for a short to
C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 AX

YES : Go to Step 6.
NO : Go to Step 51.
TEST
HARNESS
AC608179 AY
TSB Revision
DIAGNOSIS
54C-151

D-35-2 for a short to ground. Measure the resistance at
(CAN1).
HARNESS
Harness side: C-06

AC608179 AZ

Harness side: C-06
YES (vehicles without hands free system) : Go to Step 8.
HARNESS
AC608179 BA
TSB Revision
DIAGNOSIS

(CAN1) C-06 and hands free module connector C-110 for a
(CAN1) C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 BB

Harness side: C-06
YES : Go to Step 8.
NO : Go to Step 53.
TEST
HARNESS
AC608179 BC
TSB Revision
DIAGNOSIS
54C-153

(CAN1) C-06 and A/C-ECU connector C-20 for a short to
C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608179 BD

HARNESS
AC608179 BE
TSB Revision
DIAGNOSIS

connector C-104 for a short to ground. Measure the
(CAN1).
HARNESS
Harness side: C-06

AC608179 BF

HARNESS
AC608179 BG
TSB Revision
DIAGNOSIS
54C-155

(CAN1).
HARNESS
Harness side: C-06

AC608179 BF

HARNESS
AC608179 BG
TSB Revision
DIAGNOSIS

C-17 for a short to ground. Measure the resistance at joint
(CAN1).
HARNESS
Harness side: C-06

AC608179 BH

NO : Go to Step 57.
TEST
HARNESS
AC608179 BI
TSB Revision
DIAGNOSIS
54C-157

connector C-301, and measure the resistance at the wiring
HARNESS
Harness side: C-06

AC608179 BJ

HARNESS
AC608179 BK
TSB Revision
DIAGNOSIS

connector C-301 and body ground for a short to power
supply. Measure the voltage at ETACS-ECU connector
C-301.
connector.
HARNESS
Harness side: C-301
AC608178 AL

HARNESS
NO : Go to Step 14.
Harness side: C-301
AC608178 AM
TSB Revision
DIAGNOSIS
54C-159

(CAN1).
(2) Connect the negative battery terminal.
HARNESS
Harness side: C-06
AC608178 AN

TEST NO (vehicles with KOS and WCM) : Go to Step 48.
HARNESS
AC608178 AO
TSB Revision
DIAGNOSIS

connector (CAN1) C-06 and KOS-ECU connector C-31 for a
(CAN1).
HARNESS
Harness side: C-06

AC608178 AP

NO : Go to Step 49.
TEST
HARNESS
AC608178 AQ
TSB Revision
DIAGNOSIS
54C-161

connector (CAN1) C-06 and WCM connector C-09 for a
(CAN1).
HARNESS
Harness side: C-06

AC608178 AR

NO : Go to Step 50.
TEST
HARNESS
AC608178 AS
TSB Revision
DIAGNOSIS

a short to power supply. Measure the voltage at joint
(CAN1).
HARNESS
Harness side: C-06

AC608178 AT

NO : Go to Step 51.
TEST
HARNESS
AC608178 AU
TSB Revision
DIAGNOSIS
54C-163

connector D-35-2 for a short to power supply. Measure the
voltage at joint connector (CAN1) C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608178 AV

20.
TEST YES (vehicles with hands free system) : Go to Step 19.
AC608178 AW
TSB Revision
DIAGNOSIS

(CAN1).
HARNESS
Harness side: C-06

AC608178 AX

NO : Go to Step 53.
TEST
HARNESS
AC608178 AY
TSB Revision
DIAGNOSIS
54C-165

connector (CAN1) C-06 and A/C-ECU connector C-20 for a
(CAN1).
HARNESS
Harness side: C-06

AC608178 AZ

HARNESS
AC608178 BA
TSB Revision
DIAGNOSIS

changer connector C-104 for a short to power supply.
Measure the voltage at joint connector (CAN1) C-06.
(CAN1).
HARNESS
Harness side: C-06

AC608178 BB

HARNESS
AC608178 BC
TSB Revision
DIAGNOSIS
54C-167

(CAN1).
HARNESS
Harness side: C-06

AC608178 BB

HARNESS
AC608178 BC
TSB Revision
DIAGNOSIS

(CAN1).
HARNESS
Harness side: C-06

AC608178 BD

NO : Go to Step 57.
TEST
HARNESS
AC608178 BE
TSB Revision
DIAGNOSIS
54C-169

connector C-301, and measure the voltage at the wiring
HARNESS
Harness side: C-06

AC608178 BF

HARNESS
AC608178 BG
STEP 25. Check the wiring harness for line-to-line short.

Measure the resistance at ETACS-ECU connector C-301
CAUTION
to P.54C-7.
(1) Disconnect ETACS-ECU connector C-301, and check that
there is continuity at the harness side of ETACS-ECU.
(2) Check that there is continuity between ETACS-ECU
Harness side: C-301 connector terminals 6 and 7.
OK: No continuity
TEST Q: Is the check result normal?
HARNESS
TEST YES : Go to Step 37.
AC608179 BN
TSB Revision
DIAGNOSIS

C-04 for line-to-line short. Measure the resistance at joint
HARNESS
NO (vehicles with KOS or WCM) : Go to Step 48.
TEST
HARNESS
AC608179 BO

connector (CAN1) C-06 and KOS-ECU connector C-31 for
HARNESS
NO : Go to Step 49.
TEST
HARNESS
AC608179 BP

connector (CAN1) C-06 and WCM connector C-09 for
HARNESS
NO : Go to Step 50.
TEST
HARNESS
AC608179 BQ
TSB Revision
DIAGNOSIS
54C-171

HARNESS
NO : Go to Step 51.
TEST
HARNESS
AC608179 BR

connector D-35-2 for line-to-line short. Measure the
HARNESS
32.
TEST
AC608179 BS

HARNESS
NO : Go to Step 53.
TEST
HARNESS
AC608179 BT
TSB Revision
DIAGNOSIS

connector (CAN1) C-06 and A/C-ECU connector C-20 for
(2) Check that there is continuity between joint connector
Harness side: C-06
HARNESS
NO : Go to Step 54.
TEST
HARNESS
AC608179 BU

changer connector C-104 for line-to-line short. Measure
the resistance at joint connector (CAN1) C-06.
HARNESS
NO : Go to Step 55.
TEST
HARNESS
AC608179 BV

for line-to-line short. Measure the resistance at joint
HARNESS
NO : Go to Step 56.
TEST
HARNESS
AC608179 BV
TSB Revision
DIAGNOSIS
54C-173

HARNESS
NO : Go to Step 57.
TEST
HARNESS
AC608179 BW

connector (CAN1) C-06 and EATCS-ECU connector C-301
for line-to-line short. Measure the resistance at joint
connector C-301, and check that there is continuity at the
HARNESS
TEST
HARNESS
AC608179 BX
TSB Revision
DIAGNOSIS

C-04.
CAUTION
(1) Disconnect joint connector (CAN1) C-06 and combination
meter connector C-301, and check the wiring harness.
(terminal 14)
(terminal 15)
C-06 and combination meter connector C-04 in good
condition?
NO ((vehicles with KOS or WCM) : Go to Step 48.

connector (CAN1) C-06 and KOS-ECU connector C-31.
(1) Disconnect joint connector (CAN1) C-06 and KOS-ECU
1)
2)
C-06 and KOS-ECU connector C-31 in good condition?
NO : Go to Step 49.

connector (CAN1) C-06 and WCM connector C-09.
(1) Disconnect joint connector (CAN1) C-06 and WCM
C-06 and WCM connector C-09 in good condition?
NO : Go to Step 50.
TSB Revision
DIAGNOSIS
54C-175

connector (CAN1) C-06 and SRS-ECU connector C-122.
(1) Disconnect joint connector (CAN1) C-06 and SRS-ECU
C-06 (terminal 8) and SRS-ECU connector C-122 (terminal
10)
C-06 (terminal 21) and SRS-ECU connector C-122
(terminal 9)
C-06 and SRS-ECU connector C-122 in good condition?
NO : Go to Step 51.

connector D-35-2.
classification-ECU connector D-35-2, and check the wiring
harness.
C-06 and occupant classification-ECU connector D-35-2
in good condition?
43.
NO : Go to Step 52.

C-110.
hands free module connector C-110, and check the wiring
harness.
(terminal 4)
(terminal 16)
C-06 and hands free module connector C-110 in good
condition?
NO : Go to Step 53.
TSB Revision
DIAGNOSIS

connector (CAN1) C-06 and A/C-ECU connector C-20.
(1) Disconnect joint connector (CAN1) C-06 and A/C-ECU
11)
12)
NO : Go to Step 54.

changer connector C-104.
(1) Disconnect joint connector (CAN1) C-06 and radio and CD
player or CD changer connector C-104, and check the
wiring harness.
C-06 and radio and CD player or CD changer connector
NO : Go to Step 55.

connector (CAN1) C-06 and CAN box unit connector C-108.
(1) Disconnect joint connector (CAN1) C-06 and CAN box unit
(terminal 8)
(terminal 9)
C-06 and CAN box unit connector C-108 in good
condition?
NO : Go to Step 56.
TSB Revision
DIAGNOSIS
54C-177

C-17.
(1) Disconnect joint connector (CAN1) C-06 and satellite radio
tuner connector C-17, and check the wiring harness.
(terminal 4)
(terminal 11)
C-06 and satellite radio tuner connector C-17 in good
condition?
NO : Go to Step 57.

connector (CAN1) C-06 and ETACS-ECU connector C-301.
(terminal 6)
(terminal 7)
condition?
TSB Revision
DIAGNOSIS

bus line. (checking the combination meter for internal
failure)
CAUTION
CAUTION
(1) Disconnect combination meter connector C-04.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check combination meter connector C-04, and repair
AC608017AD
if necessary. If the combination meter connector is in
good condition, replace the combination meter.
TSB Revision
DIAGNOSIS
54C-179

bus line. (checking the KOS-ECU for internal failure)
CAUTION
CAUTION
(1) Disconnect KOS-ECU connector C-31.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check KOS-ECU connector C-31, and repair if
AC608017AD
necessary. If the KOS-ECU connector is in good
condition, replace the KOS-ECU.
TSB Revision
DIAGNOSIS

bus line. (checking the WCM for internal failure)
CAUTION
CAUTION
(1) Disconnect WCM connector C-09.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check WCM connector C-09, and repair if necessary.
AC608017AD
If the WCM connector is in good condition, replace
the WCM.
TSB Revision
DIAGNOSIS
54C-181

bus line. (checking the SRS-ECU for internal failure)
CAUTION
CAUTION
(1) Disconnect SRS-ECU connector C-122.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check SRS-ECU connector C-122, and repair if
AC608017AD
necessary. If the SRS-ECU connector is in good
condition, replace the SRS-ECU.
TSB Revision
DIAGNOSIS

bus line. (checking the occupant classification-ECU for
internal failure)
CAUTION
CAUTION
(1) Disconnect occupant classification-ECU connector D-35-2.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
connector D-35-2.
AC608017AD
NO : Check occupant classification-ECU connector D-35-2,
and repair if necessary. If the occupant
classification-ECU connector is in good condition,
replace the occupant classification-ECU.
TSB Revision
DIAGNOSIS
54C-183

bus line. (checking the hands free module for internal
failure)
CAUTION
CAUTION
(1) Disconnect hands free module connector C-110.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
C-110.
AC608017AD
NO : Check hands free module connector C-110, and
repair if necessary. If the hands free module
connector is in good condition, replace the hands free
module.
TSB Revision
DIAGNOSIS

bus line. (checking the A/C-ECU for internal failure)
CAUTION
CAUTION
(1) Disconnect A/C-ECU connector C-20.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check A/C-ECU connector C-20, and repair if
AC608017AD
necessary. If the A/C-ECU connector is in good
condition, replace the A/C-ECU.
TSB Revision
DIAGNOSIS
54C-185

bus line. (checking the radio and CD player or CD changer
for internal failure)
CAUTION
CAUTION
(1) Disconnect radio and CD player or CD changer connector
C-104.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
connector C-104.
AC608017AD
NO : Check radio and CD player or CD changer connector
C-104, and repair if necessary. If the radio and CD
player or CD changer connector is in good condition,
replace the radio and CD player or CD changer.
TSB Revision
DIAGNOSIS

bus line. (checking the CAN box unit for internal failure)
CAUTION
CAUTION
(1) Disconnect CAN box unit connector C-108.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check CAN box unit connector C-108, and repair if
AC608017AD
necessary. If the CAN box unit connector is in good
condition, replace the CAN box unit.
TSB Revision
DIAGNOSIS
54C-187

bus line. (checking the satellite radio tuner for internal
failure)
CAUTION
CAUTION
(1) Disconnect satellite radio tuner connector C-17.
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
NO : Check satellite radio tuner connector C-17, and repair
AC608017AD
if necessary. If the satellite radio tuner connector is in
good condition, replace the satellite radio tuner.
TSB Revision
DIAGNOSIS

bus line. (trouble symptom check)
CAUTION
CAUTION
Data link connector
MB991910
MB991824
MB991827 AC608435 AB
ETACS
J/C (2)
J/C (3)
illustration?
AC608017AB
NO : Check the ETACS-ECU connector C-301, and repair
if necessary. If the ETACS-ECU connector is in good
TSB Revision
DIAGNOSIS
54C-189
CAN COMMUNICATION-RELATED DTC (U-CODE) TABLE
M1548300300546
Code Diagnostic item Output ECU Action

No.
U0001 Bus Off (CAN-C) ECM, TCM, ABS-ECU, ETACS-ECU CAN main bus line
U0019 Bus Off (CAN-B) KOS-ECU or WCM, SRS-ECU, diagnostics
Combination meter, radio and CD player
or CD changer, CAN box unit, Satellite
radio tuner, ETACS-ECU, A/C-ECU
U0020 CAN-B Bus off performance Occupant classification-ECU
U0021 CAN-B Bus(+) circuit open
U0022 CAN-B Bus(+) shorted to circuit
ground
U0023 CAN-B Bus(+) shorted to circuit
Power Supply
U0024 CAN-B Bus(-) circuit Open
U0025 CAN-B Bus(-) shorted to circuit
ground
U0026 CAN-B Bus(-) shorted to circuit
Power Supply
U0100 Engine time-out TCM, ABS-ECU, Combination meter,
ETACS-ECU
U0101 CVT time-out ECM, ETACS-ECU
U0121 ABS-ECU time-out ECM, TCM, ETACS-ECU
U0141 ETACS-ECU time-out ECM, TCM, ABS-ECU, KOS-ECU or
WCM, SRS-ECU, Occupant
classification-ECU, Combination meter,
CAN box unit, Satellite radio tuner,
A/C-ECU
U0151 SRS time-out KOS-ECU or WCM, Occupant
classification-ECU, Combination meter,
radio and CD player or CD changer,
CAN box unit, Satellite radio tuner,
ETACS-ECU, A/C-ECU
U0154 Occupant Classification-ECU KOS-ECU or WCM, SRS-ECU,
time-out Combination meter, radio and CD player
U0155 Meter time-out KOS-ECU or WCM, SRS-ECU,
Occupant classification-ECU, radio and
CD player or CD changer, CAN box unit,
Satellite radio tuner, ETACS-ECU,
A/C-ECU
U0164 A/C time-out KOS-ECU or WCM, SRS-ECU,
Occupant classification-ECU,
radio tuner, ETACS-ECU
TSB Revision
DIAGNOSIS
Code Diagnostic item Output ECU Action

No.
U0167 CAN immobilizer ECM CAN main bus line
(communication) diagnostics
U0168 WCM/KOS time-out SRS-ECU, Occupant classification-ECU,
U0184 Audio unit time-out KOS-ECU or WCM, SRS-ECU,
Combination meter, Satellite radio tuner,
ETACS-ECU, A/C-ECU
U0195 Satellite radio tuner time-out KOS-ECU or WCM, SRS-ECU,
Occupant classification-ECU, radio and
ETACS-ECU, A/C-ECU
U0197 Hands free module time-out KOS-ECU or WCM, SRS-ECU,
U0245 Audio visual navigation unit KOS-ECU or WCM, Occupant
time-out classification-ECU, Combination meter,
ETACS-ECU
U1180 Combination meter time-out ECM
U1108 Excess CAN-B ECU detection ETACS-ECU Diagnose CAN main
U1120 Bus line (CAN-C) low input bus lines and confirm
input signals.
U1121 Bus line (CAN-C) high input
U1412 Implausible vehicle speed signal KOS-ECU or WCM
received
U1414 Defective coding data SRS-ECU
U1415 Coding not completed/Data fail ABS-ECU, KOS-ECU or WCM,
SRS-ECU, Combination meter, radio and
A/C-ECU
U1417 Implausible coding data ABS-ECU, KOS-ECU or WCM, CAN box
unit
TSB Revision
54C-1
GROUP 54C
CONTROLLER
AREA NETWORK
(CAN)
CONTENTS
GENERAL INFORMATION . . . . . . . . 54C-2 SELF-DIAGNOSIS . . . . . . . . . . . . . . . 54C-6
STRUCTURE . . . . . . . . . . . . . . . . . . . 54C-3 CAN BUS DIAGNOSTICS . . . . . . . . . 54C-7
SYSTEM OPERATION. . . . . . . . . . . . 54C-4

GENERAL INFORMATION
GENERAL INFORMATION
M2542000100308
CAN, an abbreviation for Controller Area Network, is CAN offers the following advantages.
an ISO-certified international standard for a serial Transmission rates are much faster than those in
multiplex communication protocol*. A communication conventional communication (up to 1 Mbps),
circuit employing the CAN protocol connects each allowing much more data to be sent.
ECU, and sensor data can be shared among, which It is exceptionally immune to noise, and the data
enables more reduction in wiring. obtained from each error detection device is more
reliable.
NOTE: *: The regulations have been decided in
Each ECU connected via the CAN communicates
detail, from software matters such as the necessary
independently, therefore if the ECU enters dam-
transmission rate for communication, the system,
aged mode, communications can be continued in
data format, and communication timing control
some cases.
method to hardware matters such as the harness
type and length and the resistance values.
STRUCTURE
54C-3
STRUCTURE
M2542000200479
TERMINAL RESISTOR
ETACS-ECU
CAN_L CAN_H
WCM OR
SRS-ECU
KOS-ECU
DATA LINK
ABS-ECU CONNECTOR
OCCUPANT
CLASSIFICATION- A/C-ECU
ECU M.U.T.-III
DIAGNOSIS CAN-C
HANDS-FREE RADIO AND
TCM MODULE CD PLAYER OR
CD CHANGER
SATELLITE
CAN BOX
RADIO
UNIT
TUNER
MAIN BUS LINE
CAN_L CAN_H
CAN_L CAN_H
MAIN BUS LINE
COMBINATION
TERMINAL ECM METER
RESISTOR
: INDICATES MAIN BUS LINE
: INDICATES SUB BUS LINE
CAN-C CAN-B
AC608015AB
A gateway function has been integrated to The CAN bus line connecting two dominant
ETACS-ECU as the network central ECU. (Refer ECUs is the main bus line, and the CAN bus line
to GROUP 54A, ETACS-ECU P.54A-31.) connecting each ECU is the sub-bus line.
The CAN system consists of the following three With CAN-C, the terminal resistors are incorpo-
networks: CAN-B (middle-speed body network), rated in ECU. Resistors with approximately 120
CAN-C (high-speed power train network), and the ohms is used for the dominant ECU, and that with
diagnosis CAN-C (diagnosis exclusive network). 4.7 kiloohms is used for the non-dominant ECU.
Each ECU is connected to one of the networks NOTE: .
depending on its functions. Dominant ECU: ETACS-ECU and engine
The CAN bus line consists of two lines, CAN_L ECU
and CAN_H (CAN Low and CAN High, respec- Non-dominant ECU: ECU and sensor on
tively), as well as two terminal resistors (A CAN-C network, excluding ETACS-ECU and
twisted-pair cable, highly resistant to noise, is engine ECU
used for the communications line).
SYSTEM OPERATION
To the CAN bus line, ECU, sensor, and data link CAN box unit <vehicles with Mitsubishi
connector are connected as follows for each net- Multi-Communication System (MMCS)>
work. Hands-free module <vehicles with hands-free
CAN-B system>
Wireless control module (WCM) <vehicles Satellite radio tuner <vehicles with satellite
without KOS> radio>
KOS-ECU <vehicles with KOS> Combination meter
SRS-ECU CAN-C
Occupant classification-ECU ABS-ECU <vehicles with ABS>
A/C-ECU Transaxle control module (TCM)
Radio and CD player or CD changer <vehi- Engine control module (ECM)
cles without Mitsubishi Multi-Communication DIAGNOSIS CAN-C
System (MMCS)> Data link connector
SYSTEM OPERATION
M2542000300272
Data frames
A A A A
ECU-1
Interval "a"
B B B
ECU-1
Transmission
Interval "b" suspended by
mediation
C C C
ECU-2
Interval "c" Re-

transmission
A B C A B A C B A
CAN bus
AC206267
AC206267AD
The CAN communication system is described below. A single ECU transmits multiple data frames.
Each ECU communicating with CAN periodically When data frames conflict with one another
sends several sensors information on CAN bus (when plural ECUs transmit signals simulta-
as data frame (called periodical sending data). neously), data is prioritised for transmission by
For further details, consult the data frame section. mediation, therefore, plural data frames are not
ECUs requiring data on CAN bus can receive sent simultaneously. For further details, consult
data frames sent from each ECU simultaneously. the mediation section.
The data sent from each ECU conducting CAN Data is transmitted not by the conventional volt-
communication is transmitted at 10-1000 msec age-using method but by voltage potential differ-
interval depending on necessity of data. ence. For further details, consult the section on
NOTE: In the figure above, the data frame A is CAN bus voltage transformation .
transmitted in "a" intervals, while the data frames
B and C are transmitted at intervals "b" and "c,"
respectively.
SYSTEM OPERATION
54C-5
Reliability of each ECU transmitting signals via 1. Data frame with high priority is transmitted first
CAN communication is secured by several error according to ID codes memorized in data frames.
detection and recovery processes. For further 2. Transmission of low-priority data (data frames) is
details, consult the sections on error detection suspended by the issuing ECUs until the bus
and system recovery. clears (when no transmission data exists on the
For major communication signals (transmitting CAN bus).
signals) among ECUs.
.
NOTE: If the suspended state continues for a
MEDIATION specific time, new data (data frame content) is
Because each ECU transmits data independently on created and sent.
the CAN bus, there are cases of data collision when 3. ECU containing suspended data frames trans-
multiple data frames that ECUs attempt to transmit mits the data when the bus becomes available.
simultaneously (if multiple ECUs transmit at nearly NOTE: There is enough capacity on the CAN bus,
the same moment). At this moment, processing of which never prevents data frames from being sent.
the ECUs attempting transmission is performed in .
the following way.

VOLTAGE TRANSFORMATION ON THE CAN-B BUS and CAN-C BUS
<CAN-C> <CAN-B>
CAN_L 5V
VOLTAGE 3.5 V
4V
TRANSFORMATION
IN CAN_H
2.5 V
VOLTAGE 1V
TRANSFORMATION CAN_H 0V
IN CAN_L 1.5 V
RECESSIVE DOMINANT RECESSIVE RECESSIVE DOMINANT RECESSIVE

STATE:
0 0
LOGIC VALUE:
1 1
AC507623AB
The voltage transformation (output signal) when the sends 0 to 4 V signals to the CAN_H side, and 1 to 5
data frame is sent to the CAN-C bus line has a dis- V signals to the CAN_L side. "Recessive" is a state
tinctive CAN-C profile. The transmitting ECU through in which CAN_H is at 0 V and CAN_L is at 5 V, and
the CAN_H and CAN_L bus lines sends 2.5 to 3.5 V "Dominant" is a state in which CAN_H is at 4 V and
signals to the CAN_H side and 2.5 to 1.5 V signals to CAN_L is at 1 V. By transformation mainly to 2.5 V,
the CAN_L side. The receiving ECU reads the data even in cases when voltage is rendered 0 from faulty
from the CAN_H and CAN_L potential difference. grounding or the like (causing a problem of an
"Recessive" refers to the state where both CAN_H approximate 0.5 V increase on the communications
and CAN_L are under the 2.5-V state, and "Domi- line), communication can be continued uninter-
nant" refers to the state where CAN_H is under the rupted. Employing dual communications lines
3.5-V state and CAN_L is under the 1.5-V state. On improves reliability to prevent the presence of noise,
the other hand, the voltage transformation (output compared to the conventional communication
signal) when the data frame is sent to the CAN-B bus method.
line has a distinctive CAN-B profile. The transmitting .
ECU through the CAN_H and CAN_L bus lines

SELF-DIAGNOSIS
DATA FRAMES
DATA FRAMES
ID CONTROL CRC ACK

SOF DATA REGION EOF
REGION REGION REGION REGION
AC504950AB
SOF (Start of Frame) ACK (Acknowledge) region

Indicates the start of the frame Region where to conform the reception of sent
data
ID (Identifier) region
Identifies the data content while specifying prior- EOF (End of Frame)
ity rank in case of mediation Indicates the end of the frame
Control region .
Specifies the frame type, data length, etc. ERROR DETECTION AND RECOVERY
CAN protocol secures its reliability of communication
Data region
by providing several error detection function such as
Values used for data control, etc.
CRC shown in data frame, and the recovery function
Cyclic Redundancy Check (CRC) region (recovery is performed by resending, from abnormal
Region where to check for errors in sent data. state such as transmission errors). If an error is
The transmitting ECU calculates data regions by detected but it is not resolved even after recovery,
applying prescribed operations and stores the communication is stopped. This state is called "Bus
results. The receiving ECU detects erroneous Off."
communication by comparing the CRC region
with the data region.
SELF-DIAGNOSIS
M2542000400235
CAN self-diagnosis is performed by each ECU TIME-OUT
connected to the CAN bus. Each ECU transmits data frames periodically. If the
diagnosis codes related to communication are data frame is not received within the specified period,
named with the capital letter U, and are called the intended receiving ECU transmits a diagnosis
"U-codes." code indicating communication time-out for the ECU
A summary of the CAN self-diagnosis system is that failed to transmit.
presented below. For further details on each
diagnosis code stored by the ECUs.
.
.
BUS OFF
Related to a communication error that persists even
after the transmitting ECU attempts recovery for a
specified number of attempts or that persists for a
specified period after recovery. Communication is
stopped and this diagnostic code is issued.
CAN BUS DIAGNOSTICS
54C-7
CAN BUS DIAGNOSTICS
M2542000500254
As ECUs are connected via CAN bus (including Confirmation of diagnosis code of ETACS-ECU
M.U.T.-III), always diagnose CAN bus to confirm its Confirmation of communication of all ECUs
normality when inspecting. Simply by performing
M.U.T.-III screen operations, the following inspec-
tions can be performed automatically, and the result
can be used to verify the CAN bus status.
NOTES
55-1
GROUP 55
HEATER, AIR
CONDITIONING AND
VENTILATION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 55-2 A/C COMPRESSOR . . . . . . . . . . . . . . 55-9
HEATER AND AIR CONDITIONING CONDENSER . . . . . . . . . . . . . . . . . . . 55-9

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 55-4
DUCT. . . . . . . . . . . . . . . . . . . . . . . . . . 55-10
HEATER CONTROL . . . . . . . . . . . . . 55-6
VENTILATION SYSTEM. . . . . . . . . . . 55-11
A/C-ECU. . . . . . . . . . . . . . . . . . . . . . . 55-7
55-2 HEATER, AIR CONDITIONING AND VENTILATION
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M2551001500040
The blower, heater, and evaporator have been inte- Enhancement of fuel economy by the cooling fan
grated with the heater and A/C system to achieve a control depending on the refrigerant pressure and
greater fan power and noise reduction. vehicle speed.
FEATURES
.
ENHANCEMENT IN SAFETY
A/C system is stopped when the air bags are
.
ENHANCEMENTS IN COMFORT
deployed.
With the adoption of fully-automatic A/C, the out-
Crushable space has been adopted to heater unit
side/inside air circulation switching, air outlet, and
to reduce the risk of passenger injuries in case of
outlet air temperature are automatically con-
a collision.
trolled according to the ambient temperature,
solar radiation, and passenger compartment tem- .
perature so that the optimum air conditioner is GLOBAL ENVIRONMENT PROTECTION

achieved. <Automatic A/C> New refrigerant system (HFC134a) has been
By the adoption of clean air filter, the air quality adopted.
inside the passenger compartment has been By the optimisation of A/C system, the refrigerant
enhanced. charging amount has been reduced.
Clean air filter media and its cover are separated
to reduce waste materials.
.
ENHANCEMENTS IN OPERATION
PERFORMANCE .
Operability has been enhanced by the adoption ENHANCEMENTS IN SERVICE QUALITY

of large triple dial. Reduction of refrigerant gas leakage and
Customise function has been added for the enhancement in serviceability by incorporating
enhanced convenience. condenser and receiver
Clean air filter is installed to the backside of glove
.
box to facilitate the filter replacement.

