2001 Mitsubishi Lancer Evo IX.

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR
INPUT SIGNAL PROCEDURES
54B-267
NOTE:
Connector: C-113 <LHD>
Step 6. Retest the system. Check that all the driver's door switch signals are received normally.
Q: Is the check result normal? YES : The trouble can be an intermittent
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the ETACS-ECU.
AC310452AF
Connectors: C-214, C-217 <LHD> Junction block (front view)
C-214
C-217 C-214 Harness side

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-217 Harness side
AC310449AB
Prior to the wiring harness inspection, check intermediate connector C-113 <RH> and junction block connector C-214 <RH> or C-217 <LH>, and repair if necessary. Check the input line for open circuit.
Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness between each of
the door switches and the ETACS-ECU.
54B-268

INSPECTION PROCEDURE L-10: All the door switch signals are not received. <RH drive vehicles>
CAUTION Whenever the ECU is replaced, ensure that the input signal circuit is normal.
All Door Switches Input Circuit <RHD>
ETACS-ECU
J/B SIDE
DOOR SWITCH (FRONT: LH)
DOOR SWITCH (REAR: LH)
DOOR SWITCH (REAR: RH)
DOOR SWITCH (FRONT: RH)
Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
SB : Sky blue
COMMENTS ON TROUBLE SYMPTOM

Input signals from all the door switches are used to operate the functions below. If the signal(s) are abnormal, these functions will not work normally. Keyless entry system Room lamps
POSSIBLE CAUSES
Malfunction of the door switches Malfunction of the ETACS-ECU Damaged harness wires and connectors

54B-269
DIAGNOSTIC PROCEDURE
Step 1. Pulse check Check the input signal from the door switch (front: RH). System switch door switch (front: RH) Check condition When the driver's door is opened
Step 2. Connector check: D-18 <front: LH>, D-01 <front: RH>, D-08 <rear: RH> or D-11 <rear: LH> door switch connectors, and C-226 ETACS-ECU connector
Connector: C-226 <RHD> Junction block (rear view)
OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.

Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure L-3 "The door
Junction block side
AC310461AB
switch (front: RH) signal is not received P.54B-244."
Connector: D-01 <RHD>
Harness side
AC310471AB
Connectors: D-08, D-11, D-18 <RHD>
D-08 D-011
D-18
D-08 Harness side
D-11 Harness side
D-18 Harness side

AC310474 AB
Q: Is the check result normal? YES : Go to Step 3. NO : Repair the defective connector.
54B-270

Step 3. Check the installation condition. Check that the door switch is installed on the body correctly.
Q: Is the check result normal? YES : Go to Step 4. NO : Correct the installation condition.
Step 5. Check the wiring harness from terminal No.2 of the D-18 <front: LH>, D-01 <front: RH>, D-08 <rear: RH> or D-11 <rear: LH> door switch connector to terminal No.7 of the C-226 ETACS-ECU connector.
Step 4. Check the door switch. Refer to GROUP 42 Door P.42-27.

Q: Is the check result normal? YES : Go to Step 5. NO : Replace the door switch.
Junction block side

AC310461AB
Harness side
AC310471AB
D-08 D-011
D-18
D-08 Harness side
D-11 Harness side
D-18 Harness side

AC310474 AB

54B-271
NOTE:
Connector: C-127 <RHD>
the door switches and the ETACS-ECU. Step 6. Retest the system. Check that all the driver's door switch signals are received normally.
AC310455AC
Connectors: C-214, C-217 Junction block (front view) <RHD>
C-214
C-214 Harness side
C-217
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-217 Harness side
AC310459AB
Prior to the wiring harness inspection, check intermediate connector C-127 <LH> and junction block connector C-217 <RH> or C-214 <LH>, and repair if necessary. Check the input line for open circuit.
54B-272

INSPECTION PROCEDURE L-11: The front door lock actuator (LH) switch signal is not received. <LH drive vehicles>
Front Door Lock Actuator Input Circuit <LHD>
ETACS-ECU
DOOR LOCK ACTUATOR (FRONT: LH)
SB : Sky blue

Input signal from the front door lock actuator (LH) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Central door locking Keyless entry system Room lamps
POSSIBLE CAUSES
Malfunction of the front door lock actuator (LH) Malfunction of the ETACS-ECU Damaged harness wires and connectors

54B-273
Step 1. Connector check: E-04 front door lock actuator (LH) connector
Connector: E-04 <LHD> Front door (LH)
Step 3. Resistance measurement at the E-04 front door lock actuator (LH) connector
Harness side E-04(B)
AC310484 AB
AC310484 AB
(1) Disconnect the connector, and measure at the wiring harness side.
Connector E-04 (Harness side)
Step 2. Check the front door lock actuator (LH). Refer to GROUP 42 Door P.42-31.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the front door lock actuator (LH).
3 2 1 6 5 4
AC301541 GW
(2) Resistance between E-04 front door lock actuator (LH) connector terminal No.1 and body earth OK: 2 or less
Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.
54B-274

Step 4. Check the wiring harness between E-04 front door lock actuator (LH) connector terminal No.1 and body earth
Step 6. Check the wiring harness from E-04 front door lock actuator (LH) connector terminal Nos.2 and 3 to C-227 ETACS-ECU connector terminal Nos.35 and 36.
Connector: C-227 <LHD> Junction block (rear view)
Harness side E-04(B) Harness side

29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310484 AB
NOTE:
Connector: C-17 <LHD> Connector: E-04 <LHD>
AC310450AG
Front door (LH)
AC310446 AC
AC310484 AB
Prior to the wiring harness inspection, check intermediate connector C-17, and repair if necessary. Check the earth wires for open circuit.
NOTE:
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness.
Step 5. Connector check: C-227 ETACS-ECU connector

AC310446 AC
Prior to the wiring harness inspection, check intermediate connector C-17, and repair if necessary. Check the input line for open circuit.
Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310450AG
Step 7. Retest the system. Check that the front door lock actuator (LH) switch signal is received normally.

54B-275
INSPECTION PROCEDURE L-11: The front door lock actuator (RH) switch signal is not received. <RH drive vehicles>
Front Door Lock Actuator Input Circuit <RHD>
ETACS-ECU
DOOR LOCK ACTUATOR (FRONT: RH)
SB : Sky blue

Input signal from the front door lock actuator (RH) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Central door locking Keyless entry system Room lamps
POSSIBLE CAUSES
Malfunction of the front door lock actuator (RH) Malfunction of the ETACS-ECU Damaged harness wires and connectors
54B-276

Step 1. Connector check: E-15 front door lock actuator (RH) connector
Connector: E-15 <RHD>
3 2 1 6 5 4
AC301541HR
Harness side
E-15 (B)
(2) Resistance between E-15 front door lock actuator (RH) connector terminal No.3 and body earth OK: 2 or less
AC310493 AF
Step 2. Check the front door lock actuator (RH). Refer to GROUP 42 Door P.42-31.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the front door lock actuator (RH).
Step 4. Check the wiring harness between E-15 front door lock actuator (RH) connector terminal No.3 and body earth
Step 3. Resistance measurement at the E-15 front door lock actuator (RH) connector
Harness side
E-15 (B)
AC310493 AF
NOTE:
Connector: C-110 <RHD> Harness side E-15 (B)
AC310493 AF
AC310456 AE

54B-277

Step 6. Check the wiring harness from E-15 front door lock actuator (RH) connector terminal Nos.1 and 2 to C-227 ETACS-ECU connector terminal Nos.36 and 35.
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
Harness side
AC310461AF
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF
Harness side
E-15 (B)
AC310493 AF
NOTE:
AC310456 AE
Step 7. Retest the system. Check that the front door lock actuator (RH) switch signal is received normally.
54B-278

INSPECTION PROCEDURE L-12: The vehicle speed sensor signal is not received.
Vehicle Speed Sensor Input Circuit <LHD> ETACS-ECU
VEHICLE SPEED SENSOR
Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple

54B-279
Vehicle Speed Signal Input Circuit <RHD> ETACS-ECU

Vehicle speed sensor signal is used to operate the windshield wiper (vehicle speed-dependent wiper function). If this signal is abnormal, the windshield wipers do not work normally.
Step 1. Check the speedometer. Check that the speedometer works normally.
Q: Is the check result normal? YES : Go to Step 2. NO : Diagnose the combination meter (Refer to
POSSIBLE CAUSES
Malfunction of the vehicles speed sensor Malfunction of the ETACS-ECU Damaged harness wires and connectors
GROUP 54A Combination meter P.54A-34).
54B-280

Step 2. Connector check: B-04 vehicles speed sensor connector and C-228 ETACS-ECU connector
Step 3. Check the wiring harness between B-04 vehicles speed sensor connector terminal No.3 and C-228 ETACS-ECU connector terminal No.63.
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310450AH
AC310450AH
Junction block (rear view)
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310461AG
AC310461AG
Connector: B-04 <LHD> B-04(B) Harness side
AC310439AB
AC310439AB
Connector: B-04 <RHD> B-04(B) Harness side
AC310477AB
AC310477AB
Q: Are the check result normal? YES : Go to Step 3. NO : Repair the defective connector.

54B-281
NOTE:
Connector: C-21,C-124 <LHD> C-21 (B)
Connector: B-27 <RHD>
C-124 (B) Connector: C-124 <RHD> C-21
AC310477AC
C-124
AC310454AD AC310447AD
Harness side
Prior to the wiring harness inspection, check joint connector C-21 <LH driver vehicles>, combination meter connector C-101 <RH drive vehicles> and intermediate connector B-27 and C-124, and repair if necessary. Check the input line for open circuit.
AC310456AF
Connector: B-27 <LHD>
Step 4. Retest the system. Check that the vehicle speed sensor signal is received normally.
AC310439 AC
54B-282

INSPECTION PROCEDURE L-13: Each switch signal of the keyless entry transmitter is not received.
Transmitter Input Circuit ETACS-ECU
KEYLESS ENTRY RECEIVER
KEYLESS ENTRY TRANSMITTER
W3Z10E39AA

Input signal from the keyless entry transmitter is used to operate the keyless entry system. If the signal is abnormal, the keyless entry system will not work normally.
Step 2. Check the transmitter battery. Refer to GROUP 42 Keyless entry system P.42-47.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the keyless entry transmitter
POSSIBLE CAUSES
Malfunction of the keyless entry transmitter Defective battery of the keyless entry transmitter Malfunction of the ETACS-ECU
battery. Step 3. Register the encrypted code, and then retest the system. (1) Register the keyless entry transmitter again. (2) Check that each signal is received from the keyless entry transmitter.
Step 1. Pulse check Check whether the ETACS-ECU receives signal from a transmitter or not. For this check, you should use the 2-button-type transmitter (integrated with a key), which cover screw is silver and has already been registered. NOTE: For how to register the keyless entry transmitter encrypted code, refer to GROUP 42 On-vehicle Service P.42-43. System switch Check condition Keyless entry transmitter When the switch is "LOCK/UNLOCK" switch turned from off to on OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the keyless entry transmitter.
Step 4. Retest the system. Check that each signal is received from the keyless entry transmitter.

54B-283
INSPECTION PROCEDURE L-14: The rear fog lamp switch signal is not received.
Rear Fog Lamp Switch Input Circuit ETACSECU
FOG LAMP SWITCH
<LHD>
<RHD>
SB : Sky blue

Input signal from the rear fog lamp switch is used to operate the rear fog lamps. If the signal is abnormal, the rear fog lamps will not illuminate and extinguish normally.
POSSIBLE CAUSES
Malfunction of the fog lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54B-284

Step 1. Connector check: C-20 fog lamp switch connector
Step 3. Resistance measurement at the C-20 fog lamp switch connector

Harness side Harness side

AC310446AH
AC310446AH
Connector: C-20 <RHD> Harness side Harness side
AC310456AI
AC310456AI
(1) Remove the fog lamp switch, and measure at the wiring harness side.
Connector C-20 (Harness side)
Step 2. Check the rear fog lamp switch. Refer to GROUP 54A Rear fog lamp P.54A-64.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the fog lamp switch.
AC301541HA
(2) Continuity between C-20 fog lamp switch connector terminal No.6 and body earth OK: 2 or less

54B-285
Step 4. Check the wiring harness between C-20 fog lamp switch connector terminal No.6 and body earth.

Harness side Connector: C-227 <LHD> Junction block (rear view)
AC310446AH
Harness side Connector: C-20 <RHD>

29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310450AG
Harness side Connector: C-227 <RHD> Junction block (rear view)
AC310456AI
NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF
Harness side
AC310446AF
Harness side
AC310456AG
Prior to the wiring harness inspection, check joint connector C-101 <LH driver vehicles> or C-06 <RH drive vehicles>, and repair if necessary. Check the earth wires for open circuit.
54B-286

Step 6. Check the wiring harness between C-227 ETACS-ECU connector terminal No.21 and C-20 fog lamp switch connector terminal No.5.
Step 7. Retest the system. Check that the rear fog lamp switch signal is received normally.
Harness side
AC310446AH
Harness side
AC310456AI
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310450AG
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF
Check the input line for open circuit.


54B-287
INSPECTION PROCEDURE L-15: Interior lamp loaded signal is not detected.
Interior Lamp Automatic Shutdown Function Circuit IGNITION SWITCH (ACC) IGNITION SWITCH (IG1) BATTERY
RELAY BOX
<LHD>
<RHD>
ETACS-ECU
KEEP RELAY
INTERIOR LAMP CUT BACK-UP CIRCUIT POWER SOURCE
LOAD DETERMINATION CIRCUIT
J/B SIDE
COMBINATION METER
LUGGAGE COMPARTMENT LAMP FRONT ROOM LAMP REAR ROOM LAMP
SB : Sky blue
54B-288


The interior lamp automatic shutdown function operates in accordance with the interior lamp loaded signal. If this signal is abnormal, the functions below will not work normally. Ignition key cylinder illumination lamp Room lamps
Step 3. Voltage measurement at the C-226 ETACS-ECU connector

POSSIBLE CAUSES
Malfunction of the ETACS-ECU Damaged wiring harness or connector(s)
Junction block side
Step 1. Check the power supply circuit. When the ignition switch is turned to the LOCK (OFF) position, check if the hazard warning lamps illuminate.
Q: Is the check result normal? YES : Go to Step 2. NO : Refer to inspection procedure A-2 "Check
AC310450AB
Junction block side

AC310461AB
the battery power supply circuit to the ETACS-ECU P.54B-42." Step 2. Connector check: C-226 ETACS-ECU connector
(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Turn the ignition switch to the ON position.
Connector C-226 (Junction block side)

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Junction block side

AC301541GU
AC310450AB
(3) Voltage between C-226 ETACS-ECU connector terminal No.8 and body earth OK: System voltage
Junction block side

AC310461AB

54B-289
Step 4. Check the wiring harness between C-226 ETACS-ECU connector terminal No.8 and the ignition switch (IG1).

Junction block side
AC310450AB
Junction block (rear view) Junction block side
AC310450AB
Connector: C-226 <RHD> Junction block side

AC310461AB
NOTE:
Connector: C-211 <LHD> Junction block (front view)
Junction block side

AC310461AB
Harness side
2 1 6 5 4 3
(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Turn the ignition switch to the ACC position.
AC310448AB
Junction block (front view)

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
AC301541HB
AC310458AB
Prior to the wiring harness inspection, check junction block connector C-211, and repair if necessary. Check the power supply line to the ignition switch (IG1) for open circuit.
54B-290

Step 6. Check the wiring harness between C-226 ETACS-ECU connector terminal No.4 and the ignition switch (ACC).
NOTE:
Connector: C-23 <RHD> C-23 (B)
Harness side
Junction block side Connector: C-210 <LHD> Junction block (front view)
AC310456AJ
AC310450AB
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310448AK
Junction block side

AC310461AB
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310458AH
AC310446AI

54B-291
Step 7. Retest the system. Check that the interior lamp loaded signal is received normally.
AC310454AJ
Prior to the wiring harness inspection, check joint connector C-23 <RH drive vehicles>, junction block connector C-210 or intermediate connector C-129, and repair if necessary. Check the power supply line to the ignition switch (ACC) for open circuit.
54B-292

INSPECTION PROCEDURE L-16: The door lock key cylinder switch signal is not detected.
Door Lock Key Cylinder Switch Input Circuit ETACS-ECU
DOOR LOCK KEY CYLINDER SWITCH

Input signal from the door lock key cylinder switch is used to operate the central door locking function. If the signal is abnormal, the central door locking function will not work normally.
POSSIBLE CAUSES
Malfunction of the door lock key cylinder switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

54B-293
Step 1. Connector check: E-12 door lock key cylinder switch connector
Connector: E-12 <LHD> Front door (RH)
Step 3. Resistance measurement at the E-12 door lock key cylinder switch connector
E-12(B) Harness side E-12(B) Harness side

AC310488AC
AC310488AC
Connector: E-12 <RHD> E-12(B) Harness side E-12(B)
Harness side
AC310498AB
AC310498AB

3 2 1
Step 2. Check the door lock key cylinder switch. Refer to GROUP 42 Door P.42-31.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the door lock key cylinder switch.
AC301541DM
(2) Resistance between E-12 door lock key cylinder switch connector terminal No.2 and body earth OK: 2 or less
54B-294

INPUT SIGNAL PROCEDURES Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP
Step 4. Check the wiring harness between E-12 door lock key cylinder switch connector terminal No.2 and body earth.
00 How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness.
E-12(B) Harness side

AC310488AC
Harness side Connector: E-12 <RHD>

29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
Harness side E-12(B) Connector: C-227 <RHD>
AC310450AG
AC310498AB
NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF
AC310452AG
AC310454 AK
Prior to the wiring harness inspection, check intermediate connector C-110 <LH drive vehicles> or C-17 <RH drive vehicles>, and repair if necessary. Check the earth wires for open circuit.

54B-295
Step 6. Check the wiring harness from E-12 door lock key cylinder switch connector terminal Nos.1 and 3 <LHD> or 3 and 1 <RHD> to C-227 ETACS-ECU connector terminal Nos.33 and 34.
NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310452AG
AC310450AG
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310454 AK
AC310461AF
Prior to the wiring harness inspection, check intermediate connector C-110 <LH drive vehicles> or C-17 <RH drive vehicles>, and repair if necessary. Check the input line for open circuit.
Connector: E-12 <LHD>
Front door (RH)
Step 7. Retest the system. Check that the door lock key cylinder switch signal is received normally.
Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP
AC310488AC
00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the ETACS-ECU.
AC310498AB
54B-296

CHECK AT ECU TERMINAL

M1549001200823
ETACS-ECU
C-227 C-226 C-228
AC005554AI
NOTE: Terminal numbers 1 to 20 can not be measured as the ETACS-ECU is mounted on the junction block directly. The values are for reference only.
Terminal Check item No. Check condition Normal condition
1 2
Output to the power window relay Power supply to the central door locking system (battery positive voltage) Earth (for ECU) Ignition switch (ACC) Output to room lamp Power supply to interior lamp (battery positive voltage) Input from all the door switches Power supply from ignition switch (IG1) Output to right turn-signal lamps Input from driver's door switch Power supply to turn-signal lamps (battery positive voltage) Output to central door locking (for locking the doors) Output to central door locking (for unlocking the doors other than the driver's door) Output to left turn-signal lamps
When the power windows are operative Always
System voltage System voltage
3 4 5 6 7 8 9 10 11 12 13
Always Ignition switch: ACC When the room lamp is on Always (when the interior lamp off function is off)
0V System voltage 2 V or less System voltage
One of the door switches: ON (door 0 V open) Ignition switch: ON System voltage
When right turn-signal lamps are on System voltage Driver's door switch: ON (door open) Always When the door lock actuators lock the doors When the door lock actuators unlock the doors 0V System voltage System voltage System voltage
14
When the left turn-signal lamps are System voltage on Ignition switch: ACC Always Rear fog lamp switch: ON System voltage System voltage 0V
15 to 17 18 19 20 21 Power supply from ignition switch (ACC) Battery power supply (for ECU) Input from rear fog lamp switch

CHECK AT ECU TERMINAL Terminal Check item No. Check condition
54B-297
Normal condition
22
Output to central door locking (for unlocking the driver's door) Input of collision signal Input to key reminder switch
When the door lock actuators unlock the doors Key reminder switch: ON (ignition key removed) Driver's door lock: Locked Driver's door lock: Unlocked When diagnosis code is set (the M.U.T.-II/III is connected or the diagnosis connector terminal No.1 is earthed) When input check signal is sent
System voltage 0V 0V 0V 0 to 12 V (pulse signal)
23 to 28 29 30
31 to 34 35 36 Input to driver's door lock actuator (lock switch) Input to driver's door lock actuator (unlock switch) Setting diagnosis code or sending input check signal
37 to 44 51
0 V, 12 V (input signal is fluctuating) 0V 0V 0 to 12 V (pulse signal) 0 to 12 V (pulse signal) 0 to 2.5 V
52 53 54 55 56 57, 58 59 63 64, 65 66
Output to door-ajar indicator lamp Input from hazard warning lamp switch Earth (for sensor) SWS communication line Input of vehicle speed signal Input from windshield intermittent wiper volume Input from diagnosis control Input of SWS request signal Output to ignition key cylinder illumination lamp Power supply to interior lamp Output to rear fog lamp
Hazard warning lamp switch: ON Always Always When the vehicle is being driven Turn the ignition switch to the ACC position, and move the wiper volume from "Fast" to "Slow." When M.U.T.-II/III is connected Always When ignition key cylinder illumination is on Always (when the interior lamp off function is off) When rear fog lamp is on
When door-ajar indicator lamp is on 0 V
60 to 62
67 68 69 70 71 72, 73 74
0V 0 to 12 V (pulse signal) 2 V or less System voltage System voltage
54B-298
COLUMN SWITCH
C-206

AC005555AG
Terminal Check item No.
Check condition
Normal condition
1 2 3 4 5 6
Battery power supply Input of SWS request signal SWS communication line Earth Output to windshield intermittent wiper volume
Always Always Always Always
System voltage 0 to 12 V (pulse signal) 0 to 12 V (pulse signal) 0V
Ignition switch: ACC 0 to 2.5 V Move the wiper volume from "Fast" to "Slow."
7 8
Back-up output to windshield wiper Windshield low-speed wiper switch 0 V switch or windshield high-speed wiper switch: ON Power supply from ignition switch (IG1) Ignition switch: ON System voltage 0V
9 10
Back-up output to headlamp switch Headlamp switch: ON

54B-299
FRONT-ECU
A-10X
1 2 3 4 5 6 7 8 9 10 11
A-11X
2122 23242526 272829 30 31 AC305097 AB
NOTE: Measurement is not possible as the front-ECU is mounted on the relay box directly. The values are for reference only.
1 2 3, 4 5 6 7 8 9 to 11 21 22 23 24 25 26
Output to headlamp (high-beam) Battery power supply (for headlamp) Output to headlamp (low-beam) Battery power supply (for ECU) Output to tail lamps Output to windshield washer SWS communication line Input of automatic stop signal to windshield wiper Power supply to ignition switch (ACC) Input of backup signal from headlamp switch
When headlamps (high-beam) are on Always
System voltage System voltage System voltage System voltage System voltage System voltage System voltage 0 12 V (pulse signal) System voltage System voltage 0V
Battery power supply (for tail lamp) Always When headlamps (low-beam) are on Always When tail lamps are on When windshield washer is on Always When windshield wiper is on Ignition switch: "ACC" Headlamp switch: ON
Input of backup signal to windshield Windshield low-speed wiper switch 0 V wiper or windshield high-speed wiper switch: ON Output to windshield wiper (low-speed) Output to windshield wiper (high-speed) Power supply to ignition switch (IG2) Earth When windshield wiper is on (at low System voltage speed) When windshield wiper is on (at high speed) Ignition switch: "ON" Always System voltage System voltage 0V
27 28 29 30 31
54B-300

POWER WINDOW MAIN SWITCH

E-05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 AC103264 AG
Check condition
Normal condition
1 2 3 4 5 6 7 8 9 10 11 12
Output to power window regulator motor Earth SWS communication line (to ETACS-ECU) Power supply Output to power window regulator motor Input from power window regulator motor (pulse sensor earth) Input from power window regulator motor (pulse sensor signal) Input from power window regulator motor (pulse sensor signal) SWS communication line (power window sub switch) Input from power window regulator motor (power supply to pulse sensor)
Always Always Power window relay: ON When the power windows are operating When the power windows are operating Power window relay: ON When the power windows are operating
0V 0 to 12 V (pulse signal) System voltage 0V 0 to 5 V (pulse signal) 0 to 5 V (pulse signal) 0 to 12 V (pulse signal) 5V
13, 14

54B-301
POWER WINDOW SUB SWITCH

E-14 (front), E-08 (rear: LH), E-17 (rear: RH)
1 2 3 4 5 6 7 8
AC103265 AI
Check condition
Normal condition
1 2 3 4 5 6 7 8
Earth Input from power window regulator motor Input from power window regulator motor Power supply Output to power window regulator motor SWS communication line Output to power window regulator motor Input from power window regulator motor
Always Power window relay: ON Power window relay: ON
0V System voltage 0 to 12 V (pulse signal)
54B-302

ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
CONFIGURATION FUNCTION <VEHICLES WITH KEYLESS ENTRY SYSTEM>
M1549002500634
According to the configuration mode entry conditions of the input switch, the following functions can be adjusted. The data on configuration will be memorized even if the battery is removed. Keyless entry system hazard answerback function Vehicle speed-dependent wiper function Headlamp automatic-shutdown function Interior lamp automatic-shutdown function Delayed lamp-off time of the room lamp Initialisation of all functions (Returns to initial settings) 1. Conditions for entering the configuration mode i. Set each switch to the following state. Hazard lamp switch: OFF Diagnosis control: ON (Connect the M.U.T.-II or earth No.1 pin of the 16-pin diagnosis connector). Key reminder switch: OFF (Insert the ignition key)
Ignition switch: "LOCK" (OFF) position Driver's door switch: OFF (driver's door closed) ii. When the windshield washer switch is ON for more than ten seconds, the buzzer in the ETACS-ECU sounds for three seconds, and the configuration mode will be set. 2. Conditions for exiting the configuration mode Diagnosis control: OFF (Disconnect the M.U.T.-II or the earth of No.1 pin of the 16-pin diagnosis connector disconnected). Key reminder switch: ON (Remove the ignition key) Ignition switch: Turning to any position other than "LOCK" (OFF) position Driver's door switch: ON (driver's door opened) When three minutes pass without configurations performed When the other warning buzzer output is generated 3. Configurations of various functions

ON-VEHICLE SERVICE
54B-303
Function Keyless entry system hazard answerback function
Configuration procedure When the lock button of the transmitter is pressed twice continuously within two seconds, the hazard answerback function during the lock state will be switched between available or unavailable. Function available: Buzzer sounds once. (Initial state) Function not available: Buzzer sounds twice. When the unlock button of the transmitter is pressed twice continuously within two seconds, the hazard answerback function during the unlock state will be switched between available or unavailable. Function available: Buzzer sounds once. (Initial state) Function not available: Buzzer sounds twice. When the windshield wiper mist switch is turned ON for more than two seconds, the vehicle speed-dependent wiper function is switched between available or unavailable. Function available: Buzzer sounds once. (Initial state) Function not available: Buzzer sounds twice. When the passing switch is turned ON for more than two seconds with the head lamp switch ON and the turn signal lamp switch turned to RH, the headlamp automatic-shutdown function is switched between available or unavailable. Function available: Buzzer sounds once. (Initial state) Function not available: Buzzer sounds twice. When the hazard switch is turned ON for more than two seconds, the interior lamp automatic-shutdown function is switched between available or unavailable. Function available: Buzzer sounds once. (Initial state) Function not available: Buzzer sounds twice. When the turn signal lamp switch is set in the order of RH to LH to RH to LH within three seconds from the LH position, the delayed lamp-off time switches (Returns to a after e, and repeats from a in order). a. 15 seconds: Buzzer sounds four times. (Initial state) b. 7.5 seconds: Buzzer sounds five times. c. 30 seconds: Buzzer sounds once. d. 10 seconds: Buzzer sounds twice. e. 0 seconds (No delay time): Buzzer sounds three times. When the windshield washer switch is ON for more than 20 seconds continuously, the buzzer sounds twice, and all functions will be initialised (Settings are returned to their initial states). The configuration mode entry buzzer sounds after 10 seconds, however to initialise all functions, the ON state should be continued for 20 seconds. When the windshield washer switch is ON for more than 20 seconds continuously without the configuration mode set, the configuration mode will be set after 10 seconds without the initialisation of all functions.
Vehicle speed-dependent wiper function
Headlamp automatic-shutdown function
Interior lamp automatic-shutdown function
Delayed lamp-off time of the interior lamp
Initialisation of all functions
NOTES
54C-1
GROUP 54C
SMART WIRING SYSTEM (SWS) USING SWS MONITOR

CONTENTS
GENERAL INFORMATION . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . .
PRIOR TO TROUBLESHOOTING . . . . . . . STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING . . . . . . . . . . . . . . . . HOW TO CONNECT THE SWS MONITOR ECU CHECK . . . . . . . . . . . . . . . . . . . . . . . . DATA LIST CHECK . . . . . . . . . . . . . . . . . . PULSE CHECK. . . . . . . . . . . . . . . . . . . . . .
54C-2 54C-2 54C-4

54C-4 54C-4 54C-5 54C-10 54C-11 54C-19
OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION PROCEDURES . . . . . . . . . . . . . . . . . . 54C-25 SYMPTOM PROCEDURES . . . . . . . . 54C-26
BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTRAL DOOR LOCKING SYSTEM . . . . POWER WINDOW . . . . . . . . . . . . . . . . . . . 54C-57 54C-59 54C-86
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . 54C-137 WINDSHIELD WIPER AND WASHER . . . . 54C-142 IGNITION KEY CYLINDER ILLUMINATION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54C-169 HEADLAMP AND TAIL LAMP . . . . . . . . . . . 54C-173 FLASHER TIMER . . . . . . . . . . . . . . . . . . . . 54C-208 FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 54C-231 INTERIOR LAMP. . . . . . . . . . . . . . . . . . . . . 54C-244
M.U.T.-II/III DRIVE RECORDER FUNCTION 54C-20
TROUBLE SYMPTOM CHART . . . . .
54C-20
CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK. . . . . . . . . . . 54C-24
INPUT SIGNAL PROCEDURES. . . . . 54C-258 CHECK AT ECU TERMINAL . . . . . . . 54C-316
54C-2

GENERAL INFORMATION
GENERAL INFORMATION
For the general information regarding the SWS, refer to GROUP 54B General Information P.54B-2.
M1549000100555
SPECIAL TOOLS
M1549000300786
Tool
Number MB991502
Name M.U.T.-II sub-assembly
Use Check the SWS (ECU check and service data)
B991502
MB991824
MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826
MB991827
DO NOT USE
MB991910
MB991911
M.U.T.-III sub-assembly A: Vehicle communication interface (V.C.I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
SWS communication line check (ECU check and service data)
CAUTION M.U.T.-III main harness B (MB991911) should be used. M.U.T.-III main harness A should not be used for this vehicle.
MB991825
MB991826 MB991955

SPECIAL TOOLS
54C-3
Tool
A
Number MB991813 A: MB991806 B: MB991812 C: MB991822
Name SWS monitor kit A: SWS monitor cartridge B: SWS monitor harness (for column-ECU) C: Probe harness
Use SWS communication line check (ECU check and service data)
B991813
MB991529
Diagnosis code check Input signal check by using a harness voltmeter
MB991529
MB991223 a. MB991219 b. MB991220 c. MB991221 d. MB991222
Harness set a. Check harness b. LED harness c. LED harness adapter d. Probe
Continuity check and voltage measurement at harness wire or connector a. For checking connector pin contact pressure b. For checking power supply circuit c. For checking power supply circuit d. For connecting a locally sourced tester
DO NOT USE
MB991223BA
MB992006
Extra fine probe
Continuity check and voltage measurement at harness wire or connector
MB992006
54C-4
Tool

TROUBLESHOOTING
Number MB991896
Name Adapter harness for door communication
Use Door communication line check (service data)
MB991896
TROUBLESHOOTING
PRIOR TO TROUBLESHOOTING
Before carrying out troubleshooting, check the following two items. Make sure that the ETACS-ECU, the junction block (J/B), the front-ECU and the engine compartment relay box are connected securely.
1. Gather information about the problem from the customer.
M1549014700505
Check that the system fuses and fusible links are not burned out.
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

M1549000500694
2. Verify that the condition described by the customer exists. Check that the ETACS-ECU is applicable for the 3. Confirming version number and destination OK NG vehicle specifications. If the ECU is not applicable for them, replace it with correct one.
4. ECU check on the SWS monitor OK
NG
Check the power supply circuit for the ECU communication lines and repair if necessary.
5. Check the data list by using the SWS monitor. OK
NG
6. Check of input signal circuit system
7. Check of output signal circuit system

AC211883AB
1. Gather information about the problem from the customer. 2. Verify that the condition described by the customer exists.
NOTE: If an error occurs in the SWS communication line, the ECU isolated from the communication line performs a fail-safe or backup operation, so the problem may not match the one shown in the Trouble Symptom Chart. However, the cause of the failure can be tracked down by performing the following troubleshooting with the SWS monitor.

TROUBLESHOOTING
54C-5
M1549014800524
3. Confirming version number and destination Check whether the SWS version number (0) and destination (EU W/O DRL) meet the vehicle specifications. If they are different, replace the ETACS-ECU with a correct one. 4. ECU check on the SWS monitor Check whether the communication status of the input- or output-signal-side ECU associated with the defective function is normal. If "OK " is displayed for all related ECUs, they communicate with each other normally and the input or output signal circuit system may be defective. Therefore, check SWS monitor service data. If "NG" is displayed for any of the related ECUs, something may be wrong with the ECU for which "NG" appears, its power supply or earthing system, or a wiring harness or connector between the SWS monitor and the ECU. Check the wiring harness and connectors associated with the ECU and examine the ECU itself. 5. Check the data list by using the SWS monitor. Select the defective function from the function-specific diagnostic menu, and check the service data that appears for each function item. This allows you to check whether the transmission data is normal or not. You can judge which circuit is the cause of the trouble, input circuit or output circuit. NOTE: In addition to the function-specific diagnostic menu, a service data menu is available for SWS monitor service data to check all items for each ECU. The switch condition does not meet the service data display: Input signal system related to defective functions The switch condition meets the service data display: Output signal system related to defective functions 6. Check of input signal circuit system Check relevant switch, sensor, input signal-side ECU and their wiring harness and connector. 7. Check of output signal circuit system Check an output signal-side ECU, electrical load components and their wiring harness and connector.
HOW TO CONNECT THE SWS MONITOR

CAUTION Always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the SWS monitor and the M.U.T.-II/III.
HOW TO CONNECT THE SWS COMMUNICATION LINE

1. Connect M.U.T.-II/III to the diagnostic connector. 2. Remove the steering column cover. 3. Remove the steering column switch connector.
Column switch connector Column switch connector at harness side
MB991812
AC103262AE
4. Connect special tool SWS monitor harness (for column-ECU) MB991812 to the column switch connector and column switch harness connector.
HOW TO ESTABLISH COMMUNICATION BETWEEN DOORS

MB991822 MB991812
MB991896
AC103783AC
1. Connect special tool SWS monitor harness (for column-ECU) MB991812 to special tool adapter harness for door communication MB991896. 2. Connect special tool Probe harness MB991822 to special tool adapter harness for door communication MB991896 assembled in step 1.
54C-6

TROUBLESHOOTING
3. Confirm that all the harnesses are connected. Then insert the probe of special probe harness MB991822 to each female connector terminal on special tool adapter harness for door communication MB991896 by backprobing. NOTE: For the connectors and their terminal numbers on the door communication line for the probe to insert, refer to the reference table.
Reference table of connectors and their terminal numbers on door communication line
Insert the probe of the probe harness to each female connector terminal on the door communication line by backprobing.
<LH DRIVE VEHICLES>

Connector name Intermediate connector Instrument panel wiring harness and front door wiring harness (LH) combination Instrument panel wiring harness and front door wiring harness (RH) combination Instrument panel wiring harness and floor wiring harness (RH) combination Instrument panel wiring harness and floor wiring harness (LH) combination Floor wiring harness (RH) and rear door wiring harness (RH) combination Floor wiring harness (LH) and rear door wiring harness (LH) combination Power window main switch Front power window sub switch Rear power window sub switch (LH) Rear power window sub switch (RH) Connector number C-17 [Front door wiring harness (LH) side] Terminal No. 7
C-110 [Front door wiring harness 8 (RH) side] C-113 (Instrument panel wiring harness side) C-127 (Instrument panel wiring harness side) D-04 [Floor wiring harness (RH) side] D-15 [Floor wiring harness (LH) side] E-05 E-14 E-08 E-17 20
11 6 6 6

TROUBLESHOOTING
Connectors: C-17, C-127 <LHD> Connector: D-04 <LHD>
54C-7
C-17 C-127
AC310463AE
Connector: D-15 <LHD> C-17 C-127
AC310447AH
AC310465AE
Connectors: C-110, C-113 <LHD>
4 5 6 1 2 3 7 8 9 10 111213 14
C-110 C-113 Connector: E-14 <LHD> C-110 C-113

AC310484AF
Front door (RH)
AC310453AC
AC310488AF
54C-8
Connector: E-08

TROUBLESHOOTING
Connector: E-17 Rear door (RH)
Rear door (LH)
AC310486AF
AC310491AE
<RH DRIVE VEHICLES>

Connector name Intermediate connector Instrument panel wiring harness and floor wiring harness (LH) combination Instrument panel wiring harness and front door wiring harness (RH) combination Instrument panel wiring harness and front door wiring harness (LH) combination Instrument panel wiring harness and floor wiring harness (LH) combination Floor wiring harness (RH) and rear door wiring harness (RH) combination Floor wiring harness (LH) and rear door wiring harness (LH) combination Power window main switch Front power window sub switch Rear power window sub switch (RH) Rear power window sub switch (LH) Connector number Terminal No. C-17 [Front door wiring harness 8 (LH) side] C-110 [Front door wiring harness (RH) side] C-113(Instrument panel wiring harness side) C-127 (Instrument panel wiring harness side) 7
13
D-04 [Floor wiring harness (RH) 7 side] D-15 [Floor wiring harness (LH) 7 side] E-05 E-14 E-17 E-08 11 6 6 6

TROUBLESHOOTING
Connectors: C-110, C-113 <RHD> Connector: D-04 <RHD>
54C-9
C-110 C-113
AC310471AE
C-110
C-113
AC310473AF AC310457AC
Connectors: C-17, C-127 <RHD>
Connector: E-05 <RHD> Front door (RH)
4 5 6 1 2 3 7 8 9 10 111213 14
C-17 C-127 Connector: E-14 <RHD> Front door (LH) C-17 C-127
AC310493AI
AC310455AF
AC310498 AE
54C-10
Connector: E-08

TROUBLESHOOTING
ECU CHECK
Rear door (LH)
AC310486AF
Use the M.U.T.-II/III and the SWS monitor to check ECUs (Refer to M.U.T.-II Reference Manual or M.U.T.-III Users Manual). 1. The following ECUs can be checked by using the M.U.T.-II/III and the SWS monitor. NOTE: If a malfunction is found by the "ECU Check," proceed "Symptom Procedure" (Refer to P.54C-20).
M1549014900457
Connector: E-17
Rear door (RH)
AC310491AE
SWS MONITOR-COMPATIBLE ECUS AND THEIR CONDITIONS

Item No. 80 ECUs to be checked Column switch (column-ECU) ETACS-ECU Display on M.U.T.-II/III COLUMN ECU Normal condition OK*1 ECU condition All of the column switch, power supply, earth and interconnecting communication line are normal All of the ETACS-ECU switch, power supply, earth and interconnecting communication line are normal All of the front-ECU, power supply, earth and interconnecting communication line are normal
83
ETACS ECU
OK
84
Front-ECU
FRONT ECU
OK*2
85
Power window main switch (power window module) Other SWS-related ECUs
*1
P/W MODULE
OK*2 (when All of the power window main switch, power supply, earth and the ignition switch is ON) interconnecting communication line are normal NG ECUs are not used
NOTE: .
Other ECUs
: If "NG" is displayed beside the ETACS-ECU while the ignition switch is off, "NG" is also displayed beside the column-ECU. : If "NG" is displayed beside the ETACS-ECU, "NG" is also displayed beside the front-ECU and the power window main switch (power window module).
*2

TROUBLESHOOTING
54C-11
DATA LIST CHECK

M1549015000480
1. Use the M.U.T.-II/III and the SWS monitor to check "DATA LIST." This "DATA LIST" check is applicable for signals, which are transmitted and received through the SWS communication line and the communication lines routed from one door to another. For the input signals which are not applicable for the SWS monitor check, refer to pulse check procedure P.54C-24.
NOTE: If a problem is found in the "DATA LIST" check, refer to the Problems during Input Signal Check <Service data, function diagnosis or pulse check> (Refer to P.54C-24). 2. The following input signals can be checked by using the M.U.T.-II/III and the SWS monitor.
DATA LIST REFERENCE TABLE COLUMN SWITCH (COLUMN-ECU)

Item No. Check item 00 01 02 03 05 Headlamp switch Tail lamp switch Dimmer switch Display on M.U.T.-II/III HEADLAMP SW Check condition Lighting switch: HEAD Lighting switch: Other than HEAD Lighting switch: OFF DIMMER SW Dimmer switch: ON Dimmer switch: OFF Passing lamp which: ON Passing lamp which: OFF Wiper switch: Other than INT LO WIPER SW Wiper switch: LO Wiper switch: Other than LO HI WIPER SW Wiper switch: HI Wiper switch: Other than HI MIST WIPER SW Wiper switch: Mist Wiper switch: Other than mist Normal condition ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF EQUIP NONE
TAIL LAMP SW Lighting switch: TAIL
Passing lamp PASSING SW switch Windshield intermittent wiper switch Windshield low-speed wiper switch Windshield high-speed wiper switch Wind shield mist wiper switch Windshield washer switch Turn-signal lamp switch (RH) Turn-signal lamp switch (LH)
INT WIPER SW Wiper switch: INT
06
07
08
09
FRONT WASH. Windshield washer switch: ON SW Windshield washer switch: OFF TURN SIG. RH Turn-signal lamp switch: RH Turn-signal lamp switch: Other than RH TURN SIG. LH Turn-signal lamp switch: LH Turn-signal lamp switch: Other than LH
10
11
15
With or INT WIP KNOB Vehicles with intermittent wiper control without Vehicles without intermittent wiper control windshield intermittent wiper control
54C-12
ETACS-ECU
Item No. Check item 30 31 32 Ignition switch (IG1)

TROUBLESHOOTING
Display on M.U.T.-II/III IG SW(IG1)
Check condition Ignition switch: ON or START Ignition switch: LOCK (OFF) or ACC Ignition switch: ACC or ON Ignition switch: LOCK (OFF) or START
Normal condition ON OFF ON OFF ON
Ignition IG SW(ACC) switch (ACC)
Driver's door DR DOOR SW Driver's door switch ON (The drivers door switch is open).
Driver's door switch OFF (The driver's door OFF is closed). 33 Reception of P/W SW power ACCEPT window switch Headlamp automatic shutdown function Ignition switch: ON or START PERMIT Ignition switch: from ON or START to LOCK from PERMIT to (OFF) or ACC PROHIBIT (after approximately 30 seconds) OFF to ON (after approximately one second)
35
HD AUTO-CUT 1. Lighting switch: Other than OFF 2. Ignition switch: from ON or START to LOCK (OFF) or ACC 3. Driver's door switch: ON (driver's door open) When requirements for the headlamp automatic shutdown are not satisfied
OFF The M.U.T.-II/III displays intermittent wiper interval in response to the intermittent wiper control positions ON OFF ON
37
Windshield INT WIPE intermittent TIME wiper interval
1. Ignition switch: ACC or ON 2. Operate the intermittent wiper control, and change the wiper interval
41 43
Back-up lamp switch Buzzer
INHIBITOR SW Back-up lamp switch: ON Back-up lamp switch: OFF BUZZER 1. Ignition switch: LOCK (OFF) 2. Tail lamp or headlamp switch: ON 3. Driver's door switch: ON (driver's door open) When requirements for sounding each warning buzzer are not satisfied
OFF

TROUBLESHOOTING
54C-13
Normal condition
FRONT-ECU
Item No. Check item 70 Display on M.U.T.-II/III Check condition
Response by FRONT ECU the ACK front-ECU
Lighting switch: Other than OFF (excluding NORMAL ACK when high-beam is on) or the wiper switch is at position other than OFF Ignition switch: ON or START Lighting switch: OFF Lighting switch: HEAD Headlamps: at high beam SLEEP ACK HI-BEAM ACK NO ACK
NOTE: For item number 70, the M.U.T.-II/III also displays "NG" under the "ECU Check" when it displays "NO ACK" under the front-ECU check.
POWER WINDOW MAIN SWITCH (POWER WINDOW MODULE)

Item No. Check item 71 Response from power window module Display on M.U.T.-II/III Check condition Normal condition NORMAL ACK
P/W ECU ACK Ignition switch: ON or START
INPUT CHECK 1. Ignition switch: ON or START 2. Operate any switch of the power window (only momentarily when switch is main switch. operated) NO ACK
NOTE: For item number 71, the M.U.T.-II/III also displays "NG" under the "ECU Check" when it displays "NO ACK" under the "P/W ECU ACK" check.
COMMUNICATION BETWEEN DOORS

Item No. Check item C0 Front passenger's power window UP switch Front passenger's power window DOWN switch Display on M.U.T.-II/III Check condition Normal condition ON OFF ON OFF
PASS DOR UP Front passenger's power window switch: UP Front passenger's power window switch: Other than "UP" PASS DOR DOWN Front passenger's power window switch: DOWN Front passenger's power window switch: Other than "DOWN" Front passenger's power window switch: AUTO Front passenger's power window switch: Other than "AUTO"
C1
C2
Front PASS DOR passenger's AUTO power window AUTO switch
ON OFF
54C-14
Item No. Check item C4 Rear right power window UP switch Rear right power window DOWN switch

TROUBLESHOOTING
Display on M.U.T.-II/III REAR RH UP
Check condition Rear right power window switch: UP
Normal condition ON
Rear right power window switch: Other than OFF "UP" REAR RH DOWN Rear right power window switch: DOWN ON
C5
Rear right power window switch: Other than OFF "DOWN" Rear right power window switch: AUTO ON
C6
Rear right REAR RH power AUTO window AUTO switch Rear left power window UP switch Rear left power window DOWN switch REAR LH UP
Rear right power window switch: Other than OFF "AUTO" Rear left power window switch: UP Rear left power window switch: Other than "UP" ON OFF ON OFF
C8
C9
REAR LH DOWN
Rear left power window switch: DOWN Rear left power window switch: Other than "DOWN" Rear left power window switch: AUTO Rear left power window switch: Other than "AUTO"
CA
Rear left REAR LH power AUTO window AUTO switch Power window lock switch Multi-stop
ON OFF ON OFF ON (only momentarily when switch is operated) OFF PERMIT
CB
P/W LOCK SW Power window lock switch: ON Power window lock switch: OFF MLT-MODE STOP 1. When multi-mode is working 2. Either function of keyless entry transmitter: ON Other than the conditions above Ignition switch: ON or START
CD
CE
Reception of P/W SW power RECEPT window switch Ignition switch (IG1) IG1
Ignition switch: from ON or START to LOCK from PERMIT to (OFF) or ACC PROHIBIT (after approximately 30 seconds) Ignition switch: ON or START Ignition switch: LOCK (OFF) or ACC ON OFF
CF
NOTE: Service data of door communication will be sent from the power window main switch to the door communication line. Therefore, the display will remain "OFF" unless the probe is inserted.