ENHANCEMENTS IN FUEL ECONOMY
The high efficiency compressor with a 2-step pro- .
file oil separator has been installed, thus enhanc- ENHANCEMENTS IN RESPONSIBILITY
ing the fuel economy. Reliable information transmission is achieved by
The idle-up speed is controlled in two steps to connecting A/C-ECU and each ECU via CAN com-
secure the air cooling performance during sum- munication.
mer and to enhance the fuel economy in the sea-
sons with moderate temperature.
SPECIFICATIONS
ITEM SPECIFICATION
Air conditioning switch type Rotary type
Compressor type MSC90CAS
Cooling output 5.5 kw
Heating output 5.7 kw
Refrigerant Type R134a (HFC-134a)
Charge quantity g (oz.) 480 - 520 (16.9 - 18.3)
HEATER, AIR CONDITIONING AND VENTILATION
GENERAL DESCRIPTION
55-3
<AUTOMATIC AIR CONDITIONING>
Interior temperature
sensor AC608755AC
<AUTOMATIC AIR CONDITIONING>
Ambient air temperature sensor
Photo sensor
AC608756AC AC608760AB
Low-pressure side valve

High-pressure
side valve Suction
flexible hose
Heater unit
Liquid pipe
A/C pressure sensor
Discharge
flexible hose
A/C compressor Condenser
AC607816AB
HEATER AND AIR CONDITIONING SYSTEM
Mode selection
damper control motor
Outside / inside air selection
damper control motor
Intake duct
Air thermo sensor
Power transistor
Air mixing damper control Blower case

motor
A/C-ECU Blower motor

AC607858AB

M2551001000614
HEATER UNIT ASSEMBLY
Heater unit
Mode selection damper
Evaporator
Intake duct
Air mixing damper
Outside / inside air

selection damper
Blower case
Heater core
Clean air filter

AC607857AB
55-5
The following new unit integrated blower, heater and Fin thermo sensor to directly measure evaporator
evaporator to increase the air flow, reduce noise, and temperature reduces occurrence risk of an evap-
enhanced cooler and heater performance;: orator freeze which will lead to the compressor
Integrated heater/cooling unit has been adopted lock.
for large air flows and low noise. Clean air filter has been introduced as standard
Crushable space has been secured to reduce the to protect the unit from the intrusion of foreign
risk of passenger injuries. materials (fallen leaves and others). and, it
Air mix damper that is also used as a reheating removes the pollen and dust, and enhances the
prevention damper has been adopted to enhance air quality inside the passenger compartment.
the air cooling performance. Clean air filter media and cover have been sepa-
The A/C condensate water outlet (drain port) has rated to reduce the waste material amount gener-
been installed to behind the evaporator to ated during the filter replacement.
restrain the clogging of drain by foreign materials. The installation position of clean air filter has
The outlet air temperature of the defroster has been set to the backside of glove box to facilitate
been set lower than that of foot to prevent over- the filter replacement operation. And, the
heating the drivers face. one-touch tab structure has been adopted for the
cover installation to enable the replacement oper-
ation without tools.
OPERATION
CRUSHABLE SPACE
Front defroster
Side defroster Side defroster Side
outlet Crushable space
Center Crushable space
Recirculation outlet
Fresh
Side
outlet Front side
Heater core
Clean air filter

Heater outlet Heater outlet
Blower motor to compartment
Evaporator AC506490AB
Evaporator Heater core
.
Drain port AC506491AB
The evaporator and heater core has been longitudi-

nally installed in the vehicle length, and the crush-
able space has been adopted so that the structure
absorbs the impact in case of a collision and reduces
the risk of passenger injuries.
HEATER CONTROL
HEATER CONTROL
M2551000900421
HEATER CONTROLLER
.
<MANUAL A/C>
<Vehicles for USA> <Vehicles for CANADA>
Rear window defogger switch Outside/Inside air Rear window

Outside/Inside air
selection switch A/C switch selection switch A/C switch defogger switch
AC608071 AC608070
Maximum Blower knob
A/C position Mode selection knob Blower knob
Temperature
Temperature adjustment knob adjustment knob Mode selection knob
<AUTOMATIC A/C>
<Vehicles for USA> <Vehicles for CANADA>
Rear window defogger switch Outside/Inside air Rear window
Outside/Inside air
selection switch A/C switch selection switch A/C switch defogger switch
AC608069 AC608068
Blower knob
Mode selection knob Temperature Blower knob
Temperature adjustment knob
adjustment knob Mode selection knob
AC608329AB
The features of the heater controller described below AUTO and OFF positions of the fan volume con-
have been designed for better appearance, easier trol dial have been exchenged with one another.
operation, and enhanced visibility. This change prevents the dial to pass the AUTO
Each dial for the air outlet switching, fan volume position when the fan volume control is turned
control, and temperature adjustment has been OFF, and eliminates the necessity of manual
enlarged to enhance operability. reselection when switching the inside/outside air
Ring lights have been adopted to inside the dials selection manually, thus enhancing the operabil-
to enhance appearance during nighttime. <Vehi- ity. <Vehicles with automatic A/C>
cles with automatic A/C> When the air outlet switching dial and fan volume
control dial are turned to the AUTO position, the
A/C switch has been made to automatically turn
ON to enhance convenience. (Using the custom-
ize function, this function can be cancelled. Refer
to P.55-7.) <Vehicles with automatic A/C>
A/C-ECU
55-7
A/C-ECU
M2551001200265
CONTROL NOTE: "*" indicates that when the automatic control

. is not cancelled using the customise function, the
FORCED DEF CONTROL manual operation is disabled.
When air outlet position is switched to DEF, A/C is
automatically turned ON, and outside/inside air
.
REAR WINDOW DEFOGGER TIMER

selection damper is set to the fresh air position to
quickly defrost the windshield screen.
CONTROL
In order to prevent battery consumption, the defog-
.
ger is automatically turned OFF, 20 minutes after it is

MAX A/C CONTROL <MANUAL A/C> turned ON.
When the temperature adjustment knob is turned to
the maximum A/C position with the blower knob at .
position other than OFF, the following controls are

IDLE-UP CONTROL
made by the A/C-ECU. A/C-ECU and the engine ECU communicate with
each other through the CAN communication. The
Subject to control MAX COOL idle-up speed of the engine is controlled in two steps
Air mix damper MAX COOL position depending on the A/C load to secure the air cooling
Air outlet mode Selected position performance during summer and to enhance fuel
economy in seasons with moderate temperature.
Air volume Selected position
Outside/inside air Air recirculation position*
.
DETECTION CONTROL FOR

selection damper
REFRIGERANT LEAKS
Air conditioner switch ON* A/C-ECU determines if the refrigerant amount is less
NOTE: "*" Manual operation is disabled during max than specified or refrigerant pressure is abnormal by
A/C control. using the ambient temperature (ambient temperature
.
sensor to measure refrigerant inflation rate) and
MAX COOL, MAX HOT CONTROL refrigerant pressure (measured by the A/C pressure
sensor). When refrigerant amount or refrigerant pres-
<AUTOMATIC A/C>
sure is judged abnormal, the compressor is cut-off to
When the set temperature is at 18.0 C <61 F> protect the A/C system.
(MAX COOL) or at 32.0 C <89 F> (MAX HOT) with
the air outlet and air volume at the AUTO positions, NOTE: When abnormality occurs, the A/C indicator
the following controls are made automatically by the flashes.
A/C-ECU. .
Subject to MAX COOL MAX HOT

PROTECTION CONTROL AT AIR BAG
control DEPLOYMENT (DURING COLLISION)
When the air bag deployment is detected, the A/C
Air mix MAX COOL MAX HOT
system is stopped.
damper position position
Air outlet FACE position FOOT position .
mode
CUSTOMISE FUNCTION
Depending on the user's preference, the following
Air volume Maximum Maximum functions can be selected. The programmed informa-
Outside/insid Air recirculation Fresh air tion is held even when the battery is disconnected.
e air position* position* Automatic control for inside/outside air selection
selection Press and hold (approximately for 10 seconds)
damper the inside/outside air selection switch to cancel
Air ON* OFF* the automatic control for inside/outside air selec-
conditioner tion.
switch A/C automatic control
Press and hold (approximately for 10 seconds)
the A/C switch to cancel the A/C automatic con-
trol.
A/C-ECU
COMMUNICATION
CAN communication
SERIAL communication
SRS-ECU
Engine-ECU
Heater control panel A/C-ECU
ETACS-ECU
Combination meter
: Interactive communication
AC506202AC
A/C-ECU performs the signal transmission and NOTE: : For details of CAN communication, refer to
reception with each ECU via CAN (Controller Area GROUP 54C Controller Area Network P.54C-2.
Network)*1. Also, with the heater control panel, it
transmits and receives signals via serial communica-
tion.
CAN COMMUNICATION INPUT SIGNALS TABLE

Signal Transmitter ECU
Engine coolant temperature signal ENGINE-ECU
Vehicle speed signal
Engine speed signal
Ambient temperature signal ETACS-ECU
Wiper signal
Ignition key signal
Average ambient temperature signal COMBINATION METER
DIAGNOSTIC FUNCTION Service data output

A/C-ECU has the following functions for easier sys- Actuator test
tem checks. NOTE: For each item, refer to the Workshop Manual.
DIAGNOSTIC FUNCTION
A/C COMPRESSOR
55-9
A/C COMPRESSOR
M2551001100268
HIGH EFFICIENCY COMPRESSOR WITH MAGNETIC CLUTCH WITH THERMAL

INTEGRATED OIL SEPARATOR FUSE
High efficiency compressor with integrated oil sepa- At the compressor lock, the thermal fuse integrated
rator has been adopted to enhance fuel economy by in the magnet clutch is blown due to the frictional
reducing the A/C operating rate. heat against the compressor in order to reduce risk
of the drive belt breakage. The thermal fuse, together
with the coil, is coated with resin to enhance resis-
tance to corrosion.
2-STEP PROFILE COMPRESSOR

The centre area of the scroll in the compressor pro-
vides 2-step profile, and thickness of area "B" shown
in the figure has been increased to enhance
strength. With this feature, thickness of area "A"
shown where lesser load is applied is reduced, thus
compressor performance is enhanced by compress-
ing refrigerant even in central area, comparing to the
previous model.
<2-step profile
<Previous model> compressor>
Front view Front view
Section a - a Section b - b
A A
B B
a a b b
AC507301AC
CONDENSER
M2551001400140
Condenser The condenser has been integrated with the radiator (cooling
Radiator module) to optimise ventilation and reduce weight.
AC608768AB
DUCT
DUCT
M2551001300358
To windshield (Defroster)
To front door window

(Side defroster)
Side ventilator
Center ventilator
To front door window
Side ventilator (Side defroster)
To driver seat footwell
To passenger seat footwell
To rear seat footwell

(Vehicle with rear duct)
To rear seat footwell

(Vehicle with rear duct)
AC608058 AB
The rear heater duct has been introduced, and the

air distribution ratio to front and rear seats has been
optimised in order to enhance the air heating perfor-
mance for the rear seats, and to prevent the circula-
tion of cooled air back to the front seats. <Vehicles
with rear duct>
VENTILATION SYSTEM
55-11
VENTILATION SYSTEM
M2551002000554
Rear ventilator duct AC608060 AB
Fresh air is sucked from the front deck and

exhausted through the air outlet behind the rear
bumper. Optimizing areas of the outside air induction
hole and the air outlet enhances ventilated air
amount, reducing noise.
NOTES
55-1
GROUP 55
HEATER, AIR
CONDITIONING AND
VENTILATION
CONTENTS
HEATER, AIR CONDITIONING AND VENTILATION. . . . . . . . . 55A
AUTOMATIC AIR CONDITIONING. . . . . . . . . . . . . . . . . . . . . . . 55B

NOTES
55A-1
GROUP 55A
HEATER, AIR
CONDITIONING AND
VENTILATION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 55A-3 SPECIAL TOOLS . . . . . . . . . . . . . . . . 55A-109
SERVICE PRECAUTIONS. . . . . . . . . 55A-5 ON-VEHICLE SERVICE . . . . . . . . . . . 55A-112

CAUTION LABELS . . . . . . . . . . . . . . . . . . . 55A-5 REFRIGERANT LEVEL TEST . . . . . . . . . . 55A-112
A/C COMPRESSOR CLUTCH TEST . . . . . 55A-112
MANUAL A/C DIAGNOSIS . . . . . . . . 55A-5 SIMPLE INSPECTION OF THE A/C
INTRODUCTION TO HEATER, A/C AND PRESSURE SENSOR. . . . . . . . . . . . . . . . . 55A-112
VENTILATION DIAGNOSIS . . . . . . . . . . . . 55A-5 COMPRESSOR DRIVE BELT
HEATER, A/C AND VENTILATION DIAGNOSTIC ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 55A-113
TROUBLESHOOTING STRATEGY . . . . . . 55A-5 CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . 55A-113
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 55A-6 PERFORMANCE TEST . . . . . . . . . . . . . . . 55A-114
DIAGNOSTIC TROUBLE CODE CHART . . 55A-8 REFRIGERANT LEAK REPAIR
DIAGNOSTIC TROUBLE CODE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55A-115
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 55A-9 COMPRESSOR NOISE CHECK . . . . . . . . . 55A-116
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 55A-64 POWER RELAY CHECK. . . . . . . . . . . . . . . 55A-116
SYMPTOM PROCEDURES . . . . . . . . . . . . 55A-64 IDLE-UP OPERATION CHECK. . . . . . . . . . 55A-117
DATA LIST REFERENCE TABLE . . . . . . . 55A-107 REPLACE THE CLEAN AIR FILTER . . . . . 55A-118
ACTUATOR TEST REFERENCE . . . . . . . . 55A-107
CHECK AT A/C-ECU TERMINAL . . . . . . . . 55A-108 Continued on next page
WARNING
NOTE
55A-2
HEATER UNIT AND BLOWE REMOVAL AND INSTALLATION . . . . . . . . 55A-128

R ASSEMBLY*. . . . . . . . . . . . . . . . . . 55A-119 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55A-129
REMOVAL AND INSTALLATION . . . . . . . . 55A-119 DISASSEMBLY AND ASSEMBLY . . . . . . . 55A-130
DISASSEMBLY AND REASSEMBLY. . . . . 55A-122 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55A-132
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55A-123
CONDENSER ASSEMBLY. . . . . . . . . 55A-133
HEATER CONTROL UNIT. . . . . . . . . 55A-118 REMOVAL AND INSTALLATION . . . . . . . . 55A-133
REFRIGERANT LINE . . . . . . . . . . . . . 55A-134
MOTORS AND TRANSISTOR. . . . . . 55A-124 REMOVAL AND INSTALLATION . . . . . . . . 55A-134
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55A-125 DUCTS*. . . . . . . . . . . . . . . . . . . . . . . . 55A-136
AMBIENT TEMPERATURE SENSOR 55A-126
REMOVAL AND INSTALLATION . . . . . . . . 55A-126 VENTILATORS . . . . . . . . . . . . . . . . . . 55A-137
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55A-126 REMOVAL AND INSTALLATION . . . . . . . . 55A-137
A/C-ECU. . . . . . . . . . . . . . . . . . . . . . . 55A-127 SPECIFICATIONS . . . . . . . . . . . . . . . 55A-138

REMOVAL AND INSTALLATION . . . . . . . . 55A-127 FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 55A-138
COMPRESSOR ASSEMBLY AND GENERAL SPECIFICATIONS . . . . . . . . . . 55A-138
TENSION PULLEY. . . . . . . . . . . . . . . 55A-128 SERVICE SPECIFICATIONS . . . . . . . . . . . 55A-138
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 55A-138
GENERAL DESCRIPTION
55A-3
GENERAL DESCRIPTION
M1552000100685
The blower, heater, and evaporator have been inte-
grated with the heater and A/C system to achieve
greater fan power and noise reduction.
ITEM SPECIFICATION
Heater control assembly Dial type
Compressor mode MSC90CAS
Compressor type Scroll type
Refrigerant and quantity g (oz) R-134a (HFC-134a), 480 520 (16.9 18.3)
SAFETY PRECAUTIONS CAUTION
WARNING Keep R-134a containers upright when charging
Wear safety goggles and gloves when servic- the system.
ing the refrigeration system to prevent In most instances, moderate heat is required to bring
severe damage to eyes and hands. the pressure of the refrigerant in its container above
Because R-134a refrigerant is a hydro fluorocarbon the pressure of the system when charging or adding
(HFC) which contains hydrogen atoms in place of refrigerant.
chlorine atoms, it will not cause damage to the ozone A bucket or large pan of hot water not over 40 C
layer. (104.0 F) is all the heat required for this purpose. Do
Ozone filters out harmful radiation from the sun. To not heat the refrigerant container with a blow torch or
assist in protecting the ozone layer, Mitsubishi any other means that would raise temperature and
Motors Corporation recommends an R-134a refriger- pressure above this temperature. Do not weld or
ant recycling device. steam-clean on or near the system components or
Refrigerant R-134a is transparent and colorless in refrigerant lines.
both the liquid and vapor state. Since it has a boiling WARNING
point of 29.8 C (21.64 F) at atmospheric pressure, The leak detector for R-134a should be used
it will be a vapor at all normal temperatures and pres- to check for refrigerant gas leaks.
sures. The vapor is heavier than air, non-flammable, CAUTION
and non-explosive. The following precautions must Do not allow liquid refrigerant to touch bright
be observed when handling R-134a. metal or it will be stained.
WARNING When metering R-134a into the refrigeration system,
Do not heat R-134a above 40 C (104.0 F) or keep the supply tank or cans in an upright position. If
it may catch fire and explode. the refrigerant container is on its side or upside
R-134a evaporates so rapidly at normal atmospheric down, liquid refrigerant will enter the system and
pressures and temperatures that it tends to freeze damage the compressor.
anything it contacts. For this reason, extreme care Refrigerant will tarnish bright metal and chrome sur-
must be taken to prevent any liquid refrigerant from faces, and in combination with moisture can severely
contacting the skin and especially the eyes. Always corrode all metal surfaces.
wear safety goggles when servicing the refrigeration
part of the A/C system. Keep a bottle of sterile min- OPERATION
eral oil handy when working on the refrigeration sys- .
tem. CONDENSER FAN AND RADIATOR FAN

1. Should any liquid refrigerant get into your eyes, CONTROL
use a few drops of mineral oil to wash them out. The ECM judges the required revolution speed of
R-134a is rapidly absorbed by the oil. radiator fan motor and condenser fan motor using
2. Next, splash your eyes with plenty of cold water. the input signals transmitted from A/C switch, sec-
ondary pulley speed sensor <CVT> or vehicle speed
3. Call your doctor immediately even if irritation has
sensor (VSS) <M/T> and engine coolant temperature
ceased.
sensor.
.
TSB Revision
55A-4 HEATER, AIR CONDITIONING AND VENTILATION
GENERAL DESCRIPTION
COMPRESSOR CONTROL When the air thermo sensor is activated, and the
ignition switch, blower switch, and A/C switch are
When operating the A/C switch ON, the A/C compressor clutch relay is ener-
The air thermo sensor, which senses the temper- gized.
ature of the air flowing out of the evaporator,
deactivates the compressor at 1 C (33.8 F) or When operating the mode selection dial
below. The A/C will work when the mode selection dial is
The dual pressure switch turns OFF when the set to the "Defroster" or "Defroster/foot" position,
refrigerant pressure becomes excessively high or or the temperature control dial is set to the "MAX
low, thus protecting the compressor circuit (See A/C" position. In other dial positions, when the
Table below). A/C switch is turned on, the A/C will work.
A/C Compressor Clutch Relay ON Conditions

Ignition switch (IG2) ON NOTE: A/C compressor clutch relay is
Blower switch ON de-energized when any one switch, sensor
or control unit shown on the left turns off.
A/C switch, mode selection dial defroster, ON
defroster/foot position or temperature control MAX NOTE: The components marked by *
A/C communicate with the ECM. If the air thermo
sensor detects a temperature of 1 C
Air thermo sensor *
(33.8 F), the A/C-ECU will turn off the A/C
Pressure detected 2.94 MPa (427psi) or less (If ON compressor clutch relay.
by A/C pressure the refrigerant pressure
sensor exceeds 2.94 MPa (427psi),
A/C compressor clutch relay is
not ON condition until the
refrigerant pressure has been
measured up to 2.35 MPa
(341psi) a or less.)
0.19 MPa (27psi) or more (If
the refrigerant pressure falls
short of 0.19 MPa (27psi), A/C
compressor clutch relay is not
ON condition until the
(32psi) or more.)
A/C compressor clutch relay driving transistor (within ON
powertrain control module)
TSB Revision
SERVICE PRECAUTIONS
55A-5
SERVICE PRECAUTIONS
CAUTION LABELS
M1552017400321
The refrigerant gas caution label must be affixed in the location
shown in the figure on the left. Follow the instructions on the
label when servicing.
AC609178AB
1 2 3
No. Contents
1 Name of A/C manufacturer
2 Amount of refrigerant
3 Name of compressor oil
3 2 AC200079AC
MANUAL A/C DIAGNOSIS

INTRODUCTION TO HEATER, A/C AND VENTILATION DIAGNOSIS
M1552012200407
Air is drawn into the heater assembly from either the If the system does not cool properly, look for a prob-
outside, or from the inside of the passenger cabin if lem with the refrigerant, blower or air distribution sys-
DEFROST, maximum cooling or RECIRCULATION tems. If the system does not heat properly, look for a
are selected. The air is then forced through the evap- problem with the coolant, blower or air distribution
orator where heat is removed, cooling and de-humid- systems. In either case all system fuses, circuit
ifying the air. Depending on the temperature breaker and relays should be checked.
selected, a portion of this air is then forced through
the heater core to achieve the selected discharge
temperature.
HEATER, A/C AND VENTILATION DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1552009600483
heater, A/C and ventilation fault. Chart.
1. Gather information from the customer. 4. Verify that the malfunction is eliminated.
TSB Revision
DIAGNOSTIC FUNCTION
M1552019800154

CAUTION
position.
MB991910
position.
NOTE: When the special tool MB991824 is energized, the
special tool MB991824 indicator light will be illuminated in a
green color.
NOTE: Disconnecting the scan tool special tool MB991824 is
MB991827
the reverse of the connecting sequence, making sure that the
AC608435 AB
ignition switch is at the "LOCK" (OFF) position.

TROUBLE CODES
TSB Revision
55A-7
CAUTION
not be output. Check the battery if scan tool MB991958 does
not display.
MB991910
MB991824 Information" is displayed, check the contents.
5. Select "AUTO A/C" from "System List," and press the "OK"
button.
MB991827 AC608435 AB 8. Choose "Erase DTCs" to erase the DTC.

CAUTION
diagnosed.
MB991910
5. Select "view vehicle information" button.
that it matches the vehicle which is diagnosed CAN bus line.
8. When the options are displayed, choose the options (mark
MB991827 AC608435 AB
the check) and then select "OK".
TSB Revision

M1554004900894
CAUTION
During diagnosis, a DTC code associated with
other system may be set when the ignition switch
is turned on with connector(s) disconnected. On
completion of repairs, check all systems for DTC
Diagnostic Diagnostic item Reference
trouble code No. page
B1000 Control panel communication error P.55A-9
B1003 Mode dial SW error P.55A-14
B1018 Temperature control dial SW error P.55A-17
B1021 Fan dial SW error P.55A-20
B1031 Air thermo sensor system (short circuit) P.55A-20
B1032 Air thermo sensor system (open circuit) P.55A-20
B1034* Ambient air temperature sensor system (short circuit) P.55A-26
B1035* Ambient air temperature sensor system (open circuit) P.55A-26
B1079 Refrigerant leaks P.55A-29
B2214 Control panel failure P.55A-33
B223B Control panel improperly assembled P.55A-37
U1415 Coding not completed P.55A-37
U0019 Bus off (CAN1) P.55A-42
U0141 ETACS-ECU time-out P.55A-43
U0151 SRS-ECU time-out P.55A-46
U0154 Occupant classification-ECU time-out P.55A-48
U0155 Combination meter time-out P.55A-51
U0168 WCM time-out P.55A-53
U0184 Audio time-out P.55A-56
U0195 Satellite radio tuner time-out P.55A-59
U0197 Hands free module time-out P.55A-61
NOTE: The diagnostic trouble codes marked by * are
set from the ETACS-ECU.
TSB Revision
55A-9
DTC B1000: Control Panel Communication Error
A/C Control Panel Circuit
ETACS-ECU
A/C
CPU CONTROL
PANEL
POWER INTERFACE
SUPPLY CIRCUIT
A/C-ECU

Junction block
C-20 (B)
AC608146AB AC608152 AE
DTC SET CONDITION

DTC B1000 will be set when the communication between
A/C-ECU and A/C control panel cannot be performed.
.

Current trouble
The A/C-ECU, the A/C control panel, or connector(s) or wir-
ing between the two may be defective.
TSB Revision
Past trouble
If DTC B1000 is stored as a past trouble, carry out diagno-
sis with particular emphasis on wiring and connector(s)
between the A/C-ECU and the A/C control panel. If the con-
nectors and wiring are normal, and obviously the ECU is the
cause of the trouble, replace the ECU. If in doubt, do not
replace the ECU.
.
TROUBLESHOOTING HINT
Malfunction of connector.
Malfunction of the harness.
Malfunction of the A/C control panel.
Malfunction of the A/C-ECU.
DIAGNOSIS

line.
Data link connector (3) Diagnose the CAN bus line.
YES : Go to Step 2.
NO : Repair the CAN bus lines. Repair the CAN bus lines
(Refer to GROUP 54C, Diagnosis-Can Bus
Diagnostic Chart P.54C-16).
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
55A-11

Recheck if the DTC is set.
(1) Erase the DTC.
Q: Is the DTC set?
YES : Go to Step 3.
NO : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Cope with Intermittent Malfunctions P.00-13.
STEP 3. Check A/C control panel connector C-120 for

Q: Is A/C control panel connector C-120 in good condition?
YES : Go to Step 4.
NO : Repair or replace the connector. Refer to GROUP
STEP 4. Measure the voltage at A/C control panel

connector C-120.
(1) Disconnect A/C control panel connector C-120, and
measure the voltage at the harness side.
CONNECTOR C-120
The measured value should be approximately 12 volts
(HARNESS SIDE)
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 6.
NO : Go to Step 5.
AC608254AP
STEP 5. Check the wiring harness between A/C control

panel connector C-120 (terminal 6) and ETACS-ECU
Q: Is the wiring harness between A/C control panel
YES : It can be assumed that this malfunction is intermittent.
TSB Revision
STEP 6. Measure the resistance at A/C control panel

connector C-120.
(1) Disconnect A/C control panel connector C-120, and
CONNECTOR C-120
measure the resistance at the wiring harness side.
(HARNESS SIDE)
ground.
The measured value should be 2 ohms or less.
this range?
YES : Go to Step 8.
NO : Go to Step 7.
AC608255BM
STEP 7. Check the wiring harness between A/C control

panel connector C-120 (terminal 7) and ground.
Q: Is the wiring harness between A/C control panel
condition?
STEP 8. Check A/C-ECU connector C-20 for loose,

in the connector.
Q: Is A/C-ECU connector C-20 in good condition?
YES : Go to Step 9.
STEP 9. Check the wiring harness between A/C-ECU

connector C-20 (terminal 9 and 10) and A/C control panel
connector C-120 (terminals 9 and 1).
Q: Is the wiring harness between A/C-ECU connector C-20
(terminal 9 and 10) and A/C control panel connector
C-120 (terminals 9 and 1) in good condition?
TSB Revision
55A-13

(1) Erase the DTC.
Q: Is the DTC set?
YES : Replace the A/C control panel. Then go to Step 11.

(1) Erase the DTC.
Q: Is the DTC set?
TSB Revision
DTC B1003: Mode Dial SW Error
A/C
CPU CONTROL
PANEL
INTERFACE
CIRCUIT
A/C-ECU
Connector: C-20, C-120
C-120
C-20 (B)
AC608146BG
DTC SET CONDITION

DTC B1003 will be set when the A/C-ECU cannot receive the
signal of mode selection knob.
.

Current trouble
Past trouble
replace the ECU.
.
TSB Revision
55A-15
DIAGNOSIS

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
Q: Is the DTC set?
YES : Go to Step 3.
TSB Revision
STEP 3. Check A/C control panel connector C-120 and

A/C-ECU connector C-20 for loose, corroded or damaged
Q: Are A/C control panel connector C-120 and A/C-ECU
YES : Go to Step 4.

YES : Go to Step 5.

(1) Erase the DTC.
Q: Is the DTC set?

(1) Erase the DTC.
Q: Is the DTC set?
TSB Revision
55A-17
DTC B1018: Temperature Control Dial SW Error
A/C
CPU CONTROL
PANEL
INTERFACE
CIRCUIT
A/C-ECU
C-120
C-20 (B)
AC608146BG
DTC SET CONDITION

signal of temperature adjustment knob.
.

Current trouble
Past trouble
replace the ECU.
.
TSB Revision
DIAGNOSIS

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
Q: Is the DTC set?
YES : Go to Step 3.
TSB Revision
55A-19

YES : Go to Step 4.

YES : Go to Step 5.

(1) Erase the DTC.
Q: Is the DTC set?

(1) Erase the DTC.
Q: Is the DTC set?
TSB Revision
DTC B1021: Fan Dial SW Error
A/C
CPU CONTROL
PANEL
INTERFACE
CIRCUIT
A/C-ECU
C-120
C-20 (B)
AC608146BG
DTC SET CONDITION

signal of blower knob.
.

Current trouble
Past trouble
replace the ECU.
.
TSB Revision
55A-21
DIAGNOSIS

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
Q: Is the DTC set?
YES : Go to Step 3.
TSB Revision

YES : Go to Step 4.

YES : Go to Step 5.

(1) Erase the DTC.
Q: Is the DTC set?

(1) Erase the DTC.
Q: Is the DTC set?
TSB Revision
55A-23
DTC B1031, B1032: Air Thermo Sensor System
Air Thermo Sensor Circuit
AIR THERMO
SENSOR
A/C-ECU
C-119 C-19 (B)
AC608146BH
DTC SET CONDITION

DTC B1031 is set if there is a short circuit in the air thermo
sensor input circuit.
DTC B1032 is set if there is a defective connector connec-
tion, or if there is an open circuit in the harness.
.

Current trouble
The A/C-ECU, the air thermo sensor, or connector(s) or wir-
Past trouble
If DTC B1031 or B1032 is stored as a past trouble, carry out
diagnosis with particular emphasis on wiring and connec-
tor(s) between the A/C-ECU and the air thermo sensor. If
the connectors and wiring are normal, and obviously the
ECU is the cause of the trouble, replace the ECU. If in
doubt, do not replace the ECU.
.
TSB Revision
Malfunction of the air thermo sensor.
DIAGNOSIS

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
Q: Is the DTCset?
YES : Go to Step 3.
TSB Revision
55A-25
STEP 3. Check air thermo sensor connector C-119 and

Q: Are air thermo sensor connector C-119 and A/C-ECU
YES : Go to Step 4.

connector C-19 (terminal 22 and 21) and air thermo sensor
(terminal 22 and 21) and air thermo sensor connector
YES : Go to Step 5.
STEP 5. Check the air thermo sensor.

Resistance 25 Measure the resistance between connector terminals 1 and 2
(k) 20
under at least two different temperatures. The resistance val-
ues should generally match those in the graph.
15
NOTE: The temperature at the check should not exceed the
10 range in the graph.
5 Q: Is the air thermo sensor in good condition?
0 YES : Replace the A/C-ECU. Then go to Step 6.
-10 0 10 20 30 40 NO : Replace the air thermo sensor. Then go to Step 6.
(14) (32) (50) (68) (86) (104)
Temperature C (F) AC609399AB

Check again if the DTC is set.
(1) Connect scan tool MB991958 to the data link connector
Q: Is the DTC set?
TSB Revision
DTC B1034, B1035: Ambient air temperature Sensor System
Ambient Temperature Sensor Circuit
ETACS-ECU
ANALOG
INTERFACE
CIRCUIT
AMBIENT AIR
TEMPERATURE
SENSOR
Connectors: A-36 Connector: C-312

Junction block
A-36 (B)
AC608142AJ AC608152 AP
DTC SET CONDITION

DTC B1034 is set if there is a short circuit in the ambient air
temperature sensor input circuit.
DTC B1035 is set if there is a defective connector connec-
.

Current trouble
The A/C-ECU, the ambient air temperature sensor, or con-
nector(s) or wiring between the two may be defective.
Past trouble
If DTC B1034 or B1035 is stored as a past trouble, carry out
diagnosis with particular emphasis on wiring and connec-
tor(s) between the A/C-ECU and the ambient air tempera-
ture sensor. If the connectors and wiring are normal, and
obviously the ECU is the cause of the trouble, replace the
ECU. If in doubt, do not replace the ECU.
.
TSB Revision
55A-27
Malfunction of the ambient air temperature sensor.
DIAGNOSIS

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
Q: Is the DTC set?
YES : Go to Step 3.
TSB Revision
STEP 3. Check ambient air temperature sensor connector

A-36 and ETACS-ECU connector C-312 for loose, corroded
connector.
Q: Are ambient air temperature sensor connector A-36 and
ETACS-ECU connector C-312 in good condition?
YES : Go to Step 4.
STEP 4. Check the wiring harness between ambient air

temperature sensor connector A-36 (terminals 2 and 1) and
ETACS-ECU connector C-312 (terminals 7 and 14).
Q: Is the wiring harness between ambient air temperature
sensor connector A-36 (terminals 2 and 1) and
ETACS-ECU connector C-312 (terminals 7 and 14) in
good condition?
YES : Go to Step 5.
STEP 5. Check the ambient air temperature sensor.

Resistance Measure the resistance between connector terminals 1 and 2
(k) 10 under at least two different temperatures. The resistance val-
8 ues should generally match those in the graph.
6 NOTE: The temperature at the check should not exceed the
range in the graph.
4
Q: Is the ambient air temperature sensor in good
2
condition?
0 YES : Replace the A/C-ECU. Then go to Step 6.
-10 0 10 20 30 40
(14) (32) (50) (68) (86) (104) NO : Replace the ambient air temperature sensor. Then go
Temperature C (F) AC209192 AB
to Step 6.

Q: Is the DTC set?
TSB Revision
55A-29
DTC B1079: Refrigerant Leaks
A/C Pressure Sensor Circuit
A/C PRESSURE
SENSOR
JOINT
CONNECTOR (2)
A/C-ECU
Connector: A-42 Connector: C-128
A-42 (B)
AC608141AN AC608145BP
Connector: C-20
C-20 (B)
AC608146AB
TSB Revision
.
DTC SET CONDITION

DTC B1079 will be set when the A/C pressure sensor detects
the refrigerant pressure of specified level or less.
NOTE: When DTC B1079 is set, the A/C indicator of A/C con-
trol panel flashes.
.

Current trouble
The refrigerant amount is not at the specified level, or the
wiring harness or connector between the A/C-ECU and A/C
pressure sensor, and the A/C-ECU itself or A/C pressure
sensor itself may have failed.
Past trouble
between the A/C-ECU and the A/C pressure sensor. If the
connectors and wiring are normal, and obviously the ECU is
the cause of the trouble, replace the ECU. If in doubt, do not
replace the ECU.
.
Malfunction of the A/C pressure sensor.
DIAGNOSIS
TSB Revision
55A-31

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
Q: Is the DTC set?
YES : Go to Step 3.
STEP 3. Check A/C pressure sensor connector A-42 and

Q: Are air A/C pressure sensor connector A-42 and
A/C-ECU connector C-20 in good condition?
YES : Go to Step 4.
TSB Revision

connector C-20 (terminals 20, 16 and 19) and A/C pressure
sensor connector A-42 (terminals 3, 2 and 1).
(terminals 20, 16 and 19) and A/C pressure sensor
connector A-42 (terminals 3, 2 and 1) in good condition?
YES : Go to Step 5.
STEP 5. Check the A/C pressure sensor operation.

(1) Assemble a gauge manifold on the high pressure service
valve.
A/C pressure sensor (2) Disconnect the A/C pressure sensor connector and connect
special tool test harness MB991658 as shown in the
illustration.
(3) Turn ON the engine and then turn ON the A/C switch.
AC609413AB
A/C
PRESSURE
SENSOR HARNESS SIDE
SIDE
MB991658
AC307368 AB
OUTPUT VOLTAGE (4) At this time, check to see that the voltage of A/C pressure
(V)
sensor terminal No. 2 reflects the specifications of the
5
figure.
4
NOTE: The allowance shall be defined as 5%.
3
Q: Is the A/C pressure sensor operating properly?
2
YES : Go to Step 6.
1
NO : Replace the A/C pressure sensor. Then go to Step 7.
0 1 (145) 2 (290) 3 (435)
REFRIGERANT PRESSURE MPa (psi)
AC208297AD
TSB Revision
55A-33
STEP 6. Check the refrigerant level.

Use the refrigerant recovery station to remove all of the refrig-
erant, and then calculate the amount of the refrigerant and
charge it.
Q: Is the refrigerant level correct?
YES : Go to Step 7.
NO : Correct the refrigerant level (Refer to On-vehicle
Service P.55A-113). Then go to Step 7.

Q: Is the DTC set?
DTC B2214: Control Panel Failure
A/C
CPU CONTROL
PANEL
INTERFACE
CIRCUIT
A/C-ECU
TSB Revision
C-120
C-20 (B)
AC608146BG
DTC SET CONDITION

DTC B2214 will be set when the A/C-ECU detects the A/C con-
trol panel abnormality.
.

Current trouble
Past trouble
replace the ECU.
.
DIAGNOSIS
TSB Revision
55A-35

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
Q: Is the DTC set?
YES : Go to Step 3.

YES : Go to Step 4.
TSB Revision

YES : Go to Step 5.

(1) Erase the DTC.
Q: Is the DTC set?

(1) Erase the DTC.
Q: Is the DTC set?
TSB Revision
55A-37
DTC B223B: Control Panel Improperly Assembled
A/C
CPU CONTROL
PANEL
INTERFACE
CIRCUIT
A/C-ECU
C-120
C-20 (B)
AC608146BG
DTC SET CONDITION

DTC B223B will be set when the A/C control panel sends an
abnormal data, the A/C control panel for RHD is improperly
assembled, or the ETACS-ECU sends incorrect vehicle infor-
mation (information for RHD is sent).
.

Current trouble
Past trouble
If DTC B223B is stored as a past trouble, carry out diagno-
replace the ECU.
.
TSB Revision
DIAGNOSIS

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

(1) Erase the DTC.
Q: Is the DCT set?
YES : Go to Step 3.
TSB Revision
55A-39

YES : Go to Step 4.

YES : Go to Step 5.

(1) Erase the DTC.
Q: Is the DTC set?

(1) Erase the DTC.
Q: Is the DTC set?
TSB Revision
DTC B222C: Coding Not Completed

If DTC U222C is set in the A/C-ECU, diagnose the The A/C-ECU receives the vehicle information sig-
CAN main bus line. nals from the ETACS-ECU via the CAN bus lines. If
CAUTION incorrect global coding data is received or coding
Whenever the ECU is replaced, ensure that the data cannot be received with the ignition switch
communication circuit is normal. turned ON when the coding confirmation is com-
.
pleted, diagnostic trouble code B222C is stored.
.
DIAGNOSIS
MB991824: V.C.I.

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
55A-41
STEP 2. Using scan tool MB991958 read the ETACS-ECU

Check whether an ETACS DTC.
(2) Check for the DTC related to the ETACS-ECU.
Q: Is the DTC set?
Diagnostic Trouble Code P.54A-482 ).
NO : Go to Step 3.

Check if a DTC, which relates to CAN communication-linked
systems below, is set.
WCM <vehicles with WCM>
B2204: Coding data unmatched
KOS <vehicles with KOS>
B2204: Coding data unmatched
(2) Check for a DTC related to the relevant system.
Q: Is the DTC set?
YES : Go to Step 5.
NO : Go to Step 4.

Q: Is the DTC set?
YES : Replace the ETACS-ECU. On completion, check that
the DTC is not reset.
NO : A poor connection, open circuit or other intermittent
malfunction is present in the lines between the
ETACS-ECU and the A/C-ECU (Refer to GROUP
00E, Harness Connector Inspection P.00E-2).

Q: Is the DTC set?
YES : Replace the A/C-ECU. On completion, check that the
DTC is not reset.
NO : A poor connection, open circuit or other intermittent
malfunction is present in the lines between the
ETACS-ECU and the A/C-ECU (Refer to GROUP
00E, Harness Connector Inspection P.00E-2).
TSB Revision
DTC U0019: Bus Off (CAN1)

.

If DTC U0019is set in the A/C-ECU, diagnose the The wiring harness wire or connectors may have
CAN main bus line. loose, corroded, or damage terminals, or terminals
CAUTION pushed back in the connector, or the A/C-ECU may
Whenever the ECU is replaced, ensure that the be defective.
communication circuit is normal. .
.
TROUBLE JUDGMENT
DTC U0019 will be stored when the A/C-ECU ceases Defective connector(s) or wiring harness
CAN communication (bus off) and then resumes the Malfunction of the A/C-ECU
communication when the ignition switch is turned to
DIAGNOSIS
MB991824: V.C.I.

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
55A-43

Q: Is the DTC set?
DTC is not reset.
NO : There is an intermittent malfunction such as poor
engaged connector(s) or open circuit (Refer to
Malfunctions P.00-13.)
DTC U0141: ETACS-ECU Time-out
CAUTION Past trouble

If DTC U0141 is set in the A/C-ECU, diagnose the If DTC U0141 is stored as a past trouble, carry
CAN main bus line. out diagnosis with particular emphasis on wiring
and connector(s) in the CAN bus line between
CAUTION the A/C-ECU and the ETACS-ECU, and the
Whenever the ECU is replaced, ensure that the power supply system to the ETACS-ECU. If the
communication circuit is normal. connectors and wiring are normal, and obviously
.
TROUBLE JUDGMENT the ECU is the cause of the trouble, replace the
The A/C-ECU receives air conditioning opera- ECU. If in doubt, do not replace the ECU.
tion-related signals from the ETACS-ECU via the NOTE: For a past trouble, you cannot find it by
CAN bus lines. If the ECU cannot receive any of the the scan tool CAN bus diagnostics even if there is
air conditioning control-related signals from the a failure in CAN bus lines. In this case, refer to
ETACS-ECU, the diagnostic trouble code U0141 is GROUP 00, How to Use Troubleshooting/Inspec-
stored. tion Service Points How to Cope with Intermit-
tent Malfunctions P.00-13) and check the CAN
bus lines. You can narrow down the possible
.

cause of the trouble by referring to the DTC,
Current trouble which is set regarding the CAN communica-
Connector(s) or wiring harness in the CAN bus tion-linked ECUs (Refer to GROUP 54C, Expla-
lines between the ETACS-ECU and the nation about the scan too CAN bus diagnostics
A/C-ECU, the power supply system to the P.54C-16).
ETACS-ECU, the ETACS-ECU itself, or the
A/C-ECU may be defective.
.
DIAGNOSIS
MB991824: V.C.I.
TSB Revision


line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958 read the ETACS-ECU

Check whether an ETACS-ECU DTCs are set or not.
(2) Check for ETACS-ECU DTCs.
Q: Is the DTC set?
Diagnostic Trouble Code P.54A-482).
NO : Go to Step 3.
TSB Revision
55A-45

Combination meter
DTC indicating a time-out error related to the engine or
automatic transaxle control system
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

Q: Is the DTC set?
YES : Replace the ETACS-ECU. On completion, check that

Q: Is the DTC set?
DTC is not reset.
TSB Revision
DTC U0151: SRS-ECU Time-out

CAUTION the A/C-ECU and the SRS-ECU, and the power
Whenever the ECU is replaced, ensure that the supply system to the SRS-ECU. If the connectors
communication circuit is normal. and wiring are normal, and obviously the ECU is
.
TROUBLE JUDGMENT the cause of the trouble, replace the ECU. If in

The A/C-ECU receives air conditioning opera- doubt, do not replace the ECU.
tion-related signals from the SRS-ECU via the CAN NOTE: For a past trouble, you cannot find it by
bus lines. If any of the air conditioning control-related the scan tool CAN bus diagnostics even if there is
signals from the SRS-ECU cannot be received, the a failure in CAN bus lines. In this case, refer to
diagnostic trouble code U0151 is stored. GROUP 00, How to Use Troubleshooting/Inspec-
tion Service Points How to Cope with Intermit-
.

Current trouble cause of the trouble by referring to the DTC,
Connector(s) or wiring harness in the CAN bus which is set regarding the CAN communica-
lines between the SRS-ECU and the A/C-ECU, tion-linked ECUs (Refer to GROUP 54C, Expla-
the power supply system to the SRS-ECU, the nation about the scan too CAN bus diagnostics
SRS-ECU itself, or the A/C-ECU may be defec- P.54C-16).
tive. .
DIAGNOSIS
MB991824: V.C.I.
TSB Revision
55A-47

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958 read the SRS-ECU

Check whether an SRS-ECU DTCs are set or not.
(2) Check for SRS-ECU DTCs.
Q: Is the DTC set?
YES : Diagnose the SRS-ECU (Refer to GROUP 52B,
Diagnostic Trouble Code P.52B-31).
NO : Go to Step 3.

ETACS-ECU
DTC indicating a time-out error related to the SRS-ECU
system
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.
TSB Revision

Q: Is the DTC set?
YES : Replace the SRS-ECU. On completion, check that

Q: Is the DTC set?
DTC is not reset.
DTC U0154: Occupant classification ECU time out

If DTC U0154 is set in the A/C-ECU, diagnose the Current trouble
CAN main bus line. Connector(s) or wiring harness in the CAN bus
CAUTION lines between the SRS-ECU and the A/C-ECU,
Whenever the ECU is replaced, ensure that the the power supply system to the SRS-ECU, the
communication circuit is normal. SRS-ECU itself, or the A/C-ECU may be defec-
.
tive.
TROUBLE JUDGMENT
The A/C-ECU receives air conditioning opera- Past trouble
tion-related signals from the SRS-ECU via the CAN If DTC U0151 is stored as a past trouble, carry
bus lines. If any of the air conditioning control-related out diagnosis with particular emphasis on wiring
signals from the SRS-ECU cannot be received, the and connector(s) in the CAN bus line between
diagnostic trouble code U0154 is stored. the A/C-ECU and the SRS-ECU, and the power
supply system to the SRS-ECU. If the connectors
.
and wiring are normal, and obviously the ECU is

the cause of the trouble, replace the ECU. If in
doubt, do not replace the ECU.
TSB Revision
55A-49
NOTE: For a past trouble, you cannot find it by cause of the trouble by referring to the DTC,
the scan tool CAN bus diagnostics even if there is which is set regarding the CAN communica-
a failure in CAN bus lines. In this case, refer to tion-linked ECUs (Refer to GROUP 54C, Expla-
GROUP 00, How to Use Troubleshooting/Inspec- nation about the scan too CAN bus diagnostics
tion Service Points How to Cope with Intermit- P.54C-16).
.
DIAGNOSIS
MB991824: V.C.I.

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
STEP 2. Using scan tool MB991958 read the SRS-ECU

Check whether an SRS-ECU DTCs are set or not.
(2) Check for SRS-ECU DTCs.
Q: Is the DTC set?
YES : Diagnose the SRS-ECU (Refer to GROUP 52B,
Diagnostic Trouble Code P.52B-280).
NO : Go to Step 3.

ETACS-ECU
DTC indicating a time-out error related to the SRS-ECU
system
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

Q: Is the DTC set?
TSB Revision
55A-51

Q: Is the DTC set?
DTC is not reset.
DTC U0155: Combination meter Time-out

CAUTION the A/C-ECU and the combination meter, and the
Whenever the ECU is replaced, ensure that the power supply system to the combination meter. If
communication circuit is normal. the connectors and wiring are normal, and obvi-
.
TROUBLE JUDGMENT ously the ECU is the cause of the trouble, replace
The A/C-ECU receives the air conditioning con- the ECU. If in doubt, do not replace the ECU.
trol-related signals from the combination meter via NOTE: For a past trouble, you cannot find it by
the CAN bus lines. If any of the air conditioning con- the scan tool CAN bus diagnostics even if there is
trol-related signals from the combination meter can- a failure in CAN bus lines. In this case, refer to
not be received, the diagnostic trouble code U0155 is GROUP 00, How to Use Troubleshooting/Inspec-
.

lines between the combination meter and the nation about the scan too CAN bus diagnostics
A/C-ECU, the power supply system to the combi- P.54C-9).
nation meter, the combination meter itself, or the
.
Malfunction of the combination meter
DIAGNOSIS
MB991824: V.C.I.
TSB Revision

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB

Q: Is the DTC set?
YES : Diagnose the combination meter (Refer to GROUP
54A, Diagnostic Trouble Code P.54A-23).
NO : Go to Step 3.
TSB Revision
55A-53

ETACS-ECU
DTC indicating a time-out error related to the combination
meter system
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

Q: Is the DTC set?
YES : Replace the combination meter. On completion,
check that the DTC is not reset.

Q: Is the DTC set?
DTC is not reset.
DTC U0168: WCM Time-out

.

If DTC U0168 is set in the A/C-ECU, diagnose the The A/C-ECU receives the air conditioning con-
CAN main bus line. trol-related signals from the WCM-ECU via the CAN
CAUTION bus lines. If any of the air conditioning control-related
Whenever the ECU is replaced, ensure that the signals from the WCM-ECU cannot be received,
communication circuit is normal. diagnostic trouble code U0168 is stored.
TSB Revision
NOTE: For a past trouble, you cannot find it by

.
TECHNICAL DESCRIPTION (COMMENT) the scan tool CAN bus diagnostics even if there is
Current trouble a failure in CAN bus lines. In this case, refer to
Connector(s) or wiring harness in the CAN bus GROUP 00, How to Use Troubleshooting/Inspec-
lines between the WCM-ECU and the A/C-ECU, tion Service Points How to Cope with Intermit-
the power supply system to the WCM-ECU, the tent Malfunctions P.00-13) and check the CAN
WCM-ECU itself, or the A/C-ECU may be defec- bus lines. You can narrow down the possible
tive. cause of the trouble by referring to the DTC,
which is set regarding the CAN communica-
Past trouble
tion-linked ECUs (Refer to GROUP 54C, Expla-
If DTC U0168 is stored as a past trouble, carry
nation about the scan too CAN bus diagnostics
out diagnosis with particular emphasis on wiring
P.54C-9).
the A/C-ECU and the WCM-ECU, and the power .
supply system to the WCM-ECU. If the connec- TROUBLESHOOTING HINTS

tors and wiring are normal, and obviously the Malfunction of the WCM-ECU
ECU is the cause of the trouble, replace the ECU. Malfunction of the A/C-ECU
If in doubt, do not replace the ECU. Damaged harness wires and connectors
DIAGNOSIS
MB991824: V.C.I.
TSB Revision
55A-55

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958 read the WCM-ECU

Check whether an WCM-ECU DTCs are set or not.
(2) Check for WCM-ECU DTCs.
Q: Is the DTC set?
YES : Go to Step 3.
NO : Diagnose the WCM-ECU (Refer to GROUP 42C,
Diagnostic Trouble Code P.42C-14).

ETACS-ECU
DTC indicating a time-out error related to the WCM-ECU
system
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.
TSB Revision

Q: Is the DTC set?
YES : Replace the WCM-ECU. On completion, check that

Q: Is the DTC set?
DTC is not reset.
DTC U0184: Audio Time-out

CAUTION lines between the Audio and the A/C-ECU, the
Whenever the ECU is replaced, ensure that the power supply system to the Audio, the Audio
communication circuit is normal. itself, or the A/C-ECU may be defective.
.
TROUBLE JUDGMENT Past trouble

The A/C-ECU receives air conditioning opera- If DTC U0184 is stored as a past trouble, carry
tion-related signals from the audio via the CAN bus out diagnosis with particular emphasis on wiring
lines. If any of the air conditioning control-related sig- and connector(s) in the CAN bus line between
nals from the audio cannot be received, the diagnos- the A/C-ECU and the Audio, and the power sup-
tic trouble code U0184 is stored. ply system to the Audio. If the connectors and
wiring are normal, and obviously the ECU is the
.
cause of the trouble, replace the ECU. If in doubt,

do not replace the ECU.
TSB Revision
55A-57
.
Malfunction of the Audio
DIAGNOSIS
MB991824: V.C.I.

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
STEP 2. Using scan tool MB991958 read the Audio

Check whether an audio DTCs are set or not.
(2) Check for Audio DTCs.
Q: Is the DTC set?
YES : Diagnose the Audio (Refer to GROUP 54A,
Diagnostic Trouble Code P.54A-239).
NO : Go to Step 3.

ETACS-ECU
DTC indicating a time-out error related to the Audio system
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

Q: Is the DTC set?
YES : Replace the Audio. On completion, check that the
DTC is not reset.

Q: Is the DTC set?
DTC is not reset.
TSB Revision
55A-59

CAUTION the A/C-ECU and the Satellite Radio, and the
Whenever the ECU is replaced, ensure that the power supply system to the Satellite Radio. If the
communication circuit is normal. connectors and wiring are normal, and obviously
.
TROUBLE JUDGMENT the ECU is the cause of the trouble, replace the
The A/C-ECU receives air conditioning opera- ECU. If in doubt, do not replace the ECU.
tion-related signals from the satellite radio via the NOTE: For a past trouble, you cannot find it by
CAN bus lines. If any of the air conditioning con- the scan tool CAN bus diagnostics even if there is
trol-related signals from the satellite radio cannot be a failure in CAN bus lines. In this case, refer to
received, the diagnostic trouble code U0195 is GROUP 00, How to Use Troubleshooting/Inspec-
.

lines between the Satellite Radio and the nation about the scan too CAN bus diagnostics
A/C-ECU, the power supply system to the Satel- P.54C-9).
lite Radio, the Satellite Radio itself, or the
.
Malfunction of the Satellite Radio
DIAGNOSIS
MB991824: V.C.I.
TSB Revision

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Using scan tool MB991958 read the Satellite Radio

Check whether an satellite radio DTCs are set or not.
(2) Check for Satellite Radio DTCs.
Q: Is the DTC set?
YES : Diagnose the Satellite Radio (Refer to GROUP 54A,
Diagnostic Trouble Code).
NO : Go to Step 3.

ETACS-ECU
DTC indicating a time-out error related to the Satellite Radio
system
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.
TSB Revision
55A-61

Q: Is the DTC set?
YES : Replace the Satellite Radio. On completion, check
that the DTC is not reset.