TROUBLESHOOTING
54C-15
FUNCTION DIAGNOSIS
The table below shows the service data and their normal condition, which are displayed during the "FUNCTION DIAG." The row "Normal condition" shows values, which are shown when each operation is made.
WIPER
Item F.WIPER INT (intermittent) Input signal Windshield intermittent wiper switch Windshield low-speed wiper switch Windshield high-speed wiper switch Wind shield mist wiper switch Item No. Display on M.U.T.-II/III 05 INT WIPER SW Normal condition ON
06
LO WIPER SW
OFF
07
HI WIPER SW
OFF
08
MIST WIPER SW FRONT WASH. SW IG SW(ACC) WIPER INT TIME
OFF OFF ON The M.U.T.-II/III displays intermittent wiper interval in response to the intermittent wiper control positions NORMAL ACK or HI-BEAM ACK OFF
Windshield washer 09 switch Ignition switch (ACC) Windshield intermittent wiper interval Response by the front-ECU F.WIPER LO (low speed) Windshield intermittent wiper switch Windshield low-speed wiper switch Windshield high-speed wiper switch Wind shield mist wiper switch 31 37
70 05
FRONT ECU ACK INT WIPER SW
06
LO WIPER SW
ON
07
HI WIPER SW
OFF
08
MIST WIPER SW FRONT WASH. SW IG SW(ACC) FRONT ECU ACK
OFF OFF ON NORMAL ACK or HI-BEAM ACK
Windshield washer 09 switch Ignition switch (ACC) Response by the front-ECU 31 70
54C-16
Item F.WIPER HI (high speed)

TROUBLESHOOTING
Input signal Windshield intermittent wiper switch Windshield low-speed wiper switch Windshield high-speed wiper switch Wind shield mist wiper switch
Item No. Display on M.U.T.-II/III 05 INT WIPER SW
Normal condition OFF
06
LO WIPER SW
OFF
07
HI WIPER SW
ON
08
MIST WIPER SW FRONT WASH. SW IG SW(ACC) FRONT ECU ACK INT WIPER SW
OFF OFF ON NORMAL ACK or HI-BEAM ACK OFF
Windshield washer 09 switch Ignition switch (ACC) Response by the front-ECU F.WIPER MIST Windshield intermittent wiper switch Windshield low-speed wiper switch Windshield high-speed wiper switch Wind shield mist wiper switch 31 70 05
06
LO WIPER SW
OFF
07
HI WIPER SW
OFF
08
MIST WIPER SW FRONT WASH. SW IG SW(ACC) FRONT ECU ACK MIST WIPER SW FRONT WASH. SW IG SW(ACC) FRONT ECU ACK
ON OFF ON NORMAL ACK or HI-BEAM ACK OFF ON ON NORMAL ACK or HI-BEAM ACK
Windshield washer 09 switch Ignition switch (ACC) Response by the front-ECU F.WIPER WASH Wind shield mist wiper switch 31 70 08
Windshield washer 09 switch Ignition switch (ACC) Response by the front-ECU 31 70

TROUBLESHOOTING
54C-17
LIGHTING
Item OFF Input signal Headlamp switch Tail lamp switch Passing lamp switch Ignition switch (IG1) Headlamp automatic shutdown function Response by the front-ECU TAIL LAMP Headlamp switch Tail lamp switch Passing lamp switch Ignition switch (IG1) Headlamp automatic shutdown function Response by the front-ECU HEADLAMP Headlamp switch LO (low-beam) Passing lamp switch Ignition switch (IG1) Headlamp automatic shutdown function Response by the front-ECU HEADLAMP HI Headlamp switch (high-beam) Dimmer switch Ignition switch (IG1) Headlamp automatic shutdown function Response by the front-ECU Item No. Display on M.U.T.-II/III 00 01 03 30 35 HEADLAMP SW TAIL LAMP SW PASSING SW IG SW(IG1) HD AUTO-CUT Normal condition OFF OFF OFF ON OFF
70 00 01 03 30 35
FRONT ECU ACK HEADLAMP SW TAIL LAMP SW PASSING SW IG SW(IG1) HD AUTO-CUT
NORMAL ACK or HI-BEAM ACK OFF ON OFF ON OFF
70 00 03 30 35
FRONT ECU ACK HEADLAMP SW PASSING SW IG SW(IG1) HD AUTO-CUT
NORMAL ACK ON OFF ON OFF
70 00 02 30 35
FRONT ECU ACK HEADLAMP SW DIMMER SW IG SW(IG1) HD AUTO-CUT
NORMAL ACK ON ON ON OFF
70
FRONT ECU ACK
HI-BEAM ACK
54C-18
Item PASSING LAMP

TROUBLESHOOTING
Input signal Passing lamp switch Response by the front-ECU
Item No. Display on M.U.T.-II/III 03 70 00 01 35 PASSING SW FRONT ECU ACK HEADLAMP SW TAIL LAMP SW HD AUTO-CUT
Normal condition ON NORMAL ACK or HI-BEAM ACK ON ON OFF
REAR FOG LAMP
Headlamp switch Tail lamp switch Headlamp automatic shutdown function Response by the front-ECU
70 00 01 30
FRONT ECU ACK HEADLAMP SW TAIL LAMP SW IG SW(IG1) DR DOOR SW HD AUTO-CUT
NORMAL ACK or HI-BEAM ACK Either is on OFF ON ON
HD AUTO-CUT Headlamp switch Tail lamp switch Ignition switch (IG1) Headlamp automatic shutdown function Response by the front-ECU NOTE: .
Driver's door switch 32 35
70
FRONT ECU ACK
NORMAL ACK or HI-BEAM ACK
1. When checking the input signals (off, tail, low-beam or high-beam), turn the ignition switch to the "ON" position in order to disable the headlamp automatic shutdown function. However, the titles on the M.U.T.-II/III screen will not be highlighted as this has nothing to do with actual lamp operation. 2. For checking item "HEADLAMP HI", the M.U.T.-II/III displays "OFF" on the item No.2 "DIMMER SW" when the headlamps are at high-beam. Therefore, the M.U.T.-II/III should display "ON" momentarily when the dimmer switch is operated.
TURN SIGNAL
Item TURN-SIG.RH Input signal Turn-signal lamp switch (RH) Turn-signal lamp switch (LH) Ignition switch (IG1) TURN-SIG.LH Turn-signal lamp switch (RH) Turn-signal lamp switch (LH) Ignition switch (IG1) Item No. Display on M.U.T.-II/III 10 11 30 10 11 30 TURN SIG.RH TURN SIG.LH IG SW(IG1) TURN SIG.RH TURN SIG.LH IG SW(IG1) Normal condition ON OFF ON OFF ON ON

TROUBLESHOOTING
54C-19
BUZZER
Item LGT MONI_ALRM Input signal Headlamp switch Tail lamp switch Ignition switch (IG1) Headlamp automatic shutdown function Buzzer Item No. Display on M.U.T.-II/III 00 01 30 HEADLAMP SW TAIL LAMP SW IG SW(IG1) DR DOOR SW HD AUTO-CUT OFF ON OFF Normal condition Either is on
Driver's door switch 32 35
43
BUZZER
ON
NOTE: The headlamp automatic shutdown function works in approximately one second after the lighting monitor buzzer starts sounding, and then the buzzer ceases sounding.
PULSE CHECK
M1549015100421
CAUTION Before connecting or disconnecting the M.U.T.-II/III, turn the ignition switch to the "LOCK" (OFF) position. 1. The input signals (signals other than communication line signals), which are compatible with the SWS monitor by using the M.U.T.-II/III or voltmeter, can be confirmed by the Pulse Check.
NOTE: If a problem is found in the "Pulse Check", refer to the Problems during Input Signal Check <Service data, function diagnosis or pulse check> (Refer to P.54C-24). 2. Use the M.U.T.-II/III or voltmeter to check the following input signals.
SWITCHES WHICH ARE APPLICABLE TO INPUT SIGNAL CHECK, AND THEIR CHECK CONDITIONS
Input signal Key reminder switch <vehicles with keyless entry system> Hazard warning lamp switch All of the door switches Driver's door lock actuator Vehicle speed signal Keyless entry transmitter Interior lamp loaded signal Door lock key cylinder switch Switches Requirements for sounding buzzer When the inserted ignition key is pulled out. When the switch is turned from off to on. A door is opened when all the doors are closed. When the driver's key cylinder or inside lock knob is unlocked or locked. When the vehicle speed has reached 10 km/h or more. When the switch is turned from off to on. When a load is applied through multi-purpose fuse No.18. Turn the key to the lock or unlock position
54C-20

TROUBLE SYMPTOM CHART
M1549027300024
M.U.T.-II/III DRIVE RECORDER FUNCTION

1. The SWS monitor cartridge memory can store the ECU check results, the service data, the communication data obtained by the function diagnosis. This communication data can be displayed as a chart or graphical form.
2. If data obtained by the M.U.T.-II/III drive recorder function has to be stored for long time, the data can be transferred to the SWS monitor cartridge. By doing this, you can disconnect the M.U.T.-II/III to prevent excessive battery drain. NOTE: For the details about the M.U.T.-II drive recorder function, refer to M.U.T.-II Reference Manual. NOTE: For the details about the M.U.T.-III drive recorder function, refer to M.U.T.-III Users Manual.

M1549000800877
Symptom
Inspection procedure number A-1 A-2 A-3 A-4 A-5
Reference page P.54C-26 P.54C-30 P.54C-36 P.54C-42 P.54C-47
Communication with the SWS monitor is not possible. Communication with the column switch (column-ECU) is not possible. Communication with the ETACS-ECU is not possible. Communication with the front-ECU is not possible. Communication with the power window main switch (power window module) is not possible.

54C-21
Reference page P.54C-57 P.54C-59 P.54C-62 P.54C-65
<FUNCTION SYSTEM>
Symptom Inspection procedure number Lamp reminder buzzer function does not work normally. B-1
Buzzer Central door locking system
Central door locking system does not work. <LH C-1 drive vehicles> Central door locking system does not work. <RH drive vehicles> A door or a tailgate cannot be locked or unlocked C-2 by the central door locking system. <LH drive vehicles> A door or a tailgate cannot be locked or unlocked by the central door locking system. <RH drive vehicles> The central door locking system can not be C-3 operated by means of the front passengers door lock key cylinder. The ignition key reminder function does not work C-4 normally. The impact detection door unlock function does not function. C-5 D-1 D-2
P.54C-72
P.54C-79
P.54C-81 P.54C-83 P.54C-86 P.54C-89
Power windows
Power windows do not work at all. Driver's power window does not work by means of the power window main switch. <LH drive vehicles> Driver's power window does not work by means of the power window main switch. <RH drive vehicles>
P.54C-91
Relevant power window(s) do not work by means D-3 of the front and rear passenger's power window sub switches. Front and/or rear passenger's power window(s) D-4 do not work by means of the power window main switch. The window glass lowers automatically while it is D-5 rising. Power window anti-trap function does not work normally. D-6
P.54C-93
P.54C-111
P.54C-123 P.54C-124
54C-22
Symptom

Inspection procedure number E-1 E-2 Keyless entry hazard warning lamp answerback function or the room lamp answerback function does not work normally. Encrypted code cannot be registered. The timer lock function does not work after the doors have been unlocked by the keyless entry system.
Reference page P.54C-137 P.54C-139
Keyless entry system Keyless entry system does not work.
E-3 E-4
P.54C-140 P.54C-141
Windshield wiper and The windshield wipers do not work at all. F-1 washer The windshield wipers do not work when the F-2 wiper switch is at "INT", "WASHER" or "MIST" position. However, the wipers work at low speed when the switch is at "LO" and "HI" position. The windshield wipers do not stop at the specified park position. The windshield wipers do not work normally. F-3 F-4
P.54C-142 P.54C-149
P.54C-151 P.54C-156 P.54C-161
The intermittent wiper interval cannot be adjusted F-5 by operating the windshield intermittent wiper volume control. The intermittent wiper interval is not changed according to the vehicle speed. The windshield washer does not work. Ignition key cylinder illumination lamp Headlamp and tail lamp The ignition key cylinder illumination lamp does not illuminate/extinguish normally. The headlamps do not illuminate when the lighting switch is at "TAIL" or "PASSING" position, but illuminate only at low beam when the switch is at "HEAD" position. However, the headlamps do not illuminate at high beam. The tail lamps do not illuminate normally. The low-beam headlamps do not illuminate normally. The high-beam headlamps do not illuminate normally. F-6 F-7 G-1 H-1
P.54C-162 P.54C-164 P.54C-169 P.54C-173
H-2 H-3 H-4
P.54C-174 P.54C-177 P.54C-180 P.54C-182 P.54C-183 P.54C-185 P.54C-192
The high-beam and low-beam headlamps do not H-5 illuminate when the passing switch is operated. The headlamp automatic shutdown function does H-6 not work normally. Any of tail lamps, position lamps or licence plate H-7 lamps does not illuminate. <LH drive vehicles> Any of tail lamps, position lamps or licence plate lamps does not illuminate. <RH drive vehicles> The headlamp(s) do not illuminate. <including high-beam indicator> H-8
P.54C-199

54C-23
Reference page P.54C-208 P.54C-213 P.54C-215 P.54C-223
Symptom
Inspection procedure number The turn-signal lamps do not illuminate. The hazard warning lamps do not illuminate. I-1 I-2
Flasher timer
Any of the turn-signal lamps does not illuminate. I-3 <LH drive vehicles> Any of the turn-signal lamps does not illuminate. <RH drive vehicles> Fog lamp The rear fog lamp do not illuminate normally. The rear fog lamp or the rear fog lamp indicator does not illuminate normally. Room lamp The front or rear room lamp does not illuminate or extinguish normally. Interior lamp automatic shutdown function does not work normally. The door-ajar warning lamp does not illuminate/extinguish normally. J-1 J-2 K-1 K-2 K-3
P.54C-231 P.54C-237 P.54C-244 P.54C-252 P.54C-254
54C-24

CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK
CHECK TROUBLE BY USING THE INPUT SIGNAL CHECK

M1549024200329
If a problem is found in the Service Data or Pulse Check inspection, observe the table below. Symptom
Inspection procedure number L-1 L-2 L-3 L-4
Reference page P.54C-258 P.54C-261 P.54C-263 P.54C-265 P.54C-267
The ignition switch (ACC) signal is not received. The ignition switch (IG1) signal is not received. The door switch (front: LH) signal is not received. <LH drive vehicles> The door switch (front: RH) signal is not received. <RH drive vehicles> Column switch (lighting and turn-signal lamp switch) The tail lamp switch signal is not received. The headlamp switch signal is not received. The dimmer switch signal is not received. The passing switch signal is not received. The turn-signal lamp switch (LH) signal is not received. The turn-signal lamp switch (RH) signal is not received. The headlamp washer switch signal is not received. Column switch (windshield The windshield mist wiper switch wiper/washer and rear wiper washer signal is not received. switch) The windshield intermittent wiper switch signal is not received. The windshield low-speed wiper switch signal is not received. The windshield high-speed wiper switch signal is not received. The windshield washer switch signal is not received. The windshield intermittent wiper volume signal is not received. Power window main switch
L-5
P.54C-268
L-6
P.54C-270 P.54C-274
When the power window main switch L-7 is operated, the switch signals are not received. L-8 L-9 L-10 L-11
The rear fog lamp switch signal is not received. The key reminder switch signal is not received. The hazard warning lamp switch signal is not received. All the door switch signals are not received. LH drive vehicles RH drive vehicles
P.54C-277 P.54C-281 P.54C-285 P.54C-289 P.54C-292
OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION PROCEDURES
54C-25
Reference page P.54C-296 P.54C-299
Symptom
Inspection procedure number L-12
The front door lock actuator (LH) switch signal is not received. <LH drive vehicles> The front door lock actuator (RH) switch signal is not received. <RH drive vehicles> The vehicle speed sensor signal is not received. Each switch signal of the keyless entry transmitter is not received. The interior lamp loaded signal is not detected. The door lock key cylinder switch signal is not detected.
L-13 L-14 L-15 L-16
P.54C-302 P.54C-306 P.54C-307 P.54C-312
OPERATION AND FUNCTION QUICK-REFERENCE TABLE FOR INPUT SIGNAL INSPECTION PROCEDURES
If troubles have occurred in the functions which use the SWS simultaneously, observe the table below to check input signals. Function Lamp reminder function Control of central door locking Key reminder function Door locking released due to impact detection. Keyless entry system Keyless entry hazard warning lamp answerback Power window control Control of windshield wiper washer Ignition key cylinder illumination lamp function Headlamp control Tail lamp control Headlamp automatic shutdown function Fog lamp control Turn-signal lamp control Dome lamp control Interior lamp automatic shutdown function Door-ajar indicator lamp L-1 (This table shows only the input signals which will cause troubles in at least two functions simultaneously). L-2 L-3 L-4 L-9 L-11 L-12
M1549020300324
L-15
54C-26

SYMPTOM PROCEDURES
SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-1: Communication with the SWS monitor is not possible.
CAUTION Whenever the ECU is replaced, ensure that the power supply circuit, the earthing circuit and the communication circuit are normal.
MUT-II/III Communication Circuit and ETACS-ECU Ground Circuit
ETACSECU
J/B SIDE
LHD
RHD
DIAGNOSIS CONNECTOR Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
FRONT SIDE

The SWS monitor may be connected improperly.
DIAGNOSIS PROCEDURE
Step 1. Check that the M.U.T.-II/III communicates with the other systems. Use the M.U.T.-II/III to confirm that it communicates with the engine-ECU.
Q: Is the check result normal? YES : Go to Step 2. NO : Diagnose the engine control system. Refer
POSSIBLE CAUSES
Malfunction of the SWS monitor body (I/F cartridge) Malfunction of the SWS monitor harness Malfunction of the ETACS-ECU Damaged harness wires and connectors
to GROUP 13A Troubleshooting P.13A-237.

SYMPTOM PROCEDURES
54C-27
Step 2. Check that the M.U.T.-II/III can communicate with the system. When the ignition switch is turned ON, check if the M.U.T.-II/III can communicate with the system.
Q: Is the check result normal? YES : Refer to Inspection Procedure A-3
Step 4. Resistance measurement at the C-228 ETACS-ECU connector

"Communication with the ETACS-ECU is not possible P.54C-36." NO : Go to Step 3.

C-228 (GR)
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69

Connector: C-228 <LHD> Junction block (rear view) Connector: C-228 <RHD> Junction block (rear view)
AC310450AC
Harness side Harness side C-228 (GR)

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69 59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
AC310450AC
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
59 58 57 5655 54 53 52 51 68 67 66 6564 63 62 61 60 71 70 69 74 73 72

AC310506AB
(2) Resistance between C-228 ETACS-ECU connector terminal No.56 and body earth OK: 2 or less
54C-28

SYMPTOM PROCEDURES Q: Are the check results normal? YES : The trouble can be an intermittent
Step 5. Check the wiring harness between C-228 ETACS-ECU connector terminal No.56 and body earth.
Step 6. Connector check: C-14 diagnosis connector

Harness side C-228 (GR)
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310450AC
Front side
C-14 (B)
AC310446 AB
Connector: C-14 <RHD> Harness side

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
NOTE:
Connector: C-06 <LHD> C-06 (GR)
C-14 (B)
Front side
AC310456 AC
AC310452 AB
Connector: C-06 <RHD> C-06 (GR)
AC310456 AB
Prior to the wiring harness inspection, check joint connector C-06, and repair if necessary. Check the earth wires for open circuit.

SYMPTOM PROCEDURES
54C-29
Step 7. Check the wiring harness from C-228 ETACS-ECU connector terminal Nos.51 and 67 to C-14 diagnosis connector terminal Nos.9 and 1.
NOTE:
C-23 (B)
Front side
C-14 (B)
AC310446AY

AC310446 AB
Front side
C-14 (B)
AC310454AB
AC310456 AC
Prior to the wiring harness inspection, check joint connector C-23 <LH drive vehicles> or C-21 <RH drive vehicles>, and repair if necessary. Check the communication lines for open circuit.
Q: Are the check results normal? YES : Replace the ETACS-ECU. NO : Repair the wiring harness.

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310450AC
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
54C-30

SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-2: Communication with the column switch (column-ECU) is not possible.
Column Switch Power Supply and SWS Communication Circuit IGNITION SWITCH (IG1)
BATTERY
RELAY BOX
LHD
RHD
LHD
RHD
NOTE : LHD : RHD
COLUMN-ECU
COLUMN SWITCH
ETACS-ECU
Wire colour code B : Black LG : Light green G : Green L: Blue W : White Y: Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

SYMPTOM PROCEDURES
54C-31

The power supply circuit to the column switch (column-ECU) may be defective. If the wiring harness of the battery power supply circuit for the ECU (column switch terminal No.1) is defective, also check the power supply circuit to the ignition switch (IG1) (column switch terminal No.9) and repair if necessary.
Step 2. Connector check: C-206 column switch connector

Harness side
TROUBLESHOOTING HINTS
Malfunction of the ETACS-ECU Malfunction of the column switch Damaged harness wires and connectors
AC310479AD
DIAGNOSIS PROCEDURE
Step 1. ECU check by using the SWS monitor. Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu.
Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure A-3
Harness side
AC310481AD
"Communication with the ETACS-ECU is not possible P.54C-36."
54C-32

SYMPTOM PROCEDURES
Step 3. Voltage measurement at C-206 column switch connector

Step 4. Check the wiring harness between C-206 column switch connector terminal No.1 and battery.
AC310479AD
Connector: C-206 <RHD> Connector: C-206 <RHD>
AC310479AD
AC310481AD
AC310481AD
5 4 3 2 1 10 9 8 7 6
AC310507AF
(2) Voltage between C-206 column switch connector terminal No.1 and body earth OK: System voltage

SYMPTOM PROCEDURES
54C-33
NOTE:
C-05 (GR)
C-129
Step 5. Resistance measurement at C-206 column switch connector

C-05
Harness side
C-129 Connector: C-206 <RHD>

AC310447AC
AC310479AD
Connectors: C-05, C-129 <RHD> C-05 (GR) Harness side
AC310481AD
C-129 Connector C-206 (Harness side)
C-05
C-129
5 4 3 2 1 10 9 8 7 6
AC310506AK
AC310455AB
Prior to the wiring harness inspection, check intermediate connector C-129, joint connector C-05, and repair if necessary. Check the power supply line for open circuit.
(2) Continuity between C-206 column switch connector terminal No.4 and body earth OK: 2 or less
54C-34

SYMPTOM PROCEDURES Q: Is the check result normal? YES : The trouble can be an intermittent
Step 6. Check the wiring harness between C-206 column switch connector terminal No.4 and body earth.
Harness side

AC310479AD
Harness side Connector: C-206 <RHD> C-228 (GR)

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310450AC
Harness side
AC310481AD
NOTE:
Connector: C-06 <LHD> C-06 (GR)
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
AC310452 AB
AC310456 AB

SYMPTOM PROCEDURES
54C-35
Step 8. Check the wiring harness from C-228 ETACS-ECU connector terminal Nos.59 and 68 to C-206 column switch connector terminal Nos.3 and 2.
NOTE:
Connector: C-101 <LHD> C-101 (L)
Harness side
AC310446AW
AC310479AD
Connector: C-206 <RHD> C-101 (L)
Harness side
AC310456 AQ
Prior to the wiring harness inspection, check joint connector C-101, and repair if necessary. Check the communication lines for open circuit.
AC310481AD
Step 9. ECU check by using the SWS monitor. Ignition switch: OFF
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310450AC
ECUS TO BE CHECKED COLUMN ECU OK: "OK" is displayed on the "COLUMN ECU" menu.
Q: Is the check result normal? YES : Go to Step 10. NO : Replace the column switch.
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
Step 10. Retest the system. Check that the ETACS-ECU communicates with the column switch.
C-228 (GR)
AC310461AC
54C-36

SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-3: Communication with the ETACS-ECU is not possible.
ETACS-ECU Power Supply and SWS Communication Circuit IGNITION SWITCH (IG1)
BATTERY
RELAY BOX
J/B SIDE
ETACSECU POWER SOURCE
COLUMN-ECU
COLUMN SWITCH

SYMPTOM PROCEDURES
54C-37

It is suspected that the power supply circuit to the ETACS-ECU is defective, or the wiring harness between the SWS monitor and the ETACS-ECU or their connector(s) is damaged. If the battery power supply circuit to the ECU (terminal No.20 of the ETACS-ECU) is damaged, also check the power supply circuit from the ignition switch (IG1) (terminal No.8 of the ETACS-ECU), and repair if necessary. If the earth circuit to the ECU (terminal No.3 of the ETACS-ECU) is defective, also check the earth circuit to the sensor (terminal No.56 of the ETACS-ECU), and repair if necessary.

Junction block side
AC310450 AB
Malfunction of the ETACS-ECU Damaged harness wires and connectors
DIAGNOSIS PROCEDURE
Connector: C-226 <LHD> Junction block (rear view) Junction block side
AC310461AE
(1) Remove the ETACS-ECU, and measure at the junction block side.
Junction block side

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC310450 AB
AC310507AB
AC310461AE
Junction block side
54C-38

SYMPTOM PROCEDURES
Connectors: C-05, C-129 <RHD> C-05 (GR)
Step 3. Check the wiring harness between C-226 ETACS-ECU connector terminal No.20 and battery.
C-129 Junction block side C-05

AC310450 AB
C-129
AC310455AB
Junction block side

AC310461AE
NOTE:
Connectors: C-05, C-129 <LHD> Harness side C-05 (GR)
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310448AD
C-129
Connector: C-210 <RHD> Junction block (front view)
C-05 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7
C-129
AC310458 AD
AC310447AC
Prior to the wiring harness inspection, check joint connector C-05, intermediate connector C-129 and junction block connector C-210, and repair if necessary. Check the power supply line for open circuit.

SYMPTOM PROCEDURES
54C-39
Step 4. Resistance measurement at the C-226 ETACS-ECU connector

Step 5. Check the wiring harness between C-226 ETACS-ECU connector terminal No.3 and body earth.
Junction block side Junction block side

AC310450 AB AC310450 AB
Junction block side

AC310461AE
Junction block side

AC310461AE
NOTE:

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310506AC
AC310448AE
(2) Resistance between C-226 ETACS-ECU connector terminal No.3 and body earth OK: 2 or less
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE
Prior to the wiring harness inspection, check junction block connector C-214, and repair if necessary. Check the earth wires for open circuit.
54C-40

SYMPTOM PROCEDURES
Step 7. Check the wiring harness from C-228 ETACS-ECU connector terminal Nos.59 and 68 to C-206 column switch connector terminal Nos.3 and 2.
Step 6. Connector check: C-228 ETACS-ECU connector and C-206 column switch connector
Harness side
Harness side
AC310479AD

AC310479AD
Harness side
AC310481AD

AC310481AD
Connector: C-228 <LHD> Junction block (rear view) Harness side C-228 (GR) Harness side C-228 (GR)
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69 59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310450AC
AC310450AC
Connector: C-228 <RHD> Junction block (rear view) Harness side

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC

SYMPTOM PROCEDURES
54C-41
NOTE:
Connector: C-101 <LHD> C-101 (L)
Step 8. ECU check by using the SWS monitor. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu.
AC310446AW
C-101 (L)
AC310456 AQ
Prior to the wiring harness inspection, check joint connector C-101, and repair if necessary. Check the communication lines for open circuit.
54C-42

SYMPTOM PROCEDURES
INSPECTION PROCEDURE A-4: Communication with the front-ECU is not possible.
Front-ECU Power Supply and SWS Communication Circuit BATTERY IGNITION SWITCH (IG2)
RELAY BOX
FRONT-ECU POWER SOURCE

NOTE : LHD : RHD
ETACS-ECU
SB : Sky blue

SYMPTOM PROCEDURES
54C-43

It is suspected that the power supply circuit to the front-ECU is defective, or the wiring harness between the SWS monitor and the front-ECU or their connector(s) is damaged. If the battery power supply circuit to the ECU (terminal No.5 of the front-ECU) is damaged, also check the power supply circuit from the ignition switch (IG2) (terminal No.22 of the front-ECU), and repair if necessary.
Step 3. Voltage measurement at A-10X front-ECU connector

Connector: A-10X
Battery
POSSIBLE CAUSES
Malfunction of the front-ECU Malfunction of the ETACS-ECU Damaged harness wires and connectors
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
DIAGNOSIS PROCEDURE
(1) Disconnect the connector, and measure at the relay box side. (2) Ignition switch: ON
Connector A-10X (Relay box side)

11 10 9 8 7 6 5 4 3 2 1
AC301541CT
(3) Voltage between A-10X front-ECU connector terminal No.7 and body earth OK: System voltage
"Communication with the ETACS-ECU is not possible P.54C-36." Step 2. Connector check: A-10X front-ECU connector
Connector: A-10X
Step 4. Check the wiring harness between A-10X front-ECU connector terminal No.7 and the battery.
Connector: A-10X
Battery Battery Relay box side

11 10 9 8 7 6 5 4 3 2 1
Relay box side

AC310572AB
11 10 9 8 7 6 5 4 3 2 1
AC310572AB
Check the power supply line for open circuit.
54C-44

SYMPTOM PROCEDURES Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 7.
Step 5. Connector check: A-11X front-ECU connector

Connector: A-11X
Step 7. Check the wiring harness between A-11X front-ECU terminal connector terminal No.31 and body earth.
Connector: A-11X
Battery Battery
Relay box side Relay box side

31 30 29 28 27 26 25 24 23 22 21 31 30 29 28 27 26 25 24 23 22 21
AC310572AC AC310572AC
Check the earth wires for open circuit.

Step 6. Resistance measurement at A-11X front-ECU connector

Connector: A-11X

Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310572AC
(1) Disconnect the connector, and measure at the relay box side.
AC310450AC

31 30 29 2827 26 25 24 2322 21
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
AC301541CU
(2) Resistance between A-11X front-ECU connector terminal No.31 and body earth OK: 2 or less

SYMPTOM PROCEDURES
54C-45
Step 9. Check the wiring harness between A-11X front-ECU connector terminal No.22 and C-228 ETACS-ECU connector terminal No.59.
Connector: A-11X
NOTE:
Connectors: C-101, C-129 <LHD> C-101 (L)
Battery C-129
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
C-101
Connector: C-228 <LHD> Junction block (rear view) C-129

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310447AG
AC310450AC
Connector: C-228 <RHD> Junction block (rear view) C-101 (L)
Harness side
AC310456 AQ
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
AC310454 AV
Prior to the wiring harness inspection, check joint connector C-101 and intermediate connector C-129, and repair if necessary. Check the communication lines for open circuit.
54C-46

Step 10. ECU check by using the SWS monitor. Check that the power supply and earth lines to the front-ECU and the SWS communication lines are normal. Ignition switch: ON ECUS TO BE CHECKED FRONT ECU OK: "OK" is displayed on the "FRONT ECU" menu.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the front-ECU.

SYMPTOM PROCEDURES
54C-47
INSPECTION PROCEDURE A-5: Communication with the power window main switch (power window module) is not possible.
Power Window Main Switch and SWS Communication Circuit FUSIBLE LINK 5
J/B SIDE
ETACS-ECU
POWER WINDOW RELAY
CPU
SB : Sky blue
54C-48

SYMPTOM PROCEDURES

The power window main switch, the power supply circuit (power window relay driving circuit) or communication circuit for that switch may be defective.
Step 3. Connector check: E-05 power window main switch connector

POSSIBLE CAUSES
Malfunction of the power window main switch Malfunction of the power window relay Malfunction of the ETACS-ECU Damaged harness wires and connectors
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
DIAGNOSIS PROCEDURE
AC310484 AD
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310493 AG
"Communication with the ETACS-ECU is not possible P.54C-36." Step 2. SWS monitor data list. <Selected item> ETACS ECU Ignition switch: ON Item No. Item 30 Item name IG SW(IG1) Normal condition ON
Step 4. Voltage measurement at the E-05 power window main switch connector
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
OK: Normal condition is displayed.

Q: Is the check result normal? YES : Go to Step 3. NO : Refer to Inspection Procedure L-2 "The
AC310484 AD
ignition switch (IG1) signal is not received P.54C-261."
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310493 AG

SYMPTOM PROCEDURES
54C-49
(2) Ignition switch: ON
Step 6. Check the power window relay. Refer to GROUP 42 Door P.42-24.
Q: Is the check result normal? YES : Go to Step 7. NO : Replace the power window relay.
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC301541BH
Step 7. Voltage measurement at C-224 power window relay connector

(3) Voltage between E-05 power window main switch connector terminal No.6 and body earth OK: System voltage
Junction block side
AC310448AI
Step 5. Connector check: C-224 power window relay connector


AC310458AG
AC310448AI
(1) Remove the power window relay, and measure at the junction block side.
Junction block side
AC310458AG
AC310507AG
(2) Voltage between C-224 power window relay connector terminal No.5 and body earth OK: System voltage
54C-50

SYMPTOM PROCEDURES
Connectors: C-211, C-224 <RHD> Junction block (front view)
Step 8. Check the wiring harness between C-224 power window relay connector terminal No.5 and fusible link (5).
Fusible link: No.5
C-211
C-224
Harness side C-211

AC310523AC
Connectors: C-211, C-224 <LHD> Junction block (front view) C-211 Junction block side C-224
AC310459AD
C-224
NOTE:
Harness side C-211
Junction block side C-224

AC310446 AD

AC310449AD
AC310454 AF
Prior to the wiring harness inspection, check intermediate connector C-126 and junction block connector C-211, and repair if necessary. Check the power supply line for open circuit.

SYMPTOM PROCEDURES
54C-51
Step 9. Resistance measurement at C-224 power window relay connector

3 2 1 4 5
Junction block side

AC310506AL
AC310448AI
(2) Resistance between C-224 power window relay connector terminal No.3 and body earth OK: 2 or less
Junction block side
AC310458AG
(1) Remove the power window relay, and measure at the junction block side.
54C-52

Step 10. Check the wiring harness between C-224 power window relay connector terminal No.3 and body earth.
C-214

Connector: C-226 <LHD> Junction block (rear view) C-224
Harness side C-214
Junction block side
AC310450 AB
AC310449AO
Junction block side

AC310461AE
C-214 C-224
Harness side C-214
AC310459AO
NOTE: Prior to the wiring harness inspection, check junction block connector C-214, and repair if necessary. Check the earth wires for open circuit.

SYMPTOM PROCEDURES
54C-53
Step 12. Check the wiring harness between C-224 power window relay connector terminal No.4 and E-05 power window main switch connector terminal No.6.
NOTE:
Junction block side Connector: C-110 <RHD>
AC310446 AE
AC310448AI
Junction block side
AC310456 AH

AC310458AG
Connector: E-05 <LHD> Front door (LH) Harness side
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310448AJ
AC310484 AD
Connector: E-05 <RHD> Front door (RH) Harness side
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310458AI
AC310493 AG
Prior to the wiring harness inspection, check intermediate connectors C-17 <LH drive vehicles> or C-110 <RH drive vehicles> and junction block connector C-211, and repair if necessary. Check the power supply line for open circuit.
54C-54

SYMPTOM PROCEDURES
Step 13. Resistance measurement at the E-05 power window main switch connector
Step 14. Check the wiring harness between E-05 power window main switch connector terminal No.2 and body earth.
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310484 AD AC310484 AD
Connector: E-05 <RHD> Front door (RH) Connector: E-05 <RHD> Front door (RH)
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310493 AG
AC310493 AG
NOTE:
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC301541BI
AC310446 AE
(2) Resistance between E-05 power window main switch connector terminal No.2 and body earth OK: 2 or less
AC310456 AH
Prior to the wiring harness inspection, check intermediate connectors C-17 <LH drive vehicles> or C-110 <RH drive vehicles>, and repair if necessary. Check the earth wires for open circuit.

54C-55
Step 16. Check the wiring harness between C-228 ETACS-ECU connector terminal No.59 and E-05 power window main switch connector terminal No.4.

Harness side C-228 (GR) Harness side

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310450AC
C-228 (GR)
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310450AC
Connector: C-228 <RHD> Junction block (rear view) Harness side

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
Connector: E-05 <LHD> C-228 (GR)

AC310461AC
Front door (LH)
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310484 AD
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310493 AG
54C-56
NOTE:

SYMPTOM PROCEDURES
Connectors: C-17, C-101 <LHD> C-101 (L)
Step 17. ECU check by using the SWS monitor. Check that the power supply and earth lines to the power window main switch (power window module) and the SWS communication lines are normal. Ignition switch: ON ECUS TO BE CHECKED P/W MODULE OK: "OK" is displayed on the "P/W MODULE" menu.
C-17
C-17
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the power window main switch.
C-101
AC310447AF
AC310456 AH
C-101 (L)
AC310456 AQ
Prior to the wiring harness inspection, check intermediate connector C-17 <LH drive vehicles> or C-110 <RH drive vehicles> and joint connector C-101, and repair if necessary. Check the communication lines for open circuit.

SYMPTOM PROCEDURES
54C-57
BUZZER
INSPECTION PROCEDURE B-1: Lamp reminder buzzer function does not work normally.
CAUTION Whenever the ECU is replaced, ensure that the input and output signal circuits are normal.
Lamp Reminder Tone Alarm Function ETACS-ECU
INPUT SIGNAL FRONT DOOR SWITCH (RH) <RHD> FRONT DOOR SWITCH (LH) <LHD> HEADLAMP SWITCH IGNITION SWITCH (IG1) TAIL LAMP SWITCH

The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Driver's door switch Tail lamp switch Headlamp switch
If this function does not work normally, these input signal circuit(s) or the ETACS-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the driver's door switch Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-58

SYMPTOM PROCEDURES Q: Is the check result normal? Normal conditions displayed for all the items : Go
DIAGNOSIS PROCEDURE
Step 1. ECU check by using the SWS monitor. Check that the power supply and earth lines to the ETACS-ECU and the column switch (column-ECU) and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU COLUMN ECU OK: "OK" is displayed for all the items
Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "ETACS ECU" menu. :
to Step 3.
Normal condition is not displayed for item No.00 or No.01 : Refer to Inspection Procedure L-4 "The
column switch (lighting and turn-signal lamp switch) signal is not received P.54C-267."
Normal condition is not displayed for item No.30 :
Refer to Inspection Procedure L-2 "The ignition switch (IG1) signal is not received P.54C-261."
Refer to Inspection Procedure A-3 "Communication with the ETACS-ECU is not possible P.54C-36."
"NG" is displayed on the "COLUMN ECU" menu. :
Refer to Inspection Procedure L-3 "The door switch (front: LH) signal is not received <LH drive vehicles>P.54C-263 ," or refer to Inspection Procedure L-3 "The door switch (front: RH) signal is not received <RH drive vehicles>P.54C-265 ."
Refer to Inspection Procedure A-2 "Communication with the column switch (column-ECU) is not possible P.54C-30." Step 2. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the lamp reminder function. <Selected item> BUZZER - LGT MONI. ALRM Ignition switch: OFF (key removed) lighting switch: HEAD Driver's door: open Item No. Item name Item 00 Item 01 Item 30 Item 32 Item 43 Normal condition HEADLAMP SW ON when the lighting switch is at HEAD TAIL LAMP SW IG SW(IG1) DR DOOR SW BUZZER ON when the lighting switch is at TAIL OFF ON ON
Replace the ETACS-ECU. Step 3. Retest the system. The lamp reminder buzzer function should work normally.
OK: Normal conditions are displayed for all the items.

SYMPTOM PROCEDURES
54C-59
CENTRAL DOOR LOCKING SYSTEM
INSPECTION PROCEDURE C-1: Central door locking system does not work. <LH drive vehicles>
Central Door Lock Power Supply Circuit <LHD> FUSIBLE LINK 1
J/B SIDE
ETACS-ECU
DOOR UNLOCK RELAY DOOR LOCK RELAY
SB : Sky blue
54C-60

SYMPTOM PROCEDURES
COMMENT ON TROUBLE SYMPTOM

If the central door locking system does not work at all, the front door lock actuator (LH) or the ETACS-ECU may be defective.
POSSIBLE CAUSES
DIAGNOSIS PROCEDURE
AC310484 AB
Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu.
Step 4. Check the front door lock actuator (LH) Check that the front door lock actuator (LH) works normally. Refer to GROUP 42 Door P.42-31.
"Communication with the ETACS-ECU is not possible P.54C-36." Step 2. Pulse check Check the input signal from the driver's door lock actuator switch. System switch Check condition Driver's door lock When the driver's key cylinder actuator switch or inside lock knob is unlocked or locked OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.

Junction block side
AC310450 AB
driver's door lock actuator signal is not received <LH drive vehicles>P.54C-296 ."

SYMPTOM PROCEDURES
54C-61
Step 6. Check the wiring harness between C-226 ETACS-ECU connector terminal No.2 and fusible link (1).
Step 7. Retest the system. Check that the central door locking system works normally.
Junction block side
AC310450 AB
Fusible link: No.1
AC310523AB
NOTE:
AC310446 AD
Connector: C-212 <LHD> Junction block (front view) C-212 (B)
Harness side
AC310448 AF
Prior to the wiring harness inspection, check intermediate connector C-126 and junction block connector C-212, and repair if necessary. Check the power supply line for open or short circuit.
54C-62

SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-1: Central door locking system does not work. <RH drive vehicles>
Central Door Lock Power Supply Circuit <RHD> FUSIBLE LINK 1
J/B SIDE
ETACS-ECU
DOOR UNLOCK RELAY DOOR LOCK RELAY
SB : Sky blue

SYMPTOM PROCEDURES
54C-63

If the central door locking system does not work at all, the front door lock actuator (RH) or the ETACS-ECU may be defective.
POSSIBLE CAUSES
Harness side E-15 (B)
DIAGNOSIS PROCEDURE
AC310493 AF
Step 4. Check the front door lock actuator (RH) Check that the front door lock actuator (RH) works normally. Refer to GROUP 42 Door P.42-31.
"Communication with the ETACS-ECU is not possible P.54C-36." Step 2. Pulse check Check the input signal from the driver's door lock actuator switch. System switch Check condition Driver's door lock When the driver's key cylinder actuator switch or inside lock knob is unlocked or locked OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.

Junction block side

AC310461AE
driver's door lock actuator signal is not received <RH drive vehicles>P.54C-299 ."
54C-64

SYMPTOM PROCEDURES Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness.
Step 6. Check the wiring harness between C-226 ETACS-ECU connector terminal No.2 and fusible link (1).
Step 7. Retest the system. Check that the central door locking system works normally.
Junction block side

AC310461AE
Fusible link: No.1
AC310523AB
NOTE:
AC310454 AF
C-212 (B)
Harness side
AC310458 AF
Prior to the wiring harness inspection, check intermediate connector C-126 and junction block connector C-212, and repair if necessary. Check the power supply line for open or short circuit.

SYMPTOM PROCEDURES
54C-65
INSPECTION PROCEDURE C-2: A Door or a tailgate cannot be locked or unlocked by the central door locking system. <LH drive vehicles>
Central Door Lock Circuit <LHD>

J/B SIDE
ETACS-ECU DOOR UNLOCK RELAY DOOR LOCK RELAY
DOOR LOCK ACTUATOR (FRONT:RH)
DOOR LOCK ACTUATOR (REAR: RH)
DOOR LOCK ACTUATOR (REAR: LH)
54C-66

SYMPTOM PROCEDURES

If a door or the tailgate cannot be locked or unlocked by the central door locking system, the door lock actuator or the tailgate lock actuator may be defective.
Step 3. Check the front door lock actuator (LH) Check that the front door lock actuator (LH) works normally. Refer to GROUP 42 Door P.42-31.
POSSIBLE CAUSES
Malfunction of the door lock actuator Malfunction of the tailgate lock actuator Damaged harness wires and connectors
Step 4. Connector check: C-226, C-227 ETACS-ECU connector

Connectors: C-226, C-227 <LHD> Junction block (rear view)
DIAGNOSIS PROCEDURE
Step 1. Confirm which door lock actuator is defective.
Q: Which door fails to lock correctly? Driver's door : Go to Step 2. Front passenger's door : Go to Step 6. Rear right door : Go to Step 10. Rear left door : Go to Step 14.
C-226
Harness side C-227
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310451AB
AC310484 AB

SYMPTOM PROCEDURES
54C-67
Step 5. Check the wiring harness from C-226 ETACS-ECU connector terminal No.12 and C-227 ETACS-ECU connector terminal No.22 to E-04 front door lock actuator (LH) connector terminal Nos.4 and 6.
Connectors: C-226, C-227 <LHD> Junction block (rear view)
NOTE:
AC310446 AE
C-226
C-227 Junction block side C-226 Harness side

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
Harness side C-227

29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310448AE
Prior to the wiring harness inspection, check intermediate connector C-17 and junction block connector C-214, and repair if necessary. Check the input and output lines for open circuit.
AC310451AB
AC310484 AB
Harness side
E-15(B)
AC310488AB
54C-68

SYMPTOM PROCEDURES
Step 7. Check the front door lock actuator (RH). Check that the front door lock actuator (RH) works normally. Refer to GROUP 42 Door P.42-31.
Step 9. Check the wiring harness from C-226 ETACS-ECU connector terminal Nos.12 and 13 to E-15 front door lock actuator (RH) connector terminal Nos.4 and 6.

Connector: C-226 <LHD> Junction block (rear view) Junction block side
AC310450 AB
Connector: E-15 <LHD> Junction block side
Front door (RH)
AC310450 AB
Harness side
E-15(B)
AC310488AB
NOTE:
AC310452 AC
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310448AE

54C-69

Step 10. Connector check: E-18 rear door lock actuator (RH) connector
Connector: E-18 Rear door (RH) Junction block side
AC310450 AB
Harness side
E-18 (B)
AC310491AB
Step 13. Check the wiring harness from C-226 ETACS-ECU connector terminal Nos.12 and 13 to E-18 rear door lock actuator (RH) connector terminal Nos.4 and 6.
Step 11. Check the rear door lock actuator (RH). Check that the rear door lock actuator (RH) is in good condition. Refer to GROUP 42 Door P.42-31.
Q: Is the check result normal? YES : Go to Step 12. NO : Replace the rear door lock actuator (RH).
Junction block side
AC310450 AB
Connector: E-18
Rear door (RH)
Harness side
E-18 (B)
AC310491AB
54C-70
NOTE:

SYMPTOM PROCEDURES
Step 14. Connector check: E-07 rear door lock actuator (LH) connector
Connector: E-07 Rear door (LH)

AC310452AD
E-07 (B)
AC310486AC
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
Step 15. Check the rear door lock actuator (LH). Check that the rear door lock actuator (LH) is in good condition. Refer to GROUP 42 Door P.42-31.
Q: Is the check result normal? YES : Go to Step 16. NO : Replace the rear door lock actuator (LH).
AC310448AE
Connector: D-04 <LHD>

AC310463AB
Prior to the wiring harness inspection, check C-112, D-04 intermediate connectors and C-214 junction block connector, and repair if necessary. Check the input and output lines for open circuit.
Junction block side
AC310450 AB

SYMPTOM PROCEDURES
54C-71
Step 17. Check the wiring harness from C-226 ETACS-ECU connector terminal Nos.12 and 13 to E-07 rear door lock actuator (LH) connector terminal Nos.4 and 6.
Junction block side
AC310450 AB
Connector: E-07
Rear door (LH)
Harness side
E-07 (B)
AC310486AC
NOTE:
Harness side
AC310448 AG
AC310465AC
Prior to the wiring harness inspection, check D-15 intermediate connectors and C-217 junction block connector, and repair if necessary. Check the input and output lines for open circuit.
54C-72

SYMPTOM PROCEDURES
INSPECTION PROCEDURE C-2: A door or a tailgate cannot be locked or unlocked by the central door locking system. <RH drive vehicles>
Central Door Lock Circuit <RHD>

J/B SIDE
ETACS-ECU DOOR UNLOCK RELAY DOOR LOCK RELAY
DOOR LOCK ACTUATOR (FRONT:RH)
DOOR LOCK ACTUATOR (REAR: RH)
DOOR LOCK ACTUATOR (REAR: LH)

SYMPTOM PROCEDURES
54C-73

If a door or the tailgate cannot be locked or unlocked by the central door locking system, the door lock actuator or the tailgate lock actuator may be defective.
Step 3. Check the front door lock actuator (RH) Check that the front door lock actuator (RH) works normally. Refer to GROUP 42 Door P.42-31.
POSSIBLE CAUSES
Malfunction of the door lock actuator Malfunction of the tailgate lock actuator Damaged harness wires and connectors
Step 4. Connector check: C-226, C-227 ETACS-ECU connector

Connectors: C-226, C-227 <RHD> Junction block (rear view) C-226
DIAGNOSIS PROCEDURE
Step 1. Confirm which door lock actuator is defective.
Q: Which door fails to lock correctly? Driver's door : Go to Step 2. Front passenger's door : Go to Step 6. Rear right door : Go to Step 10. Rear left door : Go to Step 14.
Harness side C-227

29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
Harness side
AC310462AB
E-15(B)
AC310495 AC
54C-74

SYMPTOM PROCEDURES
Step 5. Check the wiring harness from C-226 ETACS-ECU connector terminal No.12 and C-227 ETACS-ECU connector terminal No.22 to E-15 front door lock actuator (RH) connector terminal Nos.4 and 6.
Connectors: C-226, C-227 <RHD> Junction block (rear view) C-226
NOTE:
AC310456 AH
C-227 Junction block side C-226 Harness side

14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side C-227

29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE
AC310462AB
Harness side
Connector: E-04 <RHD> E-15(B)
AC310495 AC
AC310493AE

SYMPTOM PROCEDURES
54C-75
Step 7. Check the front door lock actuator (LH). Check that the front door lock actuator (RH) works normally. Refer to GROUP 42 Door P.42-31.
Step 9. Check the wiring harness from C-226 ETACS-ECU connector terminal Nos.12 and 13 to E-04 front door lock actuator (LH) connector terminal Nos.4 and 6.

Junction block side

AC310461AE
Junction block side

AC310461AE
AC310493AE
NOTE:
AC310454 AH
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE
54C-76

SYMPTOM PROCEDURES
Step 13. Check the wiring harness from C-226 ETACS-ECU connector terminal Nos.12 and 13 to E-18 rear door lock actuator (RH) connector terminal Nos.4 and 6.
Step 10. Connector check: E-18 rear door lock actuator (RH) connector
Connector: E-18
Junction block side Harness side Connector: E-18 E-18 (B)

AC310495AE AC310461AE
Harness side
Step 11. Check the rear door lock actuator (RH). Check that the rear door lock actuator (RH) is in good condition. Refer to GROUP 42 Door P.42-31.
Q: Is the check result normal? YES : Go to Step 12. NO : Replace the rear door lock actuator (RH).
E-18 (B)
AC310495AE
NOTE:

Harness side
AC310458AC
Junction block side

AC310461AE
AC310471AC
Prior to the wiring harness inspection, check junction block connector C-217 and D-04, and repair if necessary. Check the input and output lines for open circuit.

54C-77

Step 14. Connector check: E-07 rear door lock actuator (LH) connector
Connector: E-07 Junction block side
AC310461AE
Harness side
E-07 (B)
AC310500AB
Step 17. Check the wiring harness from C-226 ETACS-ECU connector terminal Nos.12 and 13 to E-07 rear door lock actuator (LH) connector terminal Nos.4 and 6.
Step 15. Check the rear door lock actuator (LH). Check that the rear door lock actuator (LH) is in good condition. Refer to GROUP 42 Door P.42-31.
Q: Is the check result normal? YES : Go to Step 16. NO : Replace the rear door lock actuator (LH).
Junction block side

AC310461AE
Connector: E-07
Harness side
E-07 (B)
AC310500AB
54C-78
NOTE:

AC310454AI
Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310458 AE
AC310473AC
Prior to the wiring harness inspection, check intermediate connector C-127, D-15 and junction block connector C-214, and repair if necessary. Check the input and output lines for open circuit.

SYMPTOM PROCEDURES
54C-79
INSPECTION PROCEDURE C-3: The central door locking system can not be operated by means of the front passenger's door lock key cylinder.
Central Door Lock (Front Passenger's Door Lock Key Cyilinder Switch) Circuit
FUSIBLE LINK 1
ETACS-ECU DOOR UNLOCK RELAY DOOR LOCK RELAY INPUT SIGNAL FRONT PASSENGER'S DOOR LOCK KEY CYLINDER SWITCH
J/B SIDE
DOOR LOCK ACTUATOR (FRONT: LH) DOOR LOCK ACTUATOR (FRONT: RH) DOOR LOCK ACTUATOR (REAR: LH) DOOR LOCK ACTUATOR (REAR: RH)

If the central door locking system does not work by means of the front passenger's door lock key cylinder, the front passenger's door lock key cylinder or the ETACS-ECU may be defective.
DIAGNOSIS PROCEDURE
Step 1. Check the operation of the central door locking system. Check that the central door locking system works normally by means of the driver's door lock key cylinder and inside lock knob.
Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure C-1 "Central
POSSIBLE CAUSES
Malfunction of the front passenger's door lock key cylinder Malfunction of the ETACS-ECU Damaged harness wires and connectors
door locking system does not work P.54C-59 <LH drive vehicles>," or refer to Inspection Procedure C-1 "Central door locking system does not work P.54C-62 <RH drive vehicles>."
54C-80

SYMPTOM PROCEDURES
Step 3. Pulse check Check the input signal from the front passengers door lock key cylinder switch. System switch Front passengers door lock key cylinder switch Check condition Turn the key to the lock or unlock position

door lock key cylinder switch signal is not received P.54C-312." Step 4. Retest the system. Check that the central door locking system works normally by means of the front passenger's door lock key cylinder.