Q: Is the DTC set?
DTC is not reset.
DTC U0197: Hands Free Module Time-out

CAUTION lines between the hands free module and the
Whenever the ECU is replaced, ensure that the A/C-ECU, the power supply system to the hands
communication circuit is normal. free module, the hands free module itself, or the
.

TROUBLE JUDGMENT
The A/C-ECU receives the air conditioning con- Past trouble
trol-related signals from the hands-free module via If DTC U0151 is stored as a past trouble, carry
the CAN bus lines. If any of the air conditioning con- out diagnosis with particular emphasis on wiring
trol-related signals from the SRS-ECU cannot be and connector(s) in the CAN bus line between
received, the diagnostic trouble code U0197 is the A/C-ECU and the hands free module, and the
stored. power supply system to the hands free module. If
the connectors and wiring are normal, and obvi-
.
ously the ECU is the cause of the trouble, replace

the ECU. If in doubt, do not replace the ECU.
TSB Revision
.
Malfunction of the hands free module
DIAGNOSIS
MB991824: V.C.I.

line
CAUTION
YES : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
55A-63
STEP 2. Using scan tool MB991958 read the hands free

Check whether an hands free module DTCs are set or not.
(2) Check for hands free module DTCs.
Q: Is the DTC set?
YES : Diagnose the hands free module (Refer to GROUP
54A, Diagnostic Trouble Code).
NO : Go to Step 3.

ETACS-ECU
DTC indicating a time-out error related to the hands free
module system
Q: Is the DTC set?
YES : Go to Step 4.
NO : Go to Step 5.

Q: Is the DTC set?
TSB Revision

Q: Is the DTC set?
DTC is not reset.
SYMPTOM CHART
M1552009900718
CAUTION
other system may be set when the ignition switch
is turned on with connector(s) disconnected. On
completion, confirm all systems for DTC code(s).
If DTC code(s) are set, erase them all.
Symptom Inspection Reference
procedure page
When the A/C is operation, temperature inside the passenger 1 P.55A-64
compartment does not decrease (Cool air is not emitted).
Malfunction of the A/C power supply system. 2 P.55A-67
The compressor does not work. 3 P.55A-71
Blower fan and motor do not turn. 4 P.55A-78
Blower air amount cannot be changed. 5 P.55A-83
Outside/inside air changeover is not possible. 6 P.55A-86
A/C outlet air temperature does not increase. 7 P.55A-88
Air outlet vent cannot be changed. 8 P.55A-91
Rear window defogger does not operate. 9 P.55A-94
Blower motor power supply system. 10 P.55A-103
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: When the A/C is Operation, Temperature Inside the Passenger
Compartment does not Decrease (Cool Air is not Emitted).
. .

The blower system or the compressor system may Malfunction of blower motor
be defective if there is no cool air coming from the Malfunction of A/C-ECU
vents. Malfunction of A/C compressor
TSB Revision
55A-65
DIAGNOSIS

trouble code.
CAUTION
Check if an A/C-ECU DTC is set.
Data link connector Scan Tool (M.U.T.-III) P.55A-6."
Q: Is the DTC set?
YES : Refer to Diagnostic Trouble Code Chart P.55A-8.
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Check that the blower motor operation when the

blower knob is moved to the "Maximum air volume"
position.
(2) Turn the blower knob to the "Maximum air volume" position
Q: Does the blower motor operate when the blower knob is
moved to the "Maximum air volume" position?
YES : Go to Step 3.
NO : Refer to Inspection procedure 4 "Blower fan and
motor do not turn P.55A-78."
TSB Revision
STEP 3. Check the rear window defogger and

outside/inside air selection damper control motor
operation.
(2) Check the engine running.
(3) Check the operations of rear window defogger and
outside/inside air selection damper control motor.
Q: Do the rear window defogger and outside/inside air
selection damper control motor work normally?
YES : Refer to Inspection procedure 3 "The A/C compressor
does not Work P.55A-71."
NO : Refer to Inspection procedure 2, "Malfunction of the
A/C-ECU power supply system P.55A-67."
TSB Revision
55A-67
INSPECTION PROCEDURE 2: Malfunction of the A/C-ECU Power Supply System.
A/C-ECU Power Supply Circuit
FUSIBLE IGNITION FUSIBLE

LINK 36 SWITCH (IG1) LINK 34
RELAY
BOX
ETACS
-ECU
IG1
RELAY
A/C-ECU
POWER POWER
SUPPLY SUPPLY

Junction block
C-20 (B)
AC608146AB AC608152 AE
TSB Revision

The A/C-ECU power system may be defective if the air condi-
tioning, defogger, and outside/inside air selection damper
motor all do not operate normally.
.
Damaged harness wires or connectors
DIAGNOSIS

in the connector.
YES : Go to Step 2.
00E, Harness Connector Inspection P.00E-2. Check
that the A/C works normally.
STEP 2. Measure the voltage at A/C-ECU connector C-20.

(1) Disconnect A/C-ECU connector C-20 and measure the
voltage at the harness side.
CONNECTOR C-20
(HARNESS SIDE) The measured value should be approximately 12 volts
YES : Go to Step 5.
NO : Go to Step 3.
AC608254 AQ

in the connector.
YES : Go to Step 4.
TSB Revision
55A-69

C-317 (terminal 5).
(terminal 15) and ETACS-ECU connector C-317 (terminal
5) in good condition?
NO : Repair the wiring harness. Check that the A/C works
normally.
STEP 5. Measure the voltage at A/C-ECU connector C-20.

(1) Disconnect A/C-ECU connector C-20 and measure the
voltage at the harness side.
CONNECTOR C-20
Q: Is the measured voltage approximately 12 V?
YES : Go to Step 7.
NO : Go to Step 6.
AC608254 AQ

connector C-20 (terminal 13) and the FUSIBLE LINK (36).
NOTE: Also check ETACS-ECU connector C-317 for loose,
corroded, or damaged terminals, or terminals pushed back in
the connector. If ETACS-ECU connector C-317 is damaged,
repair or replace the connector as described in GROUP 00E,
Harness Connector Inspection P.00E-2.
(terminal 13) and the FUSIBLE LINK (36) in good
condition?
normally.
TSB Revision
STEP 7. Measure the resistance at A/C-ECU connector

C-20.
(1) Disconnect A/C-ECU connector C-20, and measure at the
wiring harness side.
CONNECTOR C-20
(HARNESS SIDE) The measured value should be 2 ohms or less.
this range?
YES : Replace the A/C-ECU, and check that the A/C works
normally.
NO : Go to Step 8.
AC608255 BN

connector C-20 (terminal 14) and the ground.
(terminal 14) and ground in good condition?
normally.
TSB Revision
55A-71
INSPECTION PROCEDURE 3: The Compressor does not Work.
A/C Compressor Assembly Circuit
FUSIBLE
LINK 36
RELAY
BOX
A/C
COMPRESSOR
CLUTCH RELAY
ENGINE CONTROL MODULE
A/C
REFRIGERANT
TEMPERATURE
SWITCH
A/C
COMPRESSOR
CLUTCH
A/C
COMPRESSOR
ASSEMBLY
TSB Revision
Connector: A-10 Connectors: B-17
A-10
B-17 (B)
AC608142AL AC608143AB
Connector: A-13X Connector: B-109
B-109 (GR)
AC609409AH AC608144AB
FUNCTION
Compressor that recovers the refrigerant, which evaporated in
the evaporator and became a high-temperature and high-pres-
sure gas, and turns it into liquid again.
.
PROBABLE CAUSES
Insufficient refrigerant
Malfunction of the harness (A/C compressor circuit is
open/shorted to ground)
Malfunction of the A/C pressure sensor.
Malfunction of the A/C compressor.
Malfunction of the A/C compressor clutch relay.
DIAGNOSIS
MB991824: V.C.I.
TSB Revision
55A-73

line.
CAUTION
YES : Go to Step 2.
NO : Repair the CAN bus lines (Refer to GROUP 54C,
precautions on how to repair the CAN bus lines
MB991910
P.54C-16).
MB991824
MB991827 AC608435 AB

trouble code.
Q: Is the DTC set?
YES : Refer to Diagnostic Trouble Code Chart P.55A-8.
NO : Go to Step 3.
STEP 3. Check A/C compressor assembly connector B-17

Q: Is A/C compressor assembly connector B-17 in good
condition?
YES : Go to Step 4.
TSB Revision
STEP 4. Check the A/C compressor clutch operation.

Connect the compressor connector terminal to the battery posi-
tive (+) terminal and ground the batterys negative (-) terminal
to the compressor unit. At that time, the A/C compressor clutch
should make a definite operating sound.
Q: Can the sound (click) of the A/C compressor clutch
operation be heard?
YES : Go to Step 5.
NO : Replace the compressor magnet clutch.
AC506471
STEP 5. Check A/C compressor clutch relay connector

A-13X for loose, corroded or damaged terminals, or
Q: Is A/C compressor clutch relay connector A-13X in good
condition?
YES : Go to Step 6.
STEP 6. Check the A/C compressor clutch relay continuity.

Follow the table below to check the A/C compressor clutch
relay for continuity.
BATTERY TESTER SPECIFIED

VOLTAGE CONNECTION CONDITION
Connect 3 4 Less than 2 ohms
terminal 2 to the
positive battery
terminal
AC605626
Connect
A/C compressor clutch relay terminal 1 to the
negative battery
terminal
1 2 3 Q: Is the A/C compressor clutch relay in good condition?

3 4
YES : Go to Step 7.
4 1 2 NO : Replace the A/C compressor clutch relay.
AC609971AB
TSB Revision
55A-75
STEP 7. Check engine control module connector B-109 for

Q: Is engine control module connector B-109 in good
condition?
YES : Go to Step 8.
STEP 8. Measure the voltage at A/C compressor assembly

connector B-17.
(1) Disconnect A/C compressor assembly connector B-17 and
measure the voltage at the wiring harness side.
(2) Disconnect powertrain control module connector B-109 and
ground harness side terminal No.102.
(4) A/C compressor assembly connector B-17 terminal 1 and
ground.
CONNECTOR B-17
(HARNESS SIDE)
NO : Go to Step 9.
AC608254 AR
STEP 9. Measure the voltage at A/C compressor clutch

relay connector A-13X.
(1) Disconnect A/C compressor connector A-13X and measure
the voltage at the relay box side.
CONNECTOR A-13X
(HARNESS SIDE)
NO : Go to Step 10.
AC608254 AY
TSB Revision
STEP 10. Check the wiring harness between A/C

compressor clutch relay connector A-13X (terminals 2 and
4) and the fusible link (36).
Q: Is the wiring harness between A/C compressor clutch
relay connector A-13X (terminals 2 and 4) and the
fusible link (36) in good condition?
normally.
STEP 11. Check the wiring harness between A/C

compressor clutch relay connector A-13X (terminal 3) and
A/C compressor assembly connector B-17 (terminal 1).
Q: Is the wiring harness between A/C compressor clutch
relay connector A-13X (terminal 3) and A/C compressor
assembly connector B-17 (terminal 1) in good
condition?
normally.
STEP 12. Check the wiring harness between powertrain

control module connector B-109 (terminal 102) and A/C
compressor clutch relay connector A-13X (terminal 1).
Q: Is the wiring harness between powertrain control
module connector B-109 (terminal 102) and A/C
compressor clutch relay connector A-13X (terminal 1) in
good condition?
normally.
TSB Revision
55A-77
STEP 13. Check the refrigerant temperature switch.

CAUTION
Do not heat more than necessary.
(1) Dip the metal part of the cooling temperature switch into
engine oil and increase the oil temperature using a gas
burner or similar.
THERMOMETER
ENGINE OIL
AC100787 AB
(2) When the oil temperature reaches the standard value,

125C 155C check that resistance is supplied between the terminals.
(257F) (311F)
Standard value:
LESS THAN 2W ITEM TEMPERATURE
NO CONTINUITY
Less than 2 ohms Slightly below 155 C (311 F)
No continuity 155 C (311 F) or more
OIL TEMPERATURE
NOTE: When the oil temperature is 155 C (311 F) or more

AC100810AE
and there is no continuity, the resistance will not be 2 or
lower until the oil temperature reduces to 125 C (257 F) or
less.
Q: Is the refrigerant temperature switch operating
properly?
NO : Replace the refrigerant temperature switch. Check
STEP 14. Replace the A/C-ECU.

Q: Does the A/C operate normally?
NO : Replace the powertrain control module. Check that
the A/C works normally.
TSB Revision
INSPECTION PROCEDURE 4: Blower Fan and Motor do not Turn.
Blower Motor Circuit
FUSIBLE
LINK 37
ETACS-
ECU
BLOWER
RELAY
BLOWER
MOTOR
POWER
TRANSISTER
A/C-ECU
TSB Revision
55A-79
Connector: C-20, C-112, C-113
C-112
C-113
C-20 (B)
AC608146BX
CIRCUIT OPERATION
If the blower motor does not operate, the blower relay system is
suspected.
.
Malfunction of the power transistor
Malfunction of the blower motor
DIAGNOSIS
STEP 1. Check blower motor connector C-113 for loose,

in the connector.
Q: Is blower motor connector C-113 in good condition?
YES : Go to Step 2.
00E, Harness Connector Inspection P.00E-2.The
blower motor should operate normally.
TSB Revision
STEP 2. Measure the voltage at blower motor connector

C-113.
(1) Disconnect blower motor connector C-113, and measure
the voltage at the wiring harness side.
(3) Turn the blower switch to the "Maximum air volume"
position.
CONNECTOR C-113 The measured value should be approximately 12 volts
(HARNESS SIDE) (battery positive voltage).
YES : Go to Step 3.
NO : Refer to Inspection procedure 10, "Blower motor
power supply system P.55A-103."
AC608254 AS
STEP 3. Check blower motor connector C-113 for loose,

in the connector.
Q: Is blower motor connector C-113 in good condition?
YES : Go to Step 4.
STEP 4. Check the blower fan and motor operation.

Check that the motor turns when applying battery power
between the connector terminals. Also check to see that there
is no abnormal sound emitted from the motor at this time..
Q: Is there any abnormal noise?
YES : Go to Step 5.
NO : Replace the blower relay. The blower motor should
operate normally.
AC611918AC

in the connector.
YES : Go to Step 6.
TSB Revision
55A-81

connector C-20 (terminal 1) and blower motor connector
C-113 (terminal 1).
(terminal 1) and blower motor connector C-113 (terminal
1) in good condition?
YES : Go to Step 7.
NO : Repair the wiring harness. The blower motor should
operate normally.
STEP 7. Check power transistor connector C-112 for loose,

in the connector.
Q: Is power transistor connector C-112 in good condition?
YES : Go to Step 8.
STEP 8. Measure the resistance at power transistor

connector C-112.
(1) Disconnect power transistor connector C-112, and measure
the resistance at the wiring harness side.
CONNECTOR C-112 ground.
(HARNESS SIDE) OK: The measured value should be 2 ohms or less
this range?
NO : Go to Step 9.
AC608255 BN
STEP 9. Check the wiring harness between power transitor

connector C-112 (terminal 1) and ground.
Q: Is the wiring harness between power transitor
condition?
operate normally.
TSB Revision

connector C-20 (terminals 1 and 2) and power transitor
(terminals 1 and 2) and power transitor connector C-112
(terminals 2 and 4) in good condition?
operate normally.
STEP 11. Replace the power transistor and check the

trouble symptom again
Check the trouble symptom again.
NO : Replace the A/C-ECU.
TSB Revision
55A-83
INSPECTION PROCEDURE 5: Blower Air Amount cannot be Changed.
FUSIBLE
LINK 37
ETACS-
ECU
BLOWER
RELAY
BLOWER
MOTOR
POWER
TRANSISTER
A/C-ECU
TSB Revision

C-109
C-112
AC608146BJ
CIRCUIT OPERATION
If the blower motor speed cannot be changed, the power tran-
sistor circuit is suspected.
.
Malfunction of the power transistor
DIAGNOSIS
STEP 1. Check power transistor connector C-112 for loose,

in the connector.
Q: Is power transistor connector C-112 in good condition?
YES : Go to Step 2.
STEP 2. Measure the resistance at power transistor

connector C-112.
(1) Disconnect power transistor connector C-112, and measure
the resistance at the wiring harness side.
ground.
OK: The measured value should be 2 ohms or less
this range?
YES : Go to Step 4.
NO : Go to Step 3.
CONNECTOR C-112
(HARNESS SIDE)
AC608255 AM
TSB Revision
55A-85
STEP 3. Check the wiring harness between power transitor

connector C-112 (terminal 1) and ground.
Q: Is the wiring harness between power transitor
condition?
operate normally.

in the connector.
YES : Go to Step 5.

connector C-20 (terminals 1 and 2) and power transitor
(terminals 1 and 2) and power transitor connector C-112
YES : Go to Step 6.
operate normally.
STEP 6. Replace the power transistor and check the

TSB Revision
INSPECTION PROCEDURE 6: Outside/Inside Air Changeover is not possible.
Outside/Inside Air Selection Damper Control Motor Circuit
A/C-ECU
OUTSIDE/INSIDE AIR
SELECTION DAMPER
CONTROL MOTOR

C-109
C-19 (B)
AC608146BK
CIRCUIT OPERATION
If the outside/inside air selection damper control motor does not
operate normally, the outside/inside air selection damper con-
trol motor system may be defective.
.
Malfunction of the outside/inside air selection damper con-
trol motor
DIAGNOSIS
TSB Revision
55A-87
MB991824: V.C.I.
STEP 1. Using scan tool MB991958, check for diagnostic

trouble code.
CAUTION
Q: Is the DTC set?
YES : Refer to DIAGNOSTIC TROUBLE CODE CHART
P.55A-8.
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Check outside/inside air selection damper control

motor connector C-109 and A/C-ECU connector C-19 for
Q: Are outside/inside air selection damper control motor
connector C-109 and A/C-ECU connector C-19 in good
condition?
YES : Go to Step 3.
TSB Revision

connector C-19 (terminal 26, 25, 27, 24 and 29) and
outside/inside air selection damper control motor
connector C-109 (terminals 2, 5, 4. 1 and 3).
Q: Are the wiring harness between A/C-ECU connector
C-19 (terminal 26, 25, 27, 24 and 29) and outside/inside
air selection damper control motor connector C-109
(terminals 2, 5, 4. 1 and 3) in good condition?
YES : Go to Step 4.
normally.
STEP 4. Replace the outside/inside air selection damper

control motor and check the trouble symptom again
INSPECTION PROCEDURE 7: A/C Outlet Air Temperature does not Increase
Air Mixing Damper Control Motor Circuit
A/C-ECU
AIR MIXING
DAMPER CONTROL
MOTOR
TSB Revision
55A-89
C-118 C-19 (B)
AC608146BL
CIRCUIT OPERATION
If the air outlet temperature cannot be adjusted, the air mixing
damper control motor circuit may be failed.
.
Malfunction of the air mixing damper control motor
DIAGNOSIS
MB991824: V.C.I.

trouble code.
Q: Is the DTC set?
P.55A-64.
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
TSB Revision
STEP 2. Check air mixing damper control motor connector

C-118 and A/C-ECU connector C-19 for loose, corroded or
connector.
Q: Are air mixing damper control motor connector C-118
and A/C-ECU connector C-19 in good condition?
YES : Go to Step 3.

connector C-19 (terminal 29, 35, 36, 34 and 28) and air
mixing damper control motor connector C-118 (terminals
3, 2, 5. 4 and 1).
C-19 (terminal 29, 35, 36, 34 and 28) and air mixing
damper control motor connector C-118 (terminals 3, 2,
5. 4 and 1) in good condition?
YES : Go to Step 4.
normally.
STEP 4. Replace the air mixing damper control motor and

check the trouble symptom again
TSB Revision
55A-91
INSPECTION PROCEDURE 8: Air Outlet Vent cannot be Changed.
Mode Selection Damper Control Motor Circuit
A/C-ECU
MODE SELECTION
DAMPER CONTROL
MOTOR
C-111
C-19 (B)
AC608146BM
CIRCUIT OPERATION
If the air outlet cannot be switched, the mode selection damper
control motor circuit may be failed.
.
Malfunction of the mode selection damper control motor
TSB Revision
DIAGNOSIS
MB991824: V.C.I.

trouble code.
Q: Is the DTC set?
P.55A-8.
NO : Go to Step 2.
MB991910
MB991824
MB991827 AC608435 AB
STEP 2. Check mode selection damper control motor

connector C-111 and A/C-ECU connector C-19 for loose,
in the connector.
Q: Are mode selection damper control motor connector
YES : Go to Step 3.
TSB Revision
55A-93

connector C-19 (terminal 29, 31, 32, 30 and 33) and mode
selection damper control motor connector C-111
(terminals 3, 2, 5. 4 and 1).
C-19 (terminal 29, 31, 32, 30 and 33) and mode selection
damper control motor connector C-111 (terminals 3, 2, 5.
4 and 1) in good condition?
YES : Go to Step 4.
normally.
STEP 4. Replace the mode selection damper control motor

and check the trouble symptom again
TSB Revision
INSPECTION PROCEDURE 9: Rear window defogger does not operate.
Rear Window Defogger Circuit
ETACS-ECU FUSIBLE
LINK 37
RELAY BOX
PASSENGER
COMPARTMENT
REAR
WINDOW
DEFOGGER
RELAY
A/C
CONTROL
PANEL POWER
SOURCE
CPU
INTERFACE
CIRCUIT
REAR REAR WINDOW

WINDOW DEFOGGER
DEFOGGER
SWITCH
TSB Revision
55A-95
A/C
CPU CONTROL
PANEL
INTERFACE
CIRCUIT
A/C-ECU
Connectors: C-36, C-129 Connector: D-15
C-129
C-36
AC608145BU AC608166AL
Connector: C-20, C-120 Connectors: F-04, F-25

F-04 (B)
C-120 F-25 (B)
C-20 (B)
F-20
AC608146BG AC608171AR

Junction block
C-301
C-306
AC608152 AU
TSB Revision

The rear window defogger is able to turn on while engine is run-
ning. If the defogger does not operate when the rear window
defogger switch is turned on, the rear window defogger relay
system may be defective.
.
Malfunction of the rear window defogger relay
DIAGNOSIS
STEP 1. Check the A/C and outside/inside air selection

damper control motor operation.
(2) Check the engine running.
(3) Check the operations of rear window defogger and A/C.
Q: Do the A/C and outside/inside air selection damper
control motor work normally?
YES : Go to Step 2.
NO : Refer to Inspection procedure 2, "Malfunction of the
A/C-ECU power supply system P.55A-67."

condition?
YES : Go to Step 3.
00E, Harness Connector Inspection P.00E-2. The
rear window defogger system should work normally.
TSB Revision
55A-97
STEP 3. Check the rear window defogger relay continuity.

Follow the table below to check the rear window defogger relay
for continuity.

number condition
With no current applied 3 4 No
Rear window continuity
defogger relay
With current applied Continuity
()] or less)
Q: Is the rear window defogger relay in good condition?

YES : Go to Step 4.
NO : Replace the rear window defogger relay. The rear
window defogger system should work normally.
4
3
1 2
AC609147AB
STEP 4. Check rear window defogger connector F-25 and

A/C control panel connector C-120 for loose, corroded or
connector.
Q: Are rear window defogger connector F-25 and A/C
control panel connector C-120 in good condition?
YES : Go to Step 5.
00E, Harness Connector Inspection P.00E-2. The
rear window defogger system should work normally.
TSB Revision
STEP 5. Measure the voltage at rear window defogger

connector F-25.
(1) Disconnect rear window defogger connector F-25, and
measure the voltage at the harness side.
(2) Disconnect A/C-ECU connector C-120 and ground harness
side terminal No.6.
(4) Measure the voltage between rear window defogger
CONNECTOR F-25 connector F-25 terminal No.1 and ground.
NO : Go to Step 6.
AC608254 AT
STEP 6. Measure the voltage at rear window defogger relay

connector C-306.
(1) Disconnect rear window defogger relay connector C-306,
and measure the voltage at the junction block side.
CONNECTOR C-306 The measured value should be approximately 12 volts
(HARNESS SIDE) (battery positive voltage).
YES : Go to Step 8.
NO : Go to Step 7.
AC608254 AU
STEP 7. Check the wiring harness between rear window

defogger relay connector C-306 (terminal 4) and the fusible
link (37).
Q: Is the wiring harness between rear window defogger
relay connector C-306(terminal 4) and the fusible link
(37) in good condition?
YES : Check that the rear window defogger system works
normally.
NO : Repair the wiring harness. Check that the rear
window defogger system works normally.
TSB Revision
55A-99
STEP 8. Measure the voltage at rear window defogger relay

connector C-306.
(1) Disconnect rear window defogger relay connector C-306,
and measure the voltage at the junction block side.
NO : Go to Step 9.
CONNECTOR C-306
(HARNESS SIDE)
AC608254AV

in the connector.
that the rear window defogger system works normally.

defogger relay connector C-306 (terminal 1) and
ETACS-ECU C-301 (terminal 12).
relay connector C-306 (terminal 1) and ETACS-ECU
normally.
NO : Repair the wiring harness. Check that the rear
window defogger system works normally.

defogger relay connector C-306 (terminal 2) and A/C-ECU
relay connector C-306 (terminal 2) and A/C-ECU
NO : Repair or replace the wiring harness. Refer to
P.00E-2. Check that the rear window defogger
system works normally.
TSB Revision

defogger relay connector C-306 (terminal 3) and rear
window defogger connector F-25 (terminal 1).
NOTE: Also check intermediate connector C-36 and D-15 for
back in the connector. If intermediate connector C-36 and D-15
relay connector C-306 (terminal 3) and rear window
defogger connector F-25 (terminal 1) in good condition?
STEP 13. Check rear window defogger connector F-04 for

Q: Is rear window defogger connector F-04 in good
condition?
STEP 14. Measure the resistance at rear window defogger

connector F-04.
(1) Disconnect rear window defogger connector F-04, and
CONNECTOR F-04 The measured value should be 2 ohms or less.
(HARNESS SIDE)
this range?
NO : Go to Step 15.
AC608255 AN
TSB Revision
55A-101

defogger connector F-04 (terminal 1) and the ground.
connector F-04 (terminal 1) and the ground in good
condition?
normally.

in the connector.

connector C-20 (terminals 9 and 10) and A/C control panel
C-20 (terminals 9 and 10) and A/C control panel
TSB Revision
STEP 18. Check the rear window defogger.

Normal characteristics of print heater
(1) Let the engine run at 2,000 r/min, and check the printed
Voltage (V) heater with the battery fully charged.
12 (2) Turn on the rear window defogger switch, and use a
voltmeter to measure the voltage in each printed heater at
A (middle point)
middle point A on the rear window glass.
6 Approximately 6 V The value should be approximately 6 volts.
Q: Does the rear window defogger work normally?
0 YES : Go to Step 19.
NO : Repair the rear window defogger.
Abnormal characteristics of print heater

Voltage (V)
12 Disconnection
location
0
AC407247AD
STEP 19. Replace the A/C control panel and check the
TSB Revision
55A-103
INSPECTION PROCEDURE 10: Blower Motor power supply system.
FUSIBLE
LINK 37
ETACS-
ECU
BLOWER
RELAY
BLOWER
MOTOR
POWER
TRANSISTER
A/C-ECU
TSB Revision
Connectors: C-113 Connectors: C-303, C-309, C-315

Junction block
C-303
C-309 (B)
C-315
AC608146 BO AC608152 AV

If the voltage is not supplied to the blower motor, the blower
relay system may be failed.
.
Malfunction of the blower relay
DIAGNOSIS
STEP 1. Check blower relay connector C-303 for loose,

in the connector.
Q: Is blower relay connector C-303 in good condition?
YES : Go to Step 2.
TSB Revision
55A-105
STEP 2. Check the blower relay continuity.

Follow the table below to check the blower relay for continuity.
Battery voltage Tester connection Specified

condition
terminal 1 to the
positive battery
terminal
Blower relay AC605627
Connect
terminal 2 to the
negative battery
terminal
1 2 4
3
Q: Is the blower relay in good condition?
3
YES : Go to Step 3.
4 1 2 NO : Replace the rear window defogger relay.
AC609984AB
STEP 3. Measure the voltage at blower relay connector

C-303.
(1) Disconnect blower relay connector C-303, and measure the
voltage at the junction block side.
Connector C-303
(Junction block side) The measured value should be approximately 12 volts
AC608254 AW

Connector C-303 The measured value should be approximately 12 volts
(Junction block side)
YES : Go to Step 5.
NO : Go to Step 4.
AC608254 AX
TSB Revision
STEP 4. Check the wiring harness between blower relay

connector C-303 (terminals 1 and 4) and the fusible link
(37).
Q: Is the wiring harness between blower relay connector
C-303 (terminals 1 and 4) and the fusible link (37) in
good condition?
P.00E-2.
STEP 5. Check blower relay connector C-113 for loose,

in the connector.
Q: Is blower relay connector C-113 in good condition?
YES : Go to Step 6.
STEP 6. Check the wiring harness between blower relay

connector C-303 (terminal 3) and blower motor connector
C-113 (terminal 1).
Q: Is the wiring harness between blower relay connector
C-303 (terminal 3) and blower motor connector C-113
(terminal 1) in good condition?
P.00E-2.
TSB Revision
55A-107
M1554005100620
Refer to GROUP 55B - Data list reference table
P.55B-16.)
ACTUATOR TEST REFERENCE
M1554005200564
Refer to GROUP 55B - Actuator test reference
P.55B-20.)
TSB Revision
CHECK AT A/C-ECU TERMINAL

M1552010301263
C-20 C-19
1 2 3 4 5 6 7 8 9 10 21 2223 24 25 26 27 28
11 12 13 14 15 16 17 18 19 20 29 30 31 32 33 34 35 36
AC210339 AE
Terminal Check items Check conditions Normal conditions

No.
1 Power transistor (DRAIN) Air volume control dial: Maximum air 0 to 2 V
volume
2 Power transistor (GATE) Air volume control dial: Maximum air Battery voltage
volume
3 8
9 A/C control panel (input)
11, 12
14 Ground Always 0V
15 IG1 power supply Ignition switch: IG1 Battery voltage
16 A/C pressure sensor input Refer to P.55A-112. Refer to P.55A-112.
17 Interior temperature sensor Sensor probe temperature: 25 C 2.1 to 2.7 V
(77 F) (4.0 k)
18
19 Sensor ground Always 0V
20 A/C pressure sensor power Ignition switch: IG2 5V
supply
21 Air thermo sensor ground Always 0V
22 Air thermo sensor Sensor probe temperature: 25 C 2.1 to 2.7 V
(77 F) (4.0 k)
23
24 Motor for air outside/inside
air circulation switching
damper
damper
damper
damper
TSB Revision
SPECIAL TOOLS
55A-109
No.
28 Air mix damper motor
29 Motor power supply
30 Air outlet changeover
damper motor
damper motor
damper motor
damper motor
SPECIAL TOOLS
M1552000600613

and name
MB991367 MB991367-01 Armature mounting nut of
Special spanner compressor removal and
installation
B991367
MB991386 Pin MIT217213 Armature mounting nut of

compressor removal and
installation
MB991658 Tool not available Inspection of throttle position

Test harness set sensor
MB991658
TSB Revision
SPECIAL TOOLS

and name
MB991223 Harness set Continuity check and voltage
a
a. MB991219 a. Check harness measurement at harness wire or
b. MB991220 b. LED harness connector
c. MB991221 c. LED harness a. For checking connector pin
d. MB991222 adapter contact pressure
b
d. Probe b. For checking power supply
circuit
c. For checking power supply
circuit
c d. For connecting a locally sourced
tester
d
DO NOT USE
MB991223BA
MB992006 General service tool Making voltage and resistance

troubleshooting
MB992006
TSB Revision
SPECIAL TOOLS
55A-111
and name
MB991955 M.U.T.-III CAUTION
a sub-assembly
a. MB991824 For vehicles with CAN
b. MB991827 a. Vehicle communication, use M.U.T.-III
c. MB991910 Communication main harness A to send
d. MB991911 Interface (V.C.I.) simulated vehicle speed. If you
MB991824
e. MB991825 b. M.U.T.-III USB connect M.U.T.-III main harness
b cable B instead, the CAN
f. MB991826
c. M.U.T.-III main communication does not
harness A function correctly.
(Vehicles with A/C-ECU check (Diagnosis code,
MB991827 CAN service data, actuator test)
c communication
system)
d. M.U.T.-III main
harness B
MB991910 (Vehicles without
CAN
d
communication
DO NOT USE system)
e. M.U.T.-III measure
MB991911
adapter
f. M.U.T.-III trigger
e harness
MB991825
MB991826
MB991955
TSB Revision
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
REFRIGERANT LEVEL TEST
M1552008400583
Use the refrigerant recovery station to remove all of the refrig-
erant, and then calculate the amount of the refrigerant and
charge it.
A/C COMPRESSOR CLUTCH TEST

M1552019900117
1. Disconnect the A/C compressor clutch connector to the A/C
compressor clutch.
2. Connect positive battery voltage directly to the connector for
the A/C compressor clutch.
3. Supply a ground to the A/C compressor assembly.
4. If the A/C compressor clutch is normal, there will be a "click."
If the pulley and armature do not make contact ("no click"),
there is a malfunction.
AC506471
SIMPLE INSPECTION OF THE A/C PRESSURE

SENSOR
M1552014700367
1. Assemble a gauge manifold on the high pressure service

valve.
A/C pressure sensor 2. Disconnect the A/C pressure sensor connector and connect
special tool test harness MB991658 as shown in the illustra-
tion.
3. Turn ON the engine and then turn ON the air conditioner
switch.
AC609413AB
A/C
PRESSURE
SENSOR HARNESS SIDE
SIDE
MB991658
AC307368 AB
TSB Revision
ON-VEHICLE SERVICE
55A-113
OUTPUT VOLTAGE 4. At this time, check to see that the voltage of A/C pressure
(V)
sensor terminal No. 2 reflects the specifications of the fig-
5
ure.
4
NOTE: The allowance shall be defined as 5%.
3
2
1
0 1 (145) 2 (290) 3 (435)

REFRIGERANT PRESSURE MPa (psi)
AC208297AD
COMPRESSOR DRIVE BELT ADJUSTMENT

M1552001000896
Refer to GROUP 11A, On-vehicle Service Drive Belt tension
check and adjustment P.11A-9.
CHARGING
M1552001200652
Use the refrigerant recovery station to charge the refrigerant.
METHOD BY USING REFRIGERANT RECOVERY
AND RECYCLING UNIT
Using the refrigerant recovery and recycling unit, refill the
refrigerant.
NOTE: Refer to the Refrigerant Recovery and Recycling Units
Instruction Manual for operation of the unit.
DISCHARGING SYSTEM
Use the refrigerant recovery unit to discharge refrigerant gas
from the system.
NOTE: Refer to the Refrigerant Recovery and Recycling Units
Instruction Manual for operation of the unit.
REFILLING OF OIL IN THE A/C SYSTEM

Too little oil will provide inadequate compressor lubrication and
cause a compressor failure. Too much oil will increase dis-
charge air temperature.
When a compressor is installed at the factory, it contains 140
cm3 (4.7 fl.oz) of refrigerant oil. While the A/C system is in
operation, the oil is carried through the entire system by the
refrigerant. Some of this oil will be trapped and retained in vari-
ous parts of the system.
When the following system components are changed, it is nec-
essary to add oil to the system to replace the oil being removed
with the component.
Compressor oil: SUN PAG 56
Quantity:
Evaporator: 60 cm3 (2.0 fl.oz)
Condenser: 15 cm3 (0.5 fl.oz)
Suction hose: 10 cm3 (0.3 fl.oz)
TSB Revision
ON-VEHICLE SERVICE
PERFORMANCE TEST
M1552001400827
The vehicles to be tested should be parked out of direct sun-
light.
1. Close the high and low-pressure valve of the gauge
Low-pressure manifold.
valve High-pressure 2. Connect the charging hose (blue) to the low-pressure valve
valve and connect the charging hose (red) to the high-pressure
valve of the gauge manifold.
Gauge manifold
3. Install the quick joint (for low-pressure) to the charging hose
(blue), and connect the quick joint (for high-pressure) to the
Charging
Charging charging hose (red).
hose (Blue) hose (Red)
CAUTION
Adaptor
To connect the quick joint, press section A firmly
valve against the service valve until a click is heard.
A
(For When connecting, run your hand along the hose while
Sleeve
low-pres- pressing to ensure that there are no bends in the hose.
sure) Adaptor
valve 4. Connect the quick joint (for low-pressure) to the
(For high- low-pressure service valve and connect the quick joint (for
Low- High- pressure) high-pressure) to the high-pressure service valve.
pressure pressure
service service NOTE: The high-pressure service valve is on the A/C pipe
valve valve
and the low-pressure service valve is on the suction hose.
AC609415AC
5. Start the engine.
6. Set the A/C controls as follows:
A/C switch: A/C ON position
Mode selection: FACE position
Temperature control: MAXIMUM COOLING position
Air selection: RECIRCULATION position
Blower switch: Maximum air volume
7. Set the engine speed to the idle speed.
8. Engine should be warmed up with hood, doors and windows
opened.
Thermometer 9. Insert a thermometer in the center air outlet and operate the
engine for 20 minutes.
NOTE: If the A/C clutch cycles, take the reading before the
clutch disengages.
10.Note the discharge air temperature.
AC609414AB
TSB Revision
ON-VEHICLE SERVICE
55A-115
PERFORMANCE TEMPERATURE CHART
Garage 20 (68) 25 (77) 30 (86) 35 (95) 40 (104) 45 (113) 50 (122)
ambient air
temperature
C ( F)
Discharge air 4.7 (40) 10 (50) 23 15 (59) 28 20 (68) 33 26 (79) 38 31 (88) 44 36 (97) 49
temperature 17 (63) (73) (82) (91) (100) (111) (120)
C ( F)
Compressor 934 (136) 1068 (155) 1201 (174) 1335 (193) 1468 (213) 1602 (232) 1735 (252)
high pressure 1700 (247) 1850 2000 2150 2300 2450 2600
kPa (psi) (268) (290) (312) (334) (355) (377)
Compressor 170 (24.7) 215 (31.2) 260 (37.7) 305 (44.2) 350 (50.8) 395 (57.3) 440 (63.8)
low pressure 359 (52.1) 406 (58.9) 452 (65.6) 499 (72.4) 545 (79.1) 592 (85.9) 638 (92.6)
kPa (psi)
REFRIGERANT LEAK REPAIR PROCEDURE

M1552001500437
LOST CHARGE HANDLING TUBING AND FITTINGS

If the system has lost all charge due to a leak: Kinks in the refrigerant tubing or sharp bends in the
1. Evacuate the system. (Refer to P.55A-113). refrigerant hose lines will greatly reduce the capacity
2. Charge the system with approximately 0.453 kg (1 of the entire system. High pressures are produced in
pound) of refrigerant. the system when it is operating. Extreme care must
be exercised to make sure that all connections are
3. Check for leaks.
pressure tight. Dirt and moisture can enter the sys-
4. Discharge the system. tem when it is opened for repair or replacement of
5. Repair leaks. lines or components. The following precautions must
CAUTION be observed. The system must be completely dis-
Replacement filter-drier units must be sealed charged before opening any fitting of connection in
while in storage. The drier used in these units will the refrigeration system. Open fittings with caution
saturate water quickly upon exposure to the even after the system has been discharged. If any
atmosphere. When installing a drier, have all pressure is noticed as a fitting is loosened, allow
tools and supplies ready for quick assembly to trapped pressure to bleed off very slowly.
avoid keeping the system open any longer than Never attempt to rebend formed lines to fit. Use the
necessary. correct line for the installation you are servicing. A
6. Replace receiver drier. good rule for the flexible hose lines is keep the radius
of all bends at least 10 times the diameter of the
7. Evacuate and charge system.
hose.
Sharper bends will reduce the flow of refrigerant. The
LOW CHARGE flexible hose lines should be routed so that they are
If the system has not lost all of its refrigerant charge; at least 80 mm (3.1 inches) from the exhaust mani-
locate and repair all leaks. If it is necessary to fold. It is good practice to inspect all flexible hose
increase the system pressure to find the leak lines at least once a year to make sure they are in
(because of an especially low charge) add refriger- good condition and properly routed.
ant. If it is possible to repair the leak without dis- On standard plumbing fittings with O-rings, these
charging the refrigerant system, use the procedure O-rings are not reusable.
for correcting low refrigerant level.
TSB Revision
ON-VEHICLE SERVICE
COMPRESSOR NOISE CHECK

M1552008700476
You must first know the conditions when the noise ADJUSTMENT
occurs. These conditions are: weather, vehicle 1. Select a quiet area for testing. Duplicate
speed, in gear or neutral, engine temperature or any conditions as much as possible. Switch the
other special conditions. compressor on and off several times to clearly
Noises that develop during A/C operation can often identify compressor noise. To duplicate high
be misleading. For example: what sounds like a ambient conditions (high head pressure), restrict
failed front bearing or connecting rod, may be air flow through the condenser. Install a manifold
caused by loose bolts, nuts, mounting brackets, or a gauge set to make sure discharge pressure
loose clutch assembly. Verify accessory drive belt doesn't exceed 2,070 kPa (300.2 psi).
tension (power steering or generator).
2. Tighten all compressor mounting bolts, clutch
Improper accessory drive belt tension can cause a
mounting bolt, and compressor drive belt. Check
misleading noise when the compressor is engaged
to assure clutch coil is tight (no rotation or
and little or no noise when the compressor is disen-
wobble).
gaged.
Drive belts are speed-sensitive. That is, at different 3. Check refrigerant hoses for rubbing or
engine speeds, and depending upon belt tension, interference that can cause unusual noises.
belts can develop unusual noises that are often mis- 4. Check refrigerant charge (Refer to P.55A-113).
taken for mechanical problems within the compres- 5. Recheck compressor noise as in Step 1.
sor. 6. If noise still exists, loosen compressor mounting
bolts and retighten. Repeat Step 1.
7. If noise continues, replace compressor and repeat
from Step 1.
POWER RELAY CHECK

M1552008800796
A/C COMPRESSOR CLUTCH RELAY CONTINUITY

CHECK

condition
terminal 2 to the
positive battery
terminal
AC605626
Connect
A/C compressor clutch relay terminal 1 to the
negative battery
terminal
1 2 3
3 4
4 1 2
AC609971AB
TSB Revision
ON-VEHICLE SERVICE
55A-117
BLOWER RELAY CONTINUITY CHECK

condition
terminal 1 to the
positive battery
terminal
Blower relay AC605627
Connect
terminal 2 to the
negative battery
terminal
1 2 4
3 3
4 1 2
AC609984AB
IDLE-UP OPERATION CHECK

M1552001600940
Before inspection and adjustment, set vehicle in the following
condition:
Engine coolant temperature: 80 90 C (176.0 194.0 F)
Lights, electric cooling fan and accessories: OFF
Transmission: Neutral ("N" or "P" position)
Steering wheel: Straightforward
1. Check whether or not the idle speed is the standard value.
Refer to GROUP 11A, On-vehicle Service Idle Speed
Check P.11A-13.
Standard value: 700 50 r/min
2. Turn on the air conditioning switch and the blower speed
selection dial. Engine idling speed should be within the
standard value:
Standard value: 700 50 r/min
NOTE: It is not necessary to make an adjustment, because
the idling speed is automatically adjusted by the ISC sys-
tem. If, however, a deviation from the standard value occurs
for some reason, check the ISC system (Refer to GROUP
11A, On-vehicle Service Idle Speed Check P.11A-13)
TSB Revision
HEATER CONTROL UNIT
REPLACE THE CLEAN AIR FILTER

M1552020100267
1. Remove the glove box (Refer to GROUP 52A glove box,
P.52A-5).
2. Loosen the two lugs as shown to replace the clean air filter.
3. Install the glove box.
AC611715AB
HEATER CONTROL UNIT

M1554014700255
Pre-removal and Post-installation Operation

Side cover, Instrument panel garnish, Upper panel
Removal and Installation (Refer to GROUP 52A, Instru-
ment Panel P.52A-2).
Floor console Removal and Installation (Refer to GROUP
52A, Floor console P.52A-8).
1 2
AC608191AB
Removal steps
1. Center panel assembly (Refer to
GROUP 52A, Instrument panel
center panel P.52A-6)
2. Heater control
TSB Revision
HEATER UNIT AND BLOWER ASSEMBLY
55A-119
M1552020800307
WARNING
Before removing the front seat assembly, refer to GROUP 52B, Service Precautions
P.52B-24 and Air Bag Module and Clock Spring P.52B-367.
When removing and installing the front passenger seat, be sure to carry out accuracy
check occupant classification sensor after the seat has been installed in the vehicle
(Refer to GROUP 52B, On-Vehicle Service P.52B-358).
Refrigerant draining and Refilling (Refer to Charging and
Discharging P.55A-113).
Engine coolant Draining and Refilling (Refer to GROUP
00, Engine coolant P.00-65).
Steering Column Shaft Assembly Removal and Installa-
tion (Refer to GROUP 37, Steering Shaft P.37-25).
Instrument Panel Removal and Installation (Refer to
GROUP 52A, Instrument Panel P.52A-2).
Floor console Removal and Installation (Refer to GROUP
52A, Floor console P.52A-8).
TSB Revision
-Pipe coupling
2, 3 4 3
1 4.9 0.9 Nm
A/C compressor oil: 43 8 in-lb
SUN PAG 56
2
9
N 6
4
20 5 Nm
15 3 ft-lb
5
23 6 Nm
17 4 ft-lb
7 8
18 7 Nm
13 3 ft-lb
18 7 Nm
13 3 ft-lb
20 5 Nm
15 3 ft-lb
AC608202

1. Drain assembly 6. O-ring
2. Heat protector 7. Front deck crossmember
3. Heater hose connection 8. Drain hose
<<A>> 4. Suction pipe connection <> 9. Heater unit
<<A>> 5. Liquid pipe connection
TSB Revision
55A-121
.
<<A>> SUCTION PIPE AND LIQUID PIPE DISCON-

NECTION
CAUTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To prevent the entry of dust or other foreign bodies, plug the
dismantled hose and the nipples of the expansion valves.
.
<> HEATER UNIT AND DECK

CROSSMEMBER ASSEMBLY REMOVAL
Disconnect the following connectors to gain access to the front
deck crossmember.
Connector Connector name
number
C-21 Instrument panel wiring harness and floor
C-129 wiring harness combination
C-128 C-22 Instrument panel wiring harness and floor
C-127 C-130
C-36 C-125 wiring harness combination
C-35 C-126 AC608145CN
C-26 Instrument panel wiring harness and console
wiring harness combination
C-35 Instrument panel wiring harness and floor
C-114
C-115 C-36 Instrument panel wiring harness and floor
C-21 wiring harness combination
C-22
C-114 Instrument panel wiring harness and front door
wiring harness (RH) combination
C-26
AC608146 BV
wiring harness (LH) combination
wiring harness (LH) combination
C-127 Instrument panel wiring harness and front
C-130 Instrument panel wiring harness and roof wiring
harness combination
TSB Revision
DISASSEMBLY AND REASSEMBLY

M1552020900230
1
3
32 23
2
12
10
9
27 13
28 16
29
30 5
27 17 N
25
8 24
11
26
6 7
14
4 19
18 21
31
15
33
22
20
AC608203AB

1. KOS-ECU 13. Upper case assembly
2. Front center duct 14. Evaporator
3. Rear center duct 15. Air thermo sensor
4. Foot duct 16. Expansion valve
5. A/C-ECU 17. O-ring
6. Air mixing damper control motor 18. Air filter cover
7. Mode selection damper control 19. Air filter
motor 20. Power transistor
8. Mode lever 21. Blower motor
9. Outside/Inside air selection damper 22. Insulator
control motor 23. Air intake duct
10. Heater core cover 24. Blower case upper
11. Heater core 25. Outside/inside air selection damper
12. Expansion valve cover 26. Blower case lower
TSB Revision
55A-123
Disassembly steps (Continued)
27. Upper case
28. Mode selection damper (FOOT)
29. Mode selection damper (DEF)
30. Air mixing damper
31. Wiring harness
32. Aspirator
33. Lower case
INSPECTION
M1554011900197
.
AIR THERMO SENSOR CHECK

Resistance 25 Measure the resistance between the sensor terminals under at
(k) 20
least two temperatures. The resistance values should meet the
values shown.
15
NOTE: The temperature should be within the shown range.
10
5
0
-10 0 10 20 30 40
(14) (32) (50) (68) (86) (104)
Temperature C (F) AC609399AB
TSB Revision
MOTORS AND TRANSISTOR

M1551006900084
2
1
AC608213AB
Blower motor removal step Outside/inside air selection

Under cover (Refer to GROUP damper motor removal step
52A, Glove box P.52A-5). Glove box, Under cover, Upper
1. Blower motor cover (Refer to GROUP 52A, Glove
Power transistor removal step box P.52A-5).
Under cover (Refer to GROUP Foot duct (Refer to P.55A-136).
52A, Glove box P.52A-5). A/C-ECU (Refer to P.55A-127).
2. Power transistor <<A>> 4. Outside/inside air selection damper
Air mixing damper control motor motor
removal step Mode selection damper control
Glove box, Under cover (Refer to motor removal step
GROUP 52A, Glove box P.52A-5). Glove box, Under cover, Upper
Foot duct (Refer to P.55A-136). cover (Refer to GROUP 52A, Glove
A/C-ECU (Refer to P.55A-127). box P.52A-5).
<<A>> 3. Air mixing damper control motor Foot duct (Refer to P.55A-136).
A/C-ECU (Refer to P.55A-127).
<<A>> 5. Mode selection damper control
motor
TSB Revision
55A-125
.
<<A>> AIR MIXING DAMPER CONTROL MOTOR,

OUTSIDE/INSIDE AIR SELECTION DAMPER
MOTOR, MODE SELECTION DAMPER CONTROL
MOTOR REMOVAL
NOTE: A normal plate-type ratchet driver is recommended.
AC100628 AB
INSPECTION
M1551006300747
BLOWER MOTOR CHECK

Check that the motor turns when applying battery power
between the connector terminals. Also check to see that there
is no abnormal sound emitted from the motor at this time..
AC611918AC
TSB Revision
AMBIENT TEMPERATURE SENSOR
AMBIENT TEMPERATURE SENSOR

M1554003400368
1
AC609030AB
Removal step
(Refer to GROUP 51, Front bumper
assembly P.51-3).
1. Ambient air temperature sensor
INSPECTION
M1551006300736
.
AMBIENT AIR TEMPERATURE SENSOR CHECK

CAUTION
Resistance The ambient air temperature sensor should be checked
(k) 10 without removing it. If the sensor is removed, it is no
8 longer serviceable.
6
Measure the resistance between the sensor terminals under at
least two temperatures. The resistance values should meet the
4 values shown.
2 NOTE: The temperature should be within the shown range.
0
-10 0 10 20 30 40
(14) (32) (50) (68) (86) (104)
Temperature C (F) AC209192 AB
TSB Revision
A/C-ECU
55A-127
A/C-ECU
M1554016600124
AC608297AB

Glove box, Under cover (Refer to Foot duct (Refer to P.55A-136)
GRUOP 52A Glove box P.52A-5) 1. A/C-ECU
TSB Revision
COMPRESSOR ASSEMBLY AND TENSION PULLEY

M1552004100591

Refrigerant Discharging (Refer to P.55A-113). Drive Belt Tension Adjustment (Refer to GROUP 11A, On
Engine room under cover front A (Refer to GROUP 51, vehicle service Drive Belt P.11A-9).
under cover P.51-16). Refrigerant Charging (Refer to P.55A-113).
Front Under Cover RH (Refer to GROUP 51, Under cover Engine room under cover front A (Refer to GROUP 51,
P.51-16). under cover P.51-16).
Front Under Cover RH (Refer to GROUP 51, Under cover
P.51-16).
-Pipe coupling
1, 2 3
A/C compressor oil: 25 4 Nm
SUN PAG 56 3N 18 3 ft-lb
23 6 Nm
6 17 4 ft-lb 1
5
2
25 4 Nm
N 3 18 3 ft-lb
23 6 Nm
4 17 4 ft-lb
AC608280

<<A>> 1. Flexible discharge hose connection 4. Drive belt
<<A>> 2. Flexible suction hose connection <> >>A<< 5. A/C compressor
3. O-ring 6. A/C compressor bracket
TSB Revision
55A-129
.
<<A>> FLEXIBLE SUCTION HOSE AND FLEXIBLE

DISCHARGE HOSE DISCONNECTION
CAUTION
nipples.
dismantled hoses and compressor nipples.
.
<> COMPRESSOR REMOVAL

Take care not to spill any compressor oil when removing the
compressor.