SYMPTOM PROCEDURES
54C-81
INSPECTION PROCEDURE C-4: The ignition key reminder function does not work normally.
Ignition Key Reminder Function Circuit
FUSIBLE LINK 1
ETACS-ECU INPUT SIGNAL DOOR UNLOCK RELAY DOOR LOCK RELAY DRIVER'S DOOR LOCK ACTUCTOR SWITCH DRIVER'S DOOR SWITCH KEY REMINDER SWITCH
J/B SIDE
DOOR LOCK ACTUATOR (FRONT: LH) DOOR LOCK ACTUATOR (FRONT: RH) DOOR LOCK ACTUATOR (REAR: LH) DOOR LOCK ACTUATOR (REAR: RH)

If the key reminder function does not work normally, the input signal circuits below or the ETACS-ECU may be defective. Key reminder switch Drivers door switch Drivers door lock actuator
DIAGNOSIS PROCEDURE
POSSIBLE CAUSES
Malfunction of the key reminder switch Malfunction of the drivers door switch Malfunction of the drivers door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-82

SYMPTOM PROCEDURES Q: Is the check result normal? All the signals are received normally. : Go to Step
Step 2. Confirm communication data by using the SWS monitor. Check the SWS communication signals, which are related to the key reminder function. <Selected item> ETACS ECU Driver's door: open Item No. Item 32 Item name Normal condition DR DOOR SW ON
4.
The key reminder switch signal is not received. :
Refer to Inspection Procedure L-9 "The key reminder switch signal is not received P.54C-281."
The driver's door lock actuator switch signal is not received. : Refer to Inspection Procedure L-12

Q: Is the check result normal? YES : Go to Step 3. NO : Refer to Inspection Procedure L-3 "The door
switch (front: LH) signal is not received P.54C-263 <LH drive vehicles>, " or refer to Inspection Procedure L-3 "The door switch (front: RH) signal is not received P.54C-265. <RH drive vehicles>" Step 3. Pulse check Check the input signals below which are related to the key reminder function. System switch Key reminder switch Driver's door lock actuator switch Check condition When the inserted ignition key is pulled out When the driver's key cylinder or inside lock knob is unlocked or locked
"The front door lock actuator (LH) signal is not received P.54C-296 <LH drive vehicles>," or refer to Inspection Procedure L-12 "The front door lock actuator (RH) signal is not received P.54C-299 <RH drive vehicles>." Step 4. Retest the system.
Q: Does the ignition key reminder function work normally? YES : The trouble can be an intermittent

SYMPTOM PROCEDURES
54C-83
INSPECTION PROCEDURE C-5: The impact detection door unlock function does not function.
ETACS-ECU
SRS-ECU
CRASH DETECTION DOOR UNLOCK SIGNAL PROCESS CIRCUIT
Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

If the impact detection door unlock function does not work normally, the input signal circuit from the impact detection sensor, the SRS-ECU or the ETACS-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the SRS-ECU Malfunction of the ETACS-ECU Damaged harness wires and connectors
DIAGNOSIS PROCEDURE
Step 1. M.U.T.-II/III other system diagnosis code. Check that the SRS-ECU sets a diagnosis code.
Q: Is the diagnosis code set? YES : Refer to GROUP 52B Troubleshooting
P.52B-9.
NO : Go to Step 2.
54C-84

SYMPTOM PROCEDURES
Step 3. Connector check: C-12 SRS-ECU connector and C-227 ETACS-ECU connector
Step 4. Check the wiring harness between C-227 ETACS-ECU connector terminal No.29 and C-12 SRS-ECU connector terminal No.14.
Harness side Harness side C-12 (Y) C-12 (Y)

AC310446 AZ
Connector: C-12 <RHD> Connector: C-12 <RHD>
AC310446 AZ
Harness side Harness side C-12 (Y) C-12 (Y)

AC310454 BE AC310454 BE
Connector: C-227 <LHD> Junction block side (rear view)
Connector: C-227 <LHD> Junction block side (rear view)
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310450 AI
AC310450 AI
Junction block (rear view) Connector: C-227 <RHD> Junction block (rear view)
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF
Q: Are the check results normal? YES : Go to Step 4. NO : Repair the defective connector.
AC310461AF
Check the communication lines for open circuit.


SYMPTOM PROCEDURES
54C-85
Step 5. Retest the system. Replace the SRS-ECU, and check that the impact detection door unlock function works normally. (1) Replace the SRS-ECU. (2) Check that the impact detection door unlock function works normally.
54C-86
POWER WINDOW

SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-1: Power windows do not work at all.
Power Window Relay Circuit <LHD> FUSIBLE LINK 5
J/B SIDE
ETACS-ECU
POWER WINDOW RELAY
FRONT POWER WINDOW SUB SWITCH (RH)
REAR POWER WINDOW SUB SWITCH (LH)
REAR POWER WINDOW SUB SWITCH (RH)
POWER WINDOW MAIN SWITCH CPU

SYMPTOM PROCEDURES
Power Window Relay Circuit <RHD> FUSIBLE LINK
5
54C-87
J/B SIDE
POWER WINDOW RELAY
FRONT POWER WINDOW SUB SWITCH (LH)
REAR POWER WINDOW SUB SWITCH (LH)
REAR POWER WINDOW SUB SWITCH (RH)
POWER WINDOW MAIN SWITCH CPU

If the power windows do not work at all, the power window relay, the power window main switch or the ETACS-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the power window relay Malfunction of the power window main switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-88

DIAGNOSIS PROCEDURE
Step 1. ECU check by using the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the power window main switch (power window module) and the SWS communication lines are normal. Turn the ignition switch to the ON position. ECUS TO BE CHECKED ETACS ECU P/W MODULE OK: "OK" is displayed for all the items
Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "ETACS ECU" menu. :
to Step 3.
Replace the ETACS-ECU.

Replace the power window main switch. Step 3. Door communication by using the SWS monitor. Check the SWS communication signal, which are related to the power windows. <Selected item> DOOR CNT. COM. Insert the probe (For the insertion point, refer to P.54C-5). Turn the ignition switch to the ON position. Power window main switch: UP Item No. Item C0 Item name PASS DOR UP Normal condition ON
"NG" is displayed on the "P/W MODULE" menu. :
Refer to Inspection Procedure A-5 "Communication with the power window main switch (power window module) is not possible P.54C-47." Step 2. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the power windows. <Selected item> POWER WINDOW Turn the ignition switch to the ON position. Power window main switch: UP Item No. Item name Item 30 Item 33 Item 71 IG SW (IG1) P/W ECU ACK Normal condition ON INPUT CHECK (only momentarily when switch is operated)

Q: Is the check result normal? YES : Go to Step 4. NO : Replace the power window main switch.
Step 4. Retest the system. Check that the all the power windows work.
P/W SW ACCEPT PERMIT

SYMPTOM PROCEDURES
54C-89
INSPECTION PROCEDURE D-2: Driver's power window does not work by means of the power window main switch. <LH drive vehicles>
Power Window (front: LH) Circuit <LHD> POWER WINDOW RELAY
CPU
FRONT (LH)
POWER WINDOW MOTOR (FRONT: LH)
SB : Sky blue

If the driver's power window does not work by means of the power window main switch, the power window main switch or the driver's door power window regulator motor may be defective.
DIAGNOSIS PROCEDURE
STEP 1. Check the power window main switch. Check that all of the front passenger's and rear door power windows can operate by means of the power window main switch.
Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure D-1 "Power
POSSIBLE CAUSES
Malfunction of the power window main switch Malfunction of the front power window regulator motor (LH) Damaged harness wires and connectors
windows do not work at all P.54C-86."
54C-90

SYMPTOM PROCEDURES
STEP 2. Connector check: E-05 power window main switch connector and E-02 front power window regulator motor (LH) connector
Connectors: E-02, E-05 <LHD> Front door (LH)
STEP 3. Check the wiring harness from E-02 front power window regulator motor (LH) connector terminal Nos.1 and 4 to E-05 power window main switch connector terminal Nos.7 and 1.
E-02 (GR) E-02 (GR) E-05 E-05 Harness side E-02
Harness side E-02
Harness side E-05

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side E-05

AC310485AB
6 5 4 3 2 1 14 13 12 11 10 9 8 7
Q: Are the check results normal? YES : Go to Step 3. NO : Repair the connector.
AC310485AB
Check the input and output lines for open or short circuit.
STEP 4. Retest the system. After the power window main switch is replaced, check that the driver's door power window can be operated by the power window main switch. (1) Replace the power window main switch. (2) Check that the driver's power window works by means of the power window main switch.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the front power window regulator motor assembly (LH).

SYMPTOM PROCEDURES
54C-91
INSPECTION PROCEDURE D-2: Driver's power window does not work by means of the power window main switch. <RH drive vehicles>
Power Window (front: RH) Circuit <RHD> POWER WINDOW RELAY
FRONT (RH)
CPU
POWER WINDOW MOTOR (FRONT: RH)
SB : Sky blue

If the driver's power window does not work by means of the power window main switch, the power window main switch or the driver's door power window regulator motor may be defective.
DIAGNOSIS PROCEDURE
STEP 1. Check the power window main switch. Check that all of the front passenger's and rear door power windows can operate by means of the power window main switch.
POSSIBLE CAUSES
Malfunction of the power window main switch Malfunction of the front power window regulator motor (RH) Damaged harness wires and connectors
54C-92

SYMPTOM PROCEDURES
STEP 2. Connector check: E-05 power window main switch connector and E-11 front power window regulator motor (RH) connector
Connectors: E-05, E-11 <RHD> Front door (RH)
STEP 3. Check the wiring harness from E-11 front power window regulator motor (RH) connector terminal Nos.1 and 4 to E-05 power window main switch connector terminal Nos.7 and 1.
E-11 (GR) E-11 (GR) E-05 E-05 Harness side E-05

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side E-05

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side E-11
Harness side E-11
AC310494 AB
Q: Are the check results normal? YES : Go to Step 3. NO : Repair the connector.
AC310494 AB
STEP 4. Retest the system. After the power window main switch is replaced, check that the driver's door power window can be operated by the power window main switch. (1) Replace the power window main switch. (2) Check that the driver's power window works by means of the power window main switch.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the front power window regulator motor assembly (RH).

SYMPTOM PROCEDURES
54C-93
INSPECTION PROCEDURE D-3: Relevant power window(s) do not work by means of the front and rear passenger's power window sub switches.
Power Window (front: RH) Circuit <LHD>
FUSIBLE LINK 5
POWER WINDOW RELAY
ETACSECU
POWER WINDOW SUB SWITCH (FRONT)
CPU
POWER WINDOW MOTOR (FRONT: RH)
SB : Sky blue
54C-94

SYMPTOM PROCEDURES
Power Window (front: LH) Circuit <RHD>
FUSIBLE LINK 5
POWER WINDOW RELAY
ETACSECU
POWER WINDOW SUB SWITCH (FRONT)
CPU
POWER WINDOW MOTOR (FRONT: LH)
SB : Sky blue

SYMPTOM PROCEDURES
Power Window (rear) Circuit
54C-95
FUSIBLE LINK 5
POWER WINDOW RELAY
ETACS-ECU
POWER WINDOW SUB SWITCH (REAR: LH) CPU CPU
POWER WINDOW SUB SWITCH (REAR: RH)
POWER WINDOW MOTOR (REAR: LH)
POWER WINDOW MOTOR (REAR: RH)
SB : Sky blue

If the front passenger's or rear power window does not work by means of the respective power window sub switch, the power window sub switch or the power window regulator motor may be defective.
POSSIBLE CAUSES
Malfunction of the front power window sub switch (RH) <LH drive vehicles>, front power window sub switch (LH) <RH drive vehicles>, power window sub switch (rear: RH) or power window sub switch (rear: LH)
54C-96

SYMPTOM PROCEDURES
Malfunction of the front power window regulator motor (RH) <LH drive vehicles>, front power window regulator motor (LH) <RH drive vehicles>, power window regulator motor (rear: RH) or power window regulator motor (rear: LH) Damaged harness wires and connectors
Step 4. Resistance measurement at E-14 power window sub switch (front) connector
DIAGNOSIS PROCEDURE
Step 1. Check the power window main switch. Check that the power window lock switch is turned off.
Q: Is the check result normal? YES : Go to Step 2. NO : Turn off the power window lock switch.
Harness side
AC310488AD
Step 2. Determine a trouble spot.

Q: Which power window does not work? Front passenger's door <LH drive vehicles> : Go
to Step 3.
Front passenger's door <RH drive vehicles> : Go
to Step 12.
Rear right door : Go to Step 21. Rear left door : Go to Step 30.

AC303981AC
Step 3. Connector check: E-14 power window sub switch (front) connector
(2) Resistance between E-14 power window sub switch (front) connector terminal 1 and body earth OK: 2 or less
Harness side
AC310488AD
Q: Is the check result normal? YES : Go to Step 4. NO : Repair the connector.

SYMPTOM PROCEDURES
54C-97
Step 5. Check the wiring harness from E-14 power window sub switch (front) connector terminal No.1 to body earth.
(2) Turn the ignition switch to the ON position.
Harness side Connector E-14 (Harness side)

AC303982AC
AC310488AD
NOTE:
(3) Voltage between E-14 power window sub switch (front) connector terminal 4 and body earth OK: System voltage

AC310452 AC
Junction block side
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness. Step 6. Voltage measurement at E-14 power window sub switch (front) connector
AC310448AI
Harness side
AC310488AD
54C-98

Step 8. Check the wiring harness from E-14 power window sub switch (front) connector terminal No.4 to C-224 power window relay connector terminal No.4.
Connectors: C-211, C-224 <LHD> Junction block (front view) C-211
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness. Step 9. Connector check: E-11 front power window regulator motor (RH) connector
C-224 Harness side E-11 (GR)
Harness side C-211

AC310488 AE
AC310449AD
Step 10. Check the wiring harness from E-11 front power window regulator motor (RH) connector terminal Nos.1 and 4 to E-14 front power window sub switch (RH) connector terminal Nos.5 and 7.
Connectors: E-11, E-14 <LHD> Front door (RH)
Harness side
E-11 (GR)
AC310488AD
NOTE:
E-14
Harness side E-11
Harness side E-14

AC310452 AC
Prior to the wiring harness inspection, check intermediate connectors C-110 and junction block connector C-211, and repair if necessary. Check the power supply line for open circuit.
AC310489AB

54C-99
Step 13. Resistance measurement at E-14 power window sub switch (front) connector
Step 11. Retest the system. After the front power window sub switch (RH) is replaced, check that the front passenger's door power window can be operated by the front power window sub switch (RH). (1) Replace the front power window sub switch (RH). (2) Check that the front passenger's door power window can be operated by the front power window sub switch (RH).
Front door (LH)
Harness side
AC310498AC
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the power window regulator motor assembly (front RH).
Step 12. Connector check: E-14 power window sub switch (front) connector
Connector: E-14 <RHD> Front door (LH) Connector E-14 (Harness side)
AC310506 AE
Harness side
(2) Resistance between E-14 power window sub switch (front) connector terminal 1 and body earth OK: 2 or less
AC310498AC
54C-100

SYMPTOM PROCEDURES
Step 14. Check the wiring harness from E-14 power window sub switch (front) connector terminal No.1 to body earth.
Connector: E-14 <RHD> Front door (LH)
Harness side Connector E-14 (Harness side)
AC310507AD
AC310498AC
NOTE:
(3) Voltage between E-14 power window sub switch (front) connector terminal 4 and body earth OK: System voltage

AC310454 AH
Junction block side
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness. Step 15. Voltage measurement at E-14 power window sub switch (front) connector
AC310458AG
Harness side
AC310498AC

SYMPTOM PROCEDURES
54C-101
Step 17. Check the wiring harness from E-14 power window sub switch (front) connector terminal No.4 to C-224 power window relay connector terminal No.4.
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness. Step 18. Connector check: E-11 front power window regulator motor (LH) connector
Harness side
AC310498AC
E-02 (GR)
Harness side
C-211
AC310498 AD
C-224
Harness side C-211
Step 19. Check the wiring harness from E-11 front power window regulator motor (LH) connector terminal Nos.1 and 4 to E-14 power window sub switch (front) connector terminal Nos.5 and 7.
Connectors: E-02, E-14 <RHD> Front door (LH)
Junction block side C-224 E-02 (GR)

AC310459AD
NOTE:
Connector: C-17 <RHD> Harness side E-02
E-14
Harness side E-14

AC310454 AH
Prior to the wiring harness inspection, check intermediate connectors C-17 and junction block connector C-211, and repair if necessary. Check the power supply line for open circuit.
AC310499AB
54C-102

SYMPTOM PROCEDURES
Step 22. Resistance measurement at E-17 power window sub switch (rear: RH) connector
Step 20. Retest the system. After the front power window sub switch (LH) is replaced, check that the front passenger's door power window can be operated by the front power window sub switch (LH). (1) Replace the front power window sub switch (LH). (2) Check that the front passenger's door power window can be operated by the front power window sub switch (LH).
Harness side
AC310491AC
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the power window regulator motor assembly (front LH).
Step 21. Connector check: E-17 power window sub switch (rear: RH) connector
Connector: E-17 Rear door (RH) Connector E-17 (Harness side)
AC310506 AF
Harness side
(2) Resistance between E-17 power window sub switch (rear: RH) connector terminal 1 and body earth OK: 2 or less
AC310491AC

SYMPTOM PROCEDURES
54C-103
Step 23. Check the wiring harness from E-17 power window sub switch (rear: RH) connector terminal No.1 to body earth.
Step 24. Voltage measurement at E-17 power window sub switch (rear: RH) connector
AC310491AC AC310491AC
NOTE:
(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the ON position.
AC310463AB
AC310507AE
(3) Voltage between E-17 power window sub switch (rear: RH) connector terminal 4 and body earth OK: System voltage
AC310471AC
Prior to the wiring harness inspection, check intermediate connectors D-04, and repair if necessary. Check the earth wires for open circuit.
malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness.
54C-104

SYMPTOM PROCEDURES

Junction block side
C-224
AC310448AI
Harness side C-211
Connector: C-224 <RHD> Junction block (front view) Junction block side C-224 Junction block side
AC310449AD
AC310458AG
C-211
Step 26. Check the wiring harness from E-17 power window sub switch (rear: RH) connector terminal No.4 to C-224 power window connector terminal No.4.
C-224
Harness side C-211
Harness side Junction block side C-224
AC310491AC AC310459AD

SYMPTOM PROCEDURES
54C-105
NOTE:
Step 27. Connector check: E-16 power window regulator motor (rear: RH) connector

AC310452AD
E-16 (GR)
AC310491AD
AC310456 AN
Step 28. Check the wiring harness from E-16 power window regulator motor (rear: RH) connector terminal Nos.1 and 4 to E-17 power window sub switch (rear: RH) connector terminal Nos.5 and 7.
Connectors: E-16, E-17 Rear door (RH)
E-17 E-16 (GR)

AC310463AB
Connector: D-04 <RHD> Harness side E-16
Harness side E-17

AC310471AC
Prior to the wiring harness inspection, check intermediate connectors C-112 <LH drive vehicles>, C-113 <RH drive vehicles>, D-04 and junction block connector C-211, and repair if necessary. Check the power supply line for open circuit.
AC310492 AB
54C-106

SYMPTOM PROCEDURES
Step 29. Retest the system. After the power window sub switch (rear: RH) is replaced, check that the rear right door power window can be operated by the power window sub switch (rear: RH). (1) Replace the power window sub switch (rear: RH). (2) Check that the rear right door power window can be operated by the power window sub switch (rear: RH).
Step 31. Resistance measurement at E-08 power window sub switch (rear: LH) connector
Harness side
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the rear power window regulator motor assembly (RH).
AC310486 AD
Step 30. Connector check: E-08 power window sub switch (rear LH) connector
Harness side

AC303981AB
AC310486 AD
(2) Resistance between E-08 power window sub switch (rear: LH) connector terminal 1 and body earth OK: 2 or less

SYMPTOM PROCEDURES
54C-107
Step 32. Check the wiring harness from E-08 power window sub switch (rear: LH) connector terminal No.1 to body earth.
Step 33. Voltage measurement at E-08 power window sub switch (rear: LH) connector
AC310486 AD AC310486 AD
NOTE:
(1) Disconnect the connector, and measure at the wiring harness side. (2) Turn the ignition switch to the ON position.
AC310465AC

AC303982AB
(3) Voltage between E-08 power window sub switch (rear: LH) connector terminal 4 and body earth OK: System voltage
AC310473AD
Prior to the wiring harness inspection, check intermediate connectors D-15, and repair if necessary. Check the earth wires for open circuit.
54C-108

SYMPTOM PROCEDURES

Junction block side
C-224
AC310448AI
Harness side C-211
Connector: C-224 <RHD> Junction block (front view) Junction block side C-224 Junction block side
AC310449AD
AC310458AG
C-211
Step 35. Check the wiring harness from E-08 power window sub switch (rear: LH) connector terminal No.4 to C-224 power window relay connector terminal No.4.
C-224
Harness side C-211
Harness side
AC310486 AD AC310459AD

SYMPTOM PROCEDURES
54C-109
NOTE:
Step 36. Connector check: E-09 power window regulator motor (rear: LH) connector
Harness side
AC310446AO
E-09 (GR)
AC310486AB
AC310454AI
Step 37. Check the wiring harness from E-09 power window regulator motor (rear: LH) connector terminal Nos.1 and 4 to E-08 power window sub switch (rear: LH) connector terminal Nos.5 and 7.
Connectors: E-08, E-09 Rear door (LH)
E-09 (GR)
AC310465AC
E-08
Connector: D-15 <RHD> Harness side E-08
Harness side E-09

AC310473AD
Prior to the wiring harness inspection, check intermediate connectors C-127, D-15 and junction block connector C-211, and repair if necessary. Check the power supply line for open circuit.
AC310487AB
54C-110

Step 38. Retest the system. After the power window sub switch (rear: LH) is replaced, check that the rear left door power window can be operated by the power window sub switch (rear: LH). (1) Replace the power window sub switch (rear: LH). (2) Check that the rear left door power window can be operated by the power window sub switch (rear: LH).
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the rear power window regulator motor assembly (LH).

SYMPTOM PROCEDURES
54C-111
INSPECTION PROCEDURE D-4: Front and/or rear passenger's power window(s) do not work by means of the power window main switch.
Power Window Circuit <LHD>
LOCK SWITCH CPU
FRONT (RH)
REAR (RH)
REAR (LH)
CPU POWER WINDOW SUB SWITCH (FRONT)
CPU POWER WINDOW SUB SWITCH (REAR: LH)
CPU POWER WINDOW SUB SWITCH (REAR: RH)
SB : Sky blue
54C-112

SYMPTOM PROCEDURES
Power Window Circuit <RHD>
LOCK SWITCH
FRONT (LH)
REAR (RH)
CPU REAR (LH)
CPU POWER WINDOW SUB SWITCH (FRONT)
CPU POWER WINDOW SUB SWITCH (REAR: LH)
CPU POWER WINDOW SUB SWITCH (REAR: RH)
SB : Sky blue

If the passenger's and/or rear power window does not work by means of the power window main switch, the power window main switch or the respective power window sub switch(es) may be defective.
POSSIBLE CAUSES
Malfunction of the power window main switch Malfunction of the front power window sub switch (RH), rear power window sub switch (RH) or rear power window sub switch (LH) Damaged harness wires and connectors

SYMPTOM PROCEDURES
54C-113
DIAGNOSIS PROCEDURE
Step 1. ECU check by using the SWS monitor. Check that the power supply and earth lines to the power window main switch (power window module) and the SWS communication lines are normal. Turn the ignition switch to the ON position. ECUS TO BE CHECKED P/W MODULE OK: "OK" is displayed on the "P/W MODULE" menu.
Step 4. Door communication by using the SWS monitor. Check the SWS communication signals, which are used when the front and/or rear passenger's door power windows are operated by the power window main switch. <Selected item> DOOR CNT. COM. Insert a probe between a power window sub switch of a door of which power window does not work and the power window main switch (For the insertion point, refer to P.54C-5). Turn the ignition switch to the ON position. Are normal conditions displayed when each switch of the power window main switch is operated? Item No. Item name Item C0 Item C1 Item C2 Item C4 Item C5 Item C6 Item C8 Item C9 PASS DOR UP PASS DOR AUTO REAR RH UP REAR RH DOWN REAR RH AUTO REAR LH UP REAR LH DOWN Normal condition ON ON ON ON ON ON ON ON
"Communication with the power window main switch (power window module) is not possible P.54C-47." Step 2. Check the power window sub switch. Check that each power window works by means of the respective power window sub switch when the power window lock switch is turned off.
Q: Is the check result normal? YES : Go to Step 3. NO : Refer to Inspection Procedure D-3
PASS DOR DOWN ON
"Relevant power window(s) do not work by means of the front and rear passenger's power window sub switches P.54C-93." Step 3. Door communication by using the SWS monitor. Check the SWS communication signal from the power window lock switch to the ETACS-ECU. <Selected item> DOOR CNT. COM. Insert a probe between a power window sub switch of a door of which power window does not work and the power window main switch (For the insertion point, refer to P.54C-5). Turn the ignition switch to the ON position. Power window lock switch: OFF Item No. Item CB Item name P/W LOCK SW Normal condition OFF
Item CA REAR LH AUTO

Q: Is the check result normal? Normal conditions are displayed for all of items C0, C1 and C2 when the front passenger's power window does not work. : Go to Step 5. Normal conditions are displayed for none of items C0, C1 and C2 when the front passenger's power window does not work. : Go to Step 7. Normal conditions are displayed for all of items C4, C5 and C6 when the rear right power window does not work. : Go to Step 10. Normal conditions are displayed for none of items C4, C5 and C6 when the rear right power window does not work. : Go to Step 12. Normal conditions are displayed for all of items C8, C9 and CA when the rear left power window does not work. : Go to Step 15. Normal conditions are displayed for none of items C8, C9 and CA when the rear left power window does not work. : Go to Step 17. Normal condition is displayed for any of the items. : Replace the power window main switch.

Q: Is the check result normal? YES : Go to Step 4. NO : Replace the power window main switch.
54C-114

SYMPTOM PROCEDURES

Step 6. Check the wiring harness from E-05 power window main switch connector terminal No.11 to the inserted probe.
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310484 AD AC310484 AD
Connector: E-05 <RHD> Front door (RH) Connector: E-05 <RHD> Front door (RH)
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310493 AG
AC310493 AG

SYMPTOM PROCEDURES
54C-115
NOTE:
Step 7. Connector check: E-14 front power window sub switch (LH) connector
Harness side
AC310446 AE
Connector: C-17 <RHD> Connector: E-14 <RHD> Front door (LH)
AC310488AD
Harness side
AC310454 AH
AC310498AC
Step 8. Check the wiring harness from E-14 front power window sub switch (LH) connector terminal No.6 to the inserted probe.
AC310452 AC
Harness side
AC310488AD AC310456 AH
Prior to the wiring harness inspection, check intermediate connectors C-17, C-110, and repair if necessary. Check the communication lines for open circuit.
Harness side
AC310498AC
54C-116
NOTE:

SYMPTOM PROCEDURES
Step 9. Retest the system. After the front power window sub switch (LH) is replaced, check that the front passenger's door power window can be operated by the power window sub switch. (1) Replace the front power window sub switch (LH). (2) Check that the front passenger's power window works by means of the power window main switch.
AC310446 AE
AC310454 AH
Connector: C-110 <LHD> Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310484 AD

AC310452 AC

6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310493 AG
AC310456 AH
Prior to the wiring harness inspection, check intermediate connectors C-17, C-110, and repair if necessary. Check the communication lines for open circuit.

SYMPTOM PROCEDURES
54C-117
NOTE:
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310446 AE

AC310484 AD
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310456 AH

AC310493 AG
AC310463AB
AC310471AC
Prior to the wiring harness inspection, check intermediate connectors C-17 <LH drive vehicles>, C-110 <RH drive vehicles>, D-04, and repair if necessary. Check the communication lines for open circuit.
54C-118

SYMPTOM PROCEDURES
Step 12. Connector check: E-17 rear power window sub switch (RH) connector
Step 13. Check the wiring harness from E-17 rear power window sub switch (RH) connector terminal No.6 to the inserted probe.
AC310491AC
Connector: E-17 <RHD> Connector: E-17 <RHD>
AC310491AC
AC310500AC
AC310500AC

SYMPTOM PROCEDURES
54C-119
NOTE:
Step 14. Retest the system. After the rear power window sub switch (RH) is replaced, check that the rear right door power window can be operated by the power window sub switch. (1) Replace the rear power window sub switch (RH). (2) Check that the rear right power window works by means of the power window main switch.
AC310446 AE
AC310456 AH
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310484 AD

AC310463AB
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310493 AG
AC310471AC
54C-120

SYMPTOM PROCEDURES
NOTE:
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310446 AE

AC310484 AD
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310456 AH

AC310493 AG
AC310465AC
AC310473AD

SYMPTOM PROCEDURES
54C-121
Step 17. Connector check: E-08 rear power window sub switch (LH) connector
Step 18. Check the wiring harness from E-08 rear power window sub switch (LH) connector terminal No.6 to the inserted probe.
AC310486 AD AC310486 AD
Connector: E-08 <RHD> Connector: E-08 <RHD>
AC310495 AG
AC310495 AG
54C-122
NOTE:

SYMPTOM PROCEDURES
Step 19. Retest the system. After the rear power window sub switch (LH) is replaced, check that the rear left door power window can be operated by the power window sub switch. (1) Replace the rear power window sub switch (LH). (2) Check that the rear left power window works by means of the power window main switch.
AC310446 AE
AC310456 AH
AC310465AC
AC310473AD

SYMPTOM PROCEDURES
54C-123
INSPECTION PROCEDURE D-5: The window glass lowers automatically while it is rising.

If the sliding resistance is too great when the window is being raised or the window glass encounters an object, the window glass will lower by approximately 150 mm.
STEP 2. Check the power window operating current. Check that the power window operating current is normal (Refer to GROUP 42 Door On-vehicle service P.42-24).
Q: Is the check result normal? YES : Adjust the door window glass (Refer to
POSSIBLE CAUSES
Improper adjusted door window glass Incorrectly installed or warped glass slider Malfunction of the power window regulator motor Malfunction of the window regulator
DIAGNOSIS PROCEDURE
STEP 1. Check the power window anti-trap function. Check that the power window anti-trap function works. Refer to GROUP 42 Door On-vehicle Service P.42-24.
GROUP 42 Door On-vehicle service P.42-23), and then go to Step 3. NO : Replace the defective power window regulator motor assembly which operating current are abnormal.
STEP 3. Check that the door window glasses are installed correctly. Check that the door window glasses are installed correctly. Refer to GROUP 42 Door On-vehicle Service P.42-23.
Q: Is the check result normal? YES : Go to Step 4. NO : Adjust the door window glass (Refer to
window anti-trap function does not work normally P.54C-124."
GROUP 42 Door On-vehicle service P.42-23).
STEP 4. Retest the system. Check that the power window does not lower automatically while it is being raised.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the power window regulator motor assembly of the defective window.
54C-124

SYMPTOM PROCEDURES
INSPECTION PROCEDURE D-6: Power window anti-trap function does not work normally.
Power Window (front) Circuit <LHD> POWER WINDOW SUB SWITCH (FRONT)
POWER WINDOW MAIN SWITCH (FRONT: LH)
CPU
CPU
HALL IC
HALL IC POWER WINDOW MOTOR (FRONT: LH)
HALL IC
HALL IC POWER WINDOW MOTOR (FRONT: RH) SB : Sky blue

SYMPTOM PROCEDURES
Power Window (front) Circuit <RHD> POWER WINDOW MAIN SWITCH (FRONT: RH) POWER WINDOW SUB SWITCH (FRONT)
54C-125
CPU
CPU
HALL IC
HALL IC
HALL IC
HALL IC
POWER WINDOW MOTOR (FRONT: RH) Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
POWER WINDOW MOTOR (FRONT: LH) SB : Sky blue
54C-126

SYMPTOM PROCEDURES
Power Window (rear) Circuit POWER WINDOW SUB SWITCH (REAR: LH) POWER WINDOW SUB SWITCH (REAR: RH)
CPU
CPU
HALL IC
HALL IC POWER WINDOW MOTOR (REAR: LH)
HALL IC
HALL IC POWER WINDOW MOTOR (REAR: RH) SB : Sky blue

The revolution detection sensor, which is incorporated in the power window regulator motor, may be defective.
POSSIBLE CAUSES
Malfunction of the power window regulator motor
Step 2. Confirm the power window learning function. Check that the power window switch has learned the fully closed position of the windows (Refer to GROUP 42 Door P.42-29).
Q: Is the check result normal? YES : Go to Step 3. NO : Make the power window switch learn the
DIAGNOSIS PROCEDURE
Step 1. Check the power window operating current. Check that the power window operating current is normal (Refer to GROUP 42 Door On-vehicle Service P.42-24).
Q: Is the check result normal? YES : Adjust the door window glass (Refer to
fully closed position of the windows (Refer to GROUP 42 Door P.42-29). Step 3. Determine a trouble spot.
Q: Which door does the power window anti-trap function fail on? Driver's door <LH drive vehicles> : Go to Step 4. Driver's door <RH drive vehicles> : Go to Step 7. Front passenger's door <LH drive vehicles> : Go
GROUP 42 Door On-vehicle service P.42-23), and then go to Step 2. NO : Replace the defective power window regulator motor assembly which operating current are abnormal.
to Step 10.
Front passenger's door <RH drive vehicles> : Go
to Step 16.
Rear right door : Go to Step 22. Rear left door : Go to Step 28.

SYMPTOM PROCEDURES
54C-127
Step 4. Connector check: E-05 power window main switch connector and E-02 front power window regulator motor (LH) connector
Step 5. Check the wiring harness from E-05 power window main switch connector terminal Nos.8, 9, 10 and 12 to E-02 front power window regulator motor (RH) connector terminal Nos.5, 2, 3 and 6.
E-02 (GR) E-02 (GR) E-05 E-05 Harness side E-02 Harness side E-02
Harness side E-05

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side E-05

AC310485AB
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310485AB
Check the input and output lines to the revolution detection sensor for open or short circuit.
Step 6. Retest the system. After the power window main switch is replaced, check that the driver's power window anti-trap function works. (1) Replace the power window main switch. (2) Check that the driver's power window anti-trap function works.
54C-128

SYMPTOM PROCEDURES
Step 7. Connector check: E-05 power window main switch connector and E-11 front power window regulator motor (RH) connector
Step 8. Check the wiring harness from E-05 power window main switch connector terminal Nos.8, 9, 10 and 12 to E-11 front power window regulator motor (RH) connector terminal Nos.5, 2, 3 and 6.
E-11 (GR) E-11 (GR) E-05 E-05
Harness side E-05

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side E-05

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side E-11 Harness side E-11

AC310494 AB
AC310494 AB
Step 9. Retest the system. After the power window main switch is replaced, check that the driver's power window anti-trap function works. (1) Replace the power window main switch. (2) Check that the driver's power window anti-trap function works.

SYMPTOM PROCEDURES
54C-129
Step 10. Connector check: E-11 front power window regulator motor (RH) connector
Step 12. Check the wiring harness from E-11 front power window regulator motor (RH) connector terminal No.5 to body earth.
Harness side
E-11 (GR) Harness side E-11 (GR)
AC310488 AE
AC310488 AE
NOTE:
Step 11. Resistance measurement at E-11 front power window regulator motor (RH) connector
Harness side
E-11 (GR)
AC310452 AC
Prior to the wiring harness inspection, check intermediate connector C-110, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit.
AC310488 AE
Step 13. Connector check: E-14 front power window sub switch (RH) connector

AC310506AG
Harness side
(2) Resistance between E-11 front power window regulator motor (RH) connector terminal No.5 and body earth. OK: 2 or less
AC310488AD
54C-130

SYMPTOM PROCEDURES
Step 14. Check the wiring harness from E-14 front power window sub switch (RH) connector terminal Nos.2, 8 and 3 to E-11 front power window regulator motor (RH) connector terminal Nos.2, 3 and 6.
Connectors: E-11, E-14 <LHD> Front door (RH)
Step 16. Connector check: E-02 front power window regulator motor (LH) connector
E-02 (GR)
Harness side
E-11 (GR)
AC310498 AD
E-14
Harness side E-11
Step 17. Resistance measurement at E-02 front power window regulator motor (LH) connector
Harness side E-14 E-02 (GR)

AC310489AB
Front door (LH)
Harness side
AC310498 AD
Step 15. Retest the system. After the front power window sub switch (RH) is replaced, check that the front passenger's anti-trap function can be operated by the power window sub switch. (1) Replace the front power window sub switch (RH). (2) Check that the front passenger's power window anti-trap function works.

AC310506AG
(2) Resistance between E-11 power window regulator motor (front LH) connector terminal No.5 and body earth. OK: 2 or less

SYMPTOM PROCEDURES
54C-131
Step 18. Check the wiring harness from E-02 front power window regulator motor (LH) connector terminal No.5 to body earth.
Step 20. Check the wiring harness from E-14 front power window sub switch (RH) connector terminal Nos.2, 8 and 3 to E-02 front power window regulator motor (LH) connector terminal Nos.2, 3 and 6.
Connectors: E-02, E-14 <RHD> Front door (LH)
E-02 (GR)
Harness side E-02 (GR)
AC310498 AD
NOTE:
Connector: C-17 <RHD> Harness side E-02
E-14
Harness side E-14

AC310454 AH
Prior to the wiring harness inspection, check intermediate connector C-17, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit.
AC310499AB
Step 19. Connector check: E-14 front power window sub switch (LH) connector
Harness side
Step 21. Retest the system. After the front power window sub switch (LH) is replaced, check that the front passenger's anti-trap function can be operated by the power window sub switch. (1) Replace the front power window sub switch (LH). (2) Check that the front passenger's power window anti-trap function works.
AC310498AC
54C-132

SYMPTOM PROCEDURES
Step 22. Connector check: E-16 rear power window regulator motor (RH) connector
Step 23. Resistance measurement at E-16 rear power window regulator motor (RH) connector
Harness side
E-16 (GR)
Harness side
E-16 (GR)
AC310491AD
AC310491AD
E-16 (GR) Harness side
E-16 (GR) Harness side
AC310500 AD
AC310500 AD
AC310506 AE
(2) Resistance between E-16 rear power window regulator motor (RH) connector terminal No.5 and body earth. OK: 2 or less

SYMPTOM PROCEDURES
54C-133
Step 24. Check the wiring harness from E-16 rear power window regulator motor (RH) connector terminal No.5 to body earth.
Step 25. Connector check: E-17 rear power window sub switch (RH) connector
Harness side Harness side E-16 (GR)
AC310491AC AC310491AD
Harness side E-16 (GR) Harness side
AC310500AC AC310500 AD
NOTE:
AC310463AB
AC310471AC
Prior to the wiring harness inspection, check intermediate connector D-04, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit.
54C-134

SYMPTOM PROCEDURES
Step 26. Check the wiring harness from E-17 rear power window sub switch (RH) connector terminal Nos.2, 8 and 3 to E-16 rear power window regulator motor (RH) connector terminal Nos.2, 3 and 6.
Connectors: E-16, E-17 Rear door (RH)
Step 27. Retest the system. After the rear power window sub switch (RH) is replaced, check that the rear right door anti-trap function can be operated by the power window sub switch. (1) Replace the rear power window sub switch (RH). (2) Check that the rear right power window anti-trap function works.
E-17 E-16 (GR)
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the rear power window regulator motor assembly (RH).
Harness side E-16
Step 28. Connector check: E-09 rear power window regulator motor (LH) connector
Harness side E-17 Harness side
AC310492 AB
E-09 (GR) Connectors: E-16, E-17 <RHD> Connector: E-09 <RHD>
AC310486AB
E-17
E-16 (GR)
Harness side
E-09 (GR) Harness side E-16

AC310495 AH
Harness side E-17
AC310501AB

SYMPTOM PROCEDURES
54C-135
Step 29. Resistance measurement at E-09 rear power window regulator motor (LH) connector
Step 30. Check the wiring harness from E-09 rear power window regulator motor (LH) connector terminal No.5 to body earth.
E-09 (GR) Connector: E-09 <RHD>
AC310486AB
E-09 (GR) Connector: E-09 <RHD>
AC310486AB
E-09 (GR)
AC310495 AH
E-09 (GR)
AC310495 AH
NOTE:
AC310506 AI
AC310465AC
(2) Resistance between E-09 rear power window regulator motor (LH) connector terminal No.5 and body earth. OK: 2 or less
AC310473AD
Prior to the wiring harness inspection, check intermediate connector D-15, and repair if necessary. Check the input and output lines to the revolution detection sensor for open or short circuit.
54C-136

SYMPTOM PROCEDURES
Step 31. Connector check: E-08 rear power window sub switch (LH) connector
Step 32. Check the wiring harness from E-08 rear power window sub switch (LH) connector terminal Nos.8, 2 and 3 to E-09 rear power window regulator motor (LH) connector terminal Nos.3, 2 and 6.
Connectors: E-08, E-09 Rear door (LH)
Harness side
E-09 (GR)
AC310486 AD
E-08
Harness side E-08 Harness side
AC310495 AG
Harness side E-09
Connectors: E-08, E-09 <RHD>
AC310487AB
E-09 (GR)
E-08
Harness side E-08
Harness side E-09
AC310496AB

54C-137
(2) Check that the rear left power window anti-trap function works.
Step 33. Retest the system. After the rear power window sub switch (LH) is replaced, check that the rear left door anti-trap function can be operated by the power window sub switch. (1) Replace the rear power window sub switch (LH).
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the rear power window regulator motor assembly (LH).
KEYLESS ENTRY SYSTEM

INSPECTION PROCEDURE E-1: Keyless entry system does not work.
Keyless Entry System Function Circuit
ETACS-ECU
INPUT SIGNAL ALL DOOR SWITCHES DRIVER'S DOOR LOCK ACTUATOR SWITCH KEYLESS ENTRY TRANSMITTER BUTTON KEY REMINDER SWITCH

If the keyless entry system does not work normally, the input signal circuits to the components below or the ETACS-ECU may be defective. Key reminder switch All of the door switches Keyless entry transmitter Driver's door lock actuator
POSSIBLE CAUSES
Malfunction of the key reminder switch Malfunction of the door switches Malfunction of the keyless entry transmitter Malfunction of the driver's door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-138

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 2. Pulse check Check the input signals below which are related to the keyless entry system. System switch Key reminder switch All of the door switches Driver's door lock actuator switch Check condition When the inserted ignition key is pulled out A door is opened when all the doors are closed When the driver's key cylinder or inside lock knob is unlocked or locked
Keyless entry transmitter When the switch is switch turned from off to on OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.
Q: Is the check result normal? All the signals are received normally. : Go to Step
3.
All the door switch signals are not received. :
Refer to Inspection Procedure L-11 "All the door switch signals are not received <LH drive vehicles>P.54C-289 ," or refer to Inspection Procedure L-11 "All the door switch signals are not received <RH drive vehicles>P.54C-292 ."
"The front door lock actuator (LH) switch signal is not received <LH drive vehicles>P.54C-296 ," or refer to Inspection Procedure L-12 "The front door lock actuator (RH) switch signal is not received <RH drive vehicles>P.54C-299 ."
The keyless entry transmitter switch signal is not received. : Refer to Inspection Procedure L-14
"Each switch signal of the keyless entry transmitter is not received P.54C-306." Step 3. Retest the system. Check the keyless entry system works normally.

SYMPTOM PROCEDURES
54C-139
INSPECTION PROCEDURE E-2: Keyless entry hazard warning lamp answerback function or the room lamp answerback function does not work normally.
Step 3. Check the operation of the room lamps. Check that the room lamps illuminate normally.
Q: Is the check result normal? YES : Go to Step 4. NO : Refer to Inspection Procedure K-1 "The

If the hazard warning lamp and the room lamp work normally, the ETACS-ECU may be defective. Alternatively, it is possible that the keyless entry hazard warning lamp answerback function was disabled by the adjustment function.
front or rear room lamp does not illuminate or extinguish normally P.54C-244." Step 4. ECU check on the SWS monitor Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu.
POSSIBLE CAUSES
Defective turn-signal lamp Malfunction of the room lamp Malfunction of the ETACS-ECU Damaged harness wires and connectors
DIAGNOSIS PROCEDURE
Step 1. Check the adjustment function. Check that the keyless entry hazard warning lamp answerback function has been enabled by using the adjustment function.
Q: Is the check result normal? YES : Go to Step 2. NO : Enable the keyless entry hazard warning
"Communication with the ETACS-ECU is not possible P.54C-36." Step 5. Retest the system. Check that the keyless entry hazard warning lamp answerback function or the room lamp answerback function work normally.
lamp answerback function by using the adjustment function (Refer to GROUP 54B Adjustment function P.54B-302). Step 2. Check the operation of the hazard warning lamp. Check that the hazard warning lamps illuminate normally.
Q: Is the check result normal? YES : Go to Step 3. NO : Refer to Inspection Procedure I-2 "The
hazard warning lamps do not illuminate P.54C-213".
54C-140

SYMPTOM PROCEDURES
INSPECTION PROCEDURE E-3: Encrypted code cannot be registered.
Encrypted Transmitter Code Register Mode ETACS-ECU
INPUT SIGNAL HAZARD WARNING LAMP SWITCH KEYLESS ENTRY TRANSMITTER BUTTON KEY REMINDER SWITCH

If the encrypted code registration mode is not entered, the key reminder switch, the hazard warning lamp switch or the ETACS-ECU may be defective. If the registration is not possible although the registration mode is entered, the keyless entry transmitter or the ETACS-ECU may be defective.
DIAGNOSIS PROCEDURE
Step 1. Check the encrypted code registration mode. Check that the encrypted code registration mode is entered.
POSSIBLE CAUSES
Malfunction of the keyless entry transmitter Malfunction of the ETACS-ECU Damaged harness wires and connectors

SYMPTOM PROCEDURES
54C-141
Step 2. Pulse check Check the input signals below which are related to the encrypted code of the keyless entry transmitter. System switch Key reminder switch Hazard warning lamp switch Check condition When the inserted ignition key is pulled out When the switch is turned from off to on
Step 3. Retest the system. Check that the encrypted code can be registered.
Keyless entry transmitter When the switch is switch turned from off to on OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.
3.
The hazard warning lamp switch signal is not received. : Refer to Inspection Procedure L-10
"The hazard warning lamp switch signal is not received P.54C-285."

The keyless entry transmitter switch signal is not received. : Refer to Inspection Procedure L-14
"Each switch signal of the keyless entry transmitter is not received P.54C-306."
INSPECTION PROCEDURE E-4: The timer lock function does not work after the doors have been unlocked by the keyless entry system.
DIAGNOSIS PROCEDURE
Step 1. Check the operation of the keyless entry system. Check that the keyless entry system works normally.
Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure E-1 "Keyless

If the keyless entry timer lock does not work normally, the input signal circuit(s) to the keyless entry transmitter or the ETACS-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the keyless entry transmitter Malfunction of the ETACS-ECU Damaged harness wires and connectors
entry system does not work P.54C-137." Step 2. Retest the system. Check that the timer lock works normally.
54C-142

SYMPTOM PROCEDURES
WINDSHIELD WIPER AND WASHER
INSPECTION PROCEDURE F-1: The windshield wipers do not work at all.
Windshield Wiper Power Supply Circuit IGNITION SWITCH (ACC)
FRONT-ECU
WIPER SPEED SWITCHING RELAY WIPER AUTOMATIC STOP RELAY
WINDSHIELD WIPER MOTOR

CIRCUIT BREAKER
COLUMN SWITCH
COLUMNECU

SYMPTOM PROCEDURES
54C-143

The windshield wiper motor, the column switch or the front-ECU may be defective. If a problem is found in the ECU check by using the SWS monitor, also check the wiper backup circuit (between C-203 column switch connector terminal No.8 and A-11X front-ECU connector terminal No.26) and repair if necessary.
Step 2. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the windshield wiper function. <Selected item> F.WIPER INT Turn the ignition switch to the ACC position. Windshield wiper switch: INT Item No. Item name Item 05 Item 31 Item 70 INT WIPER SW IGNITION SW ACC Normal condition ON ON
POSSIBLE CAUSES
Malfunction of the windshield wiper motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors
DIAGNOSIS PROCEDURE
Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Turn the ignition switch to the ON position. ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items
Q: Is the check result normal? "OK" is displayed for all the items : Go to Step 2. "NG" is displayed on the "COLUMN ECU" menu. :
FRONT ECU ACK NORMAL ACK or HI-BEAM ACK

Q: Is the check result normal? Normal conditions displayed for all the items : Go
to Step 3.
Replace the column switch.

Refer to Inspection Procedure L-1 "The ignition switch (ACC) signal is not received P.54C-258."
Replace the front-ECU.
Refer to Inspection Procedure A-2 "Communication with the column switch (column-ECU) is not possible P.54C-30."
"NG" is displayed on the "FRONT ECU" menu. :
Refer to Inspection Procedure A-4 "Communication with the front-ECU is not possible P.54C-42."
54C-144

SYMPTOM PROCEDURES
Step 3. Connector check: B-01 windshield wiper motor connector

Connector: B-01 <LHD> B-01 (GR)
Step 5. Resistance measurement at the B-01 windshield wiper motor connector

Harness side
Harness side
AC310437AB
AC310437AB
Connector: B-01 <RHD> B-01 (GR)
Harness side
Harness side
AC310477AD
AC310477AD
Step 4. Check the windshield wiper motor assembly. Refer to GROUP 51 Windshield wiper P.51-21.
Q: Is the check result normal? YES : Go to Step 5 NO : Replace the windshield wiper motor
3 2 1 5 4
assembly.
Connector B-01 (Harness side)

AC301635 AC
(2) Continuity between B-01 windshield wiper motor connector terminal No.5 and body earth OK: 2 or less

SYMPTOM PROCEDURES
54C-145
Step 6. Check the wiring harness between B-01 windshield wiper motor connector terminal No.5 and body earth.
Step 8. Voltage measurement at the A-11X front-ECU connector

Connector: A-11X
Battery Harness side Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC AC310437AB
(1) Remove the front-ECU, and measure at the relay box side. (2) Ignition switch: ACC
Harness side
31 30 29 2827 26 25 24 2322 21
AC310477AD

AC304768 AB
(3) Check the voltage between the A-11X front-ECU connector terminal No.24 and body earth. OK: System voltage

Connector: A-11X
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
54C-146

SYMPTOM PROCEDURES
Step 9. Check the wiring harness between A-11X front-ECU connector terminal No.24 and the ignition switch (ACC).
Connector: A-11X
C-211
C-210 Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
Harness side C-210

6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310572AC
NOTE:
Harness side C-211

2 1 6 5 4 3
C-210 Connector: C-129 <LHD>
AC310459AF
Harness side C-210

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side C-211

2 1 6 5 4 3
AC310449AF
AC310446 AS
AC310454 AV
Prior to the wiring harness inspection, check the junction block connectors C-210, C-211 and intermediate connector C-129 and repair if necessary. Check the power supply line to the ignition switch (ACC) for open circuit.

SYMPTOM PROCEDURES
54C-147

Step 11. Check the wiring harness between C-206 column switch connector terminal No.8 and A-11X front-ECU connector terminal No.26.
Connector: A-11X
Harness side
Battery
Relay box side

AC310479AD
31 30 29 28 27 26 25 24 23 22 21
Connector: C-206 <RHD> Connector: C-206 <LHD>
AC310572AC
Harness side
Harness side
AC310481AD
AC310479AD
Harness side
AC310481AD
54C-148
NOTE:

SYMPTOM PROCEDURES
Step 12. Retest the system. The windshield wiper should now work normally at all.
AC310446 AS
AC310454 AV
Prior to the wiring harness inspection, check the intermediate connector C-129 and repair if necessary. Check the wiper backup circuit.

SYMPTOM PROCEDURES
54C-149
INSPECTION PROCEDURE F-2: The windshield wipers do not work when the wiper switch is at "INT", "WASHER" or "MIST" position. However, the wipers work at low speed when the switch is at "LO" and "HI" position.
Windshield Wiper Motor Drive Circuit
FRONT-ECU
WIPER SPEED SWITCHING RELAY
INPUT SIGNAL WINDSHIELD WIPER HI SPEED SWITCH WINDSHIELD WIPER INTERMIT SWITCH WINDSHIELD WIPER LO SPEED SWITCH WINDSHIELD WIPER MIST SWITCH
CIRCUIT BREAKER

The system may be at fail-safe mode as the SWS communication line is defective. If the ETACS-ECU does not receive the ignition switch (ACC) signal due to an open circuit in the SWS communication lines or other reasons when the ignition switch is at the ACC position, the system will enter the fail-safe mode.
POSSIBLE CAUSES
Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors
54C-150

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Turn the ignition switch to the ACC position. ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items
Step 2. Retest the system. The windshield wiper should now work normally.

SYMPTOM PROCEDURES
54C-151
INSPECTION PROCEDURE F-3: The windshield wipers do not stop at the specified park position.
Windshield Wiper Automatic Stop Relay Circuit IGNITION SWITCH (ACC) FRONT-ECU WIPER AUTOMATIC STOP RELAY
SB : Sky blue

The windshield wiper motor or the front-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the windshield wiper motor Malfunction of the front-ECU Damaged harness wires and connectors
54C-152

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 3. Voltage measurement at the B-01 windshield wiper motor connector

AC310437AB

AC310437AB
B-01 (GR) Connector: B-01 <RHD> B-01 (GR) Harness side
Harness side
AC310477AD
AC310477AD
(1) Disconnect the connector, and measure at the wiring harness side. (2) Ignition switch: ACC
Connector B-01 (Harness side)
3 2 1 5 4
AC304770AB
assembly.
(3) Check the voltage between the B-01 windshield wiper motor connector terminal No.4 and body earth. OK: System voltage

SYMPTOM PROCEDURES
54C-153
Step 4. Check the wiring harness between B-01 windshield wiper motor connector terminal No.4 and ignition switch (ACC).
C-210 Harness side
Harness side
AC310437AB
C-210
6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side C-211 Harness side

2 1 6 5 4 3
AC310449AF
AC310477AD
C-211
NOTE:
Connector: C-123 <LHD> C-210
C-123 (GR) Harness side C-210

AC310446AT
6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side C-211

2 1 6 5 4 3
C-123 (GR)
AC310459AF
AC310454 AX
Prior to the wiring harness inspection, check the junction connectors C-210, C-211 and the intermediate connector C-123 and repair if necessary. Check the power supply line to ignition switch (ACC) for open circuit.
54C-154

SYMPTOM PROCEDURES

Connector: A-11X
Step 6. Check the wiring harness between B-01 windshield wiper motor connector terminal No.3 and A-11X front-ECU connector terminal No.23.
Battery Harness side Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
AC310437AB
Harness side
AC310477AD
Connector: A-11X
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC

SYMPTOM PROCEDURES
54C-155
NOTE:
Connector: A-13 <LHD> A-13 (B)
Step 7. Retest the system. Check that the windshield wipers stop at the specified park position.
AC303857AB
1 2 3 4 5 6 7 8 9 10111213141516
AC310454 AY
Prior to the wiring harness inspection, check the intermediate connector A-13 <LH drive vehicles>, C-31 <RH drive vehicles> and repair if necessary. Check the input signal lines.
54C-156

SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-4: The windshield wipers do not work normally.
Windshield Wiper Motor Drive Circuit
FRONT-ECU
WIPER SPEED SWITCHING RELAY
INPUT SIGNAL WINDSHIELD WIPER HI SPEED SWITCH WINDSHIELD WIPER INTERMIT SWITCH WINDSHIELD WIPER LO SPEED SWITCH WINDSHIELD WIPER MIST SWITCH
CIRCUIT BREAKER

The windshield wiper motor, the column switch or the front-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the windshield wiper motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors

SYMPTOM PROCEDURES
54C-157
DIAGNOSIS PROCEDURE
Step 1. SWS monitor communication data. Check the SWS communication signal, which are related to the windshield wipers. <Selected item> Column switch (column-ECU) Ignition switch: ON Move the windshield wiper switch to each position. Item No. Item 05 Item 06 Item 07 Item 08 Item name INT WIPER SW LO WIPER SW HI WIPER SW MIST WIPER SW Normal condition ON ON ON ON

Harness side
AC310437AB
OK: Normal conditions are displayed for all the functions of the switch.
Q: Is the check result normal? Normal conditions are displayed for all the items. :
Harness side
Go to Step 2.
NO : Replace the column switch
AC310477AD
Step 2. Check the operation of the windshield wipers. Check that the windshield wipers work at high speed and the mist mode.
assembly. Step 5. Connector check: A-11X front-ECU connector

Connector: A-11X
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
54C-158

SYMPTOM PROCEDURES
Step 6. Check the wiring harness between A-11X front-ECU connector terminal No.27 and B-01 windshield wiper motor connector terminal No.1.
Connector: A-11X
NOTE:
Connector: A-13 <LHD>
Battery
A-13 (B)
AC310542 AC
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
Harness side
1 2 3 4 5 6 7 8 9 10111213141516
AC310454 AY
AC310437AB
Prior to the wiring harness inspection, check the intermediate connector A-13 <LH drive vehicles>, C-31 <RH drive vehicles>, and repair if necessary. Check the power supply line to front-ECU for open circuit.
Harness side
Step 7. Retest the system. Check that the windshield wipers work normally by moving the switch to each position.
AC310477AD

SYMPTOM PROCEDURES
54C-159

Step 11. Check the wiring harness between A-11X front-ECU connector terminal No.28 and B-01 windshield wiper motor connector terminal No.2.
Connector: A-11X
Harness side
Battery
Relay box side

AC310437AB
31 30 29 28 27 26 25 24 23 22 21
AC310572AC
Connector: B-01 <RHD> B-01 (GR) Connector: B-01 <LHD> B-01 (GR)
AC310477AD
AC310437AB
Harness side
assembly. Step 10. Connector check: A-11X front-ECU connector

Connector: A-11X
AC310477AD
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
54C-160
NOTE:
Connector: A-13 <LHD>

SYMPTOM PROCEDURES
Step 12. Retest the system. Check that the windshield wipers work normally by moving the switch to each position.
A-13 (B)
AC303857AB
1 2 3 4 5 6 7 8 9 10111213141516
AC310454 AY
Prior to the wiring harness inspection, check the intermediate connector A-13 <LH drive vehicles>, C-31 <RH drive vehicles>, and repair if necessary. Check the power supply line to front-ECU for open circuit.

SYMPTOM PROCEDURES
54C-161
INSPECTION PROCEDURE F-5: The intermittent wiper interval cannot be adjusted by operating the windshield intermittent wiper volume control.
Windshield Wiper Intermittent Volume Input Signal ETACS-ECU
INPUT SIGNAL WINDSHIELD WIPER INTERMITTENT VOLUME

The column switch or the front-ECU may be defective.
POSSIBLE CAUSE
Step 2. Retest the system. Check that the windshield intermittent wiper interval can be adjusted by operating the windshield intermittent wiper volume control. OK: The intermittent wiper interval is changed as the intermittent wiper volume is rotated.
DIAGNOSIS PROCEDURE
Step 1. SWS monitor data list Rotate the windshield intermittent wiper volume when the vehicle is stopped. NOTE: Also check that the windshield wiper interval changes smoothly when the windshield intermittent wiper interval adjusting knob is rotated from "SLOW" to "FAST" positions. Item No. Item 37 Item name INT WIPER TIME Normal condition 2.4 18.0 s

windshield intermittent wiper volume signal is not received P.54C-270."
54C-162

SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-6: The intermittent wiper interval is not changed according to the vehicle speed.
Vehicles Speed Input Signal
ETACS-ECU
INPUT SIGNAL VEHICLE SPEED

The ETACS-ECU calculates the intermittent wiper interval according to the vehicle speed signal which is sent by the engine-ECU. If the intermittent wiper interval does not depend on the vehicle speed, the input circuit of the vehicle speed signal and the ETACS-ECU may be defective.
DIAGNOSIS PROCEDURE
Step 1. Check the adjustment function. Check that the vehicles speed sensing function has been enabled by using the adjustment function.
Q: Is the check result normal? YES : Go to Step 2. NO : Enable the vehicles speed sensing function
POSSIBLE CAUSES
Malfunction of the vehicle speed signal (engine-ECU) Malfunction of the ETACS-ECU Damaged harness wires and connectors
by using the adjustment function. (Refer to P.54B-302). Step 2. Retest the system. Check that the windshield intermittent wiper interval can be adjusted by operating the windshield intermittent wiper volume control.
Q: Is the check result normal? YES : Go to Step 3. NO : Refer to Inspection Procedure F-5 "The
intermittent wiper interval cannot be adjusted by operating the windshield intermittent wiper volume control P.54C-161."

SYMPTOM PROCEDURES
54C-163
Step 3. SWS monitor data list Enter a simulated vehicle speed when the windshield intermittent wiper interval adjusting knob position is slow side. NOTE: Also check that the wiper interval changes smoothly when the vehicle is accelerated from 0 km/h to 25 km/h. Item No. Item name ITEM 37 INT WIPER TIME Normal condition 18.0 12.0 s
Step 4. Retest the system. Check that the intermittent wiper interval depends on the vehicle speed.

vehicle speed sensor signal is not received P.54C-302."
54C-164

SYMPTOM PROCEDURES
INSPECTION PROCEDURE F-7: The windshield washer does not work.
Windshield Washer Motor Circuit
IGNITION SWITCH (ACC)
FRONT-ECU WINDSHIELD WASHER RELAY INPUT SIGNAL WINDSHIELD WASHER
WINDSHIELD WASHER MOTOR

SYMPTOM PROCEDURES
54C-165

The windshield washer motor, the column switch or the front-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the windshield washer motor Malfunction of the column switch Malfunction of the front-ECU Damaged harness wires and connectors
Step 3. Function diagnosis by using the SWS monitor Check the SWS communication signal, which are related to the windshield washer function. <Selected item> F.WIPER WASH Turn the ignition switch to the ACC position. Windshield washer switch: ON Item No. Item name Item 09 Item 31 Item 70 IG SW (ACC) FRONT ECU ACK Normal condition ON NORMAL ACK or HI-BEAM ACK FRONT WASH. SW ON
DIAGNOSIS PROCEDURE
Step 1. Check the operation of the windshield wipers. Check that the windshield wipers work normally.
Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure F-1 "The

Q: Is the check result normal? Normal conditions are displayed for all the items :
windshield wipers do not work at all P.54C-142." Step 2. ECU check on the SWS monitor Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Turn the ignition switch to the ACC position. ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items
Go to Step 4.
Replace the column switch.

54C-166

SYMPTOM PROCEDURES
Step 4. Connector check: F-18 windshield washer motor connector

Connector: F-18 <LHD>
Step 6. Resistance measurement at the F-18 windshield washer motor connector

Harness side
Harness side
AC310467AF
AC310467AF
Connector: F-18 <RHD>
Harness side
Harness side
AC310469AF
AC310469AF
Step 5. Check the windshield washer motor assembly. Refer to GROUP 51 Windshield washer P.51-24.
Q: Is the check result normal? YES : Go to Step 6 NO : Replace the windshield washer motor.
1 2
Connector F-18 (Harness side)
AC310506 AJ
(2) Continuity between F-18 windshield washer motor connector terminal No.1 and body earth OK: 2 or less

SYMPTOM PROCEDURES
54C-167
Step 7. Check the wiring harness between F-18 windshield washer motor connector terminal No.1 and body earth.
Step 9. Check the wiring harness between F-18 windshield washer motor connector terminal No.2 and A-11X front-ECU connector terminal No.21.
Connector: A-11X
Battery Harness side
Relay box side

AC310467AF
31 30 29 28 27 26 25 24 23 22 21
Connector: F-18 <RHD> Connector: F-18 <LHD>
AC310572AC
AC310469AF

AC310467AF
Harness side

Connector: A-11X
AC310469AF
Battery
Relay box side

31 30 29 28 27 26 25 24 23 22 21
AC310572AC
54C-168
NOTE:

SYMPTOM PROCEDURES
Step 10. Retest the system. The windshield washer should now work normally.
AC310452 AO
AC310456 AN
AC310446 AS
AC310454 AV
Prior to the wiring harness inspection, check the intermediate connector C-113, C-129 and repair if necessary. Check the power supply line to the ignition switch (ACC) for open circuit.

SYMPTOM PROCEDURES
54C-169
IGNITION KEY CYLINDER ILLUMINATION LAMP
INSPECTION PROCEDURE G-1: The ignition key cylinder illumination lamp does not illuminate/extinguish normally.
Ignition Key Cylinder Illumination Lamp Circuit
ETACS-ECU
KEY REMINDER SWITCH IGNITION KEY CYLINDER ILLUMINATION LAMP
SB : Sky blue

The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Key reminder switch Driver's door switch Interior lamp loaded signal If this function does not work normally, these input signal circuit(s), the ignition key cylinder illumination lamp or the ETACS-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the key reminder switch Malfunction of the driver's door switch Malfunction of the ignition key cylinder illumination lamp Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-170

SYMPTOM PROCEDURES
Step 1. Check the operation of the room lamp. Check that the room lamps illuminate and extinguish normally.
Step 3. Connector check: C-207 key reminder switch connector

Harness side
2 1 7 6 5 4 3
front or rear room lamp does not illuminate or extinguish P.54C-244." Step 2. Pulse check Check the input signals below, which are related to the ignition key cylinder illumination lamp. System switch Check condition
Harness side
2 1 7 6 5 4 3
AC310479AE
Ignition switch (IG1) When turned from ACC to ON Key reminder switch When the inserted ignition key is pulled out Driver's door switch When the driver's door is opened OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.
AC310481AE
3.
The ignition switch (IG1) signal is not received. :
Step 4. Check the bulb of the ignition key cylinder illumination lamp. Check the bulb of the ignition key cylinder illumination lamp.
Q: Is the check result normal? YES : Go to Step 5. NO : Replace the bulb of the ignition key cylinder
The driver's door switch signal is not received. :
illumination lamp.

SYMPTOM PROCEDURES
54C-171

Step 6. Check the wiring harness from C-228 ETACS-ECU connector terminal Nos.69 and 71 to C-207 ignition key cylinder illumination lamp connector terminal Nos.1 and 2.

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
Harness side
2 1 7 6 5 4 3
AC310450AC
Connector: C-228 <RHD> Junction block (rear view) Connector: C-207 <RHD>
AC310479AE
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
Harness side
2 1 7 6 5 4 3
C-228 (GR)
AC310461AC
AC310481AE

59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
AC310450AC
Harness side
59 58 57 56 55 54 53 52 51 68 67 66 65 64 63 62 61 60 74 73 72 71 70 69
C-228 (GR)
AC310461AC
54C-172
NOTE:
Connector: C-23 <LHD> C-23 (B) Harness side

SYMPTOM PROCEDURES
Step 7. Retest the system. Check that the ignition key cylinder illumination lamp illuminates/extinguishes normally.
AC310446BB
Harness side
AC310456AJ
Prior to the wiring harness inspection, check joint connector C-23, and repair if necessary. Check the input and output lines for open circuit.

SYMPTOM PROCEDURES
54C-173
HEADLAMP AND TAIL LAMP
INSPECTION PROCEDURE H-1: The headlamps do not illuminate when the lighting switch is at "TAIL" or "PASSING" position, but illuminate only at low beam when the switch is at "HEAD" position. However, the headlamps do not illuminate at high beam.
DIAGNOSIS PROCEDURE Step 1. ECU check by using the SWS monitor. Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items

If the headlamps illuminate only at low beam regardless of the lighting switch position, the headlamp fail-safe function may be activated.
POSSIBLE CAUSES
Refer to Inspection Procedure A-4 "Communication with the front-ECU is not possible P.54C-42." Step 2. Retest the system. Check that the headlamps illuminate normally.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the column switch.
54C-174

SYMPTOM PROCEDURES
INSPECTION PROCEDURE H-2: The tail lamps do not illuminate normally.
Taillamp Relay Circuit BATTERY
FRONT-ECU TAIL LAMP RELAY
INPUT SIGNAL HEADLAMP AUTOMATIC SHUTDOWN TAIL LAMP SWITCH
RELAY BOX
<LHD> HEADLAMP ASSEMBLY (LH) REAR COMBINATION LAMP (LH) COMBINATION METER LICENCE PLATE LAMP <RHD> HEADLAMP ASSEMBLY (LH) REAR COMBINATION LAMP (LH) LICENCE PLATE LAMP
<LHD> HEADLAMP ASSEMBLY (RH) REAR COMBINATION LAMP (RH) <RHD> HEADLAMP ASSEMBLY (RH) REAR COMBINATION LAMP (RH) COMBINATION METER

If all the tail lamps do not illuminate, the tail lamp switch input circuit or the front-ECU may be defective.
POSSIBLE CAUSES

SYMPTOM PROCEDURES
54C-175
DIAGNOSIS PROCEDURE
Step 1. ECU check by using the SWS monitor. Check that the power supply and earth lines to the column switch (column-ECU) and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU FRONT ECU OK: "OK" is displayed for all the items
Step 2. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the tail lamps. <Selected item> LIGHTING - TAIL LAMP Ignition switch: ON Lighting switch: TAIL Item No. Item name Item 00 HEADLAMP SW Normal condition ON when the lighting switch is at HEAD ON when the lighting switch is at TAIL OFF ON OFF
Item 01
TAIL LAMP SW
Item 03 Item 30 Item 35 Item 70
PASSING SW IG SW(IG1) HD AUTO-CUT
FRONT ECU ACK NORMAL ACK
OK: Normal conditions displayed for all the items

Go to Step 3.
Normal condition is not displayed for item 00, 01 or 03. : Refer to Inspection Procedure L-4 "The
Normal condition is not displayed for item No.30. :
Refer to Inspection Procedure H-6 "The headlamp automatic shutdown function does not work normally P.54C-183."
54C-176

SYMPTOM PROCEDURES Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 5.

Connector: A-10X
Battery
Step 5. Check the wiring harness between A-10X front-ECU connector terminal No.5 and the battery.
Connector: A-10X Relay box side
11 10 9 8 7 6 5 4 3 2 1
Battery
AC310572AB
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB

Connector: A-10X

Battery
Relay box side

11 10 9 8 7 6 5 4 3 2 1
Step 6. Retest the system. Check that the tail lamps illuminate normally.
AC310572AB
(1) Remove the front-ECU, and measure at the relay box side.

11 10 9 8 7 6 5 4 3 2 1
AC301541 DB
(2) Voltage between A-10X front-ECU connector terminal No.5 and body earth OK: System voltage

SYMPTOM PROCEDURES
54C-177
INSPECTION PROCEDURE H-3: The low-beam headlamps do not illuminate normally.
Headlamp Relay (Low-Beam) Circuit BATTERY
FRONT-ECU HEADLAMP RELAY: LO
RELAY BOX
HEADLAMP ASSEMBLY (LH)
HEADLAMP ASSEMBLY (RH)

If the low-beam headlamps do not illuminate, the headlamp switch input circuit or the front-ECU may be defective.
POSSIBLE CAUSES
54C-178

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 2. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the low-beam headlamps. <Selected item> LIGHTING - HEADLAMP LO Ignition switch: ON Lighting switch: HEAD Item No. Item name Item 00 Item 03 Item 30 Item 35 Item 70 HEADLAMP SW PASSING SW IG SW(IG1) HD AUTO-CUT Normal condition ON OFF ON OFF
FRONT ECU ACK NORMAL ACK

Go to Step 3.
Normal condition is not displayed for item 00 or 03. : Refer to Inspection Procedure L-4 "The
Replace the front-ECU. Step 3. Connector check: A-10X front-ECU connector

Connector: A-10X
Battery
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB

SYMPTOM PROCEDURES
54C-179

Connector: A-10X
Step 5. Check the wiring harness between A-10X front-ECU connector terminal Nos.3, 4 and the battery.
Connector: A-10X
Battery Battery
Relay box side

11 10 9 8 7 6 5 4 3 2 1
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
(1) Remove the front-ECU, and measure at the relay box side.
AC310572AB


11 10 9 8 7 6 5 4 3 2 1
Step 6. Retest the system. Check that the low-beam headlamps illuminate normally.
AC301541 DC
(2) Voltage between A-10X front-ECU connector terminal Nos.3, 4 and body earth OK: System voltage
54C-180

SYMPTOM PROCEDURES
INSPECTION PROCEDURE H-4: The high-beam headlamps do not illuminate normally.
Headlamp Relay (High-Beam) Circuit BATTERY
FRONT-ECU TAIL LAMP RELAY: HI
RELAY BOX
COMBINATION METER HEADLAMP (LH)
HEADLAMP (RH)

If the high-beam headlamps do not illuminate, the dimmer switch input circuit or the front-ECU may be defective.
POSSIBLE CAUSES

SYMPTOM PROCEDURES
54C-181
DIAGNOSIS PROCEDURE
Step 2. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the high-beam headlamps. <Selected item> LIGHTING - HEADLAMP HI Ignition switch: ON Lighting switch: HEAD Dimmer switch: from OFF to ON, and then to OFF again Item No. Item name Item 00 Item 02 HEADLAMP SW DIMMER SW Normal condition ON from OFF to ON, and then to OFF again ("ON" should be displayed when the dimmer switch is operated) ON OFF NORMAL ACK
Item 03 Item 30 Item 35 Item 70
PASSING SW OFF IG SW(IG1) HD AUTO-CUT FRONT ECU ACK

Go to Step 3.
Normal condition is not displayed for item 00, 02 or 03. : Refer to Inspection Procedure L-4 "The
54C-182

SYMPTOM PROCEDURES
Step 3. Retest the system. Check that the high-beam headlamps illuminate normally.
INSPECTION PROCEDURE H-5: The high-beam and low-beam headlamps do not illuminate when the passing switch is operated.
Step 2. Check the SWS monitor data list. Check the ETACS-ECU signals which are related to the headlamps. <Selected item> COLUMN ECU Passing lamp switch: ON Item No. Item 03 Item name PASSING SW Normal condition ON

If the low-beam and high-beam headlamps are normal, the passing switch input signal circuit or the front-ECU may be defective.
POSSIBLE CAUSES

DIAGNOSIS PROCEDURE
Step 1. Check the operation of the headlamps. Check that the low-beam and high-beam headlamps illuminate normally.
Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure H-3 "The
column switch (lighting and turn-signal lamp switch) signal is not received P.54C-267." Step 3. Retest the system. When the passing switch is turned on, check if the headlamps illuminate normally.
low-beam headlamps do not illuminate normally P.54C-177." And refer to Inspection Procedure H-4 "The high-beam headlamps do not illuminate normally P.54C-180."

SYMPTOM PROCEDURES
54C-183
INSPECTION PROCEDURE H-6: The headlamp automatic shutdown function does not work normally.
Headlamp Automatic Shutdown Function
ETACS-ECU
INPUT SIGNAL DRIVER'S DOOR SWITCH HEADLAMP SWITCH IGNITION SWITCH (IG1) TAIL LAMP SWITCH

The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Driver's door switch Tail lamp switch Headlamp switch If this function does not work normally, these input signal circuit(s), the front-ECU or the ETACS-ECU may be defective. On vehicles with keyless entry system, note that this function can be disabled/enabled by the customize function (default setting; enabled).
DIAGNOSIS PROCEDURE
Step 1. Customize function by using the SWS monitor. Check that the headlamp automatic shutdown function has been enabled by using the adjustment function.
Q: Is the check result normal? YES : Go to Step 2. NO : Enable the headlamp automatic shutdown
POSSIBLE CAUSES
Malfunction of the driver's door switch Malfunction of the front-ECU Malfunction of the column switch
function by using the adjustment function. Refer to GROUP 54B Configuration Function P.54B-302.
54C-184

Step 2. ECU check by using the SWS monitor. Check that the power supply and earth lines to the column switch (column-ECU), the ETACS-ECU and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU ETACS ECU FRONT ECU OK: "OK" is displayed for all the items
to Step 4.
"NG" is displayed on the "ETACS ECU" menu. :
Normal condition is not displayed for item 35 or 70. : Replace the front-ECU.
Refer to Inspection Procedure A-4 "Communication with the front-ECU is not possible P.54C-42." Step 3. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the headlamp automatic shutdown function. <Selected item> LIGHTING - HD AUTO-CUT Ignition switch: from ON to OFF Lighting switch: "TAIL" or "HEAD" Item No. Item name Item 00 Item 01 Item 30 Item 70 Normal condition HEADLAMP SW ON when the lighting switch is at HEAD TAIL LAMP SW IG SW(IG1) ON when the lighting switch is at TAIL from ON to OFF SLEEP ACK or NORMAL ACK Normal condition ON OFF
Step 4. Retest the system. Check that the headlamp automatic shutdown function works normally.
FRONT ECU ACK Driver's door: open DR DOOR SW HD AUTO-CUT
Item No. Item name Item 32 Item 35

SYMPTOM PROCEDURES
54C-185
INSPECTION PROCEDURE H-7: Any of tail lamps, position lamps or licence plate lamps does not illuminate. <LH drive vehicles>
Taillamps, Position Lamps and License Plate Lamps Circuit <LHD> FRONT-ECU TAIL LAMP RELAY
HEADLAMP ASSEMBLY (POSITION) (RH) (LH)
COMBINATION METER
LICENCE PLATE LAMP (LH) (RH)
REAR COMBINATION LAMP (TAIL: RH)
REAR COMBINATION LAMP (TAIL: LH)
SB : Sky blue
54C-186

SYMPTOM PROCEDURES
Connectors: A-39 <LHD>

If the tail lamps, the position lamps or the licence plate lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.
A-39 Harness side
POSSIBLE CAUSES
Burned-out bulb Damaged harness wires and connectors
A-39(B)
AC310431AE
Step 1. Connector check: F-14 <tail lamp LH> or F-08 <tail lamp RH> rear combination lamp connector, A-31 <position lamp LH> or A-39 <position lamp RH> headlamp assembly connector, F-11 <licence plate lamp LH> or F-10 <licence plate lamp RH> licence plate lamp connector, C-02 <tail lamp indicator> combination meter connector
Connectors: F-08, F-10, F-11, F-14 <LHD> Connector: C-02 <LHD>
C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
F-14(B)
F-08(B) F-10(GR) F-11(GR)
Step 2. Check the bulbs of the tail lamps, the position lamp, the licence plate lamp or tail lamp indicator. Check the bulb of the lamp which does not illuminate.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb of the lamp which does not
F-08 Harness side
F-10 Harness side
illuminate.
F-11 Harness side
F-14 Harness side
AC310468AD
Connectors: A-31 <LHD> A-31 Harness side A-31(B)
AC310542AD

SYMPTOM PROCEDURES
54C-187
C-02 (L)
Step 3. Resistance measurement at the F-14 <tail lamp LH> or F-08 <tail lamp RH> rear combination lamp connector, the A-31 <position lamp LH> or A-39 <position lamp RH> headlamp assembly connector, the F-11 <licence plate lamp LH> or F-10 <licence plate lamp RH> licence plate lamp connector or C-02 <tail lamp indicator> combination meter connector
Connectors: F-08, F-10, F-11, F-14 <LHD>
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
(1) Disconnect the connector, and measure at the wiring harness side. (2) Check the resistance between the lamp connector and body earth.
F-14(B)
F-08(B) F-10(GR) F-11(GR)
Connector A-31, A-39 (Harness side)
F-08 Harness side
F-10 Harness side

AC301541HP
F-11 Harness side
F-14 Harness side
AC310468AD
Resistance between A-31 <position lamp LH> headlamp assembly connector terminal No.7 and body earth Resistance between A-39 <position lamp RH> headlamp assembly connector terminal No.7 and body earth
Connector F-08, F-14 (Harness side)
AC310542AD
AC301541HN
A-39 Harness side
Resistance between F-14 <tail lamp LH> rear combination lamp connector terminal No.5 and body earth Resistance between F-08 <tail lamp RH> rear combination lamp connector terminal No.5 and body earth
A-39(B)
AC310431AE
54C-188

SYMPTOM PROCEDURES

2 1
Step 4. Check the wiring harness from F-14 <tail lamp LH> or F-08 <tail lamp RH> rear combination lamp connector terminal No.5, A-31 <position lamp LH> or A-39 <position lamp RH> headlamp assembly connector terminal No.7, F-11 <licence plate lamp LH> or F-10 <licence plate lamp RH> licence plate lamp connector terminal No.1 or C-02 <tail lamp indicator> combination meter connector terminal No.48 to body earth.
AC301541HO
Resistance between F-11 <licence plate lamp LH> licence plate lamp connector terminal No.1 and body earth Resistance between F-10 <licence plate lamp RH> licence plate lamp connector terminal No.1 and body earth
F-14(B)
F-08(B) F-10(GR) F-11(GR)
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
F-08 Harness side
F-10 Harness side
AC301541HE
F-11 Harness side
F-14 Harness side
Resistance between C-02 <tail lamp indicator> combination meter connector terminal No.48 and body earth OK: 2 or less
AC310468AD
AC310542AD
A-39 Harness side
A-39(B)
AC310431AE

SYMPTOM PROCEDURES
54C-189
C-02 (L)

Connector: A-10X

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
F-12 (GR)
AC310467AG
NOTE: Prior to the wiring harness inspection, check intermediate connector F-12 <licence plate lamp> and repair if necessary. Check the earth wires for open circuit.
54C-190

SYMPTOM PROCEDURES
Step 6. Check the wiring harness from F-14 <tail lamp LH> or F-08 <tail lamp RH> rear combination lamp connector terminal No.3, A-31 <position lamp LH> or A-39 <position lamp RH> headlamp assembly connector terminal No.3, F-11 <licence plate lamp LH> or F-10 <licence plate lamp RH> licence plate lamp connector terminal No.2, C-02 <tail lamp indicator> combination meter connector terminal No.38 to A-10X front-ECU connector terminal No.8.
C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Connector: A-10X
Battery
F-14(B)
F-08(B) F-10(GR) F-11(GR)
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
NOTE:
Connector: C-05 <LHD> F-08 Harness side F-10 Harness side Harness side F-11 Harness side F-14 Harness side
AC310468AD
AC310446 AU
Connectors: C-129 <LHD>
C-129
AC310542AD
AC310446AP
A-39 Harness side
A-39(B)
AC310431AE AC310452AF

SYMPTOM PROCEDURES
Connectors: C-210, C-214, C-217 <LHD> Junction block (front view)
54C-191
Step 7. Retest the system. Check that the tail lamps, the position lamps and the licence plate lamps illuminate normally.
Q: Is the check result normal? The all lamps illuminate normally : The trouble can
C-210
C-214 C-217
be an intermittent malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). When the tail lamps do not illuminate : Replace the rear combination lamp socket assembly.
When the position lamps do not illuminate :
C-210 Harness side

6 5 4 3 2 1 14 13 12 11 10 9 8 7
C-214 Harness side

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
Replace the position lamp socket.

When the licence plate lamps do not illuminate :
Replace the licence plate lamp socket.

When the tail lamp indicator do not illuminate :
Replace the combination meter assembly.
C-217 Harness side
AC310449AE
F-12 (GR)
AC310467AG
Prior to the wiring harness inspection, check intermediate connector C-129 <tail lamp LH, licence plate lamp or tail lamp indicator>, C-113 <tail lamp RH> or F-12 <licence plate lamp>, joint connector C-05 <tail lamp RH>, junction block connector C-210 <tail lamp LH, licence plate lamp or tail lamp indicator>, C-214 <tail lamp indicator> or C-217 <tail lamp LH or licence plate lamp> and repair if necessary. Check the output lines for open circuit.
54C-192

SYMPTOM PROCEDURES
INSPECTION PROCEDURE H-7: Any of tail lamps, position lamps or licence plate lamps does not illuminate. <RH drive vehicles>
Taillamps, Position Lamps and License Plate Lamps Circuit <RHD> FRONT-ECU TAIL LAMP RELAY
RELAY BOX
HEADLAMP ASSEMBLY (LH) (RH)
REAR COMBINATION LAMP (RH)
REAR COMBINATION LAMP (LH)
COMBINATION METER
LICENCE PLATE LAMP (LH) (RH)
SB : Sky blue

SYMPTOM PROCEDURES
54C-193

If the tail lamps, the position lamps or the licence plate lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.
Connectors: A-39 <RHD>
A-39 Harness side
POSSIBLE CAUSES
Burned-out bulb Damaged harness wires and connectors
A-39(B)
AC310433AD
Step 1. Connector check: F-14 <tail lamp LH> or F-08 <tail lamp RH> rear combination lamp connector, A-31 <position lamp LH> or A-39 <position lamp RH> headlamp assembly connector, F-11 <licence plate lamp LH> or F-10 <licence plate lamp RH> licence plate lamp connector, C-02 <tail lamp indicator> combination meter connector
Connectors: F-08, F-10, F-11, F-14 <RHD> Connector: C-02 <RHD> C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
F-14(B)
F-08(B) F-10(GR) F-11(GR)
Step 2. Check the bulbs of the tail lamps, the position lamp, the licence plate lamp or tail lamp indicator. Check the bulb of the lamp which does not illuminate.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb of the lamp which does not
F-08 Harness side
F-10 Harness side
illuminate.
F-11 Harness side F-14 Harness side
AC310470AD
Connectors: A-31 <RHD> A-31 Harness side A-31(B)
AC310475AB
54C-194

SYMPTOM PROCEDURES
Step 3. Resistance measurement at the F-14 <tail lamp LH> or F-08 <tail lamp RH> rear combination lamp connector, the A-31 <position lamp LH> or A-39 <position lamp RH> headlamp assembly connector, the F-11 <licence plate lamp LH> or F-10 <licence plate lamp RH> licence plate lamp connector or C-02 <tail lamp indicator> combination meter connector
Connectors: F-08, F-10, F-11, F-14 <RHD>
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
F-14(B)
F-08(B) F-10(GR) F-11(GR)
F-08 Harness side
F-10 Harness side
F-11 Harness side
F-14 Harness side
AC301541HP
AC310470AD
Resistance between A-31 <position lamp LH> headlamp assembly connector terminal No.6 and body earth Resistance between A-39 <position lamp RH> headlamp assembly connector terminal No.6 and body earth
AC310475AB
AC301541HN
A-39 Harness side
A-39(B)
AC310433AD
Resistance between F-14 <tail lamp LH> rear combination lamp connector terminal No.5 and body earth Resistance between F-08 <tail lamp RH> rear combination lamp connector terminal No.5 and body earth

SYMPTOM PROCEDURES
54C-195

2 1
AC301541HO
Step 4. Check the wiring harness from F-14 <tail lamp LH> or F-08 <tail lamp RH> rear combination lamp connector terminal No.5, A-31 <position lamp LH> or A-39 <position lamp RH> headlamp assembly connector terminal No.7, F-11 <licence plate lamp LH> or F-10 <licence plate lamp RH> licence plate lamp connector terminal No.1 or C-02 <tail lamp indicator> combination meter connector terminal No.48 to body earth.
Resistance between F-11 <licence plate lamp LH> licence plate lamp connector terminal No.1 and body earth Resistance between F-10 <licence plate lamp RH> licence plate lamp connector terminal No.1 and body earth
F-14(B)
F-08(B) F-10(GR) F-11(GR)
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
F-08 Harness side

AC301541HE
F-10 Harness side
Resistance between C-02 <tail lamp indicator> combination meter connector terminal No.48 and body earth OK: 2 or less
F-11 Harness side
F-14 Harness side
AC310470AD
AC310475AB
54C-196

SYMPTOM PROCEDURES

Connector: A-10X
A-39 Harness side Battery A-39(B)

AC310433AD
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
F-12 (GR)
AC310469AG
NOTE: Prior to the wiring harness inspection, check intermediate connector F-12 <licence plate lamp> and repair if necessary. Check the earth wires for open circuit.

SYMPTOM PROCEDURES
54C-197
Step 6. Check the wiring harness from F-14 <tail lamp LH> or F-08 <tail lamp RH> rear combination lamp connector terminal No.3, A-31 <position lamp LH> or A-39 <position lamp RH> headlamp assembly connector terminal No.3, F-11 <licence plate lamp LH> or F-10 <licence plate lamp RH> licence plate lamp connector terminal No.2, C-02 <tail lamp indicator> combination meter connector terminal No.38 to A-10X front-ECU connector terminal No.8.
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
Connector: A-10X
Battery
F-14(B)
F-08(B) F-10(GR) F-11(GR) Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
F-08 Harness side
F-10 Harness side
F-11 Harness side
F-14 Harness side
AC310470AD
AC310475AB
A-39 Harness side
A-39(B)
AC310433AD
54C-198
NOTE:

SYMPTOM PROCEDURES
Step 7. Retest the system. Check that the tail lamps, the position lamps and the licence plate lamps illuminate normally.
Q: Is the check result normal? The all lamps illuminate normally : The trouble can
Harness side
AC310454BA
be an intermittent malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). When the tail lamps do not illuminate : Replace the rear combination lamp socket assembly.
When the position lamps do not illuminate :
Replace the position lamp socket.

When the licence plate lamps do not illuminate :
Replace the licence plate lamp socket.

When the tail lamp indicator do not illuminate :
Replace the combination meter assembly.
C-129
C-127 C-127
C-129
AC310455AE
Prior to the wiring harness inspection, check intermediate connector C-129 <tail lamp, licence plate lamp or tail lamp indicator>, C-127 <tail lamp LH or licence plate lamp> or F-12 <licence plate lamp>, joint connector C-05 <tail lamp RH, or tail lamp indicator>, junction block connector C-210 <tail lamp RH, or tail lamp indicator>, C-214 <tail lamp indicator> or C-217 <tail lamp RH> and repair if necessary. Check the output lines for open circuit.

SYMPTOM PROCEDURES
54C-199
INSPECTION PROCEDURE H-8: The headlamp(s) do not illuminate. <including high-beam indicator>
Headlamps Circuit
HEADLAMP RELAY: LO HEADLAMP RELAY: HI
FRONT-ECU
RELAY BOX
HEADLAMP ASSEMBLY (LH) (LO)
HEADLAMP ASSEMBLY (RH) (LO) HEADLAMP (HI: RH)
HEADLAMP (HI: LH)
COMBINATION METER
SB : Sky blue

If any of the headlamps or the high-beam indicator does not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.
POSSIBLE CAUSES
Malfunction of the headlamp bulbs Malfunction of the high-beam indicator bulb Damaged harness wires and connectors
54C-200

SYMPTOM PROCEDURES
Connectors: A-21, A-39 <LHD>
Step 1. Connector check: A-31 <headlamp (LO) RH>, A-39 <headlamp (LO) LH>, A-21 <headlamp (HI) RH>, A-15 <headlamp (HI) LH> headlamp assembly connector or C-01 <high-beam indicator> combination meter connector
A-21 A-39
A-21 Harness side A-15 A-31 A-39 Harness side
A-15 Harness side A-31 Harness side Connectors: A-21, A-39 <RHD>
AC310432AC
AC310543AC
Connectors: A-15, A-31 <RHD>
A-21 A-39
A-15 Harness side A-31 Harness side
AC310434AC
AC310476AC

SYMPTOM PROCEDURES
54C-201
Step 2. Check the bulb(s) of the headlamps or the high-beam indicator lamp. Check the bulb(s) of the defective lamp.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the bulb(s) of the defective lamp.
Harness side
AC310446AM
Harness side
AC310456AL
54C-202

SYMPTOM PROCEDURES
Step 3. Resistance measurement at A-31 <headlamp (LO) RH>, A-39 <headlamp (LO) LH>, A-21 <headlamp (HI) RH>, A-15 <headlamp (HI) LH> headlamp assembly connector or C-01 <high-beam indicator> combination meter connector
A-21 A-39
A-15 A-31
A-15 Harness side

AC310432AC
A-31 Harness side
AC310543AC
A-21 A-39
A-31 A-15
A-15 Harness side

AC310434AC
A-31 Harness side
AC310476AC

SYMPTOM PROCEDURES
54C-203
Harness side
AC310446AM
AC301541HK
Resistance between A-21 <headlamp (HI) RH> headlamp assembly connector terminal No.2 and body earth Resistance between A-15 <headlamp (HI) LH> headlamp assembly connector terminal No.2 and body earth
Harness side
AC310456AL
AC301541HL
Resistance between C-01 <high-beam indicator> combination meter connector terminal No.5 and body earth OK: 2 or less
AC301541HJ
Resistance between A-31 <headlamp (LO) RH> headlamp assembly connector terminal No.8 and body earth Resistance between A-39 <headlamp (LO) LH> headlamp assembly connector terminal No.8 and body earth
54C-204

SYMPTOM PROCEDURES
Step 4. Check the wiring harness from A-31 <headlamp (LO) RH> or A-39 <headlamp (LO) LH> headlamp connector terminal No.8, or A-21 <headlamp (HI) RH> or A-15 <headlamp (HI) LH> headlamp connector terminal No.2, or C-01 <high-beam indicator> combination meter connector terminal No.5 to body earth.
A-21 A-39
A-15 A-31
A-15 Harness side

AC310432AC
A-31 Harness side
AC310543AC
A-21 A-39
A-31 A-15
A-15 Harness side

AC310434AC
A-31 Harness side
AC310476AC

SYMPTOM PROCEDURES
54C-205

Connector: A-10X

AC310446AM
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
Harness side
AC310456AL

54C-206

SYMPTOM PROCEDURES
Step 6. Check the wiring harness from A-31 <headlamp (LO) RH> or A-39 <headlamp (LO) LH> headlamp connector terminal No.4, or A-21 <headlamp (HI) RH> or A-15 <headlamp (HI) LH> headlamp connector terminal No.1, or C-01 <high-beam indicator> combination meter connector terminal No.5 to A-10X front-ECU connector terminal No.6 <low-beam> or No.2 <high-beam>.
A-21 A-39
AC310432AC
AC310543AC
A-21 A-39
AC310434AC
AC310476AC

SYMPTOM PROCEDURES
54C-207
NOTE:
Harness side
AC310446AM
AC310446AI
Harness side
AC310456AL
AC310454AJ
Connector: A-10X
Battery
Prior to the wiring harness inspection, check intermediate connector C-129 <high-beam indicator>, and repair if necessary. Check the output lines for open circuit.
Relay box side

11 10 9 8 7 6 5 4 3 2 1
AC310572AB
Step 7. Retest the system. Check that the headlamps and the high-beam indicator lamp illuminate/extinguish normally.
Q: Is the check result normal? The lamps illuminate normally at both high and low beams. : The trouble can be an intermittent
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). When the headlamps do not illuminate : Replace the headlamp socket.
When the high-beam indicator lamp does not illuminate : Replace the combination meter.
54C-208
FLASHER TIMER

SYMPTOM PROCEDURES
INSPECTION PROCEDURE I-1: The turn-signal lamps do not illuminate.
Turn-Signal Lamp Power Supply Circuit <LHD> BATTERY
RELAY BOX
J/B SIDE
ETACS-ECU TURN-SIGNAL LAMP RELAY: LH TURN-SIGNAL LAMP RELAY: RH
HEADLAMP ASSEMBLY (LH) SIDE TURN SIGNAL LAMP (LH)
SIDE TURN SIGNAL LAMP (RH) REAR COMBINATION LAMP (RH)
COMBINATION METER
COMBINATION METER HEADLAMP ASSEMBLY (RH)
SB : Sky blue

SYMPTOM PROCEDURES
54C-209
Turn-Signal Lamp Power Supply Circuit <RHD> BATTERY
RELAY BOX
J/B SIDE
ETACS-ECU
TURN-SIGNAL LAMP RELAY: LH
TURN-SIGNAL LAMP RELAY: RH
HEADLAMP ASSEMBLY (LH) SIDE TURN SIGNAL LAMP (LH) REAR COMBINATION LAMP (LH)
HEADLAMP ASSEMBLY (RH) SIDE TURN SIGNAL LAMP (RH)
COMBINATION METER
SB : Sky blue

If all the turn-signal lamps do not illuminate, the ignition switch (IG1), the turn-signal lamp switch input circuit or the ETACS-ECU may be defective.
DIAGNOSIS PROCEDURE
Step 1. Check that the hazard warning lamps operate. Check that the hazard warning lamps illuminate normally.
POSSIBLE CAUSES
Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-210

SYMPTOM PROCEDURES


Junction block side
Junction block side
AC310450AB
AC310450AB
Junction block side

AC310461AB
Junction block side

AC310461AB

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541HF

SYMPTOM PROCEDURES
54C-211
Step 4. Check the wiring harness between C-226 ETACS-ECU connector terminal No.11 and the battery.
NOTE:
Junction block side Connector: C-129 <RHD>
AC310446AI
AC310450AB
AC310454AJ
Junction block side

AC310461AB
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310448AK
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310458AH
Prior to the wiring harness inspection, check intermediate connector C-129 and junction block connector C-210, and repair if necessary. Check the power supply line for open circuit.
54C-212

SYMPTOM PROCEDURES
Step 5. Retest the system. Check that the turn-signal lamps illuminate normally.
Step 7. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the left turn-signal lamps. <Selected item> TURN SIGNAL - TURN-SIG. LH Turn-signal lamp switch: LH Ignition switch: ON Item No. Item 10 Item 11 Item name TURN SIG.RH TURN SIG.LH Normal condition OFF ON
Step 6. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the right turn-signal lamps. <Selected item> TURN SIGNAL - TURN-SIG. RH Turn-signal lamp switch: RH Ignition switch: ON Item No. Item 10 Item 11 Item 30 Item name TURN SIG.RH TURN SIG.LH IG SW(IG1) Normal condition ON OFF ON

Go to Step 8.
column switch (lighting and turn-signal lamp switch) signal is not received P.54C-267." Step 8. Retest the system. Check that the turn-signal lamps illuminate.

Go to Step 7.

SYMPTOM PROCEDURES
54C-213
INSPECTION PROCEDURE I-2: The hazard warning lamps do not illuminate.
Hazard Warning Lamp Circuit BATTERY
RELAY BOX
J/B SIDE
ETACS-ECU INPUT SIGNAL TURN-SIGNAL LAMP RELAY: LH TURN-SIGNAL LAMP RELAY: RH HAZARD WARNING LAMP SWITCH
COMBINATION METER HEADLAMP ASSEMBLY (LH) REAR COMBINATION LAMP (LH) SIDE TURN SIGNAL LAMP (LH)
COMBINATION METER HEADLAMP ASSEMBLY (RH) REAR COMBINATION LAMP (RH) SIDE TURN SIGNAL LAMP (RH)
SB : Sky blue

If the hazard warning lamps do not illuminate, the hazard warning lamp input signal circuit or the ETACS-ECU may be defective.
POSSIBLE CAUSES
Malfunction of the hazard warning lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-214

SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
Step 1. Check that the turn-signal lamps operate. Check that the turn-signal lamps illuminate normally.
Q: Is the check result normal? YES : Go to Step 2. NO : Refer to Inspection Procedure I-1 "The turn
Step 2. Pulse check Check the input signal from the hazard warning lamp switch. System switch Hazard warning lamp switch Check condition When the hazard warning lamp switch is turned from off to on
signal lamps do not illuminate P.54C-208."

hazard warning lamp switch signal is not received P.54C-285." Step 3. Retest the system. Check that the hazard warning lamps illuminate.

SYMPTOM PROCEDURES
54C-215
INSPECTION PROCEDURE I-3: Any of the turn-signal lamps does not illuminate. <LH drive vehicles>
Turn-Signal Lamps Circuit <LHD>
J/B SIDE
ETACS-ECU TURN-SIGNAL LAMP RELAY: LH TURN-SIGNAL LAMP RELAY: RH
SIDE TURN SIGNAL LAMP (LH)
HEADLAMP REAR ASSEMBLY COMBINATION (LH) LAMP (LH)
SIDE TURN SIGNAL LAMP (RH)
COMBINATION METER

If any of the turn-signal lamps does not illuminate normally, wiring harness connector(s) or the bulb may be defective.
POSSIBLE CAUSES
Defective turn-signal lamp bulb Damaged harness wires and connectors
54C-216

SYMPTOM PROCEDURES
Connectors: F-08, F-14 <LHD>
Step 1. Connector check: A-39 <front RH> or A-31 <front LH> headlamp assembly connector, A-01 <side RH> or A-02 <side LH> side turn-signal lamp connector, F-08 <rear RH> or F-14 <rear LH> rear combination lamp connector, C-02 <turn-signal indicator lamp> and C-01 <turn-signal indicator lamp (LH)> combination meter connector
Connectors: A-01, A-39 <LHD> A-01 (GR)
F-08 F-14
F-08 Harness side A-39
F-14 Harness side
AC310468AC
A-01 Harness side
A-39 Harness side
Connectors: C-01, C-02 <LHD> C-02(L) C-01
AC310432AB
Connectors: A-02, A-31 <LHD> A-02 (GR) C-01 Harness side C-02 Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
A-31
AC310447AE
A-02 Harness side
A-31 Harness side
Step 2. Check the bulb(s) of the turn-signal lamps or the turn-signal indicator lamps. Check the bulb(s) of the defective lamp.
AC310543AB

SYMPTOM PROCEDURES
54C-217
Step 3. Resistance measurement at the A-39 <front RH> or A-31 <front LH> headlamp assembly connector, the A-01 <side RH> or A-02 <side LH> side turn-signal lamp connector, the F-08 <rear RH> or F-14 <rear LH> rear combination lamp connector, the C-02 <turn-signal indicator lamp> combination meter connector
F-08 F-14
F-14 Harness side
AC310468AC
A-01 Harness side
A-39 Harness side
C-02 (L)
AC310432AB
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
A-31
A-02 Harness side
A-31 Harness side
AC310543AB
54C-218

SYMPTOM PROCEDURES
(2) Measure the resistance between the defective lamp connector terminal and body earth.
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC301541HE
AC301541HG
Resistance between A-39 <front RH> headlamp assembly connector terminal No.7 and body earth Resistance between A-31 <front LH> headlamp assembly connector terminal No.7 and body earth
Resistance between C-02 <turn-signal indicator lamp> combination meter terminal No.48 and body earth OK: 2 or less
AC301541HH
Resistance between A-01 <side RH> side turn-signal lamp connector terminal No.1 and body earth Resistance between A-02 <side LH> side turn-signal lamp connector terminal No.1 and body earth
AC301541HI
Resistance between F-08 <rear RH> rear combination lamp connector terminal No.5 and body earth Resistance between F-14 <rear LH> rear combination lamp connector terminal No.5 and body earth

SYMPTOM PROCEDURES
54C-219
Step 4. Check the wiring harness from A-39 <front RH> or A-31 <front LH> headlamp assembly connector terminal No.7, A-01 <side RH> or A-02 <side LH> side turn-signal lamp connector terminal No.1, F-08 <rear RH> or F-14 <rear LH> rear combination lamp connector terminal No.5, or C-02 <turn-signal indicator lamp> combination meter connector terminal No.48 to body earth.
F-08 F-14
F-14 Harness side
AC310468AC
A-01 Harness side
A-39 Harness side
C-02 (L)
AC310432AB
Harness side Connectors: A-02, A-31 <LHD> A-02 (GR)

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK

A-31
A-02 Harness side
A-31 Harness side
AC310543AB
54C-220

SYMPTOM PROCEDURES

Junction block side
A-31
AC310450AB
A-02 Harness side
A-31 Harness side
Step 6. Check the wiring harness from the A-39 <front RH> or A-31 <front LH> headlamp assembly connector terminal No.2, the A-01 <side RH> or A-02 <side LH> side turn-signal lamp connector terminal No.2, the F-08 <rear RH> or F-14 <rear LH> rear combination lamp connector terminal No.1, the C-02 <turn-signal indicator lamp RH> combination meter connector terminal No.49 or C-01 <turn-signal indicator lamp LH> combination lamp connector terminal No.3 to C-226 ETACS-ECU connector terminal No.9 <RH> or 14 <LH>.
AC310543AB
F-08 F-14
A-39
F-08 Harness side
F-14 Harness side
A-01 Harness side
A-39 Harness side
AC310468AC
AC310432AB

SYMPTOM PROCEDURES
54C-221
C-01 Harness side C-02 Harness side

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310447AE
Junction block side
AC310450AB
54C-222
NOTE:

SYMPTOM PROCEDURES
Connectors: C-210, C-214, C-217 <LHD> Junction block (front view)
C-210
C-214 C-217

6 5 4 3 2 1 14 13 12 11 10 9 8 7
C-214 Harness side

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-113 Harness side
C-217 Harness side
AC310453AB
AC310449AE
Connectors: C-129 <LHD>
C-129
Prior to the wiring harness inspection, check intermediate connector C-129 <front or side LH>, C-113 <rear RH> or C-111 <side RH> and junction block connector C-210 <front LH, side or rear RH>, C-217 <rear LH> or C-214 <front RH or turn-signal indicator lamp>, and repair if necessary. Check the output lines for open circuit.
AC310446AP
Step 7. Retest the system. Check that the turn-signal lamps and the indicator lamps illuminate normally.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5).
The front turn-signal lamps do not illuminate. :
Replace the socket.