.
>>A<< COMPRESSOR INSTALLATION

If a new compressor is installed, first adjust the amount of oil
according to the procedures described below, and then install
the compressor.
1. Measure the amount [X cm3 (X fl.oz) of oil within the
removed compressor.
2. Drain (from the new compressor) the amount of oil
calculated according to the following formula, and then
install the new compressor.
New compressor oil amount = 80cm2 (2.7 fl.oz)
80 cm3 X cm3 = Y cm3 (2.7 fl.oz. X fl.oz. = Y fl.oz)
NOTE: Y cm3 (Y fl.oz) indicates the amount of oil in the refrig-
erant line, the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the same times as
the compressor, subtract the rated oil amount of each part from
Y cm3 (Y fl.oz) and discharge from the new compressor.
INSPECTION
M1552014303186
COMPRESSOR A/C COMPRESSOR CLUTCH

OPERATION CHECK
Connect the compressor connector terminal to the battery posi-
tive (+) terminal and ground the batterys negative (-) terminal
to the compressor unit. At that time, the A/C compressor clutch
should make a definite operating sound.
AC506471
TSB Revision

M1552004601072
1
3
2
11
6
10
9
16 1 Nm
12 1 ft-lb 8
7
4 5 AC505743AD
Cooling temperature switch A/C compressor clutch

disassembly steps disassembly (Continued)
1. Bracket >>B<< 7. Snap ring
2. Snap ring 8. Rotor
3. Cooling temperature switch 9. Snap ring
A/C compressor clutch >>A<< 10. Field core
disassembly 11. A/C compressor
>>D<< Air gap adjustment Required Special Tools:
<<A>> >>C<< 4. Self-locking nut MB991367: Special Spanner
5. Armature MB991386: Pin
6. Shim

.
<<A>> SELF-LOCKING NUT REMOVAL
MB991386
MB991367
AC507128AB
TSB Revision
55A-131
.
>>A<< FIELD CORE ATTACHMENT

Line up the pin hole on the compressor unit with the field core
projection and attach.
Compressor
unit pin hole
Field core
projection
AC609150AB
>>B<< SNAP RING INSTALLATION

Using snap ring pliers, fit the snap ring so that the snap rings
SNAP RING CLUTCH COIL
ROTOR tapered part is on the outside.
TAPERED PART
AC001412 AB
>>C<< SELF-LOCKING NUT INSTALLATION

Using a special tool, as when removing the nut, secure the
armature and tighten the self-locking nut.
.
>>D<< AIR GAP ADJUSTMENT

Check whether or not the air gap of the clutch is within the stan-
dard value.
Standard value:
0.3 0.5 mm (0.012 0.020 inch)
NOTE: If there is a deviation of the air gap from the standard
value, make the necessary adjustment by adjusting the number
Thickness of shims.
gauge
AC507127AC
TSB Revision
INSPECTION
M1552014303197
COOLING TEMPRATURE SWITCH

CAUTION
Do not heat more than necessary.
1. Dip the metal part of the cooling temperature switch into
engine oil and increase the oil temperature using a gas
burner or similar.
Thermometer
Engine oil
AC100787AD
2. When the oil temperature reaches the standard value, check

125C 155C that resistance is supplied between the terminals.
(257F) (311F)
Standard value:
Less than 2 ITEM TEMPERATURE
No continuity
Less than 2 ohms Slightly below 155 C (311 F)
Oil temperature No continuity 155 C (311 F) or more
NOTE: When the oil temperature is 155 C (311 F) or more

AC100810AB
and there is no continuity, the resistance will not be 2 or
lower until the oil temperature reduces to 125 C (257 F) or
less.
TSB Revision
CONDENSER ASSEMBLY
55A-133
CONDENSER ASSEMBLY
M1552015400541

Refrigerant Draining and Refilling (Refer to P.55A-113).
Air Duct Removal and Installation (Refer to GROUP 15,
Air Cleaner P.15-4).
Headlamp support panel cover Removal and Installation
(Refer to GROUP 51, Front bumper P.51-3).
9.0 2.0 Nm
-Pipe coupling 80 17 in-lb
9.0 2.0 Nm
80 17 in-lb
1
4.9 0.9 Nm
43 8 in-lb 5N
3
1, 2
3
A/C compressor oil:
SUN PAG 56
4.9 0.9 Nm
43 8 in-lb
4 5N
6
AC608285 AB
REMOVAL STEPS REMOVAL STEPS (Continued)

1. Front end upper bar assembly <<A>> 4. Liquid pipe A connection
2. Connector 5. O-ring
<<A>> 3. Flexible discharge hose connection 6. Condenser assembly

.
<<A>> FLEXIBLE SUCTION HOSE AND LIQUID

PIPE A DISCONNECTION
CAUTION
nipples.
dismantled hose and condenser assembly nipples.
TSB Revision
REFRIGERANT LINE

.
>>A<< CONDENSER INSTALLATION

When replacing the condenser, refill it with a specified amount
of compressor oil and install it to the vehicle.
Compressor oil: SUN PAG 56
Quantity: 15 cm3 (0.5 fl.oz)
REFRIGERANT LINE
M1552006401450

Refrigerant Draining and Refilling (Refer to Charging and
Discharging P.55A-113).
Headlamp support panel cover Removal and Installation
(Refer to GROUP 51, Front bumper P.51-3).
Low-pressure 7 3 Nm 2 13 2 Nm
Side service valve 61 26 in-lb 111 22 in-lb
1
High-pressure
Side service valve 3
9N
13 1 Nm 4.9 0.9 Nm
115 9 in-lb 43 8 in-lb
25 4 Nm
4.9 0.9 Nm 18 3 ft-lb 9N
43 8 inlb
4 N9
9N
8 -Pipe coupling
9N
7 9N
9 4
3, 4, 5, 6, 7, 8
A/C compressor oil: SUN PAG 56
AC607818AD

<<A>> 1. Drain assembly <<A>> 6. Liquid pipe A
<<A>> 2. Heat protector <<A>> 7. Flexible discharge hose
<<A>> 3. Flexible suction hose <<A>> 8. A/C pressure sensor
<<A>> 4. Liquid pipe B 9. O-ring
<<A>> 5. Expansion valve
TSB Revision
REFRIGERANT LINE
55A-135
.
<<A>> HOSE/PIPE DISCONNECTION

CAUTION
nipples.
To prevent the entry of other foreign bodies, plug the con-
denser, compressor, and expansion valve nipples.
TSB Revision
DUCTS
DUCTS
M1553001000714
WARNING
When removing and installing the front passenger seat, be sure to carry out accuracy check
occupant classification sensor after the seat has been installed in the vehicle. (Refer to
GROUP 52B, On-Vehicle Service P.52B-358).
4
2
7
6
5
AC608286AB
TSB Revision
VENTILATORS
55A-137
Defroster nozzle and distribution Foot duct and rear heater duct
duct removal steps removal steps (Continued)
Instrument panel (Refer to GROUP Floor carpet peeling
52A P.52A-2). Floor console assembly (Refer to
1. Center duct front GROUP 52A, Floor console
2. Center duct rear assembly P.52A-8).
3. Defroster nozzle Trunk lid release handle cover
4. Ventilator air distribution duct & (Refer to GROUP 42, Trunk lid
Side defroster duct P.42A-174).
Foot duct and rear heater duct Accelerator stopper (Refer to
removal steps GROUP 17, Accelerator cable and
Front seat assembly (Refer to pedal P.17-8).
GROUP 52A, Front seat assembly 5. Rear heater duct B
P.52A-17). 6. Rear heater duct A
Front scuff plate, cowl side trim 7. Foot duct
(Refer to GROUP 52A, Trims
P.52A-10).
VENTILATORS
M1553001600608
Cross-section A-A
A
A
Note
: Claw positions
AC608287 AM
Removal steps
Rear bumper assembly (Refer to
GROUP 51, P.51-6).
1. Rear ventilation duct
TSB Revision
SPECIFICATIONS
SPECIFICATIONS
M1552012100347
Item Specification
Armature plate mounting bolt 16 1 N m (12 1 ft-lb)
Discharge flexible hose mounting bolt (compressor side) 25 4 N m (18 3 ft-lb)
Discharge flexible hose mounting nut (condenser side) 4.9 0.9 N m (43 8 in-lb)
Connection between the liquid pipe A and B 13 1 N m (115 9 in-lb)
Liquid pipe A mounting bolt (condenser side) 4.9 0.9 N m (43 8 in-lb)
Suction flexible hose mounting bolt (compressor side) 25 4 N m (18 3 ft-lb)
Suction flexible hose mounting nut (heater unit side) 4.9 0.9 N m (43 8 in-lb)
Front deck crossmember mounting bolt (left side) 23 6 N m (17 4 ft-lb)
Front deck crossmember mounting bolt (right side) 20 5 N m (15 3 ft-lb)
Front deck crossmember mounting bolt (front deck side) 20 5 N m (15 3 ft-lb)
M1552000200325
Item Standard value

Heater control assembly Rotary type
A/C switch Push-button type
Compressor model, type MSC90CAS, Scroll type
Refrigerant Type R134a (HFC-134a)
Amount g (oz) 480 520 (16.9 18.3)
M1552000300593
Item Standard value

Idle speed r/min 700 50
Idle-up speed r/min 700 50
Air gap (A/C compressor clutch) mm (in) 0.3 0.5 (0.012 0.020)
LUBRICANTS
M1552000400534
Item Specified lubricant Quantity

Each connection of refrigerant line SUN PAG 56 As required
Compressor refrigerant unit lubricant cm3 (fl.oz) SUN PAG 56 80 100 (2.7 3.4)
TSB Revision
55B-1
GROUP 55B
AUTOMATIC AIR
CONDITIONING
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 55B-2 ACTUATOR TEST. . . . . . . . . . . . . . . . . . . . 55B-20

CHECK AT A/C-ECU TERMINAL . . . . . . . . 55B-21
AUTOMATIC A/C DIAGNOSIS . . . . . 55B-4
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 55B-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . 55B-23
AUTOMATIC AIR CONDITIONING
TROUBLESHOOTING STRATEGY . . . . . . 55B-4 SENSORS . . . . . . . . . . . . . . . . . . . . . . 55B-25
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 55B-4 REMOVAL AND INSTALLATION . . . . . . . . 55B-25
DIAGNOSTIC TROUBLE CODE CHART . . 55B-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55B-25
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 55B-9 OTHER PARTS. . . . . . . . . . . . . . . . . . 55B-26
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 55B-12 OTHER PARTS MAINTENANCE SERVICE
SYMPTOM PROCEDURES . . . . . . . . . . . . 55B-13 POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55B-26
DATA LIST REFERENCE TABLE . . . . . . . 55B-16
55B-2 AUTOMATIC AIR CONDITIONING
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1552000100696
The blower, heater, and evaporator have been inte-
grated with the heater and A/C system to achieve
greater fan power and noise reduction.
ITEM SPECIFICATION
Heater control assembly Dial type
Compressor mode MSC90CAS
Compressor type Scroll type
Refrigerant and quantity g (oz) R-134a (HFC-134a), 480 520 (16.9 18.3)
SAFETY PRECAUTIONS CAUTION
WARNING Keep R-134a containers upright when charging
Wear safety goggles and gloves when servic- the system.
ing the refrigeration system to prevent In most instances, moderate heat is required to bring
severe damage to eyes and hands. the pressure of the refrigerant in its container above
Because R-134a refrigerant is a hydro fluorocarbon the pressure of the system when charging or adding
(HFC) which contains hydrogen atoms in place of refrigerant.
chlorine atoms, it will not cause damage to the ozone A bucket or large pan of hot water not over 40 C
layer. (104.0 F) is all the heat required for this purpose. Do
Ozone filters out harmful radiation from the sun. To not heat the refrigerant container with a blow torch or
assist in protecting the ozone layer, Mitsubishi any other means that would raise temperature and
Motors Corporation recommends an R-134a refriger- pressure above this temperature. Do not weld or
ant recycling device. steam-clean on or near the system components or
Refrigerant R-134a is transparent and colorless in refrigerant lines.
both the liquid and vapor state. Since it has a boiling WARNING
point of 29.8 C (21.64 F) at atmospheric pressure, A leak detector for R-134a should be used to
it will be a vapor at all normal temperatures and pres- check for refrigerant gas leaks.
sures. The vapor is heavier than air, non-flammable, CAUTION
and non-explosive. The following precautions must Do not allow liquid refrigerant to touch bright
be observed when handling R-134a. metal or it will be stained.
WARNING When metering R-134a into the refrigeration system,
Do not heat R-134a above 40 C (104.0 F) or keep the supply tank or cans in an upright position. If
it may catch fire and explode. the refrigerant container is on its side or upside
R-134a evaporates so rapidly at normal atmospheric down, liquid refrigerant will enter the system and
pressures and temperatures that it tends to freeze damage the compressor.
anything it contacts. For this reason, extreme care Refrigerant will tarnish bright metal and chrome sur-
must be taken to prevent any liquid refrigerant from faces, and in combination with moisture can severely
contacting the skin and especially the eyes. Always corrode all metal surfaces.
wear safety goggles when servicing the refrigeration
part of the A/C system. Keep a bottle of sterile min- OPERATION
eral oil handy when working on the refrigeration sys- .
tem. CONDENSER FAN AND RADIATOR FAN

1. Should any liquid refrigerant get into your eyes, CONTROL
use a few drops of mineral oil to wash them out. The ECM judges the required revolution speed of
R-134a is rapidly absorbed by the oil. radiator fan motor and condenser fan motor using
2. Next, splash your eyes with plenty of cold water. the input signals transmitted from A/C switch, output
shaft speed sensor and engine coolant temperature
3. Call your doctor immediately even if irritation has
sensor.
ceased.
.
TSB Revision
GENERAL DESCRIPTION
55B-3
COMPRESSOR CONTROL When the air thermo sensor is activated, and the
ignition switch, blower switch, and A/C switch are
When operating the A/C switch ON, the A/C compressor clutch relay is ener-
The air thermo sensor, which senses the temper- gized.
ature of the air flowing out of the evaporator,
deactivates the compressor at 1 C (33.8 F) or When operating the mode selection dial
below. The A/C will work when the mode selection dial is
A/C-ECU detect refrigerant pressure by A/C pres- set to the "Defroster" or "Defroster/foot" position,
sure sensor and turns OFF when the refrigerant or the temperature control dial is set to the "MAX
pressure becomes excessively high or low, thus A/C" position. In other dial positions, when the
protecting the compressor circuit (See Table A/C switch is turned on, the A/C will work.
below).
A/C Compressor Clutch Relay ON Conditions
Ignition switch (IG2) ON NOTE: A/C compressor clutch relay is
Blower switch ON de-energized when any one switch, sensor
or control unit shown on the left turns off.
A/C switch, mode selection dial defroster, ON
defroster/foot position or temperature control MAX NOTE: The components marked by *
A/C communicate with the ECU. If the air thermo
sensor detects a temperature of 1 C
Air thermo sensor *
(33.8 F), the A/C-ECU will turn off the A/C
Pressure detected 2.94 MPa (427psi) or less (If ON compressor clutch relay.
by A/C pressure the refrigerant pressure
sensor exceeds 2.94 MPa (427psi),
A/C compressor clutch relay is
not ON condition until the
(341psi) a or less.)
0.19 MPa (27psi) or more (If
the refrigerant pressure falls
short of 0.19 MPa (27psi), A/C
compressor clutch relay is not
ON condition until the
(32psi) or more.)
A/C compressor clutch relay driving transistor (within ON
powertrain control module)
TSB Revision
AUTOMATIC A/C DIAGNOSIS

INTRODUCTION
M1554006200103
After air is taken in through the air selection damper,
it is fed to the evaporator by the blower fan and
motor and cooled. The air cooled by the evaporator
is mixed appropriately with the warmed air which
pass through the heater core to achieve a comfort-
able temperature. If the A/C does not operate or the
cooled air is not discharged, the system components
or relay may be faulty.
AUTOMATIC AIR CONDITIONING TROUBLESHOOTING STRATEGY
M1554004700652
heater, air conditioning and ventilation fault. Chart.
DIAGNOSTIC FUNCTION
M1552019800165

CAUTION
position.
MB991910
position.
NOTE: When the special tool MB991824 is energized, the
special tool MB991824 indicator light will be illuminated in a
green color.
NOTE: Disconnecting the scan tool special tool MB991824 is
MB991827
the reverse of the connecting sequence, making sure that the
AC608435 AB
ignition switch is at the "LOCK" (OFF) position.
TSB Revision
55B-5
TROUBLE CODES
CAUTION
not be output. Check the battery if scan tool MB991958 does
not display.
MB991910
MB991824 Information" is displayed, check the contents.
button.
MB991827 AC608435 AB 8. Choose "Erase DTCs" to erase the DTC.
HOW TO READ DATA LIST

TSB Revision
CAUTION
3. Select "Interactive Diagnosis" from the start-up screen.
4. Select "System Select."
Select "AUTO A/C" from "System List," and press the "OK" but-
ton.
MB991910
5. Select "Data List."
MB991824 6. Choose an appropriate item and select the "OK" button.
MB991827 AC608435 AB
HOW TO PERFORM ACTUATOR TEST

CAUTION
3. Select "System Select."
button.
MB991910 5. Choose "Actuator Test" from "AUTO A/C" screen.
6. Choose an appropriate item and select the "OK" button.
MB991824
MB991827 AC608435 AB
TSB Revision
55B-7
CAUTION
diagnosed.
MB991910
5. Select "view vehicle information" button.
that it matches the vehicle which is diagnosed CAN bus line.
8. When the options are displayed, choose the options (mark
MB991827 AC608435 AB
the check) and then select "OK".

M1554004900902
CAUTION
another system may be set when the ignition
switch is turned on with connector(s) discon-
nected. After completing the repair, confirm all
systems for DTC code(s). If DTC code(s) are set,
erase them all.
B10C0 Interior temperature sensor system (short circuit) P.55B-9
B10C1 Interior temperature sensor system (open circuit) P.55B-9
TSB Revision

B1000 Control panel communication error Refer to
B1003 Mode dial SW error GROUP 55A
diagnostic
B1018 Temperature control dial SW error trouble code
B1021 Fan dial SW error chart P.55A-8
B1031 Air thermo sensor system (short circuit)
B1032 Air thermo sensor system (open circuit)
B1034* Ambient air temperature sensor system (short circuit)
B1035* Ambient air temperature sensor system (open circuit)
B1079 Refrigerant leaks
B2214 Control panel failure
B223B Control panel improperly assembled
U1415 Coding not completed
U0019 Bus off (CAN1)
U0141 ETACS-ECU time-out
U0151 SRS-ECU time-out
U0154 Occupant classification-ECU time-out
U0155 Combination meter time-out
U0168 WCM time-out
U0184 Audio time-out
U0195 Satellite radio tuner time-out
U0197 Hands free module time-out
NOTE: The diagnostic trouble codes marked by * are
set from the ETACS-ECU.
TSB Revision
55B-9
DTC B10C0, B10C1: Interior Temperature Sensor System
Interior Temperature Sensor Circuit
A/C-ECU
JOINT
CONNECTOR (2)
INTERIOR
TEMPERATURE
SENSOR
Connectors: C-02, C-08 Connector: C-20
C-08
C-02 C-20 (B)
AC608145CL AC608146AB
DTC SET CONDITION

DTC B10C0 is set if there is a short circuit in the interior
temperature sensor input circuit.
DTC B10C1 is set if there is a defective connector connec-
.

Current trouble
The A/C-ECU, the interior temperature sensor, or connec-
tor(s) or wiring between the two may be defective.
TSB Revision
Past trouble
If DTC B10C0 or B10C1 is stored as a past trouble, carry
out diagnosis with particular emphasis on wiring and con-
nector(s) between the A/C-ECU and the interior tempera-
ture sensor. If the connectors and wiring are normal, and
obviously the ECU is the cause of the trouble, replace the
ECU. If in doubt, do not replace the ECU.
.
Malfunction of the interior temperature sensor.
DIAGNOSIS

line.
CAUTION
Scan Tool (M.U.T.-III) P.55B-4."
YES : Go to Step 2.
NO : Repair the CAN bus lines. Repair the CAN bus lines
(Refer to GROUP 54C, Diagnosis-Can Bus
Diagnostic Chart P.54C-16).

(1) Erase the DTC.
NO : Go to Step 3.
TSB Revision
55B-11
STEP 3. Check interior temperature sensor connector C-08

and A/C-ECU connector C-20 for loose, corroded or
connector.
Q: Are interior temperature sensor connector C-08 and
A/C-ECU connector C-20 in good condition?
YES : Go to Step 4.

connector C-20 (terminal 17 and 19) and interior
temperature sensor connector C-08 (terminals 1 and 2).
NOTE: Also check joint connector C-02 for loose, corroded, or
damaged terminals, or terminals pushed back in the connector.
If joint connector C-02 is damaged, repair or replace the con-
nector as described in GROUP 00E, Harness Connector
Inspection P.00E-2.
(terminal 17 and 19) and interior temperature sensor
YES : Go to Step 5.
STEP 5. Check the interior temperature sensor.

Measure the resistance between connector terminals 1 and 2
under at least two different temperatures. The resistance val-
ues should generally match those in the graph.
RESISTANCE NOTE: The temperature at the check should not exceed the
20
(k) range in the graph.
15 Q: Is the interior temperature sensor in good condition?
YES : Replace the A/C-ECU. Then go to Step 6.
10
NO : Replace the interior temperature sensor. Then go to
Step 6.
5
0
-10 0 10 20 30 40
(14) (32) (50) (68) (86) (104)
TEMPERATURE C (F) AC609165AB

TSB Revision
SYMPTOM CHART
M1554005000946
CAUTION
another system may be set when the ignition
switch is turned on with connector(s) discon-
nected. On completion, confirm all systems for
DTC code(s). If DTC code(s) are set, erase them
all.
Symptom Inspection Reference
procedure page
When the A/C is operation, temperature inside the passenger 1 Refer to
compartment does not decrease (Cool air is not emitted). GROUP 55A,
Malfunction of the A/C power supply system. 2 symptom chart
P.55A-64
The compressor does not work. 3
Blower fan and motor do not turn. 4
Blower air amount cannot be changed. 5
Outside/inside air changeover is not possible. 6
A/C outlet air temperature does not increase. 7
Air outlet vent cannot be changed. 8
Rear window defogger does not operate. 9
Blower motor power supply system. 10
When sunlight intensity changes, air outlet temperature does not change. 11 P.55B-13
TSB Revision
55B-13
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 11: When Sunlight Intensity Changes, Air Outlet Temperature Does Not
Change.
Photo Sensor Circuit
A/C-ECU
JOINT
CONNECTOR (2)
PHOTO
SENSOR
C-20 (B)
AC608146AB AC608145CM
CIRCUIT OPERATION
When the blower air temperature cannot be changed even if
the preset temperature is changed, the sensors may be defec-
tive.
.
Malfunction of the photo sensor
DIAGNOSIS
TSB Revision

MB991824: V.C.I.
STEP 1. Check the defogger and outside/inside air

selection damper control motor operation.
Q: Do the defogger and outside/inside air selection damper
control motor work normally?
YES : Go to Step 2.
NO : Refer to GROUP 55A, Symptom chart, P.55A-64.

trouble code.
CAUTION
YES : Go to Step 3.
NO : Refer to P.55B-7.

(2) Start the engine.
(3) Set scan tool MB991958 to the data reading mode.
Item 67: Photo sensor
(4) Cover the photo sensor and security indicator with your
hand or a shop towel.
NOTE: Check that the voltage displayed on the scan tool
changes.
Q: Does the voltage displayed on the scan tool change
when the photo sensor and security indicator is
covered?
YES : Replace the A/C-ECU. Check that the A/C works
normally.
NO : Go to Step 4.
TSB Revision
55B-15
STEP 4. Check A/C-ECU connector C-20 and photo sensor

Q: Are A/C-ECU connector C-20 and photo sensor
YES : Go to Step 5.
STEP 5. Check the wiring harness between photo sensor

connector C-101 (terminals 4 and 1) and A/C-ECU
Q: Is the wiring harness between photo sensor connector
C-101 (terminals 4 and 1) and A/C-ECU connector C-20
YES : Go to Step 6.
normally.
STEP 6. Replace the photo sensor.

Q: Does the A/C operate normally?
NO : Replace the A/C-ECU. Check that the A/C works
normally.
TSB Revision

M1554005100631
Scan tool display Item Inspection status The display contents

No. under normal
conditions
Engine speed 17 Displays correct engine
speed.
Ambient temperature sensor 19 Ambient temperature is
the same as scan tool
displayed temperature
Air thermo sensor 20 Evaporator outlet
temperature is the same
as scan tool displayed
temperature.
Interior temperature sensor 21 Interior temperature is
the same as scan tool
displayed temperature
Temperature setting 23 Displays air conditioning
set temperature.
ETC sensor 24 Engine coolant
temperature is the same
as scan tool displayed
temperature.
Vehicle speed 26 Displays vehicle speed.
A/C Compressor drive request 27 Compressor ON ON
Compressor OFF OFF
Air conditioning switch 28 Air conditioning switch ON ON
Air conditioning switch OFF OFF
Refrigerant leak 29 Normal
Idel up request 34 Displays idle-up request
signal.
Rear heater SW light* 35
PTC heater 1* 36
PTC heater 2* 37
PTC heater 3* 38
In/out select damp poten 45 Displays outside/inside
(target) air selection damper
target position.
In/out select damp 46 Displays outside/inside
potentiometer air selection damper
position.
Air outlet c/o potentiometer 55 Displays air outlet
changeover damper
position.
Air outlet c/o potentio. (Target) 56 Displays air outlet
changeover damper
target position.
TSB Revision
55B-17
No. under normal
conditions
Low pressure judgment 57 Normal
Rear defogger switch 60 Rear window defogger switch ON ON
Rear window defogger switch OFF OFF
Pressure sensor 61 Displays refrigerant
pressure.
Air mix potentiometer 63 Displays the air mix
damper position.
Photo sensor 67 Displays sunload.
Front blower fan 68 Displays blower motor
condition.
Front blower fan (Target) 69 Displays blower motor
target value.
Refrigerant pressure 73 Displays refrigerant
pressure status.
Condenser fan 74 Displays condenser fan
running condition.
Temp. set dial position 76 Displays the set
temperature output
value on the control
panel.
A/C Panel type 77 Dial/Auto/RHD
Fan set dial position 78 Displays the air volume
output value on the
control panel.
Air outlet c/o set dial position 79 Displays output value to
the air outlet
changeover dial on the
control panel.
Fan set dial operation flag 80 ON when the air volume
adjusting dial is
operated
A/C SW operation flag 81 ON when the air
conditioning switch is
operated
Temp. set dial operation flag 82 ON when the air
conditioning switch is
operated
Defogger flag 83 ON when the air outlet
changeover dial is set to
the DEF position.
In/out air c/o SW operation 84 ON when the inside
flag air/outside air
changeover switch is
operated
TSB Revision

No. under normal
conditions
Rear defogger SW operation 87 ON when the rear
flag window switch is
operated
Rear defogger SW light 88 Displays rear window
switch indicator status.
A/C SW light 89 Displays air conditioning
switch indicator status.
In/out air c/o SW light 90 Displays the status of
the inside air/outside air
changeover switch
indicator.
A/C Compressor drive flag 91 ON when the
compressor is activated.
Wiper operation flag 92 ON when the wiper is
operated.
Ignition position information 93 Ignition switch position
status
Power source voltage 94 Displays power supply
voltage.
IOD fuse equipment flag 95 IOD fuse status
A/T lock up open request 96 Displays A/T lock open
request signal.
System operation time 100
Compressor use times 101
Rear defogger use times 102
In/out air c/o poten drive time 103
Air outlet c/o poten drive time 104
Air mix potentiometer drive 105
time
Hot state time (Interior TEMP.) 106
Cold state time (Interior 107
TEMP.)
Hot state time (Ambient 108
TEMP.)
Cold state time (Ambient 109
TEMP.)
Maximum ambient 110
temperature
Minimum ambient temperature 111
Maximum Engine coolant 112
TEMP.
Engine high speed time 113
TSB Revision
55B-19
No. under normal
conditions
Maximum Engine speed 114
High pressure drive time 115
High pressure cut times 116
Maximum pressure (kPa) 117
A/C use rate 118
Compressor operation rate 119
Eco operation rate 120
Recirc use rate 121
A/C operation times 122
In/out air c/o operation times 123
Mode dial operation times 124
Blower fan dial operation 125
times
TEMP. set dial operation times 126
FACE mode use rate 127
B/L mode use rate 128
FOOT mode use rate 129
D/F mode use rate 130
DEF mode use rate 131
Fan OFF use rate 132
Fan 1-2step use rate 133
Temp 1-7 step use rate 137
Temp 8-10step use rate 138
Temp 11-13 step use rate 139
PTC heater1 use times 143
Fan LO driving time 146
Fan M1 driving time 147
TSB Revision

No. under normal
conditions
Fan M2 driving time 148
Fan HI driving time 149
Rear PTC heater counter 150
*
NOTE: shows that it is displayed but not used.
ACTUATOR TEST
M1554005200575
Item No. Check items Driven content

2 idle up request Idle-up request signal
5 In/out selection damper The moving position of outside/inside air
selection damper motor
6 Air mix damper motor The moving position of air mix damper
motor
7 Front blower fan The amount of blower motor rotation
8 Air outlet c/o damper Air outlet changeover damper motor
moving position
10 Condenser fan The amount of condenser fan rotation
11 Air conditioning A/C switch selection position
12 Rear defogger switch Rear window defogger switch selection
position
13 A/T lock open request A/T lock open request signal
TSB Revision
55B-21
CHECK AT A/C-ECU TERMINAL
M1552010301274
C-20 C-19
1 2 3 4 5 6 7 8 9 10 21 2223 24 25 26 27 28
11 12 13 14 15 16 17 18 19 20 29 30 31 32 33 34 35 36
AC210339AF

No.
1 Power transistor (DRAIN) Air volume control dial: Maximum air 0 to 2 V
volume
2 Power transistor (GATE) Air volume control dial: Maximum air Battery voltage
volume
3 8
11, 12
14 Ground Always 0V
15 IG1 power supply Ignition switch: IG1 Battery voltage
16 A/C pressure sensor input Refer to P.55A-112. Refer to P.55A-112.
17 Interior temperature sensor Sensor probe temperature: 25 C 2.1 to 2.7 V
(77 F) (4.0 k)
18 Photo sensor input Brightness 0 lux 5V
Brightness 100000 lux or more 0V
(under summer sunshine)
19 Sensor ground Always 0V
20 A/C pressure sensor power Ignition switch: IG2 5V
supply
21 Air thermo sensor ground Always 0V
22 Air thermo sensor Sensor probe temperature: 25 C 2.1 to 2.7 V
(77 F) (4.0 k)
23
damper
damper
damper
TSB Revision