The side turn-signal lamps do not illuminate. :
Replace the socket.

The rear turn-signal lamps do not illuminate. :
Replace the socket assembly.

The turn-signal indicator lamps do not illuminate. :
Replace the combination meter.

SYMPTOM PROCEDURES
54C-223
INSPECTION PROCEDURE I-3: Any of the turn-signal lamps does not illuminate. <RH drive vehicles>
Turn-Signal Lamps Circuit <RHD>
J/B SIDE
ETACS-ECU
( TURN-SIGNAL LH ) LAMP RELAY:
(TURN-SIGNAL RH) LAMP RELAY:
SIDE TURN SIGNAL LAMP (LH)
HEADLAMP ASSEMBLY (LH)
SIDE TURN SIGNAL LAMP (RH)
COMBINATION METER
SB : Sky blue
54C-224

SYMPTOM PROCEDURES
Connectors: A-02, A-31 <RHD> A-02 (GR)

If any of the turn-signal lamps does not illuminate normally, wiring harness connector(s) or the bulb may be defective.
POSSIBLE CAUSES
Defective turn-signal lamp bulb Damaged harness wires and connectors
Step 1. Connector check: A-39 <front RH> or A-31 <front LH> headlamp assembly connector, A-01 <side RH> or A-02 <side LH> side turn-signal lamp connector, F-08 <rear RH> or F-14 <rear LH> rear combination lamp connector, C-02 <turn-signal indicator lamp> and C-01 <turn-signal indicator lamp (LH)> combination meter connector
Connectors: A-01, A-39 <RHD> A-01 (GR) Connectors: F-08, F-14 <RHD>
A-31
A-02 Harness side
A-31 Harness side
AC310476AB
A-39 F-08 F-14
A-01 Harness side
A-39 Harness side F-08 Harness side F-14 Harness side
AC310434AB
AC310470 AC

SYMPTOM PROCEDURES
Connectors: C-01, C-02 <RHD> C-02(L) C-01
54C-225
Step 2. Check the bulb(s) of the turn-signal lamps or the turn-signal indicator lamps. Check the bulb(s) of the defective lamp.

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310457AB
54C-226

SYMPTOM PROCEDURES
Connectors: F-08, F-14 <RHD>
Step 3. Resistance measurement at the A-39 <front RH> or A-31 <front LH> headlamp assembly connector, the A-01 <side RH> or A-02 <side LH> side turn-signal lamp connector, the F-08 <rear RH> or F-14 <rear LH> rear combination lamp connector, the C-02 <turn-signal indicator lamp> combination meter connector
F-08 F-14
F-14 Harness side
AC310470 AC
A-01 Harness side
A-39 Harness side
AC310434AB
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
A-31
A-02 Harness side
A-31 Harness side
AC310476AB

SYMPTOM PROCEDURES
54C-227
(2) Measure the resistance between the defective lamp connector terminal and body earth.
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC301541HE
AC301541HG
Resistance between A-39 <front RH> headlamp assembly connector terminal No.7 and body earth Resistance between A-31 <front LH> headlamp assembly connector terminal No.7 and body earth
Resistance between C-02 <turn-signal indicator lamp> combination meter terminal No.48 and body earth OK: 2 or less
AC301541HH
Resistance between A-01 <side RH> side turn-signal lamp connector terminal No.1 and body earth Resistance between A-02 <side LH> side turn-signal lamp connector terminal No.1 and body earth
AC301541HI
Resistance between F-08 <rear RH> rear combination lamp connector terminal No.5 and body earth Resistance between F-14 <rear LH> rear combination lamp connector terminal No.5 and body earth
54C-228

SYMPTOM PROCEDURES
Step 4. Check the wiring harness from A-39 <front RH> or A-31 <front LH> headlamp assembly connector terminal No.7, A-01 <side RH> or A-02 <side LH> side turn-signal lamp connector terminal No.1, F-08 <rear RH> or F-14 <rear LH> rear combination lamp connector terminal No.5, or C-02 <turn-signal indicator lamp> combination meter connector terminal No.48 to body earth.
F-08 F-14
F-14 Harness side
AC310470 AC
Connector: C-02 <RHD> C-02 (L) A-01 Harness side A-39 Harness side
Harness side
AC310434AB
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
A-31

A-02 Harness side
A-31 Harness side Junction block side

AC310461AB AC310476AB

SYMPTOM PROCEDURES
54C-229
Step 6. Check the wiring harness from the A-39 <front RH> or A-31 <front LH> headlamp assembly connector terminal No.2, the A-01 <side RH> or A-02 <side LH> side turn-signal lamp connector terminal No.2, the F-08 <rear RH> or F-14 <rear LH> rear combination lamp connector terminal No.1, the C-02 <turn-signal indicator lamp RH> combination meter connector terminal No.49 or C-01 <turn-signal indicator lamp LH> combination lamp connector terminal No.3 to C-226 ETACS-ECU connector terminal No.9 <RH> or 14 <LH>.
F-08 F-14
F-08 Harness side
F-14 Harness side
A-39
AC310470 AC
Connector: C-02 <RHD> C-02 (L) A-01 Harness side A-39 Harness side
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310434AB
AC310456AK
A-31
Junction block side

AC310461AB
A-02 Harness side
A-31 Harness side
AC310476AB
54C-230
NOTE:

SYMPTOM PROCEDURES
Connectors: C-210, C-214, C-217 Junction block (front view) <RHD> C-210
C-214
C-210 Harness side C-129 C-127 C-127

6 5 4 3 2 1 14 13 12 11 10 9 8 7
C-217
C-214 Harness side

14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-129
28 27 26 25 24 23 22 21 20 19 18 17 16 15
C-217 Harness side
AC310455AE
AC310459AE
Connectors: C-111 <RHD>
Prior to the wiring harness inspection, check intermediate connector C-129 <front or side LH>, C-127 <rear LH> or C-111 <side RH> and junction block connector C-210 <front, side or rear LH>, C-217 <rear RH> or C-214 <turn-signal indicator lamp>, and repair if necessary. Check the output lines for open circuit.
AC310456AP
Step 7. Retest the system. Check that the turn-signal lamps and the indicator lamps illuminate normally.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5).
The front turn-signal lamps do not illuminate. :
Replace the socket.

The side turn-signal lamps do not illuminate. :
Replace the socket.

The rear turn-signal lamps do not illuminate. :
Replace the socket assembly.

The turn-signal indicator lamps do not illuminate. :
Replace the combination meter.

SYMPTOM PROCEDURES
54C-231
FOG LAMP
INSPECTION PROCEDURE J-1: The rear fog lamp do not illuminate normally.
Rear Fog Lamp Circuit <LHD> FUSIBLE LINK 1
REAR FOG LAMP RELAY
COMBINATION METER
REAR COMBINATION LAMP (REAR FOG)
ETACS-ECU
SB : Sky blue
54C-232

SYMPTOM PROCEDURES
Rear Fog Lamp Circuit <RHD> FUSIBLE LINK 1
REAR FOG LAMP RELAY
ETACSECU
COMBINATION METER
OPERATION
The ETACS-ECU operates this function in accordance with the input signals below. Tail lamp switch Headlamp switch
Rear fog lamp switch If the rear fog lamps do not illuminate normally, these input signal circuit(s) or the ETACS-ECU may be defective.

SYMPTOM PROCEDURES
54C-233
POSSIBLE CAUSES
Malfunction of the column switch Malfunction of the fog lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
Step 3. Function diagnosis by using the SWS monitor. Check the SWS communication signal, which are related to the fog lamps. <Selected item> LIGHTING - REAR FOG LAMP Ignition switch: ON Lighting switch: "TAIL" or "HEAD" Rear fog lamp switch: ON Item No. Item name Item 00 HEADLAMP SW Normal condition ON when the lighting switch is at HEAD ON when the lighting switch is at TAIL
DIAGNOSIS PROCEDURE
Step 1. Check that the tail lamps and headlamps operate. Check that the tail lamps and headlamps illuminate normally.
Q: Is the check result normal? YES : Go to Step 2. NO : Check the tail lamps and the headlamps
Item 01
TAIL LAMP SW
(Refer to trouble symptom chart P.54C-20). Step 2. ECU check by using the SWS monitor. Check that the power supply and earth lines to the column switch (column-ECU), the ETACS-ECU and the front-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU ETACS ECU FRONT ECU OK: "OK" is displayed for all the items

Go to Step 4.
column switch (lighting and turn-signal lamp switch) signal is not received P.54C-267." Step 4. Pulse check. Check the input signals below, which are related to the rear fog lamps. System switch Ignition switch (IG1) Rear fog lamp switch Check condition When turned from ACC to ON When the rear fog lamp switch is turned from off to on
"NG" is displayed on the "ETACS ECU" menu. :

5.
The ignition switch (IG1) signal is not received. :
The rear fog lamp switch signal is not received. :
Refer to Inspection Procedure L-8 "The rear fog lamp switch signal is not received P.54C-277."
54C-234

SYMPTOM PROCEDURES
Step 5. Connector check: C-219 rear fog lamp relay connector

Step 7. Voltage measurement at the C-219 rear fog lamp relay connector
Junction block side 2 1 4 3

AC310448AN

AC310448AN

AC310458AK

AC310458AK
(1) Remove the rear fog lamp relay, and measure at the junction block side.
Step 6. Check the rear fog lamp relay. Refer to GROUP 54A Rear fog lamp P.54A-64.
Q: Is the check result normal? YES : Go to Step 7. NO : Replace the rear fog lamp relay.

2 1 4 3
AC301541HC
(2) Check the voltage between the rear fog lamp relay connector and body earth. Voltage between C-219 rear fog lamp relay connector terminal No.3 and body earth Voltage between C-219 rear fog lamp relay connector terminal No.4 and body earth OK: System voltage

SYMPTOM PROCEDURES
54C-235
Step 8. Check the wiring harness between C-219 rear fog lamp relay connector (terminal Nos.3 and 4) and the battery.
Connectors: C-209, C-212, C-214, C-219 <LHD> Junction block (front view) C-209 C-212(B)
NOTE:
C-214 C-209 Harness side C-219 C-212 Harness side C-214 Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
AC310446AJ
Connectors: C-21, C-126 <RHD> C-21
C-219 Junction block side
2 1 4 3
C-126
AC310449AC
Connectors: C-209, C-212, C-214, C-219 <RHD> Junction block (front view) C-212(B) C-209
C-126
C-214
AC310455 AD
C-209 Harness side
C-219
Prior to the wiring harness inspection, check intermediate connector C-126, joint connector C-21 <RH drive vehicles> and junction block connectors C-209, C-212 and C-214, and repair if necessary. Check the power supply line for open circuit.

14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
2 1 4 3
AC310459AC
54C-236

SYMPTOM PROCEDURES

Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310450AH
AC310450AH
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310461AG
AC310461AG
NOTE: Prior to the wiring harness inspection, check junction block connector C-209, and repair if necessary. Check the output lines for open circuit.
Step 10. Check the wiring harness between C-219 rear fog lamp relay connector terminal No.2 and C-228 ETACS-ECU connector terminal No.74.
Step 11. Retest the system. Check that the rear fog lamps illuminate normally.

AC310448AN

AC310458AK

SYMPTOM PROCEDURES
54C-237
INSPECTION PROCEDURE J-2: The rear fog lamp or the rear fog lamp indicator does not illuminate normally.
Rear Fog Lamp Circuit <LHD> FUSIBLE LINK 1
REAR FOG LAMP RELAY
COMBINATION METER
ETACS-ECU
SB : Sky blue
54C-238

SYMPTOM PROCEDURES
Rear Fog Lamp Circuit <RHD> FUSIBLE LINK 1
REAR FOG LAMP RELAY
ETACSECU
COMBINATION METER

If any of the rear fog lamps do not illuminate, the wiring harness connector(s), the bulb or the fuse may be defective or burned out.
POSSIBLE CAUSES
Burned-out rear fog lamp bulb Damaged harness wires and connectors

SYMPTOM PROCEDURES
54C-239
DIAGNOSIS PROCEDURE
Step 1. Connector check: F-14 <LH drive vehicles>, F-08 <RH drive vehicles> rear fog lamp connector or C-02 <rear fog lamp indicator lamp> combination meter connector
Step 2. Check the bulbs of the rear fog lamps or the rear fog lamp indicator lamp. Check the bulb(s) of the defective lamp.
Harness side
AC310467AC
Harness side
AC310469AC
C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK
54C-240

SYMPTOM PROCEDURES
Step 3. Resistance measurement at the F-14 <LH drive vehicles>, F-08 <RH drive vehicles> rear fog lamp connector or C-02 <fog lamp indicator lamp> combination meter connector
(2) Check the resistance between the lamp connector and body earth.
Harness side
AC301541HD
AC310467AC
Resistance between F-14 <LH drive vehicles>, F-08 <RH drive vehicles> rear fog lamp relay connector terminal No.5 and body earth

Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310469AC
AC301541HE
C-02 (L)
Resistance between C-02 <rear fog lamp indicator lamp> combination meter connector terminal No.48 and body earth OK: 2 or less
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK

SYMPTOM PROCEDURES
54C-241
Step 4. Check the wiring harness from F-14 <LH drive vehicles>, F-08 <RH drive vehicles> rear fog lamp connector terminal No.5, C-02 <rear fog lamp indicator lamp> combination meter connector terminal No.48 to body earth.
Step 5. Connector check: C-219 rear fog lamp relay connector, C-01 <rear fog lamp indicator lamp> combination meter connector
Harness side

AC310448AN
AC310467AC
Harness side Junction block side 2 1 4 3

AC310458AK
AC310469AC
C-02 (L)

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AM
AC310446AK
Harness side
Harness side
AC310456AL
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK

54C-242

SYMPTOM PROCEDURES
Step 6. Check the wiring harness from F-14 <LH drive vehicles>, F-08 <RH drive vehicles> rear fog lamp connector terminal No.4, C-01 <rear fog lamp indicator lamp> combination meter connector terminal No.21 to C-219 rear fog lamp relay connector terminal No.1.

AC310448AN
Harness side Connector: C-219 <RHD> Junction block (front view)
AC310467AC

AC310458AK
Harness side
AC310469AC
C-02 (L)
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310446AK
Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310456AK

SYMPTOM PROCEDURES
54C-243
NOTE:
Step 7. Retest the system. Check that the rear fog lamp and the rear fog lamp indicator lamp illuminate normally.
C-112(GR)
AC310446AN
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). The rear fog lamps do not illuminate. : Replace the rear fog lamp(s).
The rear fog lamp indicator lamp does not illuminate. : Replace the combination meter.
C-112(GR)
AC310456AM
Harness side
AC310448 AO
Harness side
AC310458AL
Prior to the wiring harness inspection, check intermediate connector C-127 <LH drive vehicles - rear fog lamp>, C-112 <RH drive vehicles - rear fog lamp> and junction block connector C-209, and repair if necessary. Check the output lines for open circuit.
54C-244
INTERIOR LAMP

SYMPTOM PROCEDURES
INSPECTION PROCEDURE K--1: The front or rear room lamp does not illuminate or extinguish normally.
Room Lamp Circuit
J/B SIDE
ETACS-ECU
LUGGAGE COMPARTMENT LAMP REAR ROOM LAMP FRONT ROOM LAMP
LUGGAGE COMPARTMENT LAMP SWITCH
SB : Sky blue

The ETACS-ECU operates this function in accordance with the input signals below. Ignition switch (IG1) Key reminder switch All of the door switches Driver's door lock actuator Interior lamp loaded signal
If this function does not work normally, these input signal circuit(s), the interior lamp automatic shutdown function or the ETACS-ECU may be defective. The delay-off setting of this function can be changed by the adjustment function (default setting; 15 seconds).
POSSIBLE CAUSES
Malfunction of the key reminder switch Malfunction of the door switches Malfunction of the driver's door lock actuator Malfunction of the ETACS-ECU Damaged harness wires and connectors

SYMPTOM PROCEDURES
54C-245
DIAGNOSIS PROCEDURE
Step 1. Check the adjustment function. Check that the room lamp delay-off time has been set to other than "0 second" by the adjustment function.
Q: Is the check result normal? YES : Go to Step 2. NO : Use the adjustment function to set the room
Step 4. Pulse check Check the input signals below, which are related to the front or rear dome lamps. System switch Check condition Key reminder switch When the inserted ignition key is pulled out All of the door switches Driver's door lock actuator switch Interior lamp loaded signal A door is opened when all the doors are closed When the driver's door is unlocked or locked When a load is applied through multi-purpose fuse No.18
lamp delay-off time to other than "0 second" (Refer to GROUP 54B Adjustment function P.54B-302). Step 2. ECU check by using the SWS monitor. Check that the power supply and earth lines to the ETACS-ECU and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED ETACS ECU OK: "OK" is displayed on the "ETACS ECU" menu.

5.
"Communication with the ETACS-ECU is not possible P.54C-36." Step 3. SWS monitor data list. Check the input signals below, which are related to the front and rear dome lamps. <Selected item> ETACS ECU Ignition switch: OFF Item No. Item 30 Item name IG SW(IG1) Normal condition OFF
Refer to Inspection Procedure L-11 "All the door switch signals are not received <LH drive vehicles>P.54C-289 ," or refer to Inspection Procedure L-11 "All the door switch signals are not received <RH drive vehicles>P.54C-292 ."
"The front door lock actuator (LH) switch signal is not received <LH drive vehicles>P.54C-296 ," or refer to Inspection Procedure L-12 "The front door lock actuator (RH) switch signal is not received <RH drive vehicles>P.54C-299 ."
The interior lamp loaded signal is not received. :

Refer to Inspection Procedure L-15 "The interior lamp loaded signal is not detected P.54C-307." Step 5. Determine a trouble spot.
Q: Which lamp does not illuminate? No lamp illuminates. : Replace the ETACS-ECU. The front room lamp or the rear room lamp does not illuminate. : Go to Step 6. The luggage compartment lamp does not illuminate. : Go to Step 11.
ignition switch (IG1) signal is not received P.54C-261."
54C-246

SYMPTOM PROCEDURES
Step 6. Connector check: D-05 front room lamp connector, D-07 rear room lamp connector
Connectors: D-05, D-07 <LHD> D-05 D-07 (GR)
Step 7. Check the bulbs of the front or rear room lamps. Check that the front or rear room lamp bulbs are not burned out.
Q: Is the check result normal? YES : Go to Step 8. NO : Replace the front or rear room lamp bulb.

Connector: C-226 <LHD> Junction block (rear view) D-05 Harness side Junction block side D-07 Harness side Connector: C-226 <RHD>
AC310450AB
AC310464AB
Connectors: D-05, D-07 <RHD> D-05 D-07 (GR) Junction block side
AC310461AB
D-05 Harness side
D-07 Harness side
AC310472 AB

SYMPTOM PROCEDURES
54C-247
Step 9. Check the wiring harness from C-226 ETACS-ECU connector terminal Nos.5 and 6 to D-05 front room lamp connector terminal Nos.2 and 1 or D-07 rear room lamp connector terminal Nos.2 and 1.
Connectors: D-05, D-07 <RHD> D-05 D-07 (GR)
Junction block side
D-05 Harness side
AC310450AB
D-07 Harness side
AC310472 AB
NOTE:
Junction block side
AC310461AB
Connectors: D-05, D-07 <LHD> D-05 Harness side D-07 (GR)

AC310448AL
D-05 Harness side
Harness side
AC310458AJ
D-07 Harness side
Prior to the wiring harness inspection, check junction block connector C-218, and repair if necessary. Check the input or output lines for open circuit.
AC310464AB
54C-248

SYMPTOM PROCEDURES
Step 10. Retest the system. Check that the front or rear room lamp illuminates and extinguishes normally.
Step 11. Connector check: F-02 luggage compartment lamp connector, F-09 luggage compartment lamp switch connector
F-02
F-09 (B)
F-02 Harness side
F-09 Harness side
AC310468AB
Connectors: F-02, F-09 <RHD> F-02
F-09 (B)
F-02 Harness side
F-09 Harness side
AC310470AB

SYMPTOM PROCEDURES
54C-249
Step 12. Check the bulbs of the luggage compartment lamp. Check that the luggage compartment lamp bulb are not burned out.
Q: Is the check result normal? YES : Go to Step 13. NO : Replace the luggage compartment lamp
Step 14. Check the wiring harness from F-02 luggage compartment lamp connector terminal No.2 to F-09 luggage compartment lamp switch connector terminal No.1.
bulb. Step 13. Check the luggage compartment lamp switch. Check the luggage compartment lamp switch. Refer to GROUP 42 Trunk lid P.42-39.
Q: Is the check result normal? YES : Go to Step 14. NO : Replace the luggage compartment lamp
F-02
F-09 (B)
switch.
F-02 Harness side
F-09 Harness side
AC310468AB
Connectors: F-02, F-09 <RHD> F-02
F-09 (B)
F-02 Harness side
F-09 Harness side
AC310470AB

54C-250

SYMPTOM PROCEDURES

Step 16. Check the wiring harness from C-226 ETACS-ECU connector terminal No.6 to F-02 luggage compartment lamp connector terminal No.1.
AC310450AB
Junction block (rear view) Connector: C-226 <RHD>
AC310450AB
Junction block side

AC310461AB
Junction block side

AC310461AB
Harness side
AC310467AB
Harness side
AC310469AB

SYMPTOM PROCEDURES
54C-251
NOTE:
Step 17. Retest the system. Check that the luggage compartment lamp illuminates and extinguishes normally.
Harness side
AC310448AC
Harness side
AC310458AC
Prior to the wiring harness inspection, check junction block connector C-217, and repair if necessary. Check the power supply line for open circuit.
54C-252

SYMPTOM PROCEDURES
INSPECTION PROCEDURE K--2: Interior lamp automatic shutdown function does not work normally.
Interior Lamp Automatic Shutdown Function Circuit RELAY BOX (FUSE 22 )
J/B SIDE
ETACS-ECU INPUT SIGNAL ALL DOOR SWITCH DRIVER'S DOOR SWITCH IGNITION SWITCH (ACC) IGNITION SWITCH (IG1) INTERIOR LAMP LOADED SIGNAL KEEP RELAY
COMBINATION METER
FRONT ROOM LAMP REAR ROOM LAMP LUGGAGE COMPARTMENT LAMP

The ETACS-ECU operates the interior lamp automatic shutdown function in accordance with the input signals below. Ignition switch (ACC) Ignition switch (IG1) Driver's door switch All of the door switches Interior lamp loaded signal If this function does not work normally, these input signal circuit(s) or the ETACS-ECU may be defective. Note that this function can be disabled/enabled by the adjustment function (default setting; enabled).
DIAGNOSIS PROCEDURE
Step 1. Check the adjustment function. Check that the interior lamp automatic shutdown function has been enabled by using the adjustment function.
Q: Is the check result normal? YES : Go to Step 2. NO : Enable the interior lamp automatic
POSSIBLE CAUSES
Malfunction of the door switches Malfunction of the room lamp
shutdown function by using the adjustment function (Refer to GROUP 54B Adjustment function P.54B-302).

SYMPTOM PROCEDURES
54C-253
Step 4. Pulse check. Check the input signals below, which are related to the interior lamp automatic shutdown function. System switch All of the door switches Interior lamp loaded signal Check condition A door is opened when all the doors are closed When a load is applied through multi-purpose fuse No.18

"Communication with the ETACS-ECU is not possible P.54C-36." Step 3. SWS monitor data list. Check the input signals below, which are related to the interior lamp automatic shutdown function. <Selected item> ETACS ECU Ignition switch: OFF Driver's door: open Item No. Item 30 Item 31 Item 32 Item name IG SW(IG1) IG SW(ACC) DR DOOR SW Normal condition OFF OFF ON
5.
Refer to Inspection Procedure L-11 "All the door switch signals are not received <LH drive vehicles>P.54C-289 ." or refer to Inspection Procedure L-11 "All the door switch signals are not received <RH drive vehicles>P.54C-292 ."
The interior lamp loaded signal is not received. :
Refer to Inspection Procedure L-15 "The interior lamp loaded signal is not detected P.54C-307." Step 5. Retest the system. Check that the interior lamp automatic shutdown function works normally.

Go to Step 4.
54C-254

SYMPTOM PROCEDURES
INSPECTION PROCEDURE K--3: The door-ajar warning lamp does not illuminate/extinguish normally.
Door Ajar Indicator Lamp Circuit ETACS-ECU
INPUT SIGNAL COMBINATION METER ALL DOOR SWITCH DRIVER'S DOOR SWITCH
SB : Sky blue
OPERATION
The ETACS-ECU operates this function in accordance with all the door switch signals. If the door-ajar warning lamp does not work normally, the input signal circuits from all the door switches or the ETACS-ECU may be defective.
DIAGNOSIS PROCEDURE
Step 1. Check the operation of the room lamp. Check that the dome lamps illuminate and extinguish normally.
POSSIBLE CAUSES
All the door switches are defective. Malfunction of the ETACS-ECU Damaged harness wires and connectors
front or rear room lamp does not illuminate or extinguish normally P.54C-244."

SYMPTOM PROCEDURES
54C-255
Step 2. SWS monitor data list. Check the input signals below, which are related to the door-ajar warning lamp. <Selected item> ETACS ECU Driver's door: open Item No. Item 32 Item name DR DOOR SW Normal condition ON
Step 4. Connector check: C-01 and C-02 combination meter connector


switch (front: LH) signal is not received <LH drive vehicles>P.54C-263 ," or refer to Inspection Procedure L-3 "The door switch (front: RH) signal is not received <RH drive vehicles>P.54C-265 ." Step 3. Pulse check Check the input signals below, which are related to the door-ajar warning lamp. System switch All of the door switches Check condition A door is opened when all the doors are closed

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310447AE

Q: Is the check result normal? YES : Go to Step 4. NO : Refer to Inspection Procedure L-11 "All the
door switch signals are not received <LH drive vehicles>P.54C-289 ," or refer to Inspection Procedure L-11 "All the door switch signals are not received <RH drive vehicles>P.54C-292 ."
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310457AB
54C-256

SYMPTOM PROCEDURES
Step 5. Check the door-ajar warning lamp bulb. Check the door-ajar warning lamp bulb.
Q: Is the check result normal? YES : Go to Step 6. NO : Replace the door-ajar warning lamp bulb.

Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310450AH
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310461AG

SYMPTOM PROCEDURES
54C-257
Step 7. Check the wiring harness from C-228 ETACS-ECU connector terminal Nos.53 and 71 to C-02 combination meter connector terminal No.34 and C-01 combination meter connector terminal No.8.
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310450AH
AC310457AB
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
Check the input or output lines for open circuit.

AC310461AG
Step 8. Retest the system. Replace the ETACS-ECU, and then check that the door-ajar warning lamp illuminates/extinguishes normally. (1) Replace the ETACS-ECU. (2) Check that the door-ajar warning lamp illuminates/extinguishes normally.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the combination meter.

51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
AC310447AE
54C-258


INSPECTION PROCEDURE L-1: The ignition switch (ACC) signal is not received.
Ignition Switch (ACC) Input Circuit IGNITION SWITCH (ACC)
J/B SIDE
ETACS-ECU
SB : Sky blue

Input signal from the ignition switch (ACC) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Windshield wiper and washer Rear wiper and washer
Interior lamp automatic shutdown function
POSSIBLE CAUSES

54C-259
DIAGNOSIS PROCEDURE

Junction block side Junction block side Connector: C-226 <RHD>
AC310450AB
AC310450AB

AC310461AB AC310461AB
(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Ignition switch: ACC position

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541GT
54C-260

INPUT SIGNAL PROCEDURES Q: Is the check result normal? YES : The trouble can be an intermittent
Step 4. SWS monitor data list. <Selected item> ETACS ECU Ignition switch: ACC
Junction block side
Item No. Item 31
Item name IG SW(ACC)
Normal condition ON
AC310450AB

Junction block side

AC310461AB
NOTE:
Harness side
2 1 6 5 4 3
AC310448AB
Harness side
AC310458AB

54C-261
INSPECTION PROCEDURE L-2: The ignition switch (IG1) signal is not received.
Ignition Switch (IG1) Input Circuit IGNITION SWITCH (IG1)
J/B SIDE
ETACS-ECU
SB : Sky blue

Input signal from the ignition switch (IG1) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Headlamp automatic shutdown function Turn signal lamp Room lamps
DIAGNOSIS PROCEDURE
POSSIBLE CAUSES
Junction block side
AC310450AB
Junction block side

AC310461AB
54C-262



AC310450AB
AC310450AB

AC310461AB
(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Ignition switch: ON position
AC310461AB
NOTE:

Harness side
2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2 1 6 5 4 3
AC310448AB
AC301541GU
Harness side
AC310458AB

INPUT SIGNAL PROCEDURES Q: Is the check result normal? YES : The trouble can be an intermittent
54C-263
Step 4. SWS monitor data list. <Selected item> ETACS ECU Ignition switch: ON Item No. Item 30 Item name IG SW(IG1) Normal condition ON

INSPECTION PROCEDURE L-3: The door switch (front: LH) signal is not received. <LH drive vehicles>
Door Switch Input Circuit <LHD>
ETACS-ECU
J/B SIDE
FRONT DOOR SWITCH (LH)
SB : Sky blue

Input signal from the driver's door switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Headlamp automatic shutdown function Room lamps Door-ajar indicator lamp
POSSIBLE CAUSES
Malfunction of the driver's door switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-264

DIAGNOSIS PROCEDURE
Step 1. Check the installation condition. Check that the door switch (front: LH) is installed on the body correctly.
Step 5. Check the wiring harness between D-18 door switch (front: LH) connector terminal No.3 and C-226 ETACS-ECU connector terminal No.10.
Step 2. Connector check: D-18 door switch (front: LH) connector

Connector: D-18 <LHD> Connector: D-18 <LHD>
Junction block side
AC310450AB
AC310465AB
AC310465AB
NOTE:
Step 3. Check the door switch (front: LH). Refer to GROUP 42 Door P.42-27.
Q: Is the check result normal? YES : Go to Step 4. NO : Replace the door switch (front: LH).
Harness side

AC310448AC
Prior to the wiring harness inspection, check joint connector C-217, and repair if necessary. Check the input line for open circuit.
Junction block side
AC310450AB

54C-265
Step 6. SWS monitor data list. <Selected item> ETACS ECU Driver's door: open Item No. Item 32 Item name DR DOOR SW Normal condition ON

INSPECTION PROCEDURE L-3: The door switch (front: RH) signal is not received. <RH drive vehicles>
Door Switch Input Circuit <RHD>
ETACS-ECU
J/B SIDE
DOOR SWITCH (RH)
SB : Sky blue

Input signal from the door switch (front: RH) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Headlamp automatic shutdown function Room lamps
POSSIBLE CAUSES
Malfunction of the door switch (front: RH) Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-266

Step 1. Check the installation condition. Check that the door switch (front: RH) is installed on the body correctly.
Step 5. Check the wiring harness between D-01 door switch (front: RH) connector terminal No.3 and C-226 ETACS-ECU connector terminal No.10.
Step 2. Connector check: D-01 door switch (front: RH) connector

Junction block side

AC310461AB
Connector: D-01 <RHD> Harness side Harness side
AC310471AB
AC310471AB
NOTE:
Step 3. Check the door switch (front: RH). Refer to GROUP 42 Door P.42-27.
Q: Is the check result normal? YES : Go to Step 4. NO : Replace the door switch (front: RH).
Harness side

AC310458AC
Prior to the wiring harness inspection, check joint connector C-217, and repair if necessary. Check the input line for open circuit.
Junction block side

AC310461AB

54C-267
Step 6. SWS monitor data list. <Selected item> ETACS ECU Driver's door: open Item No. Item 32 Item name DR DOOR SW Normal condition ON

INSPECTION PROCEDURE L-4: The column switch (lighting, turn-signal lamp and headlamp washer switch) signal is not received.
Lighting Switch Input Circuit COLUMN SWITCH COLUMN-ECU
DIMMER PASSING SWITCH
TURN-SIGNAL LAMP SWITCH
LIGHTING SWITCH

Input signal from the column switch (lighting, turn-signal lamp and headlamp washer switch) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Lamp reminder function Headlamp and tail lamp Headlamp automatic shutdown function Fog lamp Turn signal lamp Headlamp washer
POSSIBLE CAUSES
Malfunction of the column switch Damaged harness wires and connectors
DIAGNOSIS PROCEDURE
Step 1. Check the column switch connector. Check that the wiper and washer switch connector, the lighting switch connector and the switch body connector are in good condition.
54C-268

Step 2. Check the column switch (lighting switch and switch body). Refer to GROUP 54A Column switch P.54A-74.
Step 4. SWS monitor data list. <Selected item> COLUMN ECU Operate each function of the switch. Item No. Item 00 Item 01 Item 02 Item 03 Item 10 Item 11 Item name HEADLAMP SW TAIL LAMP SW DIMMER SW PASSING SW TURN SIG.RH TURN SIG.LH Normal condition ON ON ON ON ON ON
Step 3. ECU check by using the SWS monitor. Check that the power supply and earth lines to the column switch (column-ECU) and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU OK: "OK" is displayed on the "COLUMN ECU" menu.
"Communication with the column switch (column-ECU) is not possible P.54C-30."
INSPECTION PROCEDURE L-5: The column switch (windshield wiper and washer switch) signal is not received.
Windshield Wiper and Washer Switch Input Circuit COLUMN SWITCH COLUMN-ECU
UPPER SIDE
UPPER SIDE WINDSHIELD WASHER SWITCH
WINDSHIELD WIPER SWITCH

54C-269

Input signal from the column switch (wiper switch) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Windshield wiper and washer Rear wiper and washer
Step 2. SWS monitor data list. <Selected item> COLUMN ECU Operate each function of the switch. Item No. Item name Item 05 Item 06 Item 07 Item 08 Item 09 INT WIPER SW LO WIPER SW HI WIPER SW MIST WIPER SW FRONT WASH.SW Normal condition ON ON ON ON ON
POSSIBLE CAUSES
Malfunction of the column switch Damaged harness wires and connectors
DIAGNOSIS PROCEDURE
Step 1. ECU check by using the SWS monitor. Check that the power supply and earth lines to the column switch (column-ECU) and the SWS communication lines are normal. Ignition switch: OFF ECUS TO BE CHECKED COLUMN ECU OK: "OK" is displayed on the "COLUMN ECU" menu.
"Communication with the column switch (column-ECU) is not possible P.54C-30."
54C-270

INSPECTION PROCEDURE L-6: The windshield intermittent wiper volume signal is not received.
Windshield Intermittent Wiper Interval Adjusting Knob Input Circuit
ETACSECU
COLUMN SWITCH
UPPER SIDE
WINDSHIELD INTERMITTENT WIPER INTERVAL ADJUSTING KNOB
UPPER SIDE
SB : Sky blue

The intermittent wiper interval is calculated in accordance with the input signal from the windshield intermittent wiper volume. If this signal is abnormal, the wiper interval can not be adjusted.
POSSIBLE CAUSES
Malfunction of the column switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

54C-271
DIAGNOSIS PROCEDURE
Step 2. Resistance measurement at the C-206 column switch connector

Harness side
Harness side
AC310479AB
AC310479AB
AC310481AB
AC310481AB
(1) Disconnect the connector, and measure at the column switch side.
AC301541GV
(2) Resistance between C-206 column switch connector terminal No.6 and body earth OK: The resistance should rise from 0 to 1 k when the windshield intermittent wiper volume is rotated from "Fast" to "Slow".
54C-272


Step 4. Check the wiring harness between C-206 column switch connector terminal No.6 and C-228 ETACS-ECU connector terminal No.66.
Harness side C-228(GR) C-228(GR)

AC310450AE
Harness side
AC310450AE
C-228(GR) Harness side Harness side C-228(GR)
AC310461AD
AC310461AD
Harness side
AC310479AB
Harness side
AC310481AB


54C-273
Step 5. SWS monitor data list. <Selected item> ETACS ECU Ignition switch: ACC Wiper switch: INT Item No. Item 37 Item name INT WIPE TIME Normal condition 2.4 to 18.0 s
OK: The display will be changed as the intermittent wiper volume is rotated.
54C-274

INSPECTION PROCEDURE L-7: When the power window main switch is operated, the switch signals are not received.
Power Window Main Switch Circuit
FUSIBLE LINK 5
J/B SIDE
ETACS-ECU
POWER WINDOW RELAY
CPU
SB : Sky blue

54C-275

Input signal from the power window main switch is used in order to check the power window main switch and confirm how the system is communicating with the ETACS-ECU. If the communication line is defective, the power windows will not work normally.
Step 2. Connector check: C-228 ETACS-ECU connector and E-05 power window main switch connector
POSSIBLE CAUSES
Malfunction of the power window main switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
DIAGNOSIS PROCEDURE
Step 1. Check the operation by using the power window main switch. Check if each window can be operated by means of the power window main switch.
Q: Can each power window be operated by means of the power window main switch? YES : Go to Step 2. NO : Refer to Inspection Procedure D-1 "Power
AC310450AH
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310461AG

6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310484AC
Front door (RH)
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310493AC
54C-276

Step 3. Check the wiring harness between C-228 ETACS-ECU connector terminal No.59 and E-05 power window main switch connector terminal No.4.
NOTE:
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310446 AC
AC310450AH
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310456 AE

AC310461AG

6 5 4 3 2 1 14 13 12 11 10 9 8 7
Harness side
AC310446AF

AC310484AC
Harness side Front door (RH)
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310456AF
AC310493AC
Prior to the wiring harness inspection, check intermediate connector C-17 <LH drive vehicles> or C-110 <RH drive vehicles> and joint connector C-101, and repair if necessary. Check the communication lines for open circuit.

54C-277
Step 4. Replace the power window main switch, and then retest the system. Replace the power window main switch, and check that the power window main switch signal is received. (1) Replace the power window main switch.
(2) Check that the power window main switch signal is received.
Q: Is the check result normal? YES : The procedure is complete. NO : Replace the ETACS-ECU.
INSPECTION PROCEDURE L-8: The rear fog lamp switch signal is not received.
Rear Fog Lamp Switch Input Circuit ETACSECU
FOG LAMP SWITCH
<LHD>
<RHD>
SB : Sky blue

Input signal from the rear fog lamp switch is used to operate the rear fog lamps. If the signal is abnormal, the rear fog lamps will not illuminate and extinguish normally.
POSSIBLE CAUSES
Malfunction of the fog lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-278

DIAGNOSIS PROCEDURE
Step 1. Connector check: C-20 fog lamp switch connector
Step 3. Resistance measurement at the C-20 fog lamp switch connector


AC310446AH
AC310446AH
AC310456AI
AC310456AI
(1) Remove the fog lamp switch, and measure at the wiring harness side.
Step 2. Check the rear fog lamp switch. Refer to GROUP 54A Rear fog lamp P.54A-64.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the fog lamp switch.
AC301541HA
(2) Continuity between C-20 fog lamp switch connector terminal No.6 and body earth OK: 2 or less

54C-279
Step 4. Check the wiring harness between C-20 fog lamp switch connector terminal No.6 and body earth.

Harness side Connector: C-227 <LHD> Junction block (rear view)
AC310446AH

29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310450AG
AC310456AI
NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF
Harness side
AC310446AF
Harness side
AC310456AG
Prior to the wiring harness inspection, check joint connector C-101 <LH driver vehicles> or C-06 <RH drive vehicles>, and repair if necessary. Check the earth wires for open circuit.
54C-280

Step 6. Check the wiring harness between C-227 ETACS-ECU connector terminal No.21 and C-20 fog lamp switch connector terminal No.5.
Step 7. Pulse check. Check the input signal from the rear fog lamp switch. System switch Rear fog lamp switch Check condition When the switch is turned from off to on

Harness side
AC310446AH
Harness side
AC310456AI
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310450AG
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF


54C-281
INSPECTION PROCEDURE L-9: The key reminder switch signal is not received.
Key Reminder Switch Input Circuit
ETACSECU
KEY REMINDER SWITCH WHEN KEY IS REMOVED
SB : Sky blue

Input signal from the key reminder switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Key reminder function Keyless entry system
Room lamps
POSSIBLE CAUSES
Malfunction of the key reminder switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-282

DIAGNOSIS PROCEDURE
Step 1. Connector check: C-207 key reminder switch connector
Step 3. Resistance measurement at the C-207 key reminder switch connector

Harness side
2 1 7 6 5 4 3
Harness side
2 1 7 6 5 4 3
AC310479AC
AC310479AC
AC310481AC
AC310481AC
2 1 7 6 5 4 3
Step 2. Check the key reminder switch. Refer to GROUP 54A Ignition switch P.54A-30.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the key reminder switch.
AC301541GY
(2) Resistance between C-207 key reminder switch connector terminal No.4 and body earth OK: 2 or less

54C-283
Step 4. Check the wiring harness between C-207 key reminder switch connector terminal No.4 and the body earth.
Harness side
2 1 7 6 5 4 3

AC310479AC
Harness side Connector: C-207 <RHD> Harness side Connector: C-227 <RHD>
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310450AG
AC310481AC
NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF
Harness side
AC310446AF
Harness side
AC310456AG
Prior to the wiring harness inspection, check joint connector C-101 <LH drive vehicles> or C-06 <RH drive vehicles>, and repair if necessary. Check the earth wires for open circuit.
54C-284

Step 6. Check the wiring harness between C-207 key reminder switch connector terminal No.6 and C-227 ETACS-ECU connector terminal No.30.
Step 7. Pulse check Check the input signal from the key reminder switch. System switch Key reminder switch Check condition When the inserted ignition key is pulled out
Harness side
2 1 7 6 5 4 3

AC310479AC
AC310481AC
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310450AG
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF


54C-285
INSPECTION PROCEDURE L-10: The hazard warning lamp switch signal is not received.
Hazard Warning Lamp Switch Input Circuit ETACSECU
HAZARD WARNING LAMP SWITCH
SB : Sky blue

Input signal from the hazard warning lamp switch is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Keyless entry system (encrypted code registration) Hazard warning lamp
POSSIBLE CAUSES
Malfunction of the hazard warning lamp switch Malfunction of the ETACS-ECU Damaged harness wires and connectors
54C-286

DIAGNOSIS PROCEDURE
Step 1. Connector check: C-03 hazard warning lamp switch connector
Step 3. Resistance measurement at the C-03 hazard warning lamp switch connector
Harness side
Harness side
AC310446AG
AC310446AG
AC310454AG
AC310454AG

4 3 2 1
Step 2. Check the hazard warning lamp switch. Refer to GROUP 54A Hazard warning lamp switch P.54A-72.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the hazard warning lamp switch.
AC301541GZ
(2) Resistance between C-03 hazard warning lamp switch connector terminal No.2 and body earth OK: 2 or less

54C-287
Step 4. Check the wiring harness between C-03 hazard warning lamp switch connector terminal No.2 and the body earth.
Harness side

AC310446AG

59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310450AH
AC310454AG
NOTE:
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
C-06 (GR)
AC310461AG
AC310452AE
AC310456 AB
54C-288

Step 6. Check the wiring harness between C-228 ETACS-ECU connector terminal No.55 and C-03 hazard warning lamp switch connector terminal No.1.
Step 7. Pulse check Check the input signal from the hazard warning lamp switch. System switch Hazard warning lamp switch Check condition When the hazard warning lamp switch is turned from off to on
Harness side

AC310446AG
Harness side
AC310454AG
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310450AH
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310461AG


54C-289
INSPECTION PROCEDURE L-11: All the door switch signals are not received. <LH drive vehicles>
All Door Switches Input Circuit <LHD>
ETACS-ECU
J/B SIDE
SB : Sky blue

POSSIBLE CAUSES
54C-290

INPUT SIGNAL PROCEDURES Q: Is the check result normal? YES : Go to Step 3. NO : Repair the defective connector.
DIAGNOSIS PROCEDURE
Step 1. SWS monitor data list. <Selected item> ETACS ECU Driver's door is open Item No. Item 32 Item name DR DOOR SW Normal condition ON

switch (front: LH) signal is not received <LH drive vehicles>P.54C-263 ." Step 2. Connector check: D-18 <front: LH>, D-01 <front: RH>, D-08 <rear: RH> or D-11 <rear: LH> door switch connectors, and C-226 ETACS-ECU connector

Junction block side
AC310450AB
Connectors: D-01, D-08 <LHD> D-01 Harness side D-01 D-08
D-08 Harness side
AC310463AC
Connectors: D-11, D-18 <LHD> D-11 Harness side D-11 D-18 Harness side D-18
AC310465AD

54C-291
C-214

14 13 12 11 10 9 8 7 6 5 4 3 2 1
Junction block side
AC310450AB
28 27 26 25 24 23 22 21 20 19 18 17 16 15
Connectors: D-01, D-08 <LHD> D-01 Harness side D-01 D-08
C-217 Harness side
AC310449AB
D-08 Harness side
AC310463AC
Prior to the wiring harness inspection, check intermediate connector C-113 <RH> and junction block connector C-214 <RH> or C-217 <LH>, and repair if necessary. Check the input line for open circuit.
Connectors: D-11, D-18 <LHD> D-11 Harness side D-11 D-18 Harness side D-18
AC310465AD
the door switches and the ETACS-ECU. Step 6. Pulse check Check the input signals from all the door switches. System switch All of the door switches Check condition A door is opened when all the doors are closed
NOTE:

AC310452AF
54C-292

INSPECTION PROCEDURE L-11: All the door switch signals are not received. <RH drive vehicles>
All Door Switches Input Circuit <RHD>
ETACS-ECU
J/B SIDE
SB : Sky blue

POSSIBLE CAUSES

54C-293
Step 1. SWS monitor data list. <Selected item> ETACS ECU Driver's door is open Item No. Item 32 Item name DR DOOR SW Normal condition ON
D-08 D-011

D-18
switch (front: RH) signal is not received <RH drive vehicles>P.54C-265 ." Step 2. Connector check: D-18 <front: LH>, D-01 <front: RH>, D-08 <rear: RH> or D-11 <rear: LH> door switch connectors, and C-226 ETACS-ECU connector
D-08 Harness side
D-11 Harness side
D-18 Harness side

AC310474 AB
Junction block side

AC310461AB

Harness side
AC310471AB
54C-294

NOTE:
Junction block side

AC310461AB
Harness side
AC310455AC
Connectors: C-214, C-217 Junction block (front view) <RHD>

AC310471AB
C-214
D-08 D-011
C-214 Harness side
C-217
14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
D-18 C-217 Harness side D-08 Harness side D-11 Harness side
AC310459AB
D-18 Harness side

AC310474 AB
Prior to the wiring harness inspection, check intermediate connector C-127 <LH> and junction block connector C-217 <RH> or C-214 <LH>, and repair if necessary. Check the input line for open circuit.
the door switches and the ETACS-ECU.

54C-295
Step 6. Pulse check Check the input signals from all the door switches. System switch All of the door switches Check condition A door is opened when all the doors are closed

54C-296

INSPECTION PROCEDURE L-12: The front door lock actuator (LH) switch signal is not received. <LH drive vehicles>
Front Door Lock Actuator Input Circuit <LHD>
ETACS-ECU
SB : Sky blue

Input signal from the front door lock actuator (LH) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Key reminder function
Central door locking Keyless entry system Room lamps
POSSIBLE CAUSES

54C-297
DIAGNOSIS PROCEDURE
Connector: E-04 <LHD> Rear door (LH)
Step 4. Check the wiring harness between E-04 front door lock actuator (LH) connector terminal No.1 and body earth
Harness side
E-04(B)
AC310486AB
Harness side
E-04(B)
AC310486AB
Step 2. Check the front door lock actuator (LH). Refer to GROUP 42 Door P.42-31.
NOTE:
Step 3. Resistance measurement at the E-04 front door lock actuator (LH) connector
AC310446 AC
Harness side
E-04(B)
AC310486AB
3 2 1 6 5 4
AC301541 GW
(2) Resistance between E-04 front door lock actuator (LH) connector terminal No.1 and body earth OK: 2 or less
54C-298


NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310446 AC
AC310450AG
Step 6. Check the wiring harness from E-04 front door lock actuator (LH) connector terminal Nos.2 and 3 to C-227 ETACS-ECU connector terminal Nos.35 and 36.
Step 7. Pulse check Check the input signal from the front door lock actuator (LH) switch. System switch Front door lock actuator (LH) switch Check condition When the driver's door is unlocked or locked
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39

AC310450AG
Rear door (LH)
Harness side
E-04(B)
AC310486AB

54C-299
INSPECTION PROCEDURE L-12: The front door lock actuator (RH) switch signal is not received. <RH drive vehicles>
Front Door Lock Actuator Input Circuit <RHD>
ETACS-ECU
SB : Sky blue

Input signal from the front door lock actuator (RH) is used to operate the functions below. If the signal is abnormal, these functions will not work normally. Key reminder function Central door locking Keyless entry system Room lamps
POSSIBLE CAUSES
54C-300

INPUT SIGNAL PROCEDURES Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4.
Step 4. Check the wiring harness between E-15 front door lock actuator (RH) connector terminal No.3 and body earth
Harness side
E-15(B)
AC310493AH
Harness side
E-15(B)
AC310493AH
Step 2. Check the front door lock actuator (RH). Refer to GROUP 42 Door P.42-31.
NOTE:
Step 3. Resistance measurement at the E-15 front door lock actuator (RH) connector
AC310456 AE
Harness side
E-15(B)
AC310493AH
3 2 1 6 5 4
AC301541HR
(2) Resistance between E-15 front door lock actuator (RH) connector terminal No.3 and body earth OK: 2 or less

54C-301

NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310456 AE
AC310461AF
Step 6. Check the wiring harness from E-15 front door lock actuator (RH) connector terminal Nos.1 and 2 to C-227 ETACS-ECU connector terminal Nos.36 and 35.
Step 7. Retest the system. Check that the front door lock actuator (RH) switch signal is received normally.
Q: Is the check result normal? YES : Go to Step 8. NO : Replace the ETACS-ECU.
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
Step 8. Pulse check Check the input signal from the front door lock actuator (RH) switch. System switch
AC310461AF
Check condition When the driver's door is unlocked or locked
Front door lock actuator (RH) switch

Harness side
E-15(B)
AC310493AH
54C-302

INSPECTION PROCEDURE L-13: The vehicle speed sensor signal is not received.
Vehicle Speed Sensor Input Circuit <LHD> ETACS-ECU

54C-303
Vehicle Speed Signal Input Circuit <RHD> ETACS-ECU

Vehicle speed sensor signal is used to operate the windshield wiper (vehicle speed-dependent wiper function). If this signal is abnormal, the windshield wipers do not work normally.
DIAGNOSIS PROCEDURE
Step 1. Check the speedometer. Check that the speedometer works normally.
Q: Is the check result normal? YES : Go to Step 2. NO : Diagnose the combination meter (Refer to
POSSIBLE CAUSES
Malfunction of the vehicles speed sensor Malfunction of the ETACS-ECU Damaged harness wires and connectors
GROUP 54A Combination meter P.54A-34).
54C-304

Step 2. Connector check: B-04 vehicles speed sensor connector and C-228 ETACS-ECU connector
Step 3. Check the wiring harness between B-04 vehicles speed sensor connector terminal No.3 and C-228 ETACS-ECU connector terminal No.63.
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310450AH
AC310450AH
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
Harness side
59 58 57 56 55 54 53 52 51 58 5756 555453 52 51 60 74 7372 71 70 69
AC310461AG
AC310461AG
AC310439AB
AC310439AB
AC310477AB
AC310477AB
Q: Are the check result normal? YES : Go to Step 3. NO : Repair the defective connector.