No.
damper
29 Motor power supply
damper motor
damper motor
damper motor
damper motor
TSB Revision
SPECIAL TOOLS
55B-23
SPECIAL TOOLS
M1552000600624

name
a
f. MB991825
ENTER key. check.
g. MB991826
M.U.T.-III
sub-assembly
MB991827 a. Vehicle
c
communication
interface (V.C.I.)
b. M.U.T.-III USB
cable
d harness A
(Vehicles with
DO NOT USE CAN
communication
MB991911
system)
d. M.U.T.-III main
e
harness B
(Vehicles
communication
MB991914 system)
harness C (for
Daimler
Chrysler
MB991825
models only)
g
f. M.U.T.-III
measurement
adapter
harness
MB991826
MB991958
TSB Revision
SPECIAL TOOLS

name
a
b
circuit
c. LED harness
tester
d. Probe
d
DO NOT USE
MB991223BA

connector
MB992006
TSB Revision
SENSORS
55B-25
SENSORS
M1554001900356
1
2
AC608224 AB
Interior temperature sensor Required Special Tools:

removal steps MB991958: Scan Tool (M.U.T.-III Sub Assembly)
Lower panel (Refer to GROUP 52A, MB991824: Vehicle Communication Interface
Instrument panel P.52A-2). (V.C.I.)
1. Interior temperature sensor MB991827: M.U.T.-III USB Cable
2. Aspirator hose MB991910: M.U.T.-III Main Harness A
Photo sensor removal steps
Instrument panel (Refer to GROUP
52A, Instrument panel P.52A-2).
3. Photo sensor
INSPECTION
M1554002000237
.
INTERIOR TEMPERATURE SENSOR CHECK

When the resistance between the sensor terminals is mea-
sured under two or more temperature conditions, the resis-
tance should approximately satisfy the illustrated values.
TSB Revision
OTHER PARTS
RESISTANCE NOTE: The temperature conditions when checking should not

20
(k) exceed the range shown in the diagram.
15
10
0
-10 0 10 20 30 40
(14) (32) (50) (68) (86) (104)
TEMPERATURE C (F) AC609165AB
PHOTO SENSOR CHECK

1. Connect scan tool MB991958, and check the data list of the
photo sensor (Refer to P.55B-16).
2. Check that the displayed value changes when you cover
the photo sensor with your hands.
OTHER PARTS
OTHER PARTS MAINTENANCE SERVICE POINTS
M1554004000426
The following maintenance service points are the
same as for the manual A/C.
Item Reference Item Reference
page page
On-vehicle Refrigerant level P.55A-112 Heater control unit P.55A-118
service test Heater unit and blower assembly P.55A-119
Air conditioning P.55A-112 Motors and transistor P.55A-124
compressor clutch
test Ambient air temperature sensor P.55A-126
Simple inspection P.55A-112 A/C-ECU P.55A-127
of the a/c pressure Compressor and tension pulley P.55A-128
sensor
Condenser P.55A-133
Compressor drive P.55A-113
belt adjustment Refrigerant line P.55A-134
Charging, P.55A-113 Ducts P.55A-137
discharging Rear ventilation duct P.55A-137
Performance test P.55A-114
Refrigerant leak P.55A-115
repair
Compressor noise P.55A-116
check
Power relay P.55A-116
continuity check
Idle-up operation P.55A-117
check
TSB Revision
70-1
GROUP 70
COMPONENT
LOCATIONS
CONTENTS
CONTROL UNIT. . . . . . . . . . . . . . . . . 70-2 GROUNDING CABLE. . . . . . . . . . . . . 70-13
OTHER DEVICES . . . . . . . . . . . . . . . 70-5 SOLENOID AND SOLENOID VALVE 70-14
SENSOR. . . . . . . . . . . . . . . . . . . . . . . 70-6 RELAY . . . . . . . . . . . . . . . . . . . . . . . . 70-16
FUSIBLE LINK, FUSE AND IOD OR INSPECTION TERMINAL . . . . . . . . . . 70-17

STORAGE CONNECTOR . . . . . . . . . 70-12
GROUNDING . . . . . . . . . . . . . . . . . . . 70-18
70-2 COMPONENT LOCATIONS
CONTROL UNIT
CONTROL UNIT
M1701000700650
NAME SYMBOL NAME SYMBOL

A/C-ECU L Hands free module F
ABS-ECU A KOS-ECU J
Audio visual navigation unit E Power window main switch O
CAN box unit E (incorporating CPU)
Column switch (incorporating C Receiver antenna module <vehicles I
column-ECU) with KOS>
Combination meter (incorporating CPU) D SRS-ECU K
Engine control module B Sunroof assembly (incorporating M
sunroof-ECU)
ETACS-ECU G Transaxle control module <CVT> H
Front seat assembly (LH) (incorporating N Wireless control module <vehicles I
occupant classification-ECU) without KOS>
A B C D E F
G H I J K L
N O
AC607488AB
TSB Revision
COMPONENT LOCATIONS
CONTROL UNIT
70-3
A B
ABS-ECU
Engine control
module
AC605629AB AC605636AB
C D
Combination meter
(incorporating CPU)
Column switch
(incorporating
column-ECU)
AC605634AB AC605635AB
E F
Hands free module
Audio visual
navigation unit CAN box unit
AC605631AB AC605638AB
G H <CVT>
ETACS-ECU Brake
Transaxle control pedal
module
AC605637AB AC606956AB
TSB Revision
CONTROL UNIT
Wireless control module

Ignition switch <vehicles without KOS>
receiver antenna module
<vehicles with KOS>
AC605640AB
J K
Knee air bag

module SRS-ECU
KOS-ECU
Rear heater
duct (LH)
AC605632AB AC605641AB
L M Sunroof assembly
(incorporating sunroof-ECU)
A/C-ECU
Heater unit
assembly
AC605628AB AC605642 AB
N O
Front seat assembly (LH)

(incorporating occupant
classification-ECU)
Power window main switch

(incorporating CPU)
AC605633AB AC605639AB
TSB Revision
COMPONENT LOCATIONS
OTHER DEVICES
70-5
OTHER DEVICES
M1701005600476

A/C compressor assembly B Power steering oil pressure switch A
(incorporating A/C refrigerant
temperature switch)
B
AC607873AB
A Power steering B
oil pump
A/C refrigerant
temperature switch
Power steering oil

pressure switch A/C compressor
assembly
AC607989AB AC606957AB
TSB Revision
SENSOR
SENSOR
M1701000601270

A/C pressure sensor J Photo sensor Q
Accelerator pedal position sensor R Primary pulley speed sensor <CVT> B
Air thermo sensor T Rear wheel speed sensor b
Ambient temperature sensor O Heated oxygen sensor (3rd) <vehicles for V
Crankshaft position sensor A California>
Engine coolant temperature sensor G Heated oxygen sensor (front) <except for C
Exhaust camshaft position sensor E California>
Front impact sensor P Heated oxygen sensor (front) <vehicles D
Front wheel speed sensor X for California>
Front passengers seat (incorporating U Heated oxygen sensor (rear) <except for V
weight sensor) California>
Fuel pump module (incorporating fuel a Heated oxygen sensor (rear) <vehicles for C
level sensor (main) and fuel tank California>
temperature sensor) Seat slide sensor Y
Fuel tank differential pressure sensor a Secondary pulley speed sensor <CVT> N
Intake camshaft position sensor F Side impact sensor Z
Interior temperature sensor S Throttle body assembly (incorporating L
Knock sensor K throttle position sensor)
Manifold absolute pressure sensor I Unlock sensor W
Mass airflow sensor M Vehicle speed sensor <M/T> H
TSB Revision
COMPONENT LOCATIONS
SENSOR
70-7
A B C D E F G H Q
I J K L M N O P * R S T
U V W*
X * Y Z * a b *
AC607488AC
NOTE: The * symbols indicate equipped at both sides.
A B <CVT>
Transaxle mount
Crank shaft
position sensor
Primary pulley
Tie rod (RH) speed sensor
AC605661AB AC607297AG
TSB Revision
SENSOR
C Heated oxygen sensor (front) Heated oxygen sensor (front) <except for California> or
connector <except for California> or Heated oxygen sensor (rear) <vehicles for California>
connector <vehicles for California>
Center reinforcement
AC607837AB
D <Vehicles for California> Heated oxygen

sensor (front)
Front exhaust pipe
Heated oxygen sensor

(front) connector
AC607181AB
E F
Exhaust camshaft Intake camshaft

position sensor position sensor
AC607087AB AC605672AB
G H <M/T>
Engine coolant
temperature sensor
Vehicle speed sensor
Shift cable and

select cable assembly
AC605665AB AC606954AB
TSB Revision
COMPONENT LOCATIONS
SENSOR
70-9
I J
Horn (high)
Manifold absolute
pressure sensor A/C pressure sensor
AC605668 AB AC605667AB
K L Throttle body assembly

(incorporating throttle
position sensor)
Knock sensor
AC605662 AB AC605663AB
M N <CVT>
Secondary pulley
speed sensor
Mass airflow
sensor
Transaxle control
cable
AC605666 AB AC607298AB
O P
Ambient temperature Front impact sensor
sensor
Horn (low)
Headlight (LH)
AC605673AB AC605688AB
TSB Revision
SENSOR
Q R
Photo sensor Accelerator pedal
position sensor
AC605669AB AC605670 AB
S T
Air thermo
sensor
Interior temperature
sensor
AC605671AB AC607381AB
U
Weight sensor Weight sensor
(rear: RH) (front: RH)
Weight sensor
(rear: LH)
Weight sensor Front passenger's

(front: LH) seat
AC605674AB
V Heated oxygen sensor (rear)

Rear heater duct <except for California> or

connector <except for California> or
connector <vehicles for California>
AC607180AB
TSB Revision
COMPONENT LOCATIONS
SENSOR
70-11
Unlock sensor
AC605683AB
Front wheel speed

sensor (RH) connector
Front wheel speed Front wheel speed
sensor (LH) connector sensor
AC607486AB
Y Driver's seat Z
Seat slide sensor
Side impact
sensor
AC605682AB AC605684AB
a Fuel tank differential

pressure sensor
Fuel pump module (incorporating

fuel level sensor (main) and
fuel tank temperature sensor)
AC605685AB
b Rear seat
belt (LH)
Rear wheel speed Rear seat

sensor (LH) connector belt (RH) Rear wheel speed Rear wheel speed
sensor (RH) connector sensor
AC607266AB
TSB Revision
FUSIBLE LINK, FUSE AND IOD OR STORAGE CONNECTOR
FUSIBLE LINK, FUSE AND IOD OR STORAGE

CONNECTOR
M1701000100993

Fuse Nos.1 to 23 and No.30 to 32 B Fusible link No. 21 (Passengers C
(Engine compartment relay box) compartment relay box)
Fuse Nos.2 to 19 (ETACS-ECU) C Fusible link Nos.24 to 29 (Engine B
compartment relay box)
Fuse Nos.22 to 25 (Passengers C Fusible link Nos.33 to 37 (Connected A
compartment relay box) directly to battery positive terminal)
Fusible link Nos.1 and No.20 C IOD or storage connector B
(ETACS-ECU)
A B
AC607487AC
A Fusible link B
Nos.33 to 37 Fusible link
Nos.24 to 29
AC605692AB AC605693AB
B IOD or storage C ETACS-ECU

connector
Fusible link No.1
Fusible link
No.21
Fuse Nos.1 to 23
and 30 to 32 Fusible link No.20
AC605694AB AC605695AB
TSB Revision
COMPONENT LOCATIONS
GROUNDING CABLE
70-13
C ETACS-ECU
Fuse
Nos.22 to 25
Fuse Nos.2 to 19
AC605696AB
GROUNDING CABLE
M1701001000795
Power steering oil pump
AC607843 AB
TSB Revision
SOLENOID AND SOLENOID VALVE

M1701000801025

CVT assembly <CVT> F Exhaust gas recirculation valve E
Evaporative emission purge solenoid D Hydraulic unit (incorporating ABS A
solenoid valve)
Evaporative emission ventilation H Intake engine oil control valve (for C
solenoid intake side)
Exhaust engine oil control valve (for B Selector switch assembly <CVT> G
exhaust side) (incorporating shift lock solenoid)
A B
C D E F G
AC607488AD
TSB Revision
COMPONENT LOCATIONS
70-15
A B
Exhaust engine oil

control valve
Hydraulic unit
(incorporating ABS solenoid valve)
AC605630AB AC605681AB
C D
Intake engine oil Evaporative emission

control valve purge solenoid
AC605689AB AC605664 AB
E F <CVT>
CVT assembly connector
Battery
CVT control solenoid
valve assembly
Center
member
Exhaust gas
recirculation valve
AC605690AB AC607299AB
G <CVT> Selector switch H

assembly
Shift lock
solenoid
Rear shipping hook AC605691AB
AC606953AB
TSB Revision
RELAY
RELAY
M1701000401113

A/C compressor clutch relay A Heated seat relay B
CVT control relay <CVT> A Horn relay A
Blower relay B Injector relay A
Condenser fan relay A MFI relay A
Daytime running light relay A Radiator fan relay A
Fan control relay A Rear window defogger relay B
Fog light relay A Selector switch assembly C
(incorporating shift lock control relay)
<CVT>
Headlight relay (high) A Starter relay A
Headlight relay (low) A Throttle actuator control motor relay A
B C
AC607487AB
A Throttle acyuator
control motor relay Fan control relay
Fog light relay

MFI relay
Horn relay
A/C compressor Headlight relay (low)

clutch relay
AC605626AB
A
Radiator fan relay Condenser fan relay
Daytime running
light relay
Starter relay
CVT control
relay <CVT>
Headlight relay (high) Injector relay
AC605626AC
TSB Revision
COMPONENT LOCATIONS
INSPECTION TERMINAL
70-17
Heated seat relay

Blower relay
Rear window defogger relay
ETACS-ECU
AC605627AB
C <CVT> Selector switch

assembly
Shift lock
control relay AC606952AB
INSPECTION TERMINAL
M1701000200848
Data link connector
Hood lock release

handle AC605324
AC607489AB
TSB Revision
GROUNDING
GROUNDING
M1701000301053
1 2 3 4 5 6 7 8 9 10 11
20 19 18 17 16 15 14 13 12
AC607582 AB
NOTE: 1 to 20 numbers correspond to the body ground point numbers in CIRCUIT DIAGRAMS.
1 2
Water inlet fitting
AC605643AB AC605653AB
TSB Revision
COMPONENT LOCATIONS
GROUNDING
70-19
3 Transaxle mount 4
assembly
AC605650AB AC605644AB
5 6 Rear heater
duct (RH)
Column switch
AC605655AB AC605645AB
7 8
AC605646AB AC605660AB
9 10
AC605647AB AC605658AB
TSB Revision
GROUNDING
11 12
Trunk lid release
handle
AC605659AB AC605649AB
13 14
ETACS-ECU
AC605652AB AC605656AB
15 16
Water inlet fitting
AC605657AB AC605654AB
17 , 18 19 , 20
Headlight (LH)
17 19
18
20
AC605651AB AC605648AB
TSB Revision
80-1
GROUP 80
CONFIGURATION
DIAGRAMS
CONTENTS
CONFIGURATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 80A
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80B

NOTES
80A-1
GROUP 80A
CONFIGURATION
DIAGRAMS
CONTENTS
OVERALL CONFIGURATION DASH PANEL . . . . . . . . . . . . . . . . . . . 80A-10

DIAGRAM. . . . . . . . . . . . . . . . . . . . . . 80A-2
FLOOR AND ROOF . . . . . . . . . . . . . . 80A-16
HOW TO READ CONFIGURATION
DIAGRAMS . . . . . . . . . . . . . . . . . . . . 80A-3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 80A-18
ENGINE COMPARTMENT. . . . . . . . . 80A-4 LUGGAGE COMPARTMENT . . . . . . . 80A-20
ENGINE AND TRANSAXLE . . . . . . . 80A-6

80A-2 CONFIGURATION DIAGRAMS
OVERALL CONFIGURATION DIAGRAM
OVERALL CONFIGURATION DIAGRAM

M1801000101818
Rear floor wiring

harness (RH) Rear bumper
wiring harness
Roof wiring
harness
Instrument panel
wiring harness
Control wiring
harness Trunk lid wiring
harness
Battery (-) wiring

harness
Engine sub
wiring harness
Rear floor wiring

harness (LH)
Rear door
wiring harness *
Front impact Console wiring

sensor wiring harness
harness
Front door
wiring harness *
Fog lamp
wiring harness Front wiring Floor wiring
Battery (+) wiring harness harness
harness
AC607582AC
NOTE: .
1. This illustration shows only major wiring harnesses.
2. *: also equipped at the right side.
TSB Revision
CONFIGURATION DIAGRAMS
HOW TO READ CONFIGURATION DIAGRAMS
80A-3
HOW TO READ CONFIGURATION DIAGRAMS
M1801000200555
The wiring harness diagrams clearly show the connector locations and harness configurations on actual vehi-
cles. Some variations are included in one configuration diagram. Accordingly, some diagrams may not be
applicable for individual vehicles.
Denotes connector No.

The same connector No. is used throughout the circuit diagrams to facilitate connector location searches.
The first alphabetical symbol indicates the location site of the connector and a number that follows is the unique number.
Numbers are usually assigned to parts in clockwise order on the diagram.
Example: A-19
Number specific to connector (serial number)
Connector location site symbol

A: ENGINE COMPARTMENT D: FLOOR AND ROOF
B: ENGINE AND TRANSAXLE E: DOOR
C: DASH PANEL F: LUGGAGE COMPARTMENT
Denotes ground point. A-19

Same ground number is used throughout circuit
diagrams to facilitate search of ground point.
Refer to GROUP 70 COMPONENT LOCATIONS
-GROUND MOUNTING LOCATIONS for details
of ground points.
FRONT
Denotes harness name. WIRING
HARNESS
(RH)
A-18
Denotes a section covered by a
corrugated tube.
A-17
The mark shows the

standard mounting position
of wiring harness.
Denotes the color of the tube A-16

(If not specified, it is black).
R: Red
Y: Yellow Y
The number of connector pins and the connector color

(except milk white)* are shown for ease of retrieval.
Example: (2-B) A-15
Connector color
(milk white if no color is indicated) A-15 (2) FOG LIGHT (RH)
A-16 (2-GR) HORN (LOW)
Number of connector pins A-17 (2-B) HEADLIGHT (RH)
A-18 (2-B) WINDSHIELD WASHER MOTOR
*: Typical connector colors A-19 (2-GR) DUAL PRESSURE SWITCH
B: Black BR: Brown
Y: Yellow V: Violet
L: Blue O: Orange
G: Green GR: Gray Indicates the device to which the
R: Red NONE: Milk white connector is connected.
AC208446AK
TSB Revision
ENGINE COMPARTMENT
ENGINE COMPARTMENT
M1801000303391
Connector
symbol A-01 A-02 A-03 A-04
A Front wiring
harness
A-47
A-46
Grounding
cable
A-45
Connector color
code
B: Black
BR: Brown
G: Green Fog light wiring
GR: Gray harness
L: Blue
NONE: Milk white
O: Orange
R: Red
V: Violet
Y: Yellow A-44 A-43 A-42 A-41
AC605702AB
A-01 (2-B) Side turn-signal light (RH) A-12X (4) Horn relay
A-02 (2-B) Front wheel speed sensor (RH) A-13X (4) A/C compressor clutch relay
A-03 (26-B) ABS-ECU A-15X (4) CVT control relay
A-04 (5-GR) Windshield wiper motor A-17X (4) Headlight relay (High)
A-05 (4-GR) Mass airflow sensor A-18X (4) Throttle actuator control motor relay
A-06 (2-B) Brake fluid level switch A-20X (4) Daytime running light relay
A-07 (2-B) Front wheel speed sensor (LH) A-21X (4) Injector relay
A-08 (2-B) Side turn-signal light (LH) A-23X (4) Condenser fan relay
A-09 (24) Front wiring harness and control A-24X (4) Stater relay
wiring harness combination A-25X (4) Headlight relay (Low)
A-10 (20) Front wiring harness and control A-26X (4) Radiator fan relay
A-11X (4) Fog light relay
TSB Revision
ENGINE COMPARTMENT
80A-5
A-05 A-06 A-07 A-08 A-09 A-10
A-11X A-12X
A-13X A-15X
A-17X A-18X
A-20X A-21X
A-23X A-24X
A-25X A-26X
A-28X A-30X
A-31
16
A-32
17
Front impact
sensor wiring
harness
18
A-33
A-40 A-39 A-38 A-37 A-36 A-35 A-34

AC605703AB
A-28X (4) Fan control relay A-39 (2-B) Front wiring harness and fog light
A-30X (4) MFI relay wiring harness combination
A-31 (12-B) Headlight assembly (LH) A-40 (2-B) Condenser fan motor
A-32 (6-B) No connection A-41 (2-Y) Front impact sensor (RH)
A-33 (4-B) Front wiring harness and front impact A-42 (3-B) A/C pressure sensor
sensor wiring harness combination A-43 (1-B) Horn (High)
A-34 (2-B) Fog light (LH) A-44 (2-B) Fog light (RH)
A-35 (2-GR) Radiator fan motor A-45 (2-B) Washer motor
A-36 (2-B) Ambient air temperature sensor A-46 (6-B) No connection
A-37 (1-B) Horn (Low) A-47 (12-B) Headlight assembly (RH)
A-38 (2-Y) Front impact sensor (LH)
TSB Revision
ENGINE AND TRANSAXLE

M1801000402373
Connector
symbol B-01 B-02 B-03
B -01
thru
-19 B-19
Control wiring
harness
B-18
B-17
Engine sub
wiring harness
Battery (+)
wiring harness
Connector color
code
B: Black
BR: Brown
B-16
G: Green
GR: Gray
L: Blue
NONE: Milk white
O: Orange
R: Red
V: Violet
B-15 B-14 B-13
Y: Yellow
AC605699AB
B-01 (3-B) Ignition coil 1 B-06 (2-B) Engine coolant temperature sensor
B-02 (3-B) Ignition coil 2 B-07 (3-B) Primary pulley speed sensor <CVT>
B-03 (3-B) Ignition coil 3 B-08 (22-B) CVT assembly < CVT>
B-04 (3-B) Ignition coil 4 B-09 (10-B) Transmission range switch <CVT>
B-05 (4-B) Heated oxygen sensor (Front) B-10 (6-B) Throttle body assembly
<Vehicles for California>
TSB Revision
80A-7
B-04 B-05 B-06
19
20
Battery (-)
wiring harness
B-12 B-11 B-10 B-09 B-08 B-07
AC605700AB
B-11 (1) Starter B-16 (3-B) Control wiring harness and engine sub
B-12 (1-B) Starter wiring harness combination
B-13 (1-B) Control wiring harness and battery (+) B-17 (1-B) Power steering pressure switch
wiring harness combination B-18 (2) Intake engine oil control valve
B-14 (1-B) A/C compressor assembly B-19 (2) Exhaust engine oil control valve
B-15 (4-GR) Generator
TSB Revision
ENGINE AND TRANSAXLE (CONTINUED)
Connector
symbol B-101 B-102 B-103
B -101
thru
-119
Control wiring
harness
B-119
Battery (+)
Connector color Engine sub wiring harness
code wiring harness
B: Black
BR: Brown
G: Green
GR: Gray
L: Blue
NONE: Milk white
O: Orange
R: Red
V: Violet
Y: Yellow
B-118 B-117 B-116
AC605699AC
B-101 (2-GR) Injector 1 B-107 (3-GR) Exhaust camshaft position sensor

B-102 (2-GR) Injector 2 B-108 (64-GR) Engine control module
B-103 (2-GR) Injector 3 B-109 (48-GR) Engine control module
B-104 (2-GR) Injector 4 B-110 (2-B) Backup light switch <M/T>
B-105 (3-GR) Crankshaft position sensor <CVT> B-111 (3-B) Vehicle speed sensor <M/T>
B-106 (3-GR) Intake camshaft position sensor
TSB Revision
80A-9
B-104 B-105 B-106 B-107 B-108 B-109
2 3 Battery (-)
wiring harness
19
20
B-110
B-115 B-114 B-113 B-112 B-111
AC605700AC
B-112 (3-GR) Crankshaft position sensor <M/T> B-116 (2-B) Knock sensor
B-113 (3-B) Secondary pulley speed sensor B-117 (3-B) Manifold absolute pressure sensor
<CVT> B-118 (1) Generator
B-114 (6-GR) Exhaust gas recirculation valve B-119 (1) Engine oil pressure switch
B-115 (2-B) Evaporative emission purge solenoid
TSB Revision
DASH PANEL
DASH PANEL
M1801000602236
Connector C-09
C-01 C-02 C-03 C-04 C-05 C-06 C-07 C-08 C-10
symbol
C -01
thru
-43
5
Instrument panel
wiring harness
13
C-42
ETACS-ECU
C-41
C-40
C-39 Front wiring

harness
C-38
Y
C-37
C-36 15
C-35
Connector color
code
B: Black
BR: Brown 14
G: Green
GR: Gray
L: Blue
NONE: Milk white
O: Orange
R: Red
V: Violet C-34 C-33 C-32 C-31 C-30 C-29
Y: Yellow C-44
AC605705AB
C-01 (4) Meter information switch C-14 (17) Audio visual navigation unit
C-02 (12) Joint connector (2) C-15 (2) Radio antenna
C-03 (24) Joint connector (1) C-16 (4-Y) Passenger's (Front) air bag module
C-04 (24) Combination meter (Squib)
C-05 (24) Joint connector (CAN2) C-17 (14) Satellite radio tuner
C-06 (24) Joint connector (CAN1) C-18 (6-B) Center panel unit
C-07 (24) Joint connector (3) C-19 (16-B) A/C-ECU
C-08 (2) Interior temperature sensor C-20 (20-B) A/C-ECU
C-09 (12) Wireless control module <Vehicles C-21 (20) Instrument panel wiring harness and
without KOS> floor wiring harness combination
C-10 (12) Receiver antenna module <Vehicles C-22 (22) Instrument panel wiring harness and
with KOS> floor wiring harness combination
C-11 (7) Audio visual navigation unit C-23 (9) Heated seat switch
C-12 (32) Audio visual navigation unit C-24 (2) Accessory socket (Rear floor console)
C-13 (5) Audio visual navigation unit
TSB Revision
DASH PANEL
80A-11
C-11 C-12 C-13 C-14 C-15 C-16
C-17
C-18
C-19
C-20
C-21
4
Floor wiring C-22
harness
C-23
Console wiring
harness
C-24
C-28 C-27 C-26 C-25

C-43
AC605706AB
C-25 (4) Floor wiring harness and console C-36 (20) Instrument panel wiring harness and
wiring harness combination floor wiring harness combination
C-26 (6) Instrument panel wiring harness and C-37 (12) Front wiring harness and floor wiring
console wiring harness combination harness combination
C-27 (10) Shift switch assembly C-38 (24) Joint connector (4)
C-28 (2) Accessory socket (Front floor console) C-39 (22) Front wiring harness and floor wiring
C-29 (4-B) Heated oxygen sensor (Rear) harness combination
<Vehicles for California> C-40 (22) Transaxle control module <CVT>
C-30 (32-Y) SRS-ECU C-41 (26) Transaxle control module <CVT>
C-31 (40) KOS-ECU C-42 (2) Clutch monitoring switch <M/T>
C-32 (4) Stoplight switch C-43 (2) Cigarette lighter (Front floor console)
C-33 (2-B) Knee air bag module (Squib) C-44 (4-B) Heated oxygen sensor (Front)
C-34 (16-B) Data link connector <Except for California>
C-35 (24) Instrument panel wiring harness and
floor wiring harness combination
TSB Revision
DASH PANEL
DASH PANEL (CONTINUED)
Connector C-101
symbol
C -101
thru
-132 C-132
Instrument panel
wiring harness
5
C-131
13
ETACS-ECU
C-130
C-129 Front wiring

harness
Y
C-128
15
C-127
Connector color
code
B: Black
BR: Brown 14
G: Green
GR: Gray
L: Blue
NONE: Milk white
O: Orange
R: Red
V: Violet C-126 C-125 C-124 C-123 C-122
Y: Yellow
AC605705AC
C-101 (6) Photo sensor C-109 (5) Outside/inside air selection damper
C-102 (24) Radio, CD player or CD changer control module
<Vehicles with audio amplifier> C-110 (24) Hands free module
C-103 (24) Instrument panel wiring harness and C-111 (5) Mode selection damper control motor
audio navigation display wiring C-112 (4) Power transistor
harness combination C-113 (2) Blower motor
C-104 (20) Radio, CD player or CD changer C-114 (12) Instrument panel wiring harness and
C-105 (20) Instrument panel wiring harness and front door wiring harness (RH)
audio navigation display wiring combination
harness combination C-115 (24-BR) Instrument panel wiring harness and
C-106 (18) Radio, CD player or CD changer front door wiring harness (RH)
C-107 (18) Instrument panel wiring harness and combination
audio navigation display wiring
harness combination
C-108 (10) CAN box unit
TSB Revision
DASH PANEL
80A-13
C-102 C-104 C-106

C-103 C-105 C-107 C-108 C-109 C-110
C-111
C-112
C-113
C-114
4 C-115
Floor wiring
harness
C-116
Console wiring
harness
C-121 C-120 C-119 C-118 C-117
AC605706AC
C-116 (3) Inside transmission antenna assembly C-126 (24-BR) Instrument panel wiring harness and
(Front) front door wiring harness (LH)
C-117 (1-B) Parking brake switch combination
C-118 (5) Air mixing damper control motor C-127 (16) Instrument panel wiring harness and
C-119 (2) Air thermo sensor front wiring harness combination
C-120 (12) A/C control panel C-128 (22) Instrument panel wiring harness and
C-121 (6-B) Audio and video adapter front wiring harness combination
C-122 (24-Y) SRS-ECU C-129 (2) Instrument panel wiring harness and
C-123 (6-B) Accelerator pedal position sensor front wiring harness combination
C-124 (24) Joint connector (CAN3) C-130 (12) Instrument panel wiring harness and
C-125 (12) Instrument panel wiring harness and roof wiring harness combination
front door wiring harness (LH) C-131 (6-GR) No connection
combination C-132 (2) Clutch interlock switch <M/T>
TSB Revision
DASH PANEL
DASH PANEL (CONTINUED)
Connector
symbol
C -201
thru
-213
Steering column
C-201 C-202
Steering sub
wiring harness
C-203
C-213
C-212
Clock spring
C-211
C-204
Instrument panel
C-205
wiring harness
Connector color
code
B: Black
BR: Brown
G: Green C-210 C-209 C-208 C-207 C-206
GR: Gray
L: Blue
NONE: Milk white
O: Orange
R: Red
V: Violet
Y: Yellow
AC605708AB
C-201 (10) Column switch C-207 (4-Y) Driver's air bag module (Squib)
C-202 (5-R) Steering wheel audio remote control C-208 (4-Y) Clock spring
switch C-209 (4-Y) Steering wheel voice control switch
C-203 (4-L) Auto-cruise control switch C-210 (3) Paddle shift switch
C-204 (5) Clock spring and steering sub wiring C-211 (5) No connection
harness combination C-212 (6) Ignition switch
C-205 (6) Clock spring C-213 (12) Key reminder switch
C-206 (1) Horn switch
TSB Revision
DASH PANEL
80A-15
Connector
symbol
ETACS-ECU
C -301
thru
-317
C-301 C-302
C-303
C-317
C-304
C-305
C-316
C-306
C-315
C-307
C-314 C-308
Connector color
code
B: Black
BR: Brown C-309
G: Green
GR: Gray
L: Blue
NONE: Milk white C-313 C-312 C-311 C-310
O: Orange
R: Red
V: Violet
Y: Yellow AC607744 AB
C-301 (24) Instrument panel wiring harness and C-311 (20) Floor wiring harness and ETACS-ECU
ETACS-ECU combination combination
C-302 (4) No connection C-312 (16) Front wiring harness and ETACS-ECU
C-303 (4) Blower relay combination
C-304 (16) Front wiring harness and ETACS-ECU C-313 (16-BR) Floor wiring harness and ETACS-ECU
combination combination
C-305 (4) Heated seat relay C-314 (2) Floor wiring harness and ETACS-ECU
C-306 (4) Rear window defogger relay combination
C-307 (2-B) Instrument panel wiring harness and C-315 (19) Instrument panel wiring harness and
ETACS-ECU combination ETACS-ECU combination
C-308 (1-GR) Instrument panel wiring harness and C-316 (6) Roof wiring harness and ETACS-ECU
ETACS-ECU combination combination
C-309 (2-B) Front wiring harness and ETACS-ECU C-317 (15) Instrument panel wiring harness and
combination ETACS-ECU combination
C-310 (4) No connection
TSB Revision
FLOOR AND ROOF
FLOOR AND ROOF

M1801000902389
D-01 D-02 D-03 D-04 D-05

Connector
symbol D-39
D D-38
D-37
7
D-36
D-35
D-34 Floor wiring

harness
Y
D-33
Y
D-32
Floor wiring
harness
6
D-31
D-40
Y
D-30
Connector color
code
B : Black
BR : Brown D-29
DG:Dark grey 12
D-28
G : Green
GR : Gray
L : Blue D-27
None : Milk white D-26 D-25
O : Orange
R : Red
V : Violet
Y : Yellow
AC605709 AB
D-01 (10) Floor wiring harness and rear door D-11 (22) Floor wiring harness and rear floor
wiring harness (RH) combination wiring harness (RH) combination
D-02 (3) Front dome light D-12 (2-Y) Floor wiring harness and rear floor
D-03 (3) Microphone unit wiring harness (LH) combination
D-04 (6-B) Sunroof switch D-13 (4-Y) No connection
D-05 (10-GR) Sunroof motor assembly D-14 (24-BR) Floor wiring harness and rear floor
D-06 (2-GR) Rear dome light wiring harness (LH) combination
D-07 (3) Rear door switch (RH) D-15 (18) Floor wiring harness and rear floor
D-08 (2) Floor wiring harness and fuel wiring wiring harness (LH) combination
harness combination D-16 (3) Rear door switch (LH)
D-09 (4-Y) No connection D-17 (3-B) Fuel tank differential pressure sensor
D-10 (2-Y) Floor wiring harness and rear floor D-18 (5-GR) Fuel pump module
TSB Revision
FLOOR AND ROOF
80A-17
D-06 D-07 D-08
D-09
D-10
8
D-11
11
D-12
Y
Floor wiring
harness D-13
D-14
D-15
D-16
D-24 D-23 D-22 D-21 D-20 D-19 D-18 D-17
AC605710AB
D-19 (3) Outside transmission antenna D-31 (4-B) Heated oxygen sensor (3rd) <Vehicles
assembly (Driver's side) for California>
D-20 (10) Floor wiring harness and rear door D-32 (2-Y) Side-airbag module (Squib) (RH)
wiring harness (LH) combination D-33 (2-B) Seat belt switch (Passenger's side)
D-21 (2-B) Seat belt pre-tensioner (LH) D-34 (4-B) Heated seat assembly (RH)
D-22 (4-Y) Side impact sensor (LH) D-35 (6) Front seat assembly (LH)
D-23 (12) Joint connector (5) D-36 (2-B) Seat belt pre-tensioner (RH)
D-24 (3) Front door switch (LH) D-37 (4-Y) Side impact sensor (RH)
D-25 (18) Audio amplifier D-38 (3) Outside transmission antenna
D-26 (14) Audio amplifier assembly (Passenger's side)
D-27 (4-B) Heated seat assembly (LH) D-39 (3) Front door switch (RH)
D-28 (2-GR) Seat slide sensor D-40 (4-B) Heated oxygen sensor (Rear) <Except
D-29 (4-B) Seat belt switch (Driver's side) for California>
D-30 (2-Y) Side-airbag module (Squib) (LH)
TSB Revision
DOOR
DOOR
M1801001402020
Connector
symbol
E
FRONT DOOR
(Driver's side) (Passenger's side)
E-01 E-02 E-03 E-04
Front wiring door Front wiring door

harness (LH) harness (RH)
E-19
E-05
E-18
E-06
E-17
E-07
Connector color code

B: Black NONE: Milk white
BR: Brown O: Orange
G: Green R: Red E-15 E-14 E-13 E-12 E-11 E-10 E-09 E-08
GR: Gray V: Violet E-28
L: Blue Y: Yellow
AC605712AB
E-01 (10) Door mirror assembly (LH) E-09 (8) Front power window sub switch
E-02 (2-B) Tweeter (LH) E-10 (6-GR) Front power window motor (RH)
E-03 (10) Door mirror assembly (RH) E-11 (2) Front door speaker (RH)
E-04 (2-B) Tweeter (RH) E-12 (11-L) Remote controlled mirror switch
E-05 (6) Unlock sensor (RH) E-13 (2) Front door speaker (LH)
E-06 (2-GR) Lock switch (RH) E-14 (6-GR) Front power window motor (LH)
E-07 (6-B) Front door lock actuator (RH) E-15 (14) Power window main switch <Vehicles
E-08 (4) Front power window sub switch with auto down mechanism>
TSB Revision
DOOR
80A-19
REAR DOOR
(LH) (RH)
Rear wiring door Rear wiring door

harness (LH) harness (RH)
E-27 E-26 E-25 E-24 E-23 E-22 E-21 E-20
AC605713AB
E-17 (6-B) Front door lock actuator (LH) E-24 (2) Rear door speaker (LH)
E-18 (2-GR) Lock switch (LH) E-25 (8) Rear power window sub switch (LH)
E-19 (6) Unlock sensor (LH) E-26 (6-GR) Rear power window motor (LH)
E-20 (6-B) Rear door lock actuator (RH) E-27 (6-B) Rear door lock actuator (LH)
E-21 (6-GR) Rear power window motor (RH) E-28 (19) Power window main switch <Vehicles
E-22 (8) Rear power window sub switch (RH) with auto up and down mechanism>
E-23 (2) Rear door speaker (RH)
TSB Revision
LUGGAGE COMPARTMENT
LUGGAGE COMPARTMENT
M1801001500764
Connector
symbol F-01 F-02 F-03
F 9
Rear window defogger
grounding
F-04
F-25
F-05
F-24 Rear floor wiring
harness (RH)
10
F-06
Rear floor wiring
harness (LH)
F-07
F-23
F-08
F-22
Trunk lid wiring F-09
harness
F-21 F-10
F-11
F-20
Rear bumper wiring F-12

F-19 harness
F-13
Connector color code
B: Black NONE: Milk white
BR: Brown O: Orange
G: Green R: Red F-18 F-17 F-16 F-15 F-14
GR: Gray V: Violet
L: Blue Y: Yellow
AC605714AB
F-01 (2) Luggage compartment light F-16 (3-GR) Outside transmission antenna
F-02 (2-B) Rear wheel speed sensor (RH) assembly (Trunk lid)
F-03 (3) Inside transmission antenna assembly F-17 (3) Backup light (LH)
F-04 (1-B) Rear window defogger () F-18 (2) Rear lid light (LH)
F-05 (2-B) Curtain air bag module (Squib) (RH) F-19 (2-GR) Evaporative emission ventilation
F-06 (4) Rear combination light (RH) solenoid
F-07 (2) Rear lid light (RH) F-20 (4) Rear combination light (LH)
F-08 (3) Backup light (RH) F-21 (2-B) Rear wheel speed sensor (LH)
F-09 (2) Trunk lid opener F-22 (4-B) Sub woofer
F-10 (2-GR) High-mounted stoplight F-23 (10) Rear floor wiring harness (LH) and
F-11 (2-GR) License plate light (RH) trunk lid wiring harness combination
F-12 (3) Trunk lid lock actuator F-24 (2-B) Curtain air bag module (Squib) (LH)
F-13 (2-GR) License plate light (LH) F-25 (1-B) Rear window defogger (+)
F-14 (2-GR) Outer tone alarm
F-15 (2-B) Rear floor wiring harness (LH) and
rear bumper wiring harness
combination
TSB Revision
80B-1
GROUP 80B
SPLICE LOCATIONS
CONTENTS
HOW TO READ SPLICE DASH PANEL . . . . . . . . . . . . . . . . . . . 80B-5

LOCATIONS. . . . . . . . . . . . . . . . . . . . 80B-2
FLOOR AND ROOF . . . . . . . . . . . . . . 80B-6
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . 80B-3
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 80B-7
ENGINE COMPARTMENT. . . . . . . . . 80B-4
LUGGAGE COMPARTMENT . . . . . . . 80B-7
ENGINE AND TRANSAXLE . . . . . . . 80B-4
80B-2 SPLICE LOCATIONS
HOW TO READ SPLICE LOCATIONS
HOW TO READ SPLICE LOCATIONS

M1802000100454
"Splice locations" describes splice points of each wiring harness on an actual vehicle. Some variations are
included in one splice location. Accordingly, some locations may not be applicable for individual vehicles.
Indicates a splice point number.

The splice point numbers are identical to those in "CIRCUIT DIAGRAMS," making them easy to use.
In addition, the splice point numbers are usually numbered clockwise.
Example: S 013
Sequential number
Prefix meaning splice point
S014 S019
S015 S020
S011 S016 S021
S009 S012 S017 S022
S010 S013 S018 S023 S024
S087 S090
S088 S091
S089
S084
S085
S086
S082
S083
S081
S078 S076
S079 S077
S080
ACX02177 AC
TSB Revision
SPLICE LOCATIONS
INDEX
80B-3
INDEX
M1802000901259
This index shows the page numbers where the splice locations are.
SPLICE PAGE SPLICE PAGE SPLICE PAGE SPLICE PAGE
LOCATION LOCATION LOCATION LOCATION
NO. NO. NO. NO.
S001 P.80B-4 S002 P.80B-4 S003 P.80B-4 S004 P.80B-4
S005 P.80B-4 S006 P.80B-4 S007 P.80B-4 S008 P.80B-4
S009 P.80B-4 S010 P.80B-4 S011 P.80B-4 S012 P.80B-4
S013 P.80B-4 S014 P.80B-4 S015 P.80B-4 S016 P.80B-4
S017 P.80B-4 S018 P.80B-4 S019 P.80B-5 S020 P.80B-5
S021 P.80B-5 S022 P.80B-5 S024 P.80B-5 S025 P.80B-5
S027 P.80B-5 S028 P.80B-5 S029 P.80B-5 S030 P.80B-5
S031 P.80B-5 S032 P.80B-5 S033 P.80B-5 S034 P.80B-5
S035 P.80B-5 S038 P.80B-5 S039 P.80B-5 S040 P.80B-5
S041 P.80B-5 S042 P.80B-5 S043 P.80B-5 S044 P.80B-5
S045 P.80B-5 S046 P.80B-5 S047 P.80B-5 S048 P.80B-5
S049 P.80B-6 S050 P.80B-6 S051 P.80B-6 S052 P.80B-6
S053 P.80B-6 S054 P.80B-6 S055 P.80B-7 S056 P.80B-7
S057 P.80B-7 S058 P.80B-7 S059 P.80B-7 S060 P.80B-7
S061 P.80B-7 S062 P.80B-7 S063 P.80B-7 S064 P.80B-7
S065 P.80B-7 S066 P.80B-7 S067 P.80B-5
TSB Revision
ENGINE COMPARTMENT
ENGINE COMPARTMENT
M1802000200860
S001
S002
S003
S004
S005
S006
S007
S009 S008 AC608018AB

M1802001400793
S010 S011 S012 S013
S014
S015
S016
S018 S017 AC608019AB
TSB Revision
SPLICE LOCATIONS
DASH PANEL
80B-5
DASH PANEL
M1802000301086
S030
S019 S020 S021 S022 S024 S025 S027 S028 S029 S031
S032
S048
S067
S047
S033
S046
S045 S034
S035
S044
S043 S042 S041 S038

S039
S040 AC607907AB
TSB Revision
FLOOR AND ROOF
FLOOR AND ROOF

M1802001200818
S051
S049 S050 S052
S054 S053
AC605711AB
TSB Revision
SPLICE LOCATIONS
DOOR
80B-7
DOOR
M1802000800710
S055 S058
S056 S059
S057
AC607912AB
LUGGAGE COMPARTMENT
M1802000700230
S060
S061 S062
S066
S065 S064 S063 AC607913AB
TSB Revision
NOTES
90-1
GROUP 90
CIRCUIT DIAGRAMS
CONTENTS
HOW TO READ CIRCUIT TAILLIGHT, POSITION LIGHT, REAR

DIAGRAMS . . . . . . . . . . . . . . . . . . . . 90-4 SIDE MAKER LIGHT, LICENSE PLATE
LIGHT AND LIGHTING MONITOR
ETACS-ECU. . . . . . . . . . . . . . . . . . . . 90-10 TONE ALARM. . . . . . . . . . . . . . . . . . . 90-74
JOINT CONNECTOR . . . . . . . . . . . . . 90-14 FOG LIGHT . . . . . . . . . . . . . . . . . . . . . 90-78
CENTRALIZED JUNCTION . . . . . . . . 90-19 DAYTIME RUNNING LIGHT. . . . . . . . 90-80
POWER DISTRIBUTION SYSTEM . . 90-26 DOME LIGHT, LUGGAGE

COMPARTMENT LIGHT AND IGNITION
STARTING SYSTEM <M/T> . . . . . . . 90-34 KEY HOLE ILLMINATION LIGHT
<VEHICLES WITHOUT KEYLESS
STARTING SYSTEM <CVT> . . . . . . . 90-35 ENTRY SYSTEM> . . . . . . . . . . . . . . . 90-84
IGNITION SYSTEM . . . . . . . . . . . . . . 90-36 DOME LIGHT, LUGGAGE

COMPARTMENT LIGHT AND IGNITION
CHARGING SYSTEM . . . . . . . . . . . . 90-40 KEY HOLE ILLMINATION LIGHT
<VEHICLES WITH KEYLESS
MFI SYSTEM . . . . . . . . . . . . . . . . . . . 90-44 ENTRY SYSTEM> . . . . . . . . . . . . . . . 90-88
COOLING SYSTEM . . . . . . . . . . . . . . 90-56 TURN-SIGNAL LIGHT AND HAZARD

WARNING LIGHT . . . . . . . . . . . . . . . . 90-94
SHIFT LOCK MECHANISM . . . . . . . . 90-59
STOPLIGHT . . . . . . . . . . . . . . . . . . . . 90-98
INVECS-III CVT . . . . . . . . . . . . . . . . . 90-60
HORN . . . . . . . . . . . . . . . . . . . . . . . . . 90-99
HEADLIGHT. . . . . . . . . . . . . . . . . . . . 90-70
90-2
BACKUP LIGHT. . . . . . . . . . . . . . . . . 90-100 CLOCK . . . . . . . . . . . . . . . . . . . . . . . . 90-184
METER AND GAUGE . . . . . . . . . . . . 90-102 MITSUBISHI MULTI

COMMUNICATION SYSTEM (MMCS) 90-186
BRAKE WARNING LIGHT, OIL
PRESSURE WARNING LIGHT, ACCESSORY SOCKET AND
FUEL WARNING LIGHT . . . . . . . . . . 90-106 CIGARETTE LIGHTER . . . . . . . . . . . . 90-202
POWER WINDOWS <VEHICLES ANTI-LOCK BRAKING SYSTEM

WITHOUT CENTRAL DOOR (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . 90-204
LOCKING SYSTEM> . . . . . . . . . . . . . 90-110
SUPPLEMENTAL RESTRAINT SYSTEM
POWER WINDOWS <VEHICLES (SRS). . . . . . . . . . . . . . . . . . . . . . . . . . 90-212
WITH CENTRAL DOOR LOCKING
SYSTEM>. . . . . . . . . . . . . . . . . . . . . . 90-116 IMMOBILIZER SYSTEM . . . . . . . . . . . 90-222
CENTRAL DOOR LOCKING SYSTEM AUTO-CRUISE CONTROL SYSTEM . 90-226

<VEHICLES WITHOUT KEYLESS
ENTRY SYSTEM> . . . . . . . . . . . . . . . 90-122 SUNROOF. . . . . . . . . . . . . . . . . . . . . . 90-232
CENTRAL DOOR LOCKING SYSTEM HEATED SEAT . . . . . . . . . . . . . . . . . . 90-234

<VEHICLES WITH KEYLESS ENTRY
SYSTEM>. . . . . . . . . . . . . . . . . . . . . . 90-128 IGNITION KEY REMINDER TONE
ALARM <VEHICLES WITHOUT KOS> 90-238
KEYLESS OPERATING SYSTEM
(KOS) . . . . . . . . . . . . . . . . . . . . . . . . . 90-138 IGNITION KEY REMINDER TONE
ALARM <VEHICLES WITH KOS> . . . 90-240
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 90-146 DOOR AJAR WARNING TONE
ALARM . . . . . . . . . . . . . . . . . . . . . . . . 90-244
WINDSHIELD WIPER AND
WASHER . . . . . . . . . . . . . . . . . . . . . . 90-158 SEAT BELT WARNING TONE
ALARM . . . . . . . . . . . . . . . . . . . . . . . . 90-248
REAR WINDOW DEFOGGER . . . . . . 90-160
HANDS FREE SYSTEM . . . . . . . . . . . 90-252
HEATED DOOR MIRROR . . . . . . . . . 90-164
CONTROLLER AREA NETWORK
REMOTE CONTROLLED MIRROR. . 90-166 (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . 90-264
AUDIO SYSTEM <VEHICLES TIRE PRESSURE MONITORING SYSTEM

WITHOUT AUDIO AMPLIFIER> . . . . 90-168 (TPMS) . . . . . . . . . . . . . . . . . . . . . . . . 90-274
AUDIO SYSTEM <VEHICLES WITH THEFT-ALARM SYSTEM . . . . . . . . . . 90-278

AUDIO AMPLIFIER> . . . . . . . . . . . . . 90-174
CIRCUIT DIAGRAMS 90-3
NOTES
TSB Revision
90-4 CIRCUIT DIAGRAMS
HOW TO READ CIRCUIT DIAGRAMS

M1901000100845
The circuit of each system from the fuse (or fusible link) to ground is shown. The power supply is shown at
the top and the ground at the bottom to facilitate understanding of how the current flows. Some variations are
included in one circuit diagram. Accordingly, some diagrams may not be applicable for individual vehicles.The
circuit diagrams show the state when switches are operated.
Indicates power source. Indicates connector number.

The same number is used in the
wiring harness diagram.
Connector and connector numbers Indicates the circuit name
Indicates that terminal is conne- are shown at the lower part of the to be connected. The arrow
cted via a plate in the relay box. page. indicates the current flow
Connector numbers not enclosed direction.
by frame indicate the device incor-
porated into wiring harness.
Each circuit diagram consists of

block(s).
Indicates splice point numbers.

These numbers are identical to
those described in "Splice Loca-
tions."
Indicates the circuit name to be

connected. The arrow indicates
the current flow direction.
Indicates the power supply in

the control unit. If no voltage is
displayed, this indicates battery
positive voltage.
An "X" at the end of a connector

number indicates that the conn-
ector is connected to a central-
ized junction that is shown in the
section "Centralized Junction."
Indicates that the diagram contin-

ues at which belongs to the
block in the same circuit.
Indicates the connector symbol.

Connectors in the circuit diagram
are indicated in numerical order.
Indicates the operating conditions Indicates shield wire. One-directional arrow indicate
of the engine coolant switch, etc. that current flows upwards.
AC106603AG
TSB Revision
CIRCUIT DIAGRAMS
90-5
Indicates input/output Indicates a wiring connector which is inside

to/from control unit the equipment and which is not shown in
(current flow direction). the wiring harness configuration diagram.
Input Output Input/ Example C-15-2 Indicates a connector
output
which is inside the
equipment, numbered Indicates that the diagram comes
in order starting from 1. from which belongs to the
block in the same circuit.
Indicates the connector number shown in
the wiring harness configuration diagram.
Indicates terminal number.
In case two or more connectors

are connected to the same de-
vice, markings indicating
the same connector is
connected by a broken line.
Bi-directional arrow indicates

that current flows in both direc-
tions due to control by an ECU.
Indicates harness junction where

wire diameter or color changes.
Indicates intersections at
which the lead wires are
not connected.
Indicates intersections at
which the lead wires are
connected.
Indicates representative vehicle

body ground point. (Same
number as that of ground point in
GROUNDING LOCATION).
Indicates that the terminal is a

spare one if the device (sensor
in this case) is not provided.
AC106604AE
TSB Revision
90-6 CIRCUIT DIAGRAMS
CONNECTOR/GROUNDING INDICATIONS
1 5
ACX02364 AC
7 2
TSB Revision
CIRCUIT DIAGRAMS
90-7
ITEM NO. CONNECTOR/ GROUNDING SYMBOL CONTENTS

Connector 1 Male terminal The male and female terminals
and terminal Male connector are indicated as shown. The
marking connector with male terminal(s)
is called as male connector and
indicated by two connector

2008 Lancer Service Manual

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

2008 Lancer Service Manual

Diunggah oleh

Hak Cipta:

Format Tersedia

00-1

GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

HOW TO USE THIS MANUAL. . . . . . 00-2 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . 00-6

HOW TO USE THIS MANUAL

ABBREVIATIONS M/T:Indicates manual transaxle, or models equipped

BETTER APPEARANCE BETTER USER-FRIENDLINESS

5. Air dam skirt panels BETTER PRODUCT PACKAGE

4. Aerodynamic front bumper SUPPORT RECYCLING OF RESOURCES

Quality improvement Side-airbag

No. Item Dimension

Technology and purpose for 4B11 engine adoption

Aluminum die-cast cylinder block X

Item High Compact and Low exhaust Low vibration Reliability

MANUAL TRANSAXLE saxle mechanism by steel belt & pulley" to achieve

Down shift lever

For some models, the paddle-shaped up shift/down

Front Trailing arm

Front axle crossmember

BRAKING SYSTEM <VEHICLES WITH ABS>

Brake warning light

Magnetic encoder for

CHECK Stoplight switch

Wheel speed sensor

SRS AIR BAGS

Curtain air bag module

Knee air bag module

SERVICEABILITY AND RELIABILITY

ENHANCED DIAGNOSIS SYSTEM ETACS

VEHICLE IDENTIFICATION NUMBER LOCATION

VEHICLE IDENTIFICATION CODE CHART PLATE

NOTE: *: Check digit means a single number, or letter X, used

VEHICLE IDENTIFICATION NUMBER LIST

VEHICLES FOR USA

(VEHICLES FOR FEDERAL EMISSION REGULATION)

(VEHICLES FOR CALIFORNIA EMISSION REGULATION)

VEHICLES FOR PUERTO RICO

VEHICLES FOR CANADA

Item CY4ASNLHL2M/ CY4ASTLHL2M/ CY4ASNSHL2M/

ITEM CY4ASTSHL2M/ CY4ASNXHL2M/ CY4ASTXHL2M/

HARNESS CONNECTOR INSPECTION INSTRUMENTS . . . . . . . . . . 00E-8

HARNESS CONNECTOR INSPECTION

CONNECTOR CONTINUITY AND VOLTAGE TEST

IMPROPER TERMINAL ENGAGEMENT CHECK

2. Push the harness wire of the terminal to be repaired deep

3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width]

4. Insert a needle through the hole provided on the terminal

ROUND WATERPROOF CONNECTOR

3. Insert a screwdriver through the hole provided on the

RECTANGULAR WATERPROOF CONNECTOR

2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into

2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into

Observe the symptom carefully. Check if there are also

In determining the probable causes, it is necessary to

Troubleshooting is carried out by making step-by-step

After the problems are corrected, be sure to check that the

INFORMATION FOR DIAGNOSIS

3. Checking with instruments

SELECTOR KNOB ACX00938AB

2. Self-powered test light

CAUTIONS IN EVENT OF BLOWN FUSE

CURRENT DOES CURRENT FLOWS

NORMALLY CLOSED (NC) TYPE

CURRENT CURRENT DOES

CABLES AND WIRES CHECK