54C-305
NOTE:
Connector: C-21,C-124 <LHD> C-21 (B)
C-124 (B) Connector: C-124 <RHD>
AC310477AC
C-21
C-124
AC310454AD AC310447AD
Harness side
Prior to the wiring harness inspection, check joint connector C-21 <LH driver vehicles>, combination meter connector C-101 <RH drive vehicles> and intermediate connector B-27 and C-124, and repair if necessary. Check the input line for open circuit.
AC310456AF
Connector: B-27 <LHD>
Step 4. Pulse check Check the vehicle speed sensor signal. System switch Vehicle speed sensor signal Check condition When the vehicle speed has reached 10 km/h or more

AC310439 AC
54C-306

INSPECTION PROCEDURE L-14: Each switch signal of the keyless entry transmitter is not received.
Transmitter Input Circuit ETACS-ECU
KEYLESS ENTRY TRANSMITTER
W3Z10E39AA

Input signal from the keyless entry transmitter is used to operate the keyless entry system. If the signal is abnormal, the keyless entry system will not work normally.
Step 2. Check the transmitter battery. Refer to GROUP 42 Keyless entry system P.42-46.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the keyless entry transmitter
POSSIBLE CAUSES
Malfunction of the keyless entry transmitter Defective battery of the keyless entry transmitter Malfunction of the ETACS-ECU
battery. Step 3. Register the encrypted code, and then retest the system. (1) Register the keyless entry transmitter again. (2) Check that each signal is received from the keyless entry transmitter.
DIAGNOSIS PROCEDURE
Step 1. Pulse check Check whether the ETACS-ECU receives signal from a transmitter or not. For this check, you should use the 2-button-type transmitter (integrated with a key), which cover screw is silver and has already been registered. NOTE: For how to register the keyless entry transmitter encrypted code, refer to GROUP 42 On-vehicle Service P.42-43. System switch Check condition Keyless entry transmitter When the switch is "LOCK/UNLOCK" switch turned from off to on OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.
malfunction (Refer to GROUP 00 How to Cope with Intermittent Malfunction P.00-5). NO : Replace the keyless entry transmitter.
Step 4. Retest the system. Check that each signal is received from the keyless entry transmitter.

54C-307
INSPECTION PROCEDURE L-15: Interior lamp loaded signal is not detected.
Interior Lamp Automatic Shutdown Function Circuit IGNITION SWITCH (ACC) IGNITION SWITCH (IG1) BATTERY
RELAY BOX
<LHD>
<RHD>
ETACS-ECU
KEEP RELAY
INTERIOR LAMP CUT BACK-UP CIRCUIT POWER SOURCE
J/B SIDE
COMBINATION METER
LUGGAGE COMPARTMENT LAMP FRONT ROOM LAMP REAR ROOM LAMP
SB : Sky blue
54C-308


The interior lamp automatic shutdown function operates in accordance with the interior lamp loaded signal. If this signal is abnormal, the functions below will not work normally. Ignition key cylinder illumination lamp Room lamps Interior lamp automatic shutdown function

POSSIBLE CAUSES
Malfunction of the ETACS-ECU Damaged wiring harness or connector(s)
Junction block side
AC310450AB
DIAGNOSIS PROCEDURE
Junction block side

AC310461AB

Junction block side
AC310450AB
Junction block side

AC310461AB

54C-309
NOTE:

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
2 1 6 5 4 3
AC310448AB
AC301541GU
Harness side
AC310458AB
Prior to the wiring harness inspection, check junction block connector C-211, and repair if necessary. Check the power supply line to the ignition switch (IG1) for open circuit.
Junction block side
AC310450AB
Junction block side

AC310461AB
54C-310



AC310450AB
AC310450AB

AC310461AB
(1) Remove the ETACS-ECU, and measure at the junction block side. (2) Turn the ignition switch to the ACC position.
AC310461AB

2019 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC301541HB

54C-311
NOTE:
Harness side
Prior to the wiring harness inspection, check joint connector C-23 <RH drive vehicles>, junction block connector C-210 or intermediate connector C-129, and repair if necessary. Check the power supply line to the ignition switch (ACC) for open circuit.
AC310456AJ
Step 7. Pulse check Check the input of the interior lamp loaded signal. System switch
Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
Check condition When a load is applied through multi-purpose fuse No.18
Interior lamp loaded signal
AC310448AK

Harness side
6 5 4 3 2 1 14 13 12 11 10 9 8 7
AC310458AH
AC310446AI
AC310454AJ
54C-312

INSPECTION PROCEDURE L-16: The door lock key cylinder switch signal is not detected.
Door Lock Key Cylinder Switch Input Circuit ETACS-ECU
DOOR LOCK KEY CYLINDER SWITCH

Input signal from the door lock key cylinder switch is used to operate the central door locking function. If the signal is abnormal, the central door locking function will not work normally.
POSSIBLE CAUSES
Malfunction of the door lock key cylinder switch Malfunction of the ETACS-ECU Damaged harness wires and connectors

54C-313
DIAGNOSIS PROCEDURE
Step 1. Connector check: E-12 door lock key cylinder switch connector
Step 3. Resistance measurement at the E-12 door lock key cylinder switch connector
E-12(B) Harness side E-12(B) Harness side

AC310488AC
AC310488AC
Connector: E-12 <RHD> E-12(B) Harness side E-12(B)
Harness side
AC310498AB
AC310498AB

3 2 1
Step 2. Check the door lock key cylinder switch. Refer to GROUP 42 Door P.42-31.
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the door lock key cylinder switch.
AC301541DM
(2) Resistance between E-12 door lock key cylinder switch connector terminal No.2 and body earth OK: 2 or less
54C-314

INPUT SIGNAL PROCEDURES Q: Is the check result normal? YES : Intermittent malfunction. (Refer to GROUP
Step 4. Check the wiring harness between E-12 door lock key cylinder switch connector terminal No.2 and body earth.
00 How to Cope with Intermittent Malfunction P.00-5). NO : Repair the wiring harness.

AC310488AC
Harness side Connector: E-12 <RHD>

29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
Harness side E-12(B) Connector: C-227 <RHD>
AC310450AG
AC310498AB
NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310461AF
AC310452AG
AC310454 AK
Prior to the wiring harness inspection, check intermediate connector C-110 <LH drive vehicles> or C-17 <RH drive vehicles>, and repair if necessary. Check the earth wires for open circuit.

54C-315
Step 6. Check the wiring harness from E-12 door lock key cylinder switch connector terminal Nos.1 and 3 <LHD> or 3 and 1 <RHD> to C-227 ETACS-ECU connector terminal Nos.33 and 34.
NOTE:
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310452AG
AC310450AG
Harness side
29 28 27 26 25 24 23 22 21 38 37 36 35 34 33 32 31 30 44 43 42 41 40 39
AC310454 AK
AC310461AF
Prior to the wiring harness inspection, check intermediate connector C-110 <LH drive vehicles> or C-17 <RH drive vehicles>, and repair if necessary. Check the input line for open circuit.
Front door (RH)
STEP 7. Pulse check Check the input signal from the door lock key cylinder switch. System switch Check condition Turn the key to the lock or unlock position Door lock key cylinder switch
AC310488AC

Harness side
E-12(B)
AC310498AB
54C-316


M1549001200823
ETACS-ECU
C-227 C-226 C-228
AC005554AI
NOTE: Terminal numbers 1 to 20 can not be measured as the ETACS-ECU is mounted on the junction block directly. The values are for reference only.
1 2
Output to the power window relay Power supply to the central door locking system (battery positive voltage) Earth (for ECU) Ignition switch (ACC) Output to room lamp Power supply to interior lamp (battery positive voltage) Input from all the door switches Power supply from ignition switch (IG1) Output to right turn-signal lamps Input from driver's door switch Power supply to turn-signal lamps (battery positive voltage) Output to central door locking (for locking the doors) Output to central door locking (for unlocking the doors other than the driver's door) Output to left turn-signal lamps
When the power windows are operative Always
System voltage System voltage
3 4 5 6 7 8 9 10 11 12 13
Always Ignition switch: ACC When the room lamp is on Always (when the interior lamp off function is off)
0V System voltage 2 V or less System voltage
One of the door switches: ON (door 0 V open) Ignition switch: ON System voltage
When right turn-signal lamps are on System voltage Driver's door switch: ON (door open) Always When the door lock actuators lock the doors When the door lock actuators unlock the doors 0V System voltage System voltage System voltage
14
When the left turn-signal lamps are System voltage on Ignition switch: ACC Always Rear fog lamp switch: ON System voltage System voltage 0V
15 to 17 18 19 20 21 Power supply from ignition switch (ACC) Battery power supply (for ECU) Input from rear fog lamp switch

CHECK AT ECU TERMINAL Terminal Check item No. Check condition
54C-317
Normal condition
22
Output to central door locking (for unlocking the driver's door) Input of collision signal Input to key reminder switch
When the door lock actuators unlock the doors Key reminder switch: ON (ignition key removed) Driver's door lock: Locked Driver's door lock: Unlocked When diagnosis code is set (the M.U.T.-II/III is connected or the diagnosis connector terminal No.1 is earthed) When input check signal is sent
System voltage 0V 0V 0V 0 to 12 V (pulse signal)
23 to 28 29 30
31 to 34 35 36 Input to driver's door lock actuator (lock switch) Input to driver's door lock actuator (unlock switch) Setting diagnosis code or sending input check signal
37 to 44 51
0 V, 12 V (input signal is fluctuating) 0V 0V 0 to 12 V (pulse signal) 0 to 12 V (pulse signal) 0 to 2.5 V
52 53 54 55 56 57, 58 59 63 64, 65 66
Output to door-ajar indicator lamp Input from hazard warning lamp switch Earth (for sensor) SWS communication line Input of vehicle speed signal Input from windshield intermittent wiper volume Input from diagnosis control Input of SWS request signal Output to ignition key cylinder illumination lamp Power supply to interior lamp Output to rear fog lamp
Hazard warning lamp switch: ON Always Always When the vehicle is being driven Turn the ignition switch to the ACC position, and move the wiper volume from "Fast" to "Slow." When M.U.T.-II/III is connected Always When ignition key cylinder illumination is on Always (when the interior lamp off function is off) When rear fog lamp is on
When door-ajar indicator lamp is on 0 V
60 to 62
67 68 69 70 71 72, 73 74
0V 0 to 12 V (pulse signal) 2 V or less System voltage System voltage
54C-318
COLUMN SWITCH
C-206

AC005555AG
Check condition
Normal condition
1 2 3 4 5 6
Battery power supply Input of SWS request signal SWS communication line Earth Output to windshield intermittent wiper volume
Always Always Always Always
System voltage 0 to 12 V (pulse signal) 0 to 12 V (pulse signal) 0V
Ignition switch: ACC 0 to 2.5 V Move the wiper volume from "Fast" to "Slow."
7 8
Back-up output to windshield wiper Windshield low-speed wiper switch 0 V switch or windshield high-speed wiper switch: ON Power supply from ignition switch (IG1) Ignition switch: ON System voltage 0V
9 10
Back-up output to headlamp switch Headlamp switch: ON

54C-319
FRONT-ECU
A-10X
1 2 3 4 5 6 7 8 9 10 11
A-11X
2122 23242526 272829 30 31 AC305097 AB
NOTE: Measurement is not possible as the front-ECU is mounted on the relay box directly. The values are for reference only.
1 2 3, 4 5 6 7 8 9 to 11 21 22 23 24 25 26
Output to headlamp (high-beam) Battery power supply (for headlamp) Output to headlamp (low-beam) Battery power supply (for ECU) Output to tail lamps Output to windshield washer SWS communication line Input of automatic stop signal to windshield wiper Power supply to ignition switch (ACC) Input of backup signal from headlamp switch
When headlamps (high-beam) are on Always
System voltage System voltage System voltage System voltage System voltage System voltage System voltage 0 12 V (pulse signal) System voltage System voltage 0V
Battery power supply (for tail lamp) Always When headlamps (low-beam) are on Always When tail lamps are on When windshield washer is on Always When windshield wiper is on Ignition switch: "ACC" Headlamp switch: ON
Input of backup signal to windshield Windshield low-speed wiper switch 0 V wiper or windshield high-speed wiper switch: ON Output to windshield wiper (low-speed) Output to windshield wiper (high-speed) Power supply to ignition switch (IG2) Earth When windshield wiper is on (at low System voltage speed) When windshield wiper is on (at high speed) Ignition switch: "ON" Always System voltage System voltage 0V
27 28 29 30 31
54C-320


E-05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 AC103264 AG
Check condition
Normal condition
1 2 3 4 5 6 7 8 9 10 11 12
Output to power window regulator motor Earth SWS communication line (to ETACS-ECU) Power supply Output to power window regulator motor Input from power window regulator motor (pulse sensor earth) Input from power window regulator motor (pulse sensor signal) Input from power window regulator motor (pulse sensor signal) SWS communication line (power window sub switch) Input from power window regulator motor (power supply to pulse sensor)
Always Always Power window relay: ON When the power windows are operating When the power windows are operating Power window relay: ON When the power windows are operating
0V 0 to 12 V (pulse signal) System voltage 0V 0 to 5 V (pulse signal) 0 to 5 V (pulse signal) 0 to 12 V (pulse signal) 5V
13, 14

54C-321
POWER WINDOW SUB SWITCH

E-14 (front), E-08 (rear: LH), E-17 (rear: RH)
1 2 3 4 5 6 7 8
AC103265 AI
Check condition
Normal condition
1 2 3 4 5 6 7 8
Earth Input from power window regulator motor Input from power window regulator motor Power supply Output to power window regulator motor SWS communication line Output to power window regulator motor Input from power window regulator motor
Always Power window relay: ON Power window relay: ON
0V System voltage 0 to 12 V (pulse signal)
NOTES
54A-1
GROUP 54A
CHASSIS ELECTRICAL
CONTENTS BATTERY. . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS. . . . . ON-VEHICLE SERVICE. . . . . . . . .
FLUID LEVEL AND SPECIFIC GRAVITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING . . . . . . . . . . . . . . . . . . . . . . BATTERY TEST . . . . . . . . . . . . . . . . . .
54A-4
54A-4 54A-4 54A-4 54A-4 54A-5
TROUBLESHOOTING . . . . . . . . . . IMMOBILIZER SYSTEM TROUBLESHOOTING . . . . . . . . . . ON-VEHICLE SERVICE . . . . . . . . .

HOW TO REGISTER ENCRYPTED CODE . . . . . . . . . . . . . . . . . . . . . . . . . . .
54A-9
54A-9 54A-22 54A-22 54A-29 54A-29 54A-30
IGNITION SWITCH . . . . . . . . . . . . .
IGNITION SWITCH* . . . . . . . . . .
GENERAL INFORMATION . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . .
54A-6
54A-6 54A-8
REMOVAL AND INSTALLATION. . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
Continued on next page
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.
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
WARNING
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative). 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, air bag module, clock spring, and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).
54A-2
COMBINATION METER ASSEMBLY . . . . . . . . . . . . . . . . 54A-31
SERVICE SPECIFICATIONS. . . . . SEALANT. . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . .
SPEEDOMETER CHECK . . . . . . . . . . . TACHOMETER CHECK . . . . . . . . . . . . FUEL TANK GAUGE UNIT CHECK . . . ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK . . . . . . . . . . . . . . 54A-31 54A-31 54A-32 54A-33 54A-53 54A-53 54A-54 54A-54 54A-56
REAR FOG LAMP . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . REAR FOG LAMP . . . . . . . . . . . . .
REMOVAL AND INSTALLATION. . . . . .
54A-63
54A-63 54A-63 54A-63 54A-63 54A-64 54A-64 54A-64
REAR FOG LAMP SWITCH . . . . . .

REMOVAL AND INSTALATION. . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
SIDE TURN-SIGNAL LAMP. . .

SPECIAL TOOL . . . . . . . . . . . . . . . SIDE TURN-SIGNAL LAMP . . . . . .
54A-65
54A-65 54A-65 54A-65
COMBINATION METER ASSEMBLY . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . .
54A-56 54A-56 54A-57 54A-58
ROOM LAMP . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . .
54A-66
54A-66
HEADLAMP . . . . . . . . . . . . . . . . 54A-58
SERVICE SPECIFICATIONS. . . . . SPECIAL TOOL . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . .
HEADLAMP AIMING . . . . . . . . . . . . . . . LUMINOUS INTENSITY MEASUREMENT . . . . . . . . . . . . . . . . . . BULB REPLACEMENT . . . . . . . . . . . . . 54A-58 54A-58 54A-59 54A-59 54A-59 54A-60 54A-60 54A-61 54A-61 54A-62 54A-62 54A-62
REAR COMBINATION LAMP .

TROUBLESHOOTING . . . . . . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . REAR COMBINATION LAMP . . . .
54A-67
54A-67 54A-67 54A-67 54A-67
HIGH-MOUNTED STOP LAMP

ON-VEHICLE SERVICE . . . . . . . . .
HIGH-MOUNTED STOP LAMP BULB REPLACEMENT <WITH REAR SHELF>
54A-68
54A-68 54A-68 54A-69 54A-69
HEADLAMP . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . .
HEADLAMP LEVELING SWITCH .

REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
HIGH-MOUNTED STOP LAMP . . .

LICENCE PLATE LAMP . . . . .

REMOVAL AND INSTALLATION .
54A-71
54A-71
Continued on next page
54A-3
HAZARD WARNING LAMP SWITCH . . . . . . . . . . . . . . . . . . . 54A-71
TROUBLESHOOTING . . . . . . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . HAZARD WARNING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-71 54A-71
CLOCK . . . . . . . . . . . . . . . . . . . . . .
54A-77 54A-77
CIGARETTE LIGHTER . . . . . .
INSPECTION . . . . . . . . . . . . . . . . .
54A-77
54A-77
SPEAKER. . . . . . . . . . . . . . . . .
54A-72 54A-72 54A-72
54A-78
54A-78
COLUMN SWITCH. . . . . . . . . . . 54A-73

SPECIAL TOOL . . . . . . . . . . . . . . . COLUMN SWITCH. . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-73 54A-73 54A-73 54A-74
ANTENNA . . . . . . . . . . . . . . . .
54A-79
54A-79
REAR WINDOW DEFOGGER .

GENERAL INFORMATION . . . . . . TROUBLESHOOTING . . . . . . . . . . ON-VEHICLE SERVICE . . . . . . . . .
PRINTED HEATER LINES CHECK . . . .
54A-79
54A-79 54A-79 54A-80 54A-80
HORN . . . . . . . . . . . . . . . . . . . . . 54A-75
REMOVAL AND INSTALLATION . HORN RELAY CONTINUITY CHECK. . . . . . . . . . . . . . . . . . . . . .
54A-75
54A-76
REAR WINDOW DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION. . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
CLOCK. . . . . . . . . . . . . . . . . . . . 54A-76
SPECIAL TOOL . . . . . . . . . . . . . . .
54A-76
54A-80 54A-80 54A-80
54A-4
SERVICE SPECIFICATIONS
CHASSIS ELECTRICAL
BATTERY
BATTERY
M1541000300209
Items Specific gravity of the battery fluid
Specification 1.220 1.290 (20C) Dt: Actually measured specific gravity t: Actually measured temperature
ON-VEHICLE SERVICE
FLUID LEVEL AND SPECIFIC GRAVITY CHECK
M1541001000438
CHARGING
M1541001100888
CAUTION If the battery fluid is below the LOWER LEVEL, the battery could explode in using. If the battery fluid is over the UPPER LEVEL, leakage could result.
1. Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks.
Thermometer Hydrometer
Battery fluid
AC504567AB
2. Use a hydrometer and thermometer to check the specific gravity of the battery fluid. Standard value: 1.220 1.290 (20C)
3. The specific gravity of the battery fluid varies with the temperature, so use the following formula to calculate the specific gravity for 20C. Use the calculated value to determine whether or not the specific gravity is satisfactory. D20 = (t 20) 0.0007 + Dt D20: Specific gravity of the battery fluid calculated for 20C Battery type Capacity (5-hour rate) Normal charging current Rapid charging current 75D23L 52 A 5.2 A 52 A
CAUTION The battery plus should be removed during charging. The battery electrolyte level may rise and overflow from the battery during charging. Explosions may occur if the battery is brought close to naked flames during charging. Be careful to avoid tasks that might produce sparks or other danger while the battery is charging. After charging is complete, replace the battery plus, pour water over the battery to rinse away any sulphuric acid, and let the battery stand to dry. Charge the battery in a well-ventilated location. Do not let the battery electrolyte temperature rise above approximately 45C (approximately 55C during rapid charging). 1. Remove the battery from the vehicle. 2. The normal charging current is a value in amperes which is 1/10th of the battery capacity. If the battery needs to be charged rapidly because of reasons such as time limitations, the maximum charging current for rapid charging is the battery capacity expressed as an ampere value.
The judgment method of a charge end

When the specific gravity of the battery electrolyte is constantly within 1.250 1.290 for a continuous period of one hour or more.
CHASSIS ELECTRICAL
BATTERY
54A-5
BATTERY TEST
BATTERY TESTING PROCEDURE
M1541001200614
(2) Turn headlamps off for two minutes to allow battery positive voltage to stabilize. (3) Disconnect the battery cables. (4) Read open circuit voltage.
Q: Is open circuit voltage 12.4 volts or more? YES : Go to Step 6. NO : Go to Step 5.
STEP 1. Check the battery cables. Remove the negative cable, then the positive cable. Check for dirty or corroded connections.
Q: Are the battery cables dirty or have corroded connections? YES : Clean the battery cables. Then go to Step 2. NO : Go to Step 2.
STEP 5. Charge battery.

Q: Charging the battery? YES : Go to Step 6. NO : Charge the battery at 5 amps for 15 hours.
STEP 2. Check the battery post. Check for loose battery post.
Q: Are the battery post faulty? YES : Replace the battery. Then go to Step 4. NO : Go to Step 3.
Then re-test, go to Step 4. STEP 6. 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? NO : Replace the battery. Then go to Step 4. YES : The battery is normal.
STEP 3. Check the battery case and cover. (1) Remove the hold-downs and shields. (2) Check for broken/cracked case or cover.
Q: Is the battery case or cover faulty? YES : Replace the battery. Then go to Step 4. NO : Go to Step 4.
STEP 4. Check the open circuit voltage. (1) Turn headlamps on for 15 seconds. LOAD TEST RATE CHART Battery type
75D23L
Charging time when fully discharged h (5-amp. rated 11 current charging) Load test (Amps) 260
LOAD TEST CHART Temperature C 21 and above Minimum voltage 9.6
16 9.5
10 9.4
4 9.3
1 9.1
7 8.9
12 8.7
18 8.5
54A-6
GENERAL INFORMATION
CHASSIS ELECTRICAL
IGNITION SWITCH
IGNITION SWITCH
M1543009901672
IGNITION KEY REMINDER BUZZER

The ignition key reminder buzzer will sound under the following condition, and warn the driver to remove the ignition key. The driver's door is opened when the ignition switch is at "LOCK" (OFF) or "ACC" position without removing the ignition key. However, the lamp reminder buzzer will take precedence over this function.
tion to activate the immobilizer system. If the requirements for starting the engine are not satisfied, the engine will be immobilized. If a registered ignition key is lost, all your ignition keys need to be registered again using M.U.T.-II/III to ensure security (Refer to P.54A-22). An additional ignition key can be registered as follows (only if no ignition keys are lost): Using M.U.T.-II/III (Refer to P.54A-22).
OPERATION
1. When the ignition switch is turned to "ON" position, the engine-ECU sends a requirement for the encrypted code to the immobilizer-ECU (at this time, the engine is remobilised). 2. When the immobilizer-ECU receives the requirement from the engine-ECU, the immobilizer-ECU supplies power to the transponder inside the ignition key via the antenna. The energized transponder sends the encrypted code back to the immobilizer-ECU via the antenna. 3. The immobilizer-ECU judges the encrypted code with its code logic in itself. If they are identical, the immobilizer-ECU sends the encrypted code to the engine-ECU. 4. If the engine-ECU can not receive the encrypted code, the engine will be immobilized.
DOOR LOCK PREVENTION FUNCTION

If the key is left in the ignition switch while the drivers door opened or the assistant door opened, all door are automatically unlock to prevent locking the ignition key in the vehicle after door is locked.
IMMOBILIZER SYSTEM
The immobilizer system consists of the ignition key with a transponder, the immobilizer-ECU, and the engine-ECU. Only the registered ignition key permits the engine to start, therefore, the engine can never be started by means of a forged key or by connecting the ignition wiring directly. The system is significantly safe and reliable against theft. In addition, the driver has only to turn the ignition switch to the "ON" posi-
Immobilizer-ECU with an antenna Ignition key Encrypted code Power (Wireless) CPU Control signal
Engine-ECU Injector CPU Ignition Memory
Transponder Encrypted code (Wireless) Steering lock M.U.T.-II/III
AC304482AC
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-7
Encrypted code registration criteria table

The ignition key contains a transponder (small transmitter), which retains an unique encrypted code. Under any of the conditions below, the encrypted code should be registered in the immobilizer-ECU again. The immobilizer-ECU can retain maximum eight different encrypted codes. This means that maximum eight ignition keys can be registered. Component to be replaced Engine-ECU Immobilizer-ECU Ignition key When engine-ECU is replaced When engine-ECU is overwritten* When immobilizer-ECU is replace When ignition key is added Should not be replaced Should not be replaced Should be replaced Should not be replaced Should be replaced All ignition keys should be registered Should not be replaced Should not be registered again Should not be replaced All ignition keys should be registered again Should not be replaced Additional ignition key should be registered All ignition keys should be registered again All the ignition keys other than the lost one should be registered again
When ignition key is lost
Should not be replaced
Should not be replaced
NOTE: *: When the engine-ECU other than immobilizer system is rewritten, it is not necessary to register the ignition key again.
54A-8
SPECIAL TOOLS
CHASSIS ELECTRICAL
IGNITION SWITCH
M1543000603034
Tool
Number MB991502
Name M.U.T.-II sub assembly
Use Immobilizer system check Encrypted code registration
B991502
MB991824
MB991827
DO NOT USE
MB991910
MB991911
M.U.T.-III sub-assembly A: Vehicle Communication Interface (V. C. I.) B: M.U.T.-III USB cable C: M.U.T.-III Main harness A (Vehicles with CAN communication system) D: M.U.T.-III Main harness B (Vehicles without CAN communication system) E: M.U.T.-III Measurement adapter F: M.U.T.-III Trigger harness
Immobilizer system check Encrypted code registration
MB991825
MB991826 MB991955
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-9
Use Making voltage and resistance measurements during troubleshooting A: Connect pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
Tool
A
Number MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Name Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe
DO NOT USE
MB991223 AZ
MB992006
Extra fine probe
MB992006
TROUBLESHOOTING
IGNITION KEY REMINDER BUZZER AND DOOR LOCK PREVENTION FUNCTION TROUBLESHOOTING
The ignition key reminder buzzers are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, Troubleshooting P.54B-33. Using SWS monitor: GROUP 54C, Troubleshooting P.54C-20. Diagnosis code No. 11 12 Diagnosis item
M1543000701187
IMMOBILIZER SYSTEM TROUBLESHOOTING

DIAGNOSIS CODE CHART
M1543007100514
CAUTION During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) disconnected. On completion, confirm all systems for diagnosis code code(s). If diagnosis code code(s) are set, erase them all. Use the following chart to develop proper diagnostic strategy.
Reference page P.54A-10. P.54A-11.
Transponder communication system or radio interference of encrypted code Encrypted codes are not the same or are not registered
54A-10
DIAGNOSTIC TROUBLE CODE PROCEDURES
CHASSIS ELECTRICAL
IGNITION SWITCH
Code No.11: Transponder Communication System or Radio Interference of Encrypted Code
Ignition Key Ring and Immobilizer-ECU Circuit IMMOBILIZER-ECU
HIGH-FREQUENCY CIRCUIT
IGNITION KEY
TRANSPONDER
ENCRYPTED CODE
IGNITION KEY RING ANTENNA
AC504325AB
DIAGNOSIS CODE SET CONDITION

Diagnosis code No.11 may be set if other ignition keys are in the vicinity of the vehicle as it is being started. The transponders encrypted code is not sent to the immobilizer-ECU immediately after the ignition switch is turned to "ON" position. NOTE: Diagnosis code No.11 is always set together with MPI system diagnosis code No.P0513.
DIAGNOSIS PROCEDURE
STEP 1. Check for presence of other key near the key in the ignition.
Q: Is there any other key near the key in the ignition? YES : Move the other key well away from key
being used. Retest the system.

NO : Go to Step 2.
Radio interference of the encrypted code. Malfunction of the transponder. Malfunction of the immobilizer-ECU.
STEP 2. Check that the engine start using the spare ignition key which encrypted code has been registered.
Q: Does the engine start using the spare ignition key for which the encrypted code has been registered? YES : Replace the ignition key that does not work.
Then register the password (secret code) and encrypted code P.54A-22. Retest the system. NO : Go to Step 3.
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-11
STEP 3. Check whether the diagnosis code is reset.

Q: Which diagnosis code is set, code No.11 or 12 the encrypted code has been registered? Code No.12 is set : Refer to P.54A-11. Code No.11 is set : Go to Step 4.
STEP 4. Connector check: Immobilizer-ECU connector C-207-1.

Connector: C-207-1 <L.H. drive vehicles>
Harness side
AC310479AH
Connector: C-207-1 <R.H. drive vehicles>
Harness side
AC310481AH
Code No.12: Encrypted Codes are not the same or are not Registered
DIAGNOSIS CODE SET CONDITION

The encrypted code sent by the transponder is not the same encrypted code which is registered in the immobilizer-ECU. NOTE: Diagnosis code No.12 is always output together with MPI system diagnosis code No.P0513.
Malfunction of immobilizer-ECU.
DIAGNOSIS PROCEDURE
Was the encrypted code registered? YES : Replace the immobilizer-ECU and then
The encrypted code in the ignition key has not been properly registered.
re-register the encrypted code (Refer to P.54A-22). NO : Register the encrypted code (Refer to P.54A-22).
SYMPTOM CHART
M1543007201279
Symptom Communication with M.U.T.-II/III is impossible. The ignition key cannot be registered. Engine does not start (cranking but no initial combustion).
Inspection procedure No. 1 2 3
Reference page P.54A-12 P.54A-20 P.54A-20
54A-12
SYMPTOM PROCEDURES
CHASSIS ELECTRICAL
IGNITION SWITCH
INSPECTION PROCEDURE 1: Communication with M.U.T.-II/III is Impossible.
Immobilizer-ECU Power Source, Earth and Engine-ECU Communication Line Circuit ENGINE CONTROL RELAY
ENGINE-ECU
L.H. drive vehicles
R.H. drive vehicles
POWER SOURCE
IMMOBILIZERECU
L.H. drive vehicles
R.H. drive vehicles
AC504327AB
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-13
TECHNICAL DESCRIPTION (COMMENT)

This malfunction may be caused by a defective immobilizer-ECU, engine-ECU, or a defect in the communication line between the immobilizer-ECU and engine-ECU. If this malfunction appears when the MPI system and M.U.T.-II/III can communicate each other, MPI system diagnosis code No.P0513 will reset. If the MPI system is normal, the engine control relay can be determined as normal. In addition, if the MPI system and M.U.T.-II/III can communicate each other, the circuits between the diagnosis connector and the engine-ECU can determined as normal. NOTE: If this malfunction appears, MPI system diagnosis code No.P0513 will be set.
STEP 2. Voltage measurement at immobilizer-ECU connector C-207-1.

Harness side
AC310479AH
Malfunction of the immobilizer-ECU. Malfunction of the engine-ECU. The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector.
Harness side
AC310481AH
DIAGNOSIS PROCEDURE
STEP 1. Check if M.U.T.-II/III can communicate with the MPI system and if an MPI system diagnosis code other than P0513 is set.
Q: Can M.U.T.-II/III communicate with the MPI system? Is an MPI system diagnosis code other than P0513 set? YES : Go to Step 2. NO : Refer to GROUP 13A, Troubleshooting
(1) Disconnect immobilizer-ECU connector C-207-1. (2) Turn the ignition switch to the "ON" position.
Connector C-207-1 (Harness side)
P.13A-17.
AC304844AC
(3) Measure the voltage between terminal 1 and earth. OK: System voltage
54A-14
CHASSIS ELECTRICAL
IGNITION SWITCH Q: Are immobilizer-ECU connector C-207-1 and engine control relay connector B-12X in good condition? YES : Go to Step 4. NO : Repair or replace the damaged
STEP 3. Connector check: Immobilizer-ECU connector C-207-1 and engine control relay connector B-12X
component(s). Confirm that M.U.T.-II/III communicates normally.
Harness side
AC310479AH
Harness side
AC310481AH
Connector: B-12X
Harness side
AC310439AD
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-15
STEP 4. Check the harness wires between immobilizer-ECU connector C-207-1 (terminal 1) and engine control relay connector B-12X (terminal 4).
Connectors: C-21, C-105, C-123 <L.H. drive vehicles> C-21
C-123(GR) Harness side
C-105
C-21
AC310479AH
C-105
Connector: C-207-1 <R.H. drive vehicles> C-123 Harness side

AC310447AT
Connectors: C-105, C-124 <R.H. drive vehicles>

AC310481AH
Connector: B-12X C-124
Harness side
C-105
C-105
AC310439AD
C-124
AC310455AK
NOTE: Prior to the wiring harness inspection, check intermediate connector C-123 <LH drive vehicles>, C-124 <RH drive vehicles>, joint connector C-21 and C-105 <LH drive vehicles>, C-105 <RH drive vehicles> and key reminder switch connector C-207, and repair if necessary.
54A-16
CHASSIS ELECTRICAL
IGNITION SWITCH
Q: Are the harness wires between immobilizer-ECU connector C-207-1 (terminal 1) and engine control relay connector B-12X (terminal 4) in good condition? YES : There is no action to be taken. NO : Replace damaged component(s). Confirm
STEP 6. Connector check: immobilizer-ECU connector C-207-1

that M.U.T.-II/III communicates normally. STEP 5. Resistance measurement at immobilizer-ECU connector C-207-1.
AC310479AH
Harness side
Connector: C-207-1 <R.H. drive vehicles> Harness side Harness side
AC310479AH

AC310481AH
Harness side
Q: Is immobilizer-ECU connector C-207-1 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged

AC310481AH
(1) Disconnect immobilizer-ECU connector C-207-1.

Connector 207-1 (Harness side)
AC304851AC
(2) Measure the resistance between terminal 4 and earth. OK: 2 ohms or less
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-17
STEP 7. Check the harness wire between immobilizer-ECU connector C-207-1 (terminal 4) and earth.
Connector: C-06 <L.H. drive vehicles> C-06(GR)
Harness side
Harness side
AC310452AX
Connector: C-207 <L.H. drive vehicles>

AC310479AH
Connector: C-207-1 <R.H. drive vehicles> Harness side Harness side
AC310479 AI
Connector: C-207 <R.H. drive vehicles>

AC310481AH
Harness side
AC310481AI
NOTE: Prior to the wiring harness inspection, check joint connector C-06 <LH drive vehicles>, key reminder switch connector C-207, and repair if necessary.
Q: Is the harness wire between immobilizer-ECU connector C-207-1 (terminal 4) and earth in good condition? YES : There is no action to be taken. NO : Repair or replace the damaged
54A-18
CHASSIS ELECTRICAL
IGNITION SWITCH Q: Are immobilizer-ECU connector C-207-1 and engine-ECU connector C-117 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged
STEP 8. Connector check: immobilizer-ECU connector C-207-1 and engine-ECU connector C-117

JAE 74 73 72 71 77 76 75 90 89 88 87 86 85 8483 82 8180 7978 100 99 9897 96 95 94 93 92 91
AC504357AB

JAE 74 73 72 71 77 76 75 90 89 88 87 86 85 8483 82 8180 7978 100 99 9897 96 95 94 93 92 91
AC504359AB
Harness side
AC310479AH
Harness side
AC310481AH
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-19
STEP 9. Check the harness wires between immobilizer-ECU connector C-207-1 (terminal 3) and engine-ECU connector C-117 (terminal 98).
Harness side C-117(GR) Harness side

JAE 74 73 72 71 77 76 75 90 89 88 87 86 85 8483 82 8180 7978 100 99 9897 96 95 94 93 92 91
AC310446BE
AC504357AB
Harness side C-117(GR) Harness side

JAE 74 73 72 71 77 76 75 90 89 88 87 86 85 8483 82 8180 7978 100 99 9897 96 95 94 93 92 91
AC310454BM

AC504359AB
Connector: C-207-1 <L.H. drive vehicles> Harness side
Harness side
AC310479 AI

AC310479AH
Harness side
Harness side
AC310481AI
AC310481AH
NOTE: Prior to the wiring harness inspection, check key reminder switch connector C-207, intermediate connector C-124, and repair if necessary.
Q: Are the harness wires between immobilizer-ECU connector C-207-1 (terminal 3) and engine-ECU connector C-117 (terminal 98) in good condition? YES : Go to Step 10. NO : Repair or replace the damaged
54A-20
STEP 10. Replace the immobilizer-ECU or engine-ECU. Replace the immobilizer-ECU.
CHASSIS ELECTRICAL
IGNITION SWITCH
STEP 11. Recheck for malfunction.

Q: Is a malfunction eliminated? YES : The procedure is complete. If no
Q: Did the communication with M.U.T.-II/III become possible after replacing the immobilizer-ECU? YES : Register the password (secret code) and
encrypted code P.54A-22. Confirm that M.U.T.-II/III communicates normally NO : Go to Step 11.
malfunctions are found in all steps, an intermittent malfunction is suspected (Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope with Intermittent Malfunction P.00-5). NO : Replace the engine-ECU.
INSPECTION PROCEDURE 2: The Ignition Key cannot be Registered.

The ignition key transponder or the immobilizer-ECU is suspected to be defective.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code.
Q: Does diagnosis code No.11 reset? YES : Refer to P.54A-9. NO : Replace the ignition key that cannot be
Malfunction of the ignition key Malfunction of immobilizer-ECU
registered. Then re-register the encrypted code. (Refer to P.54A-22). Verify that the ignition key can be registered, then Go to Step 2. STEP 2. Retest the system.
Q: Does registered ignition key function properly? YES : The procedure is complete. NO : Replace the immobilizer-ECU.
INSPECTION PROCEDURE 3: Engine does not Start (Cranking but no Initial Combustion).

If the fuel injectors are not operating, there might be a problem with the MPI system in addition to a malfunction of the immobilizer system. It is normal for this to occur if an attempt is made to start the engine using a key that has not been properly registered.
DIAGNOSIS PROCEDURE
STEP 1. Check the system voltage. Measure the system voltage during cranking.
Q: Is the voltage 8 volts or more? YES : Go to Step 2. NO : Check the battery. Refer to P.54A-4. The
Malfunction of MPI system Malfunction of immobilizer-ECU
engine should start.
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-21
STEP 2. Check the immobilizer system diagnosis code and MPI system diagnosis code.
Q: Which diagnosis code resets, the immobilizer system diagnosis code or the MPI system diagnosis code? Immobilizer system diagnosis code is set : Refer
STEP 4. Retest the system

Q: Is the malfunction eliminated? YES : The procedure is complete. If no
to P.54A-9.
MPI system diagnosis code is set : Refer to
GROUP 13A, Troubleshooting P.13A-17.

No diagnosis code is set : Go to Step 3.
malfunction are not found in all steps, an intermittent malfunction is suspected (Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points-How to Cope with Intermittent Malfunction P.00-5). NO : Replace the immobilizer-ECU.
STEP 3. Check the starting system.

Q: Does the engine start? YES : Go to Step 4. NO : Refer to GROUP 13A, Troubleshooting
Symptom Chart P.13A-233. If the malfunction is not resolved, replace the immobilizer-ECU. Then register the password (secret code) and encrypted code. (Refer to P.54A-22). The engine should start.
DATA LIST REFERENCE TABLE

M1543007300314
Item No. 01
Inspection item Key has been registered
Inspection requirement
Normal condition Number of registered ignition keys
CHECK IMMOBILIZER-ECU
M1543007600564
TERMINAL VOLTAGE CHECK TABLE
AC304799
Terminal No. 1
Signal Immobilizer-ECU power supply
Inspection condition Ignition switch: "LOCK" (OFF) Ignition switch: "ON" Always
Terminal voltage 0V System voltage 0V
2 3 4
Engine-ECU Immobilizer-ECU earth
54A-22
ON-VEHICLE SERVICE
CHASSIS ELECTRICAL
IGNITION SWITCH
Registration with the M.U.T.-II

M1543008100528
HOW TO REGISTER ENCRYPTED CODE

CAUTION Because registering the encrypted codes is done after all previously-registered codes have been erased, you should keep all of the ignition keys that have already been registered accessible. If the ignition key, immobilizer-ECU, engine-ECU is replaced or an ignition key is added, encrypted codes of all the ignition keys must be registered. (A maximum of eight different ignition key can be registered). Moreover, when the immobilizer-ECU has been replaced, you will need to use M.U.T.-II/III to register the immobilizer-ECU and input the vehicle secret code and to register the password (secret code) that the owner specifies into the immobilizer-ECU. If an attempt is made to start the engine with an unregistered ignition key, cranking occurs, but fuel supply is cut off to disable the engine. In approximately. NOTE: Engine-ECU has an encrypted code for immobilizer-ECU, and the encrypted code is registered in the immobilizer-ECU and ignition key.
CAUTION To prevent damage to M.U.T.-II, always turn the ignition switch to "LOCK" (OFF) position before connecting or disconnecting M.U.T.-II. NOTE: . Using the key ID register function will cause all key IDs that have been previously registered in the immobilizer-ECU to be erased. All keys need to be registered. Those which have been registered before should be on hand before using this function. If registering more than one key, do not disconnect M.U.T.-II halfway through the registration process. After registering key IDs, check that the engine can be started using all of the keys that have been registered. If the engine will not start, refer to Immobilizer System Diagnosis P.54A-6.
<Using the M.U.T.-II> Steering shaft
POINTS TO NOTE DURING OPERATION

If none of the functions can be used, check the diagnosis codes, and after carrying out any necessary repairs, repeat the operation. If an incorrect password is input ten times in a row, the immobilizer-ECU judges that an unauthorized operation is being attempted. Start-prevention mode will be set, and engine operation will stop and all special functions will be disabled. If the ignition switch is turned to "ON" position, "Unauthorized operation, start- prevention mode" will be cancelled.
MB991502
AC304777AB
1. Connect M.U.T.-II to diagnosis connector (16pin). 2. Turn the ignition switch to "ON" position.
KEY ID (ENCRYPTED CODE) REGISTRATION <M.U.T.-II>

All ignition keys can be registered with M.U.T.-II. Additional ignition keys can be registered with M.U.T.-II. 3. At "System Select," press "YES"
AC000522AD
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-23
AC000523AC
ACX01626 AC
4. Select "Immobilizer," press "YES".
7. Input the password. Use the "UP" and "DOWN" keys to change the current password digit to a value between 0 and 9. Use the "LEFT" and "RIGHT" keys to move to a different password digit. Press the "YES" key to accept the password. If an incorrect password is input five times in a row, this screen is displayed and the immobilizer-ECU switches to unauthorized operation, start-prevention mode. NOTE: Four separate digits must be input to make up the password.
AC000530AC
5. Select "Special Func", press "YES". If diagnosis code No.11 exists, "Can't execute" will be displayed. Check for diagnosis code No.11(Refer to P.54A-9).
ACX01561 AD
8. Press the "YES" key to start key ID registration.
AC000518AC
ACX01562 AC
ACX01558 AG
6. Select "key ID register", press "YES".
9. This will be displayed when the key ID registration is successful. If an error occurs during key ID registration, the message "Can't execute" will be displayed. If the key has already been registered, "Key ID has been registered" will be displayed.
54A-24
CHASSIS ELECTRICAL
IGNITION SWITCH
ACX01563 AC
MB991502
AC304777AB
10.The number of keys currently registered will be displayed. To register an additional key, replace the ignition key with the next key to be registered within five seconds and then press the "YES" key. Key ID registration screen will be displayed, then register another key. If key ID registration is complete, press the "NO" key. NOTE: A maximum of eight different keys can be registered. 11.This completes the registration operation. Turn the ignition switch "LOCK" (OFF) and leave it off for approximately ten seconds. 12.Check that the engine can be started with each of the ignition keys. 13.Check that the immobilizer system diagnosis code and MPI system diagnosis code did not set. 14.Turn the ignition switch to "LOCK" (OFF) position. 15.Disconnect M.U.T.-II.
1. Connect M.U.T.-II (MB991502) to the 16-pin diagnosis connector. 2. Turn the ignition switch to "ON" position.
AC000522AD
3. At "System Select," press "YES"
Registration of additional keys with the M.U.T.-II

Additional key(s) can be registered with the M.U.T.-II while keeping all existing key data.
AC000523AC
CAUTION To prevent damage to M.U.T.-II, always turn the ignition switch to "LOCK" (OFF) position before connecting or disconnecting M.U.T.-II. NOTE: To register additional keys with the M.U.T.-II, no registered keys must be lost.
4. Select "Immobilizer," press "YES".
AC000530AC
5. Select "Special Func", press "YES". If diagnosis code No.11 exists, "Can't execute" will be displayed. Check for diagnosis code No.11(Refer to P.54A-9).
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-25
AC000518AC
9. The number of keys currently registered will be displayed. To register an additional key, replace the ignition key with the next key to be registered within five seconds and then press the "YES" key. Key ID registration screen will be displayed, then register another key. NOTE: A maximum of eight different keys can be registered. If key ID registration is complete, press the "NO" key. 10.This completes the registration operation. Turn the ignition switch "LOCK" (OFF) and leave it off for approximately ten seconds. 11.Check that the engine can be started with each of the ignition keys. 12.Check that the immobilizer system diagnosis code and MPI system diagnosis code did not set. 13.Turn the ignition switch to "LOCK" (OFF) position. 14.Disconnect M.U.T.-II.
AC101478 AB
6. Select "Add key ID reg", press "YES".
KEY ID (ENCRYPTED CODE) REGISTRATION <M.U.T.-III>

All ignition keys can be registered with M.U.T.-III. Additional ignition keys can be registered with M.U.T.-III.
Registration with the M.U.T.-III

CAUTION To prevent damage to M.U.T.-III, always turn the ignition switch to "LOCK" (OFF) position before connecting or disconnecting M.U.T.-III. NOTE: . Before registration, check that no diagnosis code is set. If a diagnosis code is set, resolve the problem beforehand. Using the key ID register function will cause all key IDs that have been previously registered in the immobilizer-ECU to be erased. All keys need to be registered. Those which have been registered before should be on hand before using this function. If registering more than one key, do not disconnect M.U.T.-III halfway through the registration process. After registering key IDs, check that the engine can be started using all of the keys that have been registered. If the engine will not start, refer to Immobilizer System Diagnosis P.54A-6.
AC101477AB
7. Press the "YES" key to start key ID registration. 8. This will be displayed when the add key ID registration is successful. If an error occurs during key ID registration, the message "Can't execute" will be displayed. If the key has already been registered, "Key ID has been registered" will be displayed.
AC101476 AB
54A-26
<Using the M.U.T.-III>
CHASSIS ELECTRICAL
IGNITION SWITCH
IMMOBILIZER IMMOBILIZER
Self-diagnosis Simulated Vehicle Speed Out Resistor
POWERTRAIN
Check Chart For Problem Sy Data List Voltmeter
Special Function
AC305176
16-PIN MB991824
MB991911
5. Choose "Special Function" from "IMMOBILIZER" screen.

POWERTRAIN IMMOBILIZER
Special Function Special Function

Additional Key Registration
Key ID registration
MB991827
AC210056AF
1. Connect the M.U.T.-III to the diagnosis connector (16-pin). 2. Turn the ignition switch to "ON" position.
Function Select Menu Menu
AC305177
6. Choose "Key registration" from "Special Function" screen.

Special Function Key registration 7 4 8 5 2 9 6 3
System select
Special function
CAN bus diagnosis
Maintenance
1 0
Back Clear Space
AC209666AD
3. Select "System select" from the start-up screen.

POWER TRAIN System Select Menu CHASSIS BODY
AC207300AD
MPI/GDI/DIESEL ELC-A/T/CVT
TCL/STARLTY CONTROL
IMMOBILIZER SS4II
AUTO CRUISE
7. Enter the vehicles password (secret code) on the "Key registration" screen, and then click the check mark icon. Follow the prompts on the screen to insert key(s) into the ignition switch to begin key registration.
Special Function Key registration
IMMOBILIZER-ECU registration Progress AC305175 In-Complete
4. Choose "IMMOBILIZER" from the "POWER TRAIN" tab.

AC207302
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-27
8. If the key ID was registered successfully, "Progress" indication will turn active (gray). Then the registration process completes. If the key ID failed to be registered, "In-Complete" indication will turn active (gray). 9. The number of keys currently registered will be displayed. To register an additional key, replace the ignition key with the next key to be registered within five seconds. Key ID registration screen will be displayed, then register another key. NOTE: A maximum of eight different keys can be registered. 10.This completes the registration operation. Turn the ignition switch "LOCK" (OFF) and leave it off for approximately ten seconds. 11.Check that the engine can be started with each of the ignition keys. 12.Check that the immobilizer system diagnosis code and MPI system diagnosis code did not set. 13.If not diagnosis code is shown, terminate the M.U.T.-III. 14.Turn the ignition switch to "LOCK" (OFF) position. 15.Disconnect M.U.T.-III.
16-PIN MB991824
MB991911
MB991827
AC210056AF
Registration of additional keys with the M.U.T.-III

Additional key(s) can be registered with the M.U.T.-III while keeping all existing key data.
CAUTION To prevent damage to M.U.T.-III, always turn the ignition switch to "LOCK" (OFF) position before connecting or disconnecting M.U.T.-III. NOTE: To register additional keys with the M.U.T.-III, no registered keys must be lost.
1. Connect M.U.T.-III to the 16-pin diagnosis connector. 2. Turn the ignition switch to "ON" position. NOTE: Before registration, check that no diagnosis code is set. If a diagnosis code is set, resolve the problem beforehand. 3. Carry out steps 3 to 6 of the sub-section "Registration with M.U.T.-III."
Special Function Special Function

Additional Key Registration
Key ID registration
AC305177
4. Choose "Transponder ID addition" from "Special Function" screen.
54A-28
CHASSIS ELECTRICAL
IGNITION SWITCH
Special Function Trasponder ID addition 7 4 1 0 8 5 2 9 6 3
Password
Back Clear Space
AC207301
5. Enter the vehicles password (secret code) on the "Transponder ID addition" screen, and then click the check mark icon.
AC207301 Special Function Trasponder ID addition

Key ID register
The number of registered key
Progre
About Additional Transponder ID SET

If register another key ID, press the OK button after inserting a new key within 5 sec and turning on IG-SW IG-SW.
AC209775
6. If an additional registration is made successfully, the screen will ask if another key is registered or not. If the third ignition key is registered, remove the key, which has been registered. Then insert the third key within five seconds, and then turn it to the ON position. 7. Register the additional ignition key according to step 6 above. The number of the registered ignition keys are shown on "The number of registered key" screen. NOTE: A maximum of eight different keys can be registered. 8. This completes the registration operation. Turn the ignition switch "LOCK" (OFF) and leave it off for approximately ten seconds. 9. Check that the engine can be started with each of the ignition keys. 10.Check that the immobilizer system diagnosis code and MPI system diagnosis code did not set. 11.If not diagnosis code is shown, terminate the M.U.T.-III. 12.Turn the ignition switch to "LOCK" (OFF) position. 13.Disconnect M.U.T.-III.
CHASSIS ELECTRICAL
IGNITION SWITCH
54A-29
IGNITION SWITCH
REMOVAL AND INSTALLATION
M1543002101084
Before removal of the air bag module, refer to GROUP 52B, SRS Service Precautions and
WARNING
Air Bag Module and Clock Spring P.52B-3. When removing and installing the steering wheel, do not let it bump against the air bag module.
3 2 4
8 7 6 5
1
AC310331AB
<<A>>
Removal steps 1. Column cover lower 2. Column cover upper 3. Steering wheel and air bag module assembly (Refer to GROUP 37, Steering wheel P.37-13). 4. Clock spring and column switch assembly (Refer to GROUP 52B, Drivers, Front Passengers Air Bag Modules and Clock Spring P.52B-110). 5. Steering lock cylinder
Removal steps (Continued) Ignition switch connector 6. Ignition switch 7. Immobilizer-ECU Key reminder switch connector 8. Key reminder switch and bulb assembly
54A-30
REMOVAL SERVICE POINT <<A>> STEERING LOCK CYLINDER REMOVAL
Locking pin
CHASSIS ELECTRICAL
IGNITION SWITCH
Switch position "LOCK" (OFF)
Tester connection
Specified condition
1 2, 1 3, 1 Open circuit 4, 1 5, 1 6, 2 3, 2 4, 2 5, 2 6, 3 4, 3 5, 3 6, 4 5, 4 6, 5 6 16 Less than 2 ohms
"ACC" "ON"
AC304831AB
1 2, 1 4, 1 Less than 2 6, 2 4, 2 6, 4 ohms 6 1 2, 1 5, 2 Less than 2 5 ohms
1. Insert the key in the steering lock cylinder and turn it to the "ACC" position. 2. Using a small Phillips head screwdriver, pull the steering lock cylinder toward you.
"START"
INSPECTION
M1544009700270
KEY REMINDER SWITCH CONTINUITY CHECK
IGNITION SWITCH CONTINUITY CHECK
AC304834AB
AC304833AB
Disconnect ignition switch connector C-208 without removing the ignition switch. Then check the continuity.
Disconnect key reminder switch connector C-207 without removing the ignition switch and key reminder switch. Then check the continuity. Status of ignition key Removed Inserted Tester connection 46 46 Specified condition Less than 2 ohms Open circuit
CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY
54A-31

M1543000300432
Item Speedometer indication tolerance km/h 20 40 80 120 160 200 Tachometer indication tolerance r/min 700 2,000 3,000 4,000 5,000 6,000 7,000 8,000 Fuel tank gauge unit (main) resistance Fuel tank gauge unit (sub) resistance Fuel gauge unit (main) float height mm Fuel gauge unit (sub) float height mm Float position F (highest) Float position E (lowest) Float position F (highest) Float position E (lowest) Float position F (A) Float position E (B) Float position F (A) Float position E (B) Engine coolant temperature gauge unit resistance Combination meter internal resistance
Standard value 20 24 40 44 80 85 121 127 162 169 203 211 120 175 + 225 175 + 300 225 + 375 225 + 425 225 + 475 200 + 500 100 + 500 21 36.4 1 21 73.6 1 33.3 2.0 121.9 2.0 5.7 2.0 141.0 2.0 104 + 13.5 (at 70C)
Engine coolant 233 3 temperature gauge to earth (terminal No. 1 21) Fuel gauge to earth (terminal No. 31 51) 181 2
SEALANT
M1543024600028
Item Engine coolant temperature gauge unit
Specified sealant 3M 1215 or equivalent
54A-32
SPECIAL TOOLS
CHASSIS ELECTRICAL
M1543000603045
Tool
Number MB990784
Name Ornament remover
Use Removal of meter bezel and Instrument panel ornament
MB990784
MB991502
M.U.T.-II sub assembly Reading MPI system diagnosis code
B991502
MB991824
MB991827
DO NOT USE
MB991910
M.U.T.-III sub-assembly A: Vehicle Communication Interface (V. C. I.) B: M.U.T.-III USB cable C: M.U.T.-III Main harness A (Vehicles with CAN communication system) D: M.U.T.-III Main harness B (Vehicles without CAN communication system) E: M.U.T.-III Measurement adapter F: M.U.T.-III Trigger harness
Reading MPI system diagnosis code
MB991911
MB991825
MB991826 MB991955
CHASSIS ELECTRICAL
54A-33
Use Making voltage and resistance measurements during troubleshooting A: Connect pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
Tool
A
Number MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Name Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe
DO NOT USE
MB991223 AZ
MB992006
Extra fine probe
MB992006
TROUBLESHOOTING
SYMPTOM CHART
M1543007201280
Symptom Speedometer does not work. Tachometer does not work. Fuel gauge does not work. Engine coolant temperature gauge does not work. Combination meters does not work.
Inspection procedure No. 1 2 3 4 5
Reference page P.54A-34 P.54A-38 P.54A-41 P.54A-45 P.54A-48
54A-34
SYMPTOM PROCEDURES
CHASSIS ELECTRICAL
INSPECTION PROCEDURE 1: Speedometer does not work.
Speedometer Circuit IGNITION SWITCH (IG1) FUSIBLE LINK 1
COMBINATION METER
SPEED
CONTROL CIRCUIT
DIAGNOSIS CONNECTOR
FRONT SIDE
NOTE : L.H. drive vehicles : R.H. drive vehicles
AC504334 AB
CHASSIS ELECTRICAL
54A-35

The cause may be a faulty vehicle speed sensor circuit system or a faulty speedometer. Vehicle speed sensor is also used by the engine-ECU.
Q: Do all other meters operate? YES <other meters all operate.> : Go to Step 2. NO <one or more of the other meters does not operate.> : Refer to INSPECTION PROCEDURE
5 P.54A-48 STEP 2. Check the vehicle speed sensor. (M.U.T.-II/III MPI diagnosis code)
Malfunction of the vehicle speed sensor Malfunction of the engine-ECU Malfunction of the combination meter assembly The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector.
DIAGNOSIS PROCEDURE
STEP 1. Check with other meter.
<Using the M.U.T.-II> Steering shaft MB991502
AC304777AB
MB991502
AC304777AB
<Using the M.U.T.-III> 16-PIN MB991824 MB991911
16-PIN MB991824
MB991911 MB991827
AC210056AF
(1) Connect M.U.T.-II/III to the diagnosis connector. (2) Turn the ignition switch to the "ON" position. (3) Read the MPI system diagnosis code.
Q: Is MPI system diagnosis code P0500 set? YES : Refer to GROUP 13A Troubleshooting
P.13A-372. NO : Go to Step 3.
MB991827
AC210056AF
Check to see that the tachometer, fuel gauge and water thermometer are operating normally.
54A-36
CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY Q: Are combination meter connector C-01 and vehicle speed sensor connector B-04 in good condition? YES : Go to Step 4. NO : Repair or replace the damage
STEP 3. Check combination meter connector C-01 and vehicle speed sensor connector B-04 for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Connector : B-04
component(s).
B-04(B)
Harness side
3 2 1
AC310439AG
Harness side
AC310446BF
Harness side
AC310456 AU
CHASSIS ELECTRICAL
54A-37
STEP 4. Check the wiring harness between combination meter connector C-01 (terminal 12) and vehicle speed sensor connector B-04 (terminal 3). NOTE:
Connectors: B-04, B-27
Connectors: C-01, C-101 <R.H. drive vehicles> C-01
C-101(L)
B-04(B)
B-27(B)
Harness side C-01

212019 18 1716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-101
Harness side B-04

3 2 1
B-27
1 2 3 4 5 6 7 8
AC310457AG
Connector : C-124 <R.H. drive vehicles>
AC310440AC
Connectors: C-01, C-21, C-124 <L.H. drive vehicles> C-01 C-21

AC310454BO
C-124
Also check joint connector C-21 <LH drive vehicles> or C-101 <RH drive vehicles>, intermediate connector B-27 and C-124 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If joint connector C-21 <LH drive vehicles> or C-101 <RH drive vehicles>, intermediate connector B-27 or C-124 are damaged, repair or replace the connector.
Q: Is the wiring harness between combination meter connector C-01 (terminal 12) and vehicle speed sensor connector B-04 (terminal 3) in good condition? YES : Replace the combination meter. The
C-01
Harness side
212019 18 1716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-21
1 2 3 4 5 6 7 8 9 10 11 12 13
C-124
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25
speedometer should work normally.

NO : Repair the wiring harness. The
speedometer should work normally.

AC310447AU
54A-38
CHASSIS ELECTRICAL
INSPECTION PROCEDURE 2: Tachometer does not work.
Tachometer Circuit
TACHO
COMBINATION METER
CONTROL CIRCUIT
ENGINE-ECU ENGINE SPEED DETECTION CONNECTOR

SB : Sky blue
AC504348 AB

Ignition signal may not be received from the engine-ECU, or the combination meter assembly, the wiring harness, or the connector(s) may be defective.
DIAGNOSIS PROCEDURE
STEP 1. Check the other meters. Check to see that the speedometer, fuel gauge and water thermometer are operating normally.
Q: Do all other meters operate? Yes <other meters all operate> : Go to Step 2. NO <one of the meters do not operate.> : Refer to
Malfunction of the combination meter assembly Malfunction of the engine-ECU The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector.
INSPECTION PROCEDURE 5 P.54A-48.
CHASSIS ELECTRICAL
54A-39
STEP 2. M.U.T.-II/III MPI diagnosis code is reset.

STEP 3. Check combination meter connector C-01 and engine-ECU connector C-119 for loose, corroded or damaged terminals, or terminals pushed back in the connector.
MB991502
AC304777AB
Harness side <Using the M.U.T.-III>

AC310446BF
16-PIN MB991824
MB991911
Harness side
AC310456 AU
C-119(GR) MB991827
AC210056AF
Harness side
JAE 47 46 45 44 43 42 41 59 58 57 56 55 545352 5150 49 48 68 67 66 65 64 6362 6160
(1) Connect M.U.T.-II/III to the diagnosis connector. (2) Turn the ignition switch to the "ON" position. (3) Read the MPI system diagnosis code.
Q: Is MPI system diagnosis code P0500 set? YES : Refer to GROUP 13A Troubleshooting
AC504357AC
P.13A-372.
NO : Go to Step 3.
C-119(GR)
Harness side
JAE 47 46 45 44 43 42 41 59 58 57 56 55 545352 5150 49 48 66 65 64 6362 6160 68 67
AC504359AC
Q: Are combination meter connector C-01 and engine-ECU connector C-119 in good condition? YES : Go to Step 4. NO : Repair or replace the damage
component(s). The speedometer should work normally.
54A-40
CHASSIS ELECTRICAL
Connectors: C-105, C-119, C-122 <R.H. drive vehicles>
STEP 4. Check the wiring harness between combination meter connector C-01 (terminal 11) and engine-ECU connector C-119 (terminal 45). NOTE:
Connectors: C-01, C-105, C-123 <L.H. drive vehicles> C-01
C-119(GR)
C-105
C-122(L) C-105 C-123(GR) Harness side

JAE 47 46 45 44 43 42 41 59 58 57 56 55 545352 5150 49 48 68 67 66 65 64 6362 6160
C-105
C-123
AC504366 AB
AC310447AV
Also check joint connector C-105 and intermediate connector C-123 <LH drive vehicles> or C-122 <RH drive vehicles> for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If joint connector C-105 or intermediate connector C-123 <LH drive vehicles> or C-122 <RH drive vehicles> are damaged, repair or replace the connector.
Q: Are the wiring harness between combination meter connector C-01 (terminal 11) and engine-ECU connector C-119 (terminal 45) in good condition? YES : Go to Step 5. NO : Repair the wiring harness. The

JAE 47 46 45 44 43 42 41 59 58 57 56 55 545352 5150 49 48 68 67 66 65 64 6362 6160
AC504357AC
speedometer should work normally. STEP 5. Replace the combination meter and check operation.
Q: Does the tachometer operate? YES : There is no action to be taken. NO : Repair the engine-ECU. The tachometer
should work normally.

Harness side
AC310456 AU
CHASSIS ELECTRICAL
54A-41
INSPECTION PROCEDURE 3: Fuel gauge does not work.
Fuel Gauge Circuit COMBINATION METER
F/GA
CONTROL CIRCUIT
L.H. drive vehicles
R.H. drive vehicles
FUEL GAUGE UNIT (SUB)
FUEL PUMP AND GAUGE UNIT (MAIN)
SB : Sky blue
AC504369AB

If only the fuel gauge does not operate, fuel gauge unit the combination meter, wiring harness or connector(s) may be defective.
54A-42
CHASSIS ELECTRICAL
Malfunction of the fuel gauge unit. The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector. Malfunction of the combination meter.
STEP 3. Check the fuel gauge unit (sub) and fuel gauge unit (main). Check to see that the fuel gauge unit (sub) and fuel gauge unit (main) are normal. Refer to P.54A-54.
Q: Are fuel gauge unit (sub) and fuel gauge unit (main) normal? Yes : Go to Step 4. NO : Replace fuel gauge unit (sub) and fuel
DIAGNOSIS PROCEDURE
STEP 1. Check the other meters. Check to see that the speedometer, fuel gauge and water thermometer operate normally.
Q: Do all other meters operate? Yes <other meters all operate> : Go to Step 2. NO <one or more of the other meters does not operate.> : Refer to P.54A-48.
gauge unit (main). The fuel gauge should work normally. STEP 4. Check the earth circuit to the fuel gauge unit (main). Resistance measurement at fuel gauge unit (main) connector D-12.
Connector: D-12
STEP 2. Check fuel gauge unit (sub) connector D-10 and fuel gauge umit (main) connector D-12 for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Connectors: D-10, D-12 D-10 Harness side
Harness side D-12(GR)
AC310465AL
D-10 D-12(GR) D-12 Harness side
(1) Disconnect fuel gauge unit (main) connector D-12 and measure the resistance available at the wiring harness side of the connector.
AC310465AK
Q: Are fuel gauge unit (sub) connector D-10 and fuel gauge unit (main) connector D-12 in good condition? YES : Go to Step 3. NO : Repair or replace the damage
3 2 1 5 4
component(s). The fuel gauge should work normally.
Connector D-12 (Harness side)

AC211567AC
(2) Measure the resistance value between terminal 1 and earth. OK: 2 ohms or less
CHASSIS ELECTRICAL
54A-43
STEP 5. Check the wiring harness between fuel gauge unit (main) connector D-12 (terminal 1) and earth.
Connector: D-12
STEP 6. Check combination meter connector C-02 for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Connector : C-02 <L.H. drive vehicles> C-02(L)
Harness side D-12(GR) Harness side

AC310465AL AC310446BG
NOTE:
Connector: D-34
Connector : C-02 <R.H. drive vehicles> C-02(L)
AC310456 AV AC310463AH
Also check intermediate connector D-34 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector D-34 is damaged, repair or replace the connector.
Q: Is the wiring harness between fuel gauge unit (main) connector D-12 (terminal 1) and earth in good condition? YES : There is no action to be taken. NO : Repair the wiring harness. The fuel gauge
Q: Is combination meter connector C-02 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged
component(s). The fuel gauge should work normally.
54A-44
CHASSIS ELECTRICAL
STEP 7. Check the wiring harness between fuel gauge unit (sub) connector D-10 (terminal 1) and combination meter connector C-02 (terminal 51).
Connector: D-10
NOTE:
CONNECTOR: C-113 <L.H. drive vehicles>
Harness side
AC310452 AZ
AC310465AM
Connectors: C-23, C-112 <R.H. drive vehicles> C-23(B)
Connector : C-02 <L.H. drive vehicles>
C-02(L)

AC310446BG
C-23
Connector : C-02 <R.H. drive vehicles> C-02(L) C-112
Harness side Connector: D-34

AC310456 AV
AC310457AH
Harness side
AC310463AH
Also check intermediate connectors C-112 <RH drive vehicles>, C-113 <LH drive vehicles>, D-34 and joint connector C-23 <RH drive vehicles> for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-112 <RH drive vehicles>, C-113 <LH drive vehicles> or D-34 and joint connector C-23 <RH drive vehicles> is damaged, repair or replace the connector.
CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY Q: Is the wiring harness between fuel gauge unit (sub) connector D-10 (terminal 1) and combination meter connector C-02 (terminal 51) in good condition? YES : Go to Step 8. NO : Repair the wiring harness. The fuel gauge
54A-45
STEP 8. Check the wiring harness between fuel gauge unit (sub) connector D-10 (terminal 2) and fuel gauge unit (main) connector D-12 (terminal 2).
Connectors: D-10, D-12 D-10 Harness side D-10 D-12(GR) D-12 Harness side
AC310465AK
Q: Is the wiring harness between fuel gauge unit (sub) connector D-10 (terminal 2) and fuel gauge unit (main) connector D-12 (terminal 2) in good condition? YES : Repair or replace the combination meter.
The fuel gauge should work normally.

NO : Repair the wiring harness. The fuel gauge
INSPECTION PROCEDURE 4: Engine Coolant Temperature Gauge does not Work.
Engine Coolant Temperature Gauge Circuit T/GA COMBINATION METER
CONTROL CIRCUIT
ENGINE COOLANT TEMPERATURE GAUGE UNIT
SB : Sky blue
54A-46
CHASSIS ELECTRICAL

If only the engine coolant temperature gauge does not operate, the combination meter, the wiring harness or its connector may be defective.
STEP 3. Check the engine coolant temperature gauge unit. Check to see that the engine coolant temperature gauge unit operate normally. Refer to P.54A-56.
Q: Is the engine coolant temperature gauge unit normal? YES : Go to Step 4. NO : Replace the engine coolant temperature
Malfunction of the engine coolant temperature gauge unit The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector. Malfunction of the combination meter.
gauge unit. The engine coolant temperature gauge unit should work normally. STEP 4. Check combination meter connector C-02 for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Connector : C-02 <L.H. drive vehicles> C-02(L)
DIAGNOSIS PROCEDURE
STEP 1. Check the other meters. Check to see that the speedometer, tachometer and engine coolant temperature gauge unit operate normally.
Q: Do all other meters operate? Yes <other meters all operate> : Go to Step 2. NO <one or more of the other meters does not operate.> : Refer to P.54A-48.
Harness side
AC310446BG
STEP 2. Check engine coolant temperature gauge unit connector B-112 for loose, corroded or damaged terminals, or terminals pushed back in the connector.
Connector: B-112
Harness side
Harness side
AC310456 AV
B-112 (B)
AC310439AH
Q: Is engine coolant temperature gauge unit connector B-112 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged
component(s). The engine coolant temperature gauge unit should work normally.
component(s). The engine coolant temperature gauge unit should work normally.
CHASSIS ELECTRICAL
54A-47
STEP 5. Check the wiring harness between engine coolant temperature gauge unit connector B-112 (terminal 1) and combination meter connector C-02 (terminal 50).
Connector: B-112
Connector : C-124 <R.H. drive vehicles>
Harness side
AC310454BR
B-112 (B)
AC310439AH
NOTE: Also check intermediate connector C-124 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-124 is damaged, repair or replace the connector.
Q: Are the wiring harness between engine coolant temperature gauge unit connector B-112 (terminal 1) and combination meter connector C-02 (terminal 50) in good condition? YES : Repair or replace the combination meter.
Connectors : C-02, C-124 <L.H. drive vehicles> C-02(L)
C-124
The engine coolant temperature gauge unit should work normally. NO : Repair the wiring harness. The engine coolant temperature gauge unit should work normally.
C-02
Harness side
C-124
AC310447AW
Harness side
AC310456 AV
54A-48
CHASSIS ELECTRICAL
INSPECTION PROCEDURE 5: Combination meter does not work.
Combination Meter Power Source Circuit IGNITION SWITCH (IG1) BATTERY
RELAY BOX
L.H. drive vehicles R.H. drive vehicles
CONTROL CIRCUIT
COMBINATION METER
SB : Sky blue

The cause is thought to be malfunction of the power, earth circuitry or combination meter.
Malfunction of the combination meter Damaged wiring harness or connectors
CHASSIS ELECTRICAL
54A-49
DIAGNOSIS PROCEDURE
STEP 1. Check combination meter connector C-01 for loose, corroded or damaged terminals, or terminals pushed back in the connector.
STEP 2. Check the battery power supply circuit to the combination meter. Voltage measurement at combination meter connector C-01.
Harness side Harness side Connector: C-01 <R.H. drive vehicles>
AC310446BF
AC310446BF
AC310456 AU
AC310456 AU
(1) Disconnect combination meter connector C-01 and measure the voltage available at the wiring harness side of the connector.
component(s). If the functions, which are described in "CIRCUIT OPERATION", work normally, the input signal from the ignition switch (IG1) should be normal.
AC301541HT
Q: IS the check result normal? YES : Go to Step 4. NO : Go to Step 3.
54A-50
CHASSIS ELECTRICAL
Connectors: C-05, C-129 <R.H. drive vehicles> C-05(GR)
STEP 3. Check the wiring harness between combination meter connector C-01 (terminal 7) and battery.
Connectors: C-01, C-05, C-129 <L.H. drive vehicles> C-01 C-05(GR)
C-129 C-129
C-05
C-01 Harness side
C-129
C-05
C-129
AC310455AL
AC310447AX
NOTE: Also check intermediate connector C-129 and joint connector C-05 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-129 or joint connector C-05 is damaged, repair or replace the connector.
Q: Is the wiring harness between combination meter connector C-01 (terminal 7) and battery in good condition? YES : There is no action to be taken. NO : Repair the wiring harness. Check to see that
Harness side
all meters operate.

AC310456 AU
CHASSIS ELECTRICAL
54A-51
STEP 4. Check the ignition switch (IG1) circuit to the combination meter. Voltage measurement at combination meter connector C-01.
STEP 5. Check the wiring harness between combination meter connector C-01 (terminal 9) and ignition switch (IG1).
Connectors: C-01, C-23 <L.H. drive vehicles> C-01
C-23(B) Harness side
AC310446BF
Connector: C-01 <R.H. drive vehicles> C-01 Harness side
C-23 Harness side
AC310456 AU
(1) Disconnect combination meter connector C-01 and measure the voltage available at the wiring harness side of the connector. (2) Turn the ignition switch to the "ON" position.
AC310447AY
Harness side
AC310456 AU
AC301541HT
54A-52
NOTE:
Connectors: C-211, C-214 <L.H. drive vehicles> C-211
CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY Q: Is the wiring harness between combination meter connector C-01 (terminal 9) and ignition switch (IG1) in good condition? YES : There is no action to be taken. NO : Repair the wiring harness. Check to see that
all meters operate. STEP 6. Check the earth circuit to the combination meter. Resistance measurement at combination meter connector C-01.
Connector: C-01 <L.H. drive vehicles> Harness side C-211
C-214
Junction block (Front view)
C-214 Harness side
AC310446BF AC310449 AR
Connectors: C-211, C-214 <R.H. drive vehicles>
C-211
Harness side C-214

AC310456 AU
Junction block (Front view) Harness side C-211
(1) Disconnect combination meter connector C-01 and measure the resistance available at the wiring harness side of the connector.
C-214
Connector: C-01 (Harness side)

AC310459AR
Also check junction block connector C-211 and C-214, joint connector C-23 <LH drive vehicles> for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-211 or C-214 or joint connector C-23 <LH drive vehicles> is damaged, repair or replace the connector.
AC301541HV
CHASSIS ELECTRICAL
54A-53
Q: Is the check result normal? YES : Repair or replace the combination meter.
CAUTION Do not operate the clutch suddenly. Do not increase/decrease speed rapidly while testing.
Check to see that all meters operate.

NO : Go to Step 7.
STEP 7. Check the wiring harness between combination meter connector C-01 (terminals 1 and 2) and earth.
Wheel stopper
AC305135AB
Harness side
2. Set the vehicle onto a speedometer tester and use wheel chocks to hold the rear wheels. 3. To prevent the front wheel from moving from side to side, attach tension bars to the tie-down hook, and secure both ends to anchor plates.
Tension bar
AC310446BF
Front
Anchor plate
AC001288 AB
Harness side
AC310456 AU
Q: Are the wiring harness between combination meter connector C-01 (terminals 1 and 2) and earth in good condition? YES : There is no action to be taken. NO : Repair the wiring harness. Check to see that
4. To prevent the vehicle from moving, attach a chain or wire to the rear retraction hook, and make sure the end of the chain or wire is secured. 5. Check if the speedometer indicator range is within the standard values. Standard value: Standard indicator km/h 20 40 80 120 160 200 Allowance range km/h 20 24 40 44 80 85 121 127 162 169 203 211
all meters operate.
ON-VEHICLE SERVICE
SPEEDOMETER CHECK
M1543000900531
1. Adjust the pressure of tyres to the specified level. (Refer to GROUP 31, On-vehicle Service P.31-7).
6. If not to the standard value, inspect for proper tyre size. If not correct, replace the tyres with original size tyres and retest. If correct, replace the speedometer. If still not to standard value, replace the vehicle speed sensor.
54A-54
TACHOMETER CHECK
CHASSIS ELECTRICAL
M1543001000519
Engine speed indicator Paper clip
FUEL TANK GAUGE UNIT RESISTANCE Fuel gauge unit (main)
Earth
Fuel gauge unit
Probe for detection of engine speed
AC305138AB
1. Attach an external high quality tachometer to the engine speed detection connector on the harness side (such as with a paper clip). NOTE: For tachometer check, use an external high quality inductive tachometer. 2. Compare the readings of the vehicle tachometer and the external tachometer at every engine speed, and check if the variations are within the standard values. Standard values: Engine speed (r/min) 700 2, 000 3, 000 4, 000 5, 000 6, 000 7, 000 8, 000 Indication allowance of tachometer r/min 120 175 + 225 175 + 300 225 + 375 225 + 425 225 + 475 200 + 500 100 + 500
1 2 3 4 5
Position F
Position E
AC211789AD
1. Check that resistance value between the fuel gauge terminal and earth terminal is at the standard value when the fuel tank gauge unit float is between position "F" (highest) and position "E" (lowest). Standard values: Float Position Position F Position E Resistance of Gauge 21 36.4 1
FUEL TANK GAUGE UNIT CHECK

Remove the fuel tank gauge unit (Refer to GROUP 13B, Fuel Tank P.13B-5).
M1543001200643
2. Check that resistance value changes smoothly when the float moves slowly between position "F" (highest) and position "E" (lowest). 3. If all checks are correct, go to fuel tank gauge unit float height check. If any check is not correct, replace the fuel tank gauge unit.
Fuel gauge unit (sub)
1. Check that resistance value between the fuel gauge terminal and earth terminal is at the standard value when the fuel tank gauge unit float is between position "F" (highest) and position "E" (lowest). Standard values: Float Position Position F Position E Resistance of Gauge 21 73.6 1
;
Earth Fuel gauge unit Position F Position E
AC310332AB
CHASSIS ELECTRICAL
54A-55
FUEL TANK GAUGE UNIT FLOAT HEIGHT Fuel gauge unit (main)
A B Position F Position E Stopper
AC211788AC
1. Move the float and measure height A at position "F" (highest) and B at position "E" (lowest) with the float arm touching stopper. Standard values: Float Position Position F (A) Position E (B) Float Centre Height 33.3 2.0 mm 121.9 2.0 mm
2. If all checks are correct, go to fuel tank gauge unit float height check. If any check is not correct, replace the fuel tank gauge unit.
Fuel gauge unit (sub)

Position F A Stopper
2. Check that resistance value changes smoothly when the float moves slowly between position "F" (highest) and position "E" (lowest). 3. If all checks are correct, go to fuel tank gauge unit float height check. If any check is not correct, replace the fuel tank gauge unit.
B Position E
AC211590AD
1. Move the float and measure height A at position "F" (highest) and B at position "E" (lowest) with the float arm touching stopper. Standard values: Float Position Position F (A) Position E (B) Float Centre Height 5.7 2.0 mm 141.0 2.0 mm
2. If all checks are correct, go to fuel tank gauge unit float height check. If any check is not correct, replace the fuel tank gauge unit.
54A-56
CHASSIS ELECTRICAL
ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK

M1543001500484
Reference value Temperature C 50 60 80
Resistance 230 155 73
1. Drain the engine coolant (Refer to GROUP 14, On-vehicle Service P.14-15). 2. Remove the engine coolant temperature gauge unit.
Circuit tester
Thermometer
11 1 Nm
ACX00780AH ACX00779 AI
3. Put engine coolant temperature gauge unit into the hot water in specified temperature, and ensure that basic resistance is within standard value. Standard value: 104 13.5 (at 70C)
4. After inspection, apply specified sealant at threads of engine coolant temperature gauge unit, and tighten to the specified torque. Semi-drying sealant: 3M 1215 or equivalent 5. Add engine coolant (Refer to GROUP 14, On-vehicle Service P.14-15).

M1543021300051
4 2 3
1. Vehicle speed sensor Removal steps 2. Meter bezel 3. Instrument panel ornament 4. Combination meter assembly
AC310333AB
CHASSIS ELECTRICAL
54A-57
INSPECTION
M1543019502797
VEHICLE SPEED SENSOR CHECK
COMBINATION METER INTERNAL RESISTANCE CHECK
Turn Shaft
Resistor 3 -10 k
AC005210AC
AC305188AB
1. Remove the vehicle speed sensor and connect a 3 10 k resistor as shown in the illustration. 2. Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2 3. (1 turn = 4 pulses) 3. If within the standard value, the vehicle speed sensor is OK. If not within the standard value, replace the vehicle speed sensor. Standard value: 0 or System Voltage (1turn = 4pulses)
Use circuit tester to measure combination meter internal resistance. Standard Value: Measuring terminal No. 1-21 Terminal name Standard value () 233 3
Engine coolant temperature gauge to earth Fuel gauge to earth
31-51
181 2
54A-58
DISASSEMBLY AND REASSEMBLY
CHASSIS ELECTRICAL
HEADLAMP
M1543003100404
3 6
4 2 1 5
AC211062AC
Disassembly steps 1. Meter glass 2. Window plate 3. Circuit board cover
Disassembly steps (Continued) 4. Indicator plate 5. Bulb 6. Combination meter assembly
HEADLAMP
M1542000300473
Item Headlamp aiming Vertical direction
Standard value 0.69 below horizontal (H)
Limit 0.29 from the standard value 30,000 cd or more
Measurement of headlamp illiminous intensity cd {When a screen is set 25 m ahead of the vehicle}
SPECIAL TOOL
M1542000601165
Tool
Number MB990784
Name
Use
Ornament remover Removal of switch panel
MB990784
CHASSIS ELECTRICAL
HEADLAMP
54A-59
(1) Screen Headlamp centre line (3) Vehicle centre line
TROUBLESHOOTING
M1542000701281
Features the headlamp automatic shutdown function to avoid battery drain when the headlamps are left on. The main features are as follows: Extinguishes automatically in three minutes if the ignition switch is turned off with the lighting switch on. Extinguishes in one second if the driver's door is opened within that 3-minute period. If the headlamps are turned on with the ignition switch off, the headlamps and tail lamps will extinguish in three minutes after the driver's door is opened or closed. The headlamps are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Troubleshooting P.54B-33. Using SWS monitor: GROUP 54C, SWS Troubleshooting P.54C-20.
(2) (3) 10 m
In the centre of headlamps <low-beam>
AC211164AD
ON-VEHICLE SERVICE
HEADLAMP AIMING
M1542000900613
PRE-AIMING INSTRUCTIONS
1. Inspect for badly rusted or faulty headlamp assemblies. 2. These conditions must be corrected before a satisfactory adjustment can be made. 3. Inspect tyre inflation, and adjust if it is necessary. 4. If the fuel tank is not full, place a weight in luggage room of the vehicle to simulate weight of a full tank (0.8 kg per litre). 5. There should be no other load in the vehicle other than driver or substituted weight of approximately 75 kg placed in driver's position. 6. Thoroughly clean the headlamp lenses. 7. Place the vehicle on a level floor, perpendicular to a flat screen 10 m away from the bulb centre-marks on the headlamp lens. 8. Rock vehicle sideways to allow vehicle to assume its normal position. 9. Bounce the front suspension through three oscillations by applying the body weight to hood or bumper.
10.Four lines of adhesive tape (or equivalent markings) are required on screen or wall: (1) Position a vertical tape or mark so that it is aligned with the vehicle centre line. (2) Measure the distance from the centre-marks on the headlamp lens to the floor. Transfer the measurement to the screen. Horizontal tape or mark on the screen is for reference of vertical adjustment. NOTE: Height from the floor to the centre of the headlamps (Reference value): 840 mm (3) Measure the distance from the centre line of the vehicle to the centre of each headlamp. Transfer the measurement to the screen. Vertical tape or mark on the screen with reference to the centre line of each headlamp bulb.
HEADLAMP ADJUSTMENT
CAUTION Do not cover a headlamp for more than three minutes to prevent the plastic headlamp lens deformation. When adjusting one headlamp beam, make sure that another headlamp is off by disconnecting the connector from it. When reconnecting the connector, make sure that the headlamp beam is not disturbed accidentally. 1. The low-beam headlamp should project on the screen upper edge of the beam (cut-off).
54A-60
CHASSIS ELECTRICAL
HEADLAMP
Vertical direction
2. Using a photometer, and following its manufacturer's instruction manual, measure the headlamp centre intensity and check to be sure that the limit value is satisfied. Limit: 30,000 cd or more {When a screen is set 25m 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 headlamp 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 x r2: I = intensity (cd) E = illumination (lux) r = distance (m) from headlamps to illuminometer
AC310334AB
Vertical direction
BULB REPLACEMENT
M1542001300788
2. If not the case, turn the adjusting screws to achieve the specified low-beam cut-off location on the aiming screen.
(V) Distance of vertical direction [0.69] (H) High intensity zone
AC305155AB
HEADLAMP BULB
CAUTION Do not touch the surface of the bulb with hands or dirty gloves as the bulb may pop after a short time. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing. 1. Disconnect the battery. 2. Disconnect the connector.
Headlamp centre 15
Standard value: (Vertical direction) 0.69 below horizontal (H) Limit: Vertical direction; 0.29 from the standard value
Headlamp bulb <low-beam>
Headlamp bulb <high-beam>

AC310335AB
LUMINOUS INTENSITY MEASUREMENT

M1542001000538
1. Set the headlamps to high-beam.
3. Screw out the headlamp bulb. 4. Replace the bulb, and connect securely the connector.
CHASSIS ELECTRICAL
HEADLAMP
54A-61
POSITION LAMP BULB

CAUTION Do not touch the bulb surface bare-handed or with dirty gloves. If dirt is attached on surface of the bulb, immediately use alcohol or thinner to remove dirt, and install the bulb after well dried.
Position lamp
FRONT TURN-SIGNAL LAMP BULB

CAUTION Do not touch the bulb surface bare-handed or with dirty gloves. If dirt is attached on surface of the bulb, immediately use alcohol or thinner to remove dirt, and install the bulb after well dried.
Front turn-signal lamp

AC310336AB AC310337AB
1. Remove the splash shield. 2. Screw out the position lamp socket to pull out the position lamp bulb.
1. Remove the splash shield. 2. Screw out the front turn-signal lamp socket to pull out the front turn-signal lamp bulb.
HEADLAMP
M1542001800299
Post-installation Operation Headlamp Aiming Adjustment (Refer to P.54A-59).
4.9 0.9 Nm 2.5 0.4 Nm
4.9 0.9 Nm
2
Removal steps Air guide panel Headlamp assembly
4.9 0.9 Nm
AC310338AB
1. 2.
54A-62
HEADLAMP LEVELING SWITCH
CHASSIS ELECTRICAL
HEADLAMP
M1542013700084
2 1
AC310339AB
Removal steps 1. Switch panel 2. Headlamp levelling switch
Terminal No. 4-6

M1542011201127
Switch position 0 1 2 3 4
Resistance 750 ohms 1050 ohms 1410 ohms 1710 ohms 2010 ohms 2830 ohms
INSPECTION HEADLAMP LEVELING SWITCH RESISTANCE CHECK
5-6
0, 1, 2, 3, 4
AC305186AB
CHASSIS ELECTRICAL
REAR FOG LAMP
54A-63
REAR FOG LAMP

TROUBLESHOOTING
M1542000701623
If the rear fog lamp switch is turned ON when the headlamp is turned ON, the rear fog lamp is switched ON and OFF alternatively. If the headlamp and the rear fog lamp is turned OFF at the same time.
The rear fog lamp is controlled by the Smart Wiring System (SWS). For Troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Troubleshooting P.54B-33. Using SWS monitor: GROUP 54C, SWS Troubleshooting P.54C-20.
SPECIAL TOOL
M1542000601176
Tool
Number MB990784
Name
Use
Ornament remover Removal of switch panel
MB990784
REAR FOG LAMP

M1542009800118
3 4
2
4.9 0.9 Nm
AC310340AB
Removal steps 1. Rear combination lamp assembly 2. Rear combination lamp body
Removal steps (Continued) 3. Rear fog lamp socket 4. Bulb
54A-64
REAR FOG LAMP SWITCH
REMOVAL AND INSTALATION
CHASSIS ELECTRICAL
REAR FOG LAMP
M1542014200026
2 1
AC310880AB
Removal steps 1. Switch panel 2. Rear fog lamp switch
Switch position Tester connection Pressed

M1542011201138
Specified condition Less than 2 ohms Open circuit
INSPECTION REAR FOG LAMP SWITCH CONTINUITY CHECK
56 56
Released
AC305187 AB
CHASSIS ELECTRICAL
SIDE TURN-SIGNAL LAMP
54A-65
Tester connection 14 Specified condition Open circuit Less than 2 ohms
REAR FOG LAMP RELAY CHECK
Battery voltage Not supplied
Rear fog lamp relay
Connect 14 terminal 3 to the positive battery terminal Connect terminal 2 to the negative battery terminal
4 1 3 2
AC305279AB

SPECIAL TOOL
M1542000600913
Tool
Number MB990784
Name
Use
Ornament remover Removal of side turn-signal lamp
MB990784

M1542003300201
Side turn-signal lamps
REMOVAL SERVICE POINT

MB990784
: Front of vehicle
AC005718 AF
Use a special tool ornament remover (MB990784), etc. to remove the side turn-signal lamp by pushing the fender forward, bending the hook, and then unclamping the thumb.
54A-66
INSTALLATION SERVICE POINT
Hook Fender panel
CHASSIS ELECTRICAL
ROOM LAMP
Clamp the thumb on the fender panel the assemble the side turn-signal lamp.
Claw
Fender panel : Front of vehicle

AC005719 AE
ROOM LAMP
TROUBLESHOOTING
M1542000701634
DIMMER INTERIOR LAMP CONTROL FUNCTION

The room lamp off is delayed by ETACS-ECU. The lamps off delay time vary according to the conditions. The control details are as follows. The lamp delay off Yes/NO and delay time can be set with the settings (adjustment function). for adjustment methods and adjustment details (post-adjustment operations). ADJUSTMENT PROCEDURE Refer to GROUP 54B, SWS On-vehicle service P.54B-302. The room lamp lights up if the ignition switch is at the "LOCK" (OFF) position and either of the doors are opened (either of the door switches: ON). At this time, if all doors are closed (all door switches: OFF) then the lamp will gradually dim down to lamps off in about 15 seconds. NOTE: When the lamps are dimmed and the ignition switch is turned ON or if the door is locked, then the dimming operations stop and the lamps are turned OFF. When the ignition switch is at the ON position and one of the doors are opened (one of the door switches: ON) then the room lamp will light up. At this time, if all doors are closed (all door switches: OFF) then the lamps will dim out. When the ignition key is pulled out the room lamp lights up and then will dim out in 15 seconds. The lamp will dim out if the ignition key is inserted again and the door is locked while the timer is activated.
The room lamp is controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Troubleshooting P.54B-33. Using SWS monitor: GROUP 54C, SWS Troubleshooting P.54C-20.
INTERIOR LAMP AUTOMATIC SHUTDOWN FUNCTION

The interior lamp automatic shutdown function, dims out the room lamp and other interior lamps by activating the keep relay built-in the ETACS-ECU when the ignition switch is OFF and the multi-purpose fuse loaded signals built-in the ETACS-ECU is ON and 30 minutes passes. The lamps lights back up if the ignition switch is turned to the ON position or either of the doors is opened (either of the door switches: ON). The function Yes/No feature can be changed with the settings (adjustment function). for adjustment methods and adjustment details (post-adjustment operations). ADJUSTMENT PROCEDURE Refer to GROUP 54B, SWS On-vehicle serviceP.54B-302. The interior lamp are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Not using SWS monitor: GROUP 54B, SWS Troubleshooting P.54B-33. Using SWS monitor: GROUP 54C, SWS Troubleshooting P.54C-20.
CHASSIS ELECTRICAL
REAR COMBINATION LAMP
54A-67

TROUBLESHOOTING
M1542000701322
The lamps setup on the rear combination lamp is controlled in the same manner as the lamps of the headlamp assembly. For details go to the reference. For troubleshooting, refer to respective Groups SPECIAL TOOL below. Tool Number Name Use MB990784
Not using SWS monitor: GROUP 54B, SWS Troubleshooting P.54B-33. Using SWS monitor: GROUP 54C, SWS Troubleshooting P.54C-20.
M1542000600924
Ornament remover Removal of rear combination lamp assembly
MB990784

M1542003900537
4.9 0.9 Nm
3 4 1 2
AC310881AB
Removal steps 1. Rear combination lamp assembly 2. Rear combination lamp body
Removal steps (Continued) 3. Socket assembly 4. Bulb
54A-68
CHASSIS ELECTRICAL

ON-VEHICLE SERVICE
HIGH-MOUNTED STOP LAMP BULB REPLACEMENT <WITH REAR SHELF>
M1542014600013
Remove socket from trunk compartment, and replace bulb.
CAUTION Do not touch bulb surface bare-handed or with dirty gloves. If dirt is attached on glass surface of the bulb, immediately use alcohol or thinner to remove dirt, and install the bulb after well dried.
High-mounted stop lamp
AC305292AB
CHASSIS ELECTRICAL
54A-69

M1542005100526
<With rear shelf> 6 4

4.9 0.7 Nm
8 5 7 3 2 1
AC305293AB
1. 2. 3. 4. 5.
Removal steps Socket assembly Socket Bulb High-mounted stop lamp assembly Socket holder
6. 7. 8.
Removal steps (Continued) High-mounted stop lamp cover (front) High-mounted stop lamp cover (rear) High-mounted stop lamp body
54A-70
<With rear spoiler>
CHASSIS ELECTRICAL
AC310882AB
1. <<A>> 2.
Removal steps Rear spoiler (Refer to GROUP 51, Rear spoiler P.51-16). High-mounted stop lamp
REMOVAL SERVICE POINT <<A>> HIGH-MOUNTED STOP LAMP REMOVAL <WITH REAR SPOILER>
String Connector
Use the following steps to easily route high-mounted stop lamp harness in the event of installation:
CAUTION Ensure that the string is tightly tied.

1. Tie a string on the high-mounted stop lamp harness (at the connector side). 2. Carefully pull out the high-mounted stop lamp.
AC005190 AC
CHASSIS ELECTRICAL
LICENCE PLATE LAMP
54A-71
LICENCE PLATE LAMP

M1542004200456
2 1
AC504380AB
1. 2.
Removal steps Licence plate lamp lens Packing
3. 4.
Removal steps (Continued) Socket Licence plate lamp bulb

TROUBLESHOOTING
M1542000701333
FLASHER TIMER FUNCTION

The hazard warning lamps (flasher timer function) are controlled by the Smart Wiring System (SWS). For troubleshooting, refer to respective Groups below. Tool Number MB990784
Not using SWS monitor: GROUP 54B, SWS Troubleshooting P.54B-33. Using SWS monitor: GROUP 54C, SWS Troubleshooting P.54C-20.
SPECIAL TOOL
M1542000600935
Name
Use
Ornament remover Removal of centre panel and centre air outlet panel
MB990784
54A-72
CHASSIS ELECTRICAL

M1542006600546
3 2
5 4
AC211605AC
Removal steps 1. Knob 2. Centre panel
Removal steps (Continued) 3. Meter bezel 4. Centre air outlet panel 5. Hazard warning lamp switch
INSPECTION
M1542011200920
HAZARD WARNING LAMP SWITCH CONTINUITY CHECK
Switch position Tester connection Released Pressed 12 12
Specified condition Open circuit Less than 2 ohms
AC305304
CHASSIS ELECTRICAL
COLUMN SWITCH
54A-73
COLUMN SWITCH
SPECIAL TOOL
M1542000600946
Tool
Number MB990784
Name
Use
Ornament remover Removal of column cover
MB990784
COLUMN SWITCH
M1543009100510
Section A - A
2 A A A A
AC211607AC
A A
Claw
A A 1
Removal steps 1. Lower column cover 2. Upper column cover
Removal steps (Continued) 3. Turn-signal and lighting switch 4. Windshield wiper and washer switch
54A-74
INSPECTION
CHASSIS ELECTRICAL
COLUMN SWITCH
M1542011201804
COLUMN SWITCH (SWITCH BODY) CONTINUITY CHECK

1. Removal the lighting switch and the wiper and washer switch. 2. Check that there is continuity between the same terminals [terminals (3) and (11)] of each connector of the column switch body which is still on the steering column.
At lighting switch side

1 2 3 4 5 6 7 8 9 10 11
At wiper/washer switch side

1 2 3 4 5 6 7 8 9 10 11
AC005499 AD
Column switch body Lighting switch side connector, Wiper and washer switch side connector
Tester connection
Specified condition
3 3, 4 4, 5 Less than 2 5, 6 6, 7 ohms 7, 8 8, 9 9, 10 10, 11 11
CHASSIS ELECTRICAL
HORN
54A-75
HORN
M1543007900479
2
AC211783AC
Removal Steps 1. Horn <LO> 2. Horn <HI>
54A-76
HORN RELAY CONTINUITY CHECK
CHASSIS ELECTRICAL
CLOCK
M1543019502418
Battery voltage Not applied
Tester connection 14
Connect terminal 1 4 2 to the positive battery terminal Connect terminal 3 to the negative battery terminal
Horn relay
4 1 2 3
AC305306AB
CLOCK
SPECIAL TOOL
M1543000601663
Tool
Number MB990784
Name
Use
Ornament remover Removal of centre panel and centre air outlet panel
MB990784
CHASSIS ELECTRICAL
CIGARETTE LIGHTER
54A-77
CLOCK
M1543005900309
5 3 2 4
AC211606AC
Removal steps 1. Knob 2. Centre panel 3. Meter bezel
Removal steps (Continued) 4. Centre air outlet panel 5. Clock
CIGARETTE LIGHTER
INSPECTION
M1543005700242
CIGARETTE LIGHTER CHECK

Element Spot
Take out the plug, and check for a worn edge on the element spot connection, and for shreds of tobacco or other material on the element. Using an ohmmeter, check that the element resistance value is 1.7 ohms.
ACX01832AE
54A-78
CHASSIS ELECTRICAL
SPEAKER
SPEAKER
M1544002600573
<Tweeter> 1.5 0.5 Nm
<Front speaker>
1.5 0.5 Nm
<Rear speaker>
1.5 0.5 Nm
2 5
AC211402 AC
1.
Tweeter removal steps Front pillar trim (Refer to GROUP 52A, Trims P.52A-10). Tweeter
2. 3. 4. 5.
Front speaker removal steps Front door trim (Refer to GROUP 52A, Door trim P.52A-12). Front speaker Rear speaker removal steps Rear speaker garnish Rear speaker
CHASSIS ELECTRICAL
ANTENNA
54A-79
ANTENNA
M1544002900648
Pre-removal and Post-installation Operation Front pillar trim, Rear pillar trim, Centre pillar trim lower, Centre pillar trim upper (Refer to GROUP 52A, Trims P.52A-10). Headlining Removal and Installation (Refer to GROUP 52A, Headlining P.52A-17).
AC005156AD
1. Roof antenna pole
Antenna feeder cable removal steps 2. Roof antenna base Instrument panel assembly (Refer to GROUP 52A, Instrument panel assembly P.52A-2). 3. Antenna feeder cable
REAR WINDOW DEFOGGER

GENERAL INFORMATION
M1543000100319
TROUBLESHOOTING
The rear window defogger is controlled by the A/C-ECU. For troubleshooting, refer to GROUP 55Troubleshooting P.55-29.
M1543000701552
Rear Defogger operation

The defogger relay turns ON if the defogger switch built-in the A/C-ECU is turned ON when the ignition switch is in the "ON" position. When the defogger relay turns ON, power is supplied to the defogger and the defogger is activated. The defogger comes with a timer function that causes the defogger switch to automatically turn OFF in about 11 minutes after the defogger switch is turned ON.
54A-80
ON-VEHICLE SERVICE
PRINTED HEATER LINES CHECK
CHASSIS ELECTRICAL
REAR WINDOW DEFOGGER
REAR WINDOW DEFOGGER SWITCH

Refer to GROUP 55, Heater Control Assembly and A/C Switch P.55-108.
M1543006200314 M1543001800311
Normal characteristic curve

Voltage (V)
12
INSPECTION
M1543019502816
A (Centre point) Approximately 6 V
DEFOGGER RELAY CHECK
Positive terminal
Print heater line
Negative terminal
Abnormal characteristic curve

Voltage (V)
12
Rear window defogger relay

Open circuit point
Positive terminal
Print heater line
Negative terminal
AC407247 AC
5 4 3 1
1. Run engine at 2,000 r/min. Check heater element with battery at full. 2. Turn "ON" rear window defogger switch. Measure heater element voltage with circuit tester at rear window glass centre A. Condition is good if it indicates about six volts. 3. If 12 volts is indicated at A, there is a break in the negative terminals from A. Move test bar slowly to negative terminal to detect where voltage changes suddenly (0 volts). 4. If 0 volts is indicated at A, there is a break in the positive terminals from A. Defect where the voltage changes suddenly (12 volts) in the same method described above.
AC305319AC
Battery voltage Not supplied Connect terminal 3 to the positive battery terminal Connect terminal 1 to the negative battery terminal
Tester connection 45 45
21B-1
GROUP 21B
CLUTCH OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS . . . . . . SERVICE SPECIFICATIONS. . . . . . . TORQUE SPECIFICATIONS . . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . 21B-2 21B-2 21B-2 21B-2 CLUTCH . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
21B-3
21B-3 21B-5
CLUTCH RELEASE CYLINDER . . . .

DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
21B-6
21B-6 21B-7
21B-2
CLUTCH OVERHAUL
GENERAL SPECIFICATIONS
M1212000200171
Item Clutch disc Clutch cover Clutch control Type Facing size mm Type Set load N
Specification Dry single disc type 240 160 Diaphragm spring pull type 9320 Hydraulic system
M1212000300145
Item Depth of rivets from clutch disc facing surface Difference in height of clutch cover diaphragm spring fingers
Limit mm 0.3 0.5
TORQUE SPECIFICATIONS
M1212001800143
Item Clutch tube flare nut Clutch fluid line bracket bolt Release cylinder mounting bolt Release fork shaft mounting bolt Release cylinder union bolt Clutch cover bolt Release cylinder air breather
Torque Nm 15 2 18 3 18 3 9.8 2.0 22 2 18 3 11 1
LUBRICANTS
M1212000400153
Item Release fork to release cylinder push rod contact surface Release fork to release fork shaft rubbing surface Release fork to release bearing contact surface Piston and piston cup outer surfaces Release cylinder inner surface
Specified lubricants MITSUBISHI genuine grease Part No. 0101011 or equivalent Dia Queen Brake Fluid Super 4 or equivalent
CLUTCH OVERHAUL
CLUTCH
21B-3
CLUTCH
M1212001000158
9.8 2.0 Nm
2 12 13
18 3 Nm
18 3 Nm
15 2 Nm
8 1 9 7 6 4 5
22 2 Nm
3
18 3 Nm
10 11
20 19
21 17 17 15 14 16
AK501884 AB
18
>>E<< >>E<< >>D<<
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Removal steps Clutch fluid line bracket Clutch tube Union bolt Union Gasket Valve plate Valve plate spring Corrugate clamp bracket Release cylinder Clutch cover assembly Clutch disc
>>C<<
>>B<< >>A<<
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal steps (Continued) Sealing cap Release fork shaft Support spring (L) Packing Release fork Bushing Clutch release bearing Packing Support spring (R) Release fork boot
21B-4
REASSSEMBLY SERVICE POINTS >>A<< BUSHING INSTALLATION
CLUTCH OVERHAUL
CLUTCH
Press fit the sealing cap into the release fork to a depth indicated in the drawing, making sure it does not tilt.
>>D<< RELEASE CYLINDER INSTALLATION

Release fork
Bushings
AK203870 AD
Press fit the bushing into the release fork as shown in the drawing.
>>B<< RELEASE FORK INSTALLATION
AK203873AD
Grease the release fork at the area indicated in the drawing. Grease Brand: MITSUBISHI genuine grease Part No. 0101011 or equivalent
>>E<< VALVE PLATE SPRING / VALVE PLATE INSTALLATION

AK203871AD AK203871
Valve plate spring Release cylinder
Grease the release fork at the areas indicated in the drawing. Grease Brand: MITSUBISHI genuine grease Part No. 0101011 or equivalent
>>C<< SEALING CAP INSTALLATION
Valve plate
AK201696AF AK201696
2mm
Install the valve plate spring and valve plate with the spring's major diameter end toward the valve plate.
AK203872AD AK203872
CLUTCH OVERHAUL
CLUTCH
21B-5
INSPECTION
M1212001100133
CLUTCH COVER ASSEMBLY

1. Check the pressure plate surface for wear, cracks, or discoloration.
Depth of rivet from facing surface
2. Measure the depth of each rivet from the facing surface. Replace the clutch disc if the depth is less than the limit. Limit: 0.3 mm minimum 3. Check the torsion springs for looseness and damage. If defective, replace the clutch disc. 4. Combine the clutch disc with the input shaft and check that it slides smoothly on the shaft without excessive play in the rotating direction. If the disc does not slide smoothly, clean the shaft and disc, reassemble them, and check again for sliding condition. If the play is excessive, replace the clutch disc and/or the input shaft.
Torsion spring
AKX00764AE AKX00764
2. Check the rivets on the strap plates for looseness. If there are any loose rivets, replace the clutch cover assembly.
CLUTCH RELEASE BEARING

CAUTION The release bearing is packed with grease. Do not wash it with a cleaning solvent. 1. Check the bearing for seizure, damage, noise or improper rotation. 2. Check the pull ring on the release bearing for wear. 3. Replace bearing if its release fork contact surface is abnormally worn.
CLUTCH DISC
CAUTION Do not wash the clutch disc with cleaning solvent. 1. Check the facing for loose rivets, uneven contact, glazing due to overheating, or oil or grease contamination. Replace the clutch disc if defective.
21B-6
CLUTCH OVERHAUL
CLUTCH RELEASE CYLINDER

M1212001500142
1 2
11 2 Nm
5 4 9 3 8 6 7
AK203874AD
>>A<<
1. 2. 3. 4. 5.
Disassembly steps Cap Air breather Push rod Boot Piston assembly
6. 7. 8. 9.
Disassembly steps (Continued) Piston cups Piston Conical spring Release cylinder
CLUTCH OVERHAUL
21B-7
M1212001600149
REASSEMBLY SERVICE POINTS >>A<< PISTON ASSEMBLY INSTALLATION
INSPECTION RELEASE CYLINDER
Piston
Piston cup
AK203875 AD
AK203876AD AK203876
Apply brake fluid to the outer surfaces of the piston and piston cups and inner surface of the release cylinder, and then insert the piston assembly into the release cylinder. Brake Fluid Brand: Dia Queen Brake Fluid Super 4 or equivalent
1. Check the inner surface of the release cylinder for rust or scratches. 2. Use a cylinder gauge to measure the inside diameter of the release cylinder at three different points (innermost, middle, and outermost points). Replace the release cylinder assembly if the clearance between the piston and cylinder exceeds the limit at any of the measurement points. Limit: 0.15 mm
NOTES
21-1
GROUP 21
CLUTCH
CONTENTS CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B
NOTES
22-1
GROUP 22
MANUAL TRANSMISSION
CONTENTS MANUAL TRANSMISSION (FF) . . . . . . . . . . . . . . . . . . . . . . . . . 22A MANUAL TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . . . . 22B
NOTES
22B-1
GROUP 22B
MANUAL TRANSMISSION OVERHAUL

CONTENTS
GENERAL INFORMATION . . . . . . . . GENERAL SPECIFICATIONS . . . . . . SERVICE SPECIFICATIONS. . . . . . . SEALANTS . . . . . . . . . . . . . . . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT . . . . . . . TORQUE SPECIFICATIONS . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . .
DISASSEMBLY AND REASSEMBLY. . . . . ADJUSTMENT OF TRANSMISSION . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
22B-2 22B-4 22B-4 22B-5 22B-5 22B-6 22B-8 22B-8 22B-11

22B-11 22B-20 22B-23
INPUT SHAFT. . . . . . . . . . . . . . . . . . . 22B-24

DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 22B-24 22B-29
REVERSE IDLER GEAR . . . . . . . . . . 22B-31

DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 22B-31 22B-32
CLUTCH HOUSING . . . . . . . . . . . . . . 22B-34

DISASSEMBLY AND REASSEMBLY . . . . . 22B-34
TRANSMISSION CASE . . . . . . . . . . . 22B-36

CENTRE DIFFERENTIAL. . . . . . . . . . 22B-38

TRANSFER . . . . . . . . . . . . . . . . . . . . . 22B-41
22B-2

GENERAL INFORMATION
GENERAL INFORMATION
M1222000100142
TRANSMISSION MODEL
Transmission model W6MAA-1-GFNF Combined engine 4G63 Vehicle model CT9A
TRANSMISSION SECTIONAL VIEW
AK204394

GENERAL INFORMATION
22B-3
TRANSFER SECTIONAL VIEW
AK204401
22B-4

M1222000200194
Item Transmission model Applicable engine Transmission type Transmission gear ratio 1st 2nd 3rd 4th 5th 6th Reverse Speedometer gear ratio Final gear ratio Transfer type
Specifications W6MAA-1-GFNF 4G63 6-speed transmission 2.909 1.944 1.434 1.100 0.868 0.693 2.707 Not applicable 4.583 Constant mesh
M1222000300168
Item Differential side bearing preload Input shaft end play Main shaft end play Reverse idler gear end play Distance between input shaft front bearing and thrust washer Input shaft 6th gear bushinging end play Wear on one side of shift fork pawl Clearance between synchronizer ring and gear Clearance between synchronizer ring and synchronizer cone Backlash between differential side gear and pinion
Standard mm 0.15 0.20 0 0.06 0 0.06 0.04 0.10 167.6 167.7 0 0.1 0.025 0.150
Limit mm 0.2 0.7 0.2

SEALANTS
22B-5
M1222000500151
SEALANTS
Item Clutch housing and transaxle case contact surface Reverse switch Air breather Differential drive gear bolt Brand MITSUBISHI GENUINE PART MD997740 or equivalent 3M 8513 or equivalent 3M STUD Locking No. 4170 or equivalent
FORM-IN-PLACE GASKET (FIPG)

This transmission has several areas where the form-in-place gasket (FIPG) is used for sealing. To ensure that the FIPG fully serves its purpose, it is necessary to observe some preCAUTIONs when applying it. Bead size, continuity and location are of paramount importance. Too thin a bead can cause leaks. Too thick a bead, on the other hand, can be squeezed out of location, causing blocking or narrowing of fluid passages. To prevent leaks or blocking of passages, therefore, it is absolutely necessary to apply the FIPG evenly without a break, while observing the correct bead size.
CLEANING FIPG APPLICATION SURFACE

Thoroughly remove all substances deposited on the FIPG application surface, using a gasket scraper. Make sure that the FIPG application surface is flat and smooth. Also make sure that the surface is free of oils, greases, and foreign substances. Do not fail to remove old FIPG that may remain in the fastener fitting holes.
APPLICATION OF FIPG
Applied FIPG bead should be of the specified size and free of any break. FIPG can be wiped away unless it has completely hardened. Install the mating parts into position while the FIPG is still wet (in less than 10 minutes after application). Do not allow FIPG to spread beyond the sealing areas during installation. Avoid operating the transmission or letting oils or water come in contact with the sealed area before a time sufficient for FIPG to harden (approximately one hour) has passed. FIPG application method may vary from location to location. Follow the instructions for each particular case described later in this manual.
REMOVAL OF FIPG SEALED PARTS

Parts sealed with an FIPG can be easily removed without the use of a special method. However, the FIPG in some joints may have to be broken by tapping parts with a mallet or similar tool.
LUBRICANTS
M1222000400121
Item Transfer oil seal lip O-rings
Brand Shell Sunlight Grease 2, Retinax A, or equivalent
22B-6

SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT

M1222012000175
Adjustment shims (for differential side bearing preload adjustment) Thickness mm 0.48 0.52 0.56 0.60 0.64 0.68 Thickness mm 0.72 0.76 0.80 0.84 0.88 0.92
Adjustment shims (for input shaft end play adjustment) Thickness mm 0.44 0.48 0.52 0.56 0.60 0.64 0.68 0.72 0.76 0.80 0.84 0.88 0.92 0.96 Thickness mm 1.00 1.04 1.08 1.12 1.16 1.20 1.24 1.28 1.32 1.36 1.40 1.44 1.48 1.52
Adjustment shims (for main shaft end play adjustment) Thickness mm 0.44 0.48 0.52 0.56 0.60 0.64 0.68 0.72 0.76 Thickness mm 0.80 0.84 0.88 0.92 0.96 1.00 1.04 1.08

22B-7
Adjustment shims (for reverse idler gear end play adjustment) Thickness mm 1.76 1.80 1.84 1.88 1.92 1.96 2.00 2.04 2.08 2.12 2.16 2.20 Thrust washers (for adjustment of distance between input shaft front bearing and thrust washer) Thickness mm 3.84 3.90 3.96 Thickness mm 4.02 4.08 4.14 Thickness mm 2.24 2.28 2.32 2.36 2.40 2.44 2.48 2.52 2.56 2.60 2.64
Snap rings (for input shaft 6th gear bushinging end play adjustment) Thickness mm 1.71 1.76 1.81 1.86 1.91 1.96 Thickness mm 2.01 2.06 2.11 2.16 2.21 2.26
22B-8

M1222013900074
Item Transfer bolts Roll stopper bracket bolts Vehicle speed sensor bolts Reverse switch Stopper bolts Shift check plugs Transaxle case bolts (with sealant) Transaxle case bolts Shift check plugs Reverse lever assembly Main shaft bearing retainer bolts Drain plugs Filler plugs Differential drive gear bolts Transfer cover case bolts Plugs Magnet plugs
Torque Nm 70 10 69 9 11 1 28 5 29 1 15 2 63 1 52 1 15 2 14 1 7.3 1.0 35 4 35 4 158 7 23 3 30 2 30 2
SPECIAL TOOLS
M1222000600170
Tool
Number MB990810
Name Side bearing puller
Use Use with claws
MB990810
MB991967
Claws
Removal of differential side bearing outer race
MB991968
Bridge
Removal of differential side bearing outer race

SPECIAL TOOLS
22B-9
Tool
Number MB991969
Name
Use
Measurement adapter Measurement of differential side bearing preload
MB991966
Bearing outer race installer
Installation of differential side bearing outer race
MD998801
Bearing remover
Installation and removal of a gear, bearing, and sleeve
MD998917
Bearing remover
Installation and removal of a gear, bearing, and sleeve
MD998812
Installer cap
Use with installer and installer adapter
MD998813
Installer 100
Use with installer cap and installer adapter
MD998818
Installer adapter (38)
Installation of input shaft rear bearing and roller bearing inner race
MD998823
Installation of 3rd-4th synchronizer assembly
22B-10
Tool

SPECIAL TOOLS
Number MD998822
Name Installer adapter (46)
Use Installation of 1st gear sleeve and 1st-2nd synchronizer hub
MB990938
Handle
Use with installer adapter
MD998323
Bearing installer
Installation of input shaft oil seal
MD998800
Oil seal installer
Installation of differential oil seal and transfer oil seal
MB990936
Installer adapter
Installation of transfer taper roller bearing and transfer oil seal
MB990937
Installer adapter
Installation of transfer oil seal
MB990887
Arm bushing adapter and installer ring
Installation of transfer oil seal
MB990891
Bushing remover and Use with arm bushing adapter installer base and installer ring

TRANSMISSION
22B-11
TRANSMISSION
M1222001000502
7.3 1.0 Nm
10
11 1 Nm 15 2 Nm 28 5 Nm
5 11 12
70 10 Nm
6 13
29 1 Nm
9 8
1 4 2 7 3
18 3 Nm 70 10 Nm
69 9 Nm
AK501885AB
1. 2. 3. 4. 5. >>P<< 6. 7.
Disassembly steps Transfer O-ring Front roll stopper bracket Rear roll stopper bracket Vehicle speed sensor Back light switch Oil temperature sensor
8. 9. >>O<< 10. 11. 12. 13.
Disassembly steps (Continued) Bore plug Stopper bolt Control assembly Shift check plug Shift check spring Check ball
22B-12
Apply gear oil to all moving parts before installation. 15 2 Nm

TRANSMISSION
14
63 1 Nm 52 1 Nm
22 23 25 27 16 15
21 20
17 22 27 26 24
18 19
15 2 Nm
AK204165AF
>>N<< 14. Transmission case

15. Snap ring
Disassembly steps
>>K<< 21. Differential side bearing adjustment >>J<< >>J<< >>J<< >>J<< >>J<< >>J<<
22. 23. 24. 25. 26. 27. shim Shift check plug 5th-6th shift check spring Shift check spring Shift check sleeve Reverse shift check sleeve Check ball
Disassembly steps (Continued)
>>M<< 16. Main shaft rear bearing adjustment

17. >>M<< 18. shim Oil channel Input shaft rear bearing adjustment shim Reverse idler gear adjustment shim Differential side bearing outer race
>>M<< 19. <<A>> >>L<< 20.

TRANSMISSION
Apply gear oil to all moving parts before installation.
22B-13
36 49
36 37
38 57 40 54 42 53 55 43 52 51 47 41 44
39 50
45
33 32
14 1 Nm
28 29 48 35 46 56 35 34
30 31
AK204166AF
28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49.
Disassembly steps Reverse lever assembly Shifter cap Reverse fork rod Reverse shift fork Retaining pin Reverse bracket Reverse bracket fork rod Interlock ball Retaining pin 1st-2nd bracket 1st-2nd fork rod 1st-2nd shift fork Retaining pin C-ring 3rd-4th fork rod Interlock pin 3rd-4th bracket Retaining pin C-ring 5th-6th fork rod Interlock pin 5th-6th shift fork
50. 51. 52. 53. 54. 55. 56. 57.
>>A<< 56. >>A<< 55. >>A<< 54.

38. 37. 36. 39. 53. 42. 43. 44. 50.
57.
>>B<< >>C<< >>D<< >>D<< >>D<<
Disassembly steps (Continued) 3rd-4th shift fork 5th-6th bracket Interlock ball Shift check sleeve Main shaft assembly Input shaft assembly Reverse idler gear assembly Center differential Reassembly steps Center differential Reverse idler gear assembly Input shaft assembly Main shaft assembly 1st-2nd fork rod 1st-2nd bracket Retaining pin 1st-2nd shift fork Shift check sleeve 3rd-4th fork rod Interlock pin 3rd-4th bracket 3rd-4th shift fork
22B-14
>>D<< >>D<< >>E<< >>F<<
41. 40. 52. 47. 48. >>F<< 51. >>F<< 49. >>F<< 46.

TRANSMISSION Reassembly steps (Continued) C-ring Retaining pin Interlock ball 5th-6th fork rod Interlock pin 5th-6th bracket 5th-6th shift fork C-ring Reassembly steps (Continued) Retaining pin Interlock ball Reverse bracket fork rod Reverse bracket Retaining pin Reverse shift fork Reverse fork rod Reverse lever assembly Shifter cap
>>F<< >>G<< >>H<< >>H<<
45. 35. 34. 33. 32. 31. 30. >>I<< 28. 29.
DISASSEMBLY SERVICE POINTS <<A>> DIFFERENTIAL SIDE BEARING OUTER RACE REMOVAL
REASSEMBLY SERVICE POINTS >>A<< INPUT SHAFT ASSEMBLY / MAIN SHAFT ASSEMBLY / REVERSE IDLER GEAR ASSEMBLY INSTALLATION
Reverse idler gear assembly
AK203785
1. Heat the transmission case to about 100 C (maximum temperature: 120 C).
MB990810
AK203325AD
1. Place the reverse idler gear assembly at the installation location without actually inserting it into the clutch housing.
Input shaft assembly Main shaft assembly
MB991967 MB991968
AK204353AC AK204353
2. Using the following special tools, remove the differential side bearing outer race. Side bearing puller (MB990810) Claw (MB991967) Bridge (MB991968)
AK203326AC
CAUTION Be careful not to scratch the input shaft oil seal. (Protect it from scratches by wrapping vinyl tape around the splined portion of the input shaft assembly.)
2. Insert the input shaft assembly and then the main shaft assembly into the clutch housing, leaving some space between each assembly and the housing.

TRANSMISSION
22B-15
>>C<< SHIFT CHECK SLEEVE INSTALLATION
1st-2nd fork rod

AK203327 AB
Shift check sleeve
CAUTION Make sure to fit the lock pin at the end of the reverse idler gear assembly into the groove in the clutch housing.
3. Move the reverse idler gear assembly so that its parts fit into the spaces between the housing and the partially inserted shaft assemblies, and then insert the three assemblies together into the clutch housing.
AK204448AC
CAUTION The transmission assembly contains parts that resemble shift check sleeves. Make sure not to mistakenly install a similar part instead of the shift check sleeve (length: 36.25 mm). Install the shift check sleeve.
>>B<< 1ST-2ND FORK ROD / 1ST-2ND SHIFT FORK INSTALLATION
>>D<< 3RD-4TH BRACKET / 3RD-4TH SHIFT FORK / 3RD-4TH FORK ROD INSTALLATION
3rd-4th fork rod
Interlock pin
AK203328
AK204449AC
CAUTION The retaining pin is not reusable. When installing the retaining pin, insert an Allen wrench into the hole on the other side of the fork rod to keep the fork from slipping down. Install the 1st-2nd fork rod in the clutch housing and then install the 1st-2nd shift fork on the fork rod by hammering in the retaining pin.
CAUTION Apply Vaseline to the interlock pin and be careful not to drop it during installation.
1. Install the interlock pin on the 3rd-4th fork rod. 2. Install the 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.
CAUTION The C-ring is not reusable.

3. Install the C-ring on the 3rd-4th shift fork
22B-16

TRANSMISSION
CAUTION Apply Vaseline to the interlock pin and be careful not to drop it during installation.
1. Install the interlock pin in the 5th-6th fork rod.
CAUTION Install the 5th-6th fork rod with its three grooves facing the 5th-6th shift check parts.
AK203330
2. Install the 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod.
CAUTION The retaining pin is not reusable. When installing the retaining pin, insert an Allen wrench into the hole on the other side of the fork rod to keep the fork from slipping down.
4. Hammer the retaining pin into the 3rd-4th bracket.
CAUTION The C-ring is not reusable.

3. Install the C-ring on the 5th-6th bracket.
>>E<< INTERLOCK BALL INSTALLATION
AK203332
Interlock balls
AK204450AC
CAUTION The retaining pin is not reusable. When installing the retaining pin, insert an Allen wrench into the hole on the other side of the fork rod to keep the fork from slipping down.
4. Hammer the retaining pin into the 5th-6th shift fork.
CAUTION Make sure that the interlock balls do not fall out of their locations. Install the two interlock balls.
>>G<< INTERLOCK BALL INSTALLATION
>>F<< 5TH-6TH BRACKET / 5TH-6TH SHIFT FORK / 5TH-6TH FORK ROD INSTALLATION
Interlock balls
Interlocl pin
5th-6th fork rod

AK204452AC
5th-6th shift check parts
AK204451AC
CAUTION Make sure that the interlock steel balls do not fall out of their locations. Install the two interlock steel balls.

TRANSMISSION
22B-17
>>H<< REVERSE BRACKET FORK ROD / REVERSE BRACKET INSTALLATION

Reverse shift check parts
Reverse bracket fork rod
CAUTION The check balls are not reusable. Confirm the lengths of the shift check sleeves and check springs before installing them. (A: short, B: long) Be careful not to let the check balls drop into the air breathing grooves in the clutch housing. Install the two shift check sleeves, two check balls, two check springs and two check ball plugs into position.
AK204453AC
CAUTION Install the reverse bracket fork rod with its two grooves facing the reverse shift check parts. Install the reverse bracket fork rod and reverse bracket.
>>K<< DIFFERENTIAL SIDE BEARING ADJUSTMENT SHIM INSTALLATION

CAUTION Do not use more than two shims. Install the appropriate adjustment shims that will provide the differential side bearing with a preload within the standard value range. Standard value: 0.15 0.21 mm
L Transmission case Differential side bearing outer race
>>I<< REVERSE LEVER ASSEMBLY INSTALLATION
Reverse lever assembly
Reverse bracket
AK203322AD
Adjustment shim
AK204383AC
1. Install the shifter cap on the cam of the reverse lever assembly, and then install the reverse shift fork. 2. Raise the reverse shift fork and fit its cam in the reverse bracket.
>>J<< SHIFT CHECK SLEEVE / CHECK BALL / CHECK SPRING / CHECK BALL PLUG INSTALLATION
1. Selecting appropriate shims (1) Measure the distance between the end surface and the adjustment shim fitting surface on the transmission case (L1). Next, measure the distance between the clutch housing end surface and the differential side bearing end surface (L2). (2) Use the following equation to calculate the clearance L between the transmission case and the differential side bearing outer race: L = L1 L2 (3) Select an adjustment shim (or a set of adjustment shims) with a thickness of L plus 0.15 mm to 0.21 mm (standard value range).
AK204381AC AK204381
22B-18

TRANSMISSION
Straight edge MB991969
L1
Measurement a
CAUTION Before making the following measurement, make sure to confirm that the outer race is level by measuring the height of the outer race surface at three different points. (3) Use a height gauge to measure the distance between the differential side bearing outer race and the transmission mounting surface of the clutch housing (L2).
Straight edge
>>L<< DIFFERENTIAL SIDE BEARING OUTER RACE INSTALLATION
MB991969
AK204355AC
2. Measuring distances L1 and L2 (1) Install the special tool Adjustment adapter (MB991969) into the differential side rear bearing hole in the transmission case. Use the following equation to calculate the distance L1 (see the illustration above): L1 = 25.00 (height of MB991969) measurement "a" (2) Attach the outer race onto the differential side bearing on the final gear side, and rotate the final gear set five or more times by hand while holding the outer race down lightly to keep it from tilting. NOTE: Rotating the final gear in this way will help the bearing rollers to seat completely against their races.
Pick tester
AK203785
1. Heat the transmission case to about 100C (maximum temperature: 120C).
MB991966
AK204354AC AK204354
2. Using the special tool Bearing outer race installer (MB991966) to install the differential side bearing outer race.
Height gauge
AK204382AC

TRANSMISSION
22B-19
B A A Bolt colors A: Yellow B B: Black B B B
>>M<< ADJUSTMENT SHIM INSTALLATION (INPUT SHAFT REAR BEARING / MAIN SHAFT REAR BEARING / REVERSE IDLER GEAR)
CAUTION Use only one shim each for the main shaft rear bearing, input shaft rear bearing and reverse idler gear. Install the selected shims into the relevant locations. (Refer to adjustment of transmission - shim selection for adjustment of input shaft rear bearing end play, main shaft rear bearing end play and reverse idler gear end play)P.22B-23)
A
B A A A
A A B A A A A B B
AK204378AC
CAUTION Bolts (B) are not reusable.

4. Tighten all the bolts to the specified torque.
>>N<< TRANSMISSION CASE INSTALLATION

CAUTION The snap ring is not reusable.
1. Install the snap ring temporarily in the main shaft rear bearing location in the transmission case.
>>O<< CONTROL ASSEMBLY INSTALLATION

CAUTION The O-ring is not reusable.
1
AK204384AC AK204384 AK204379AC AK204379
2. Apply sealant as indicated in the above illustration. Specified sealant: MITSUBISHI GENUINE PART MD997740 or equivalent 3. Expand the snap ring in the main shaft rear bearing location through the bore plug mounting hole and place the transmission case over the clutch housing.
1. Install the control assembly and tighten the bolts to the specified torque. 2. With the gear shifted into 2nd, raise the main shaft and install the snap ring tightly on the main shaft rear bearing. NOTE: To shift the gear into 2nd, move the lever in the order of the numbers indicated in the illustration.
>>P<< REVERSE SWITCH INSTALLATION

1. Apply sealant to the threads on the reverse switch. Specified sealant: MITSUBISHI GENUINE PART MD997740 or equivalent 2. Install the reverse switch on the transmission case.
22B-20

TRANSMISSION
M1222013800011
ADJUSTMENT OF TRANSMISSION SHIM SELECTION FOR ADJUSTMENT OF INPUT SHAFT REAR BEARING END PLAY, MAIN SHAFT REAR BEARING END PLAY AND REVERSE IDLER GEAR END PLAY <Measurement using Solder>
CAUTION If solder is not available, select the thrust washer in accordance with Plastigage method. If the thrust washer appropriate for the standard value cannot be selected using solder, select the thrust washer in accordance with Plastigage method.
Solder
Solder
AK204386AC
3. In the case of the reverse idler gear: (1) Put the solder (1.0 mm diameter, about 10 mm long) on the surface of the reverse idler gear mounting boss in the transmission case as indicated in the Illustration. (2) Install the adjusting shim having minimum thickness. 4. Install the snap ring temporarily in the main shaft rear bearing location in the transmission case. 5. Expand the snap ring in the main shaft rear bearing location through the bore plug mounting hole, and place the transmission case over the clutch housing.
B A B A A Bolt colors A: Yellow B B: Black B A A B A A B A A A A B B
AK204378AC
AK204380AC
1. Put the solder (1.0 mm diameter, about 10 mm long) on the input shaft rear bearing as indicated in the illustration.
Solder
CAUTION In the following step, use the same transmission case bolts that were removed during disassembly.
AK204385AC
6. Install and tighten the transmission case bolts to the specified torque.
2. Put the solder (1.0 mm diameter, about 10 mm long) on the main shaft rear bearing fitting surface in the transmission case as indicated in the illustration.
1
AK204384AC AK204384

TRANSMISSION
22B-21
CAUTION In the following steps, make sure to use the same O-rings that were removed during disassembly.
7. Install the control assembly and tighten its bolts to the specified torque. 8. With the gear shifted into 2nd gear, raise the main shaft and install the snap ring tightly on the main shaft rear bearing. NOTE: Refer to CONTROL ASSEMBLY INSTALLATION for the method for shifting the gear into 2nd. 9. Return the control assembly to the neutral position and remove its mounting bolts. Remove the control assembly. 10.Remove the transmission case. 11.Remove the snap ring from the main shaft rear bearing, then remove the transmission case. 12.Remove the crushed pieces of solder. 13.If the solder has not been crushed at all: (1) In the case of the input shaft rear bearing and the main shaft rear bearing, use the thicker solder (1.6 mm diameter, about 10 mm long) and repeat steps 4 to 12. (2) In the case of the reverse idler gear, use the thicker shim and repeat steps 4 to 12.
(2) In the case of the reverse idler gear: Shim thickness: (T1 + T2 0.04 mm) to (T1 + T2 0.10 mm) T1: The crushed solder thickness mm T2: The shim thickness used for measurement mm Standard reverse idler gear end play: 0.04 mm 0.10 mm
<Measurement using Plastigage>

Plastigage
AK204380AF
1. Put the plastigage (about 10 mm long) on the input shaft rear bearing as indicated in the illustration. Install the adjusting shim having minimum thickness.
Plastigage
AK204385 AF
AK301249
14.Use a micrometer to measure the thickness of the each crushed solder beads and record the each measured value. 15.Select each shim with the thickness calculated by the following formula that will adjust each end play to a value within the standard value range. (1) In the case of the input shaft rear bearing and the main shaft rear bearing: Shim thickness: (T1 0 mm) to (T1 0.06 mm) T1: The crushed solder thickness mm Standard input shaft end play: 0 mm 0.06 mm Standard main shaft end play: 0 mm 0.06 mm
2. Put the plastigage (about 10 mm long) on the main shaft rear bearing fitting surface in the transmission case as indicated in the illustration. Install the adjusting shim having minimum thickness.
Plastigage
AK204386AF
22B-22

TRANSMISSION
3. Put the plastigage (about 10 mm long) on the surface of the reverse idler gear mounting boss in the transmission case as indicated in the Illustration. Install the adjusting shim having minimum thickness. 4. Install the snap ring temporarily in the main shaft rear bearing location in the transmission case. 5. Install the adjusting thrust washer having the minimum thickness. 6. Expand the snap ring in the main shaft rear bearing location through the bore plug mounting hole, and place the transmission case over the clutch housing.
B A A A A B A A B A A A A B B
AK204378AC
NOTE: Refer to CONTROL ASSEMBLY INSTALLATION for the method for shifting the gear into 2nd. 10.Return the control assembly to the neutral position and remove its mounting bolts. Remove the control assembly. 11.Remove the transmission case. 12.Remove the snap ring from the main shaft rear bearing, then remove the transmission case. 13.Remove the crushed pieces of plastigage. 14.If the plastigage has not been crushed at all, use thicker adjusting shim and repeat steps 4 to 13.
A A
Bolt colors A: Yellow B B: Black B B
Plastigage Shim
AK402081AI
CAUTION In the following step, use the same transmission case bolts that were removed during disassembly.
7. Install and tighten the transmission case bolts to the specified torque.
1
AK204384AC AK204384
CAUTION In the following steps, make sure to use the same O-rings that were removed during disassembly.
8. Install the control assembly and tighten its bolts to the specified torque. 9. With the gear shifted into 2nd gear, raise the main shaft and install the snap ring tightly on the main shaft rear bearing.
15.Measure the width of the each crushed plastigage at its widest part using a scale printed on the plastigage package and record the each measured value. 16.Select each shim with the thickness calculated by the following formula that will adjust each end play to a value within the standard value range. (1) In the case of the input shaft rear bearing and the main shaft rear bearing: Shim thickness: (T2 + T3 0 mm) to (T2 + T3 0.06 mm) T2: The shim thickness used for measurement mm T3: The crushed plastigage thickness mm Standard input shaft end play: 0 mm 0.06 mm Standard main shaft end play: 0 mm 0.06 mm (2) In the case of the reverse idler gear: Shim thickness: (T2 + T3 0.04 mm) to (T2 + T3 0.10 mm) T2: The shim thickness used for measurement mm T3: The crushed plastigage thickness mm Standard reverse idler gear end play: 0.04 mm 0.10 mm

TRANSMISSION
22B-23
INSPECTION
M1222001100156
BACK LIGHT SWITCH
FORK ROD / REVERSE LEVER ASSEMBLY / SHIFT FORK

Fork rod
Reverse lever assembly
AK501906
1. Check the back light switch for proper continuity between the terminals. Item Press switch Release switch Continuity Yes No
Shift fork
2. Replace the backlight switch if the continuity is not as indicated above.
OIL TEMPERATURE SENSOR
AK204455AC
1. Inspect contacting and rubbing surfaces for excessive wear, damage, bend, or other defects. Replace if necessary. (Parts with slight contact marks need not be replaced.)
AK501915
1. Measure the resistance of the oil temperature sensor in order to check of operation of it. Temperature (C) 0 20 40 60 80 100 Resistance (k) 5.790 2.45 0.14 1.148 0.5865 0.3222 0.1884
Wear on one side
Wear on one side Original finger tip width

AK204454AC
2. Check if the width of each shift fork finger tip (which rubs against the coupling sleeve) is greater than the limit. Item Limit for wear on one side mm 0.2 Original finger tip width mm 7.80 7.93 7.80 7.93 6.10 6.23 12.80 12.93
2. Replace the oil temperature sensor if the continuity is not as indicated above.
1st-2nd shift fork
3rd-4th shift fork 0.2 5th-6th shift fork 0.2 Reverse shift fork 0.2
22B-24

INPUT SHAFT
INPUT SHAFT
M1222001600162
21
20 22 23 25
26 30 29 27 28
22 24 1 2 5
32 31 8 13 10 9 11
6 8 3 4
18
17 16 7 12 15 21 19 14
AK204089AC AK204089
<<A>> <> <> <> <<C>>
>>K<< >>J<< >>I<<
<<C>> <<C>> <<D>> <<D>>
>>H<< >>G<< >>G<< >>G<< >>G<<
>>F<< >>E<<
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Disassembly steps Input shaft rear bearing Snap ring 6th gear sleeve Needle roller bearing 6th gear Synchronizer ring 5th-6th synchronizer assembly Synchronizer spring Synchronizer sleeve Synchronizer key 5th-6th synchronizer hub Synchronizer ring 5th gear Needle roller bearing 5th gear sleeve Thrust washer
<<D>> <<D>> <<D>> <<D>> <<D>>
>>D<< >>C<< >>B<< >>B<< >>B<< >>B<<
<<D>> <<D>> <<D>> <<D>> <<E>>
>>A<<
17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
Disassembly steps (Continued) 4th gear Needle roller bearing 4th gear sleeve Synchronizer ring 3rd-4th synchronizer assembly Synchronizer spring Synchronizer sleeve Synchronizer key 3rd-4th synchronizer hub Synchronizer outer ring Synchronizer cone Synchronizer inner ring 3rd gear Needle roller bearing Ball bearing Input shaft

INPUT SHAFT
22B-25
DISASSEMBLY SERVICE POINTS <<A>> INPUT SHAFT REAR BEARING REMOVAL

MD998801
Using the special tool Bearing remover (MD998917) to support the 5th gear, remove the 5th-6th synchronizer assembly, synchronizer ring, and 5th gear.
AK203338AC AK203338
<<D>> 5TH GEAR SLEEVE / THRUST WASHER / 4TH GEAR / NEEDLE BEARING / 4TH GEAR SLEEVE / 3RD-4TH SYNCHRONIZER ASSEMBLY / SYNCHRONIZER OUTER RING / SYNCHRONIZER CONE / SYNCHRONIZER INNER RING / 3RD GEAR REMOVAL
Using the special tool Bearing remover (MD998801) to support the input shaft rear bearing, remove the bearing.
MD998917
<> 6TH GEAR SLEEVE / NEEDLE BEARING / 6TH GEAR REMOVAL
MD998917
AK203341 AC
Using the special tool Bearing remover (MD998917) to support the 3rd gear, remove the 5th gear sleeve, thrust washer, 4th gear, needle bearing, 4th gear sleeve, 3rd-4th synchronizer assembly, synchronizer outer ring, synchronizer cone, synchronizer inner ring, and 3rd gear.
AK203339 AD
Using the special tool Bearing remover (MD998917) to support the 6th gear, remove the 6th gear sleeve, needle bearing, and 6th gear.
<<E>> BALL BEARING REMOVAL
<<C>> 5TH-6TH SYNCHRONIZER ASSEMBLY / SYNCHRONIZER RING / 5TH GEAR REMOVAL
MD998801
MD998917
AK203342 AC
Using the special tool Bearing remover (MD998801) to support the ball bearing, remove the bearing.
AK203340 AC
22B-26

INPUT SHAFT
REASSEMBLY SERVICE POINTS >>A<< BALL BEARING INSTALLATION

MD998812 MD998813 MD998818
CAUTION Install the synchronizer springs on the synchronizer keys so that the center steps on both springs are not positioned on the same key.
2. Install the synchronizer keys and synchronizer springs as shown in the illustration.
>>C<< 3RD-4TH SYNCHRONIZER ASSEMBLY INSTALLATION

AK203343 AC
MD998812 MD998813 MD998801 MD998823
Using the following special tools, install the ball bearing. Installer cap (MD998812) Installer 100 (MD998813) Installer adapter (MD998818)
>>B<< 3RD-4TH SYNCHRONIZER HUB / SYNCHRONIZER KEY / SYNCHRONIZER SLEEVE / SYNCHRONIZER SPRING INSTALLATION
4th gear side 3rd gear seide
AK203344 AC
Identification groove
CAUTION When press fitting the synchronizer assembly onto the main shaft, make sure that the synchronizer rings do not get caught in the hub. Using the following special tools, install the 3rd-4th synchronizer assembly. Bearing remover (MD998801) Installer cap (MD998812) Installer 100 (MD998813) Installer adapter (MD998823)
Oil grooves (4 places)
AK204333AC
>>D<< 4TH GEAR SLEEVE INSTALLATION

MD998812 MD998813 MD998801 MD998822
CAUTION The synchronizer hub is not reusable.

1. Assemble the 3rd-4th synchronizer hub and synchronizer sleeve together as shown in the illustration.
AK203345AC
Center step Center step

AK204334 AC
Using the following special tools, install the 4th gear sleeve. Bearing remover (MD998801) Installer cap (MD998812) Installer 100 (MD998813) Installer adapter (MD998822)

INPUT SHAFT
22B-27
>>E<< THRUST WASHER INSTALLATION

A
>>F<< 5TH GEAR SLEEVE INSTALLATION

MD998812 MD998813 MD998822 MD998801
B
AK204344AC AK204344
CAUTION Do not use more than one thrust washer.

1. Select a washer that allows distance A in the illustration to fall within the standard value range. Standard value: 167.6 167.7 mm Selecting appropriate washer a. Use a dial gauge to measure the distance between the 4th bearing sleeve and the front bearing (distance B in the illustration). b. Select a washer that allows distance A to fall within the standard value range when the thickness of the washer is added to the distance B measurement.
AK203347 AC
Using the following tools, install the 5th gear sleeve. Bearing remover (MD998801) Installer cap (MD998812) Installer 100 (MD998813) Installer adapter (MD998822)
>>G<< 5TH-6TH SYNCHRONIZER HUB / SYNCHRONIZER KEYS / SYNCHRONIZER SLEEVE INSTALLATION

6th gear seide 5th gear side
Identification groove
MD998812 MD998813 MD998801 MD998822
AK204171AC
CAUTION The synchronizer hub is not reusable.

AK203346 AC
2. Using the following special tools, install the thrust washer. Bearing remover (MD998801) Installer cap (MD998812) Installer 100 (MD998813) Installer adapter (MD998822)
1. Assemble the 5th-6th synchronizer hub and synchronizer sleeve together as shown in the illustration.
Center step Center step

AK204334 AC
2. Install the synchronizer keys and synchronizer springs as shown in the illustration.
22B-28

INPUT SHAFT
>>H<< 5TH-6TH SYNCHRONIZER ASSEMBLY INSTALLATION

MD998812 MD998813 MD998822 MD998801
>>J<< SNAP RING INSTALLATION
AK203350 AK203348 AC
CAUTION When press fitting the synchronizer assembly onto the main shaft, make sure that the synchronizer rings do not get caught in the hub. Using the following special tools, install the 5th-6th synchronizer assembly. Bearing remover (MD998801) Installer cap (MD998812) Installer 100 (MD998813) Installer adapter (MD998822)
Select a snap ring that allows the clearance between the snap ring and snap ring groove to fall within the standard value range. Standard value: 0 0.1 mm
>>K<< INPUT SHAFT REAR BEARING INSTALLATION

6th gear side
>>I<< 6TH GEAR SLEEVE INSTALLATION

Snap ring groove
MD998812 MD998818 MD998801

AK204345 AC
CAUTION Install the input shaft rear bearing with its snap ring groove facing the side shown in the illustration.
AK203349 AC
Using the following special tools, install the 6th gear sleeve. Bearing remover (MD998801) Installer cap (MD998812) Installer adapter (MD998818)
MD998812 MD998818 MD998801
AK203351AC
Using the following special tools, install the input shaft rear bearing onto the input shaft. Bearing remover (MD998801) Installer cap (MD998812) Installer adapter (MD998818)

INPUT SHAFT
22B-29
INSPECTION
M1222001700147
2. Check the retainer for deformation.
INPUT SHAFT
SINGLE CONE SYNCHRONIZER RING
AK204168AC AK204168
AK204170AC AK204170
Check the input shaft for damage, flaking, dents, uneven wear, bend, and other defects.
SPEED GEARS
1. Check the clutch gear on the synchronizer ring for damaged and missing teeth. 2. Check the synchronizer ring inner cone surface for damage or wear. Also check that the inside ridges are intact. 3. Check the synchronizer key contact surfaces of the synchronizer ring for damage, and excessive wear.
A Speed gear Synchronizer ring
AK204169AC AK204169
1. Check the helical gear teeth and clutch gear teeth of each speed gear for damage and excessive wear. 2. Check the synchronizer cone surface of each speed gear for roughness, damage, and excessive wear (3rd gear excepted). 3. Check the inside surface and front and back sides of each speed gear for damage and excessive wear.
AK204104 AE
4. Press the synchronizer ring against the cone of the adjacent speed gear, and check clearance A. Replace the synchronizer ring if the clearance is below the limit. Limit: 0.7 mm
NEEDLE ROLLER BEARINGS

1. Combine each needle roller bearing with the input shaft, corresponding sleeve, and gear. Rotate the assembly, checking for smooth rotation, looseness, and noise.
22B-30

INPUT SHAFT
DOUBLE CONE SYNCHRONIZER RING

Inner synchronizer ring Synchronizer ring cone
4. Combine the synchronizer rings and synchronizer cone, and check clearances A and B shown in the illustration. Replace them if either of the clearances is greater than the limit. Limit: 0.2 mm
SYNCHRONIZER KEYS
Outer synchronizer ring
AK204172AC
1. Check the clutch gear on the outer synchronizer ring for damaged and missing teeth. 2. Check the contact surfaces between each synchronizer ring and synchronizer cone for damage and wear. Also check that the cone ridges are intact. 3. Check the synchronizer key contact surfaces of the outer synchronizer ring for damage and excessive wear.
Synchronizer ring cone A
AK204174AC AK204174
Check the synchronizer hub contact surfaces of each synchronizer key for damage and excessive wear.
SYNCHRONIZER SPRINGS
Check the synchronizer springs for loss of tension, deformation, and breakage.
Outer synchronizer ring
B Inner synchronizer ring

AK204173AC

REVERSE IDLER GEAR
22B-31
REVERSE IDLER GEAR

M1222012500125
6 8 2 3 10 12 7 14 9 11 13
AK204079AC
5 1
1. 2. <<A>> >>B<< 3. >>A<< 4. 5. 6. 7. 8.
Disassembly steps Rear reverse idler gear assembly Rear reverse idler gear Reverse idler gear sleeve Insert spring Synchronizer ring Needle bearing Washer Thrust bearing
9. 10. 11. 12. 13. 14.
Disassembly steps (Continued) Front reverse idler gear Needle bearing Washer Thrust bearing Pin Reverse idler fear shaft
22B-32

REVERSE IDLER GEAR
DISASSEMBLY SERVICE POINTS <<A>> REVERSE IDLER GEAR SLEEVE REMOVAL

Match marks
CAUTION Meshing problems may occur if the spline engagement phase is changed during reassembly. Align the match marks when engaging the splines.
INSPECTION
M1222012400043
REVERSE IDLER SHAFT
AK204113AC
CAUTION Meshing problems may occur if the original spline engagement phase is changed during reassembly. Make match marks on the reverse idler gear sleeve and reverse idler gear hub.
AK204101AC AK204101
Check the reverse idler shaft for damage, flaking, dents, uneven wear, bend, and other defects.
REASSEMBLY SERVICE POINTS >>A<< INSERT SPRING INSTALLATION

Clutch housing side
THRUST BEARING
1. Check the thrust bearing for smooth rotation, without looseness or noise, when rotated together with the washers. 2. Check the retainer for deformation.
NEEDLE BEARING
1. Check the needle bearing for smooth rotation, without looseness or noise, when rotated together with the reverse idler gear and shaft. 2. Check the retainer for deformation.
AK204114AC
Install each insert spring on the reverse idler gear sleeve, making sure to insert it in the right direction.
FRONT REVERSE IDLER GEAR
>>B<< REVERSE IDLER GEAR SLEEVE INSTALLATION

Match marks
AK204102AC AK204102
AK204113AC
1. Check the helical gear teeth and clutch gear teeth of the reverse idler gear for damage and excessive wear.

REVERSE IDLER GEAR
22B-33
2. Check the synchronizer cone surface of the reverse idler gear for roughness, damage and excessive wear. 3. Check the inside surface and front and back sides of the reverse idler gear for damage and excessive wear.
REAR REVERSE IDLER GEAR AND REVERSE IDLER GEAR SLEEVE

Match marks
SYNCHRONIZER RING
AK204113AC
CAUTION When assembling the reverse idler gear sleeve and reverse idler gear sleeve, align the match marks that were made during disassembly.
AK204103AC AK204103
1. Check the clutch gear on the synchronizer ring for damaged and missing teeth. 2. Check the inner surface of the synchronizer ring cone for damage and excessive wear. Also check that the inside ridges are intact. 3. Check the synchronizer key contact surface of the synchronizer ring for damage and excessive wear.
A Reverse idler gear Synchronizer ring
Reverse idler gear
Rverse idler gear sleeve
AK204105AC
1. Check that the reverse idler gear sleeve slides smoothly on the reverse idler gear hub when they are combined.
AK204104 AD
4. Press the synchronizer ring against the cone of the reverse idler gear and check clearance A. Replace the synchronizer ring if the clearance is less than the limit. Limit: 0.7 mm
AK204106AC AK204106
2. Check the front and back ends of the inner splines of the reverse idler gear sleeve for damage. 3. Check the helical gear teeth and clutch gear teeth of the reverse idler gear for damage and excessive wear. 4. Check the front, back, and inner surfaces of the reverse idler gear for damage and excessive wear.
22B-34

CLUTCH HOUSING
CLUTCH HOUSING
M1222003700165
11
10 9
35 4 Nm
13 11
7.3 1.0 Nm
2 3 4 8 6
7 12
AK204363 AC
>>C<< <<A>> >>B<< >>D<< >>A<<
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Disassembly steps Magnet Main shaft bearing retainer Main shaft front bearing Oil channel Differential side bearing outer race Input shaft oil seal Dowel pin Knock pin Drain plug gasket Drain plug Cover A Maintenance hole cover Clutch housing
DISASSEMBLY SERVICE POINTS <<A>> DIFFERENTIAL SIDE BEARING OUTER RACE REMOVAL
AK203782
1. Heat the clutch housing to about 100 C (maximum temprerature: 120 C).

CLUTCH HOUSING
22B-35
MB990810
Install the oil channel so that the ribs located on the channel's main shaft side are fitted into the spot faced portion on the clutch housing.
MB991967 MB991968
>>C<< BEARING RETAINER INSTALLATION
AK204356AC AK204356
2. Using the following special tools, remove the differential side bearing outer race. Side bearing puller (MB990810) Claw (MB991967) Bridge (MB991968)
Stamp mark
Bearing retainer
AK203324AE
REASSEMBLY SERVICE POINTS >>A<< INPUT SHAFT OIL SEAL INSTALLATION
Install the bearing retainer so that the stamp mark is visible, and tighten the mounting bolt to the specified torque.
>>D<< DIFFERENTIAL SIDE BEARING OUTER RACE INSTALLATION

MD998323
AK203784AC AK203784
CAUTION The oil seal is not reusable. Using the special tool Bearing installer (MD998323) , install the input shaft oil seal into the clutch housing.
AK203782
1. Heat the clutch housing to about 100 C (maximum temperature: 120 C).
>>B<< OIL CHANNEL INSTALLATION
Ribs MB991966 Spot facing
AK204357AC AK204357 AK203323AD
2. Using the special tool Bearing outer race installer (MB991966) to install the differential side bearing outer race in the clutch housing.
22B-36

TRANSMISSION CASE
TRANSMISSION CASE
M1222013400121
35 4 Nm
8 9
2 10 8
AK204369AC AK204369
>>C<< >>C<< >>B<< >>A<<
1. 2. 3. 4. 5.
Disassembly steps Oil gutter Baffle plate Welch plug Differential oil seal Air breather
6. 7. 8. 9. 10.
Disassembly steps (Continued) Filler plug Drain plug gasket Rod bushing Stud Transaxle case

TRANSMISSION CASE
22B-37
REASSEMBLY SERVICE POINTS >>A<< AIR BREATHER INSTALLATION

1. Apply sealant to the entire air breather fitting surface of the transaxle case. Specified sealant: 3M 8513 or equivalent 2. Install the air breather on the transaxle case.
CAUTION The oil seal is not reusable. Using the special tool Oil seal installer (MD998800), install the differential oil seal into the transaxle case.
>>C<< BAFFLE PLATE / OIL GUTTER INSTALLATION

CAUTION Apply Vaseline to the claws of the baffle plate and oil gutter to prevent both parts from falling off. Install the baffle plate and oil gutter on the transaxle case.
>>B<< DIFFERENTIAL OIL SEAL INSTALLATION
MD998800
AK203788AC AK203788
22B-38

CENTRE DIFFERENTIAL
CENTRE DIFFERENTIAL
M1222010600030
3 8 9 12 11 7 6 4
17 14 16 15 5 13 10 1
158 7 Nm
AK204087AC
<<A>>
>>D<< >>C<< >>B<< >>B<< >>B<< >>B<< >>B<< >>B<< >>B<<
1. 2. 3. 4. 5. 6. 7. 8. 9.
Disassembly steps Center differential drive gear Taper roller bearing Center differential flange Snap ring Front output shaft Spacer Side gear Lock pin Pinion shaft
<>
>>B<< >>B<< >>B<< >>B<< >>B<< >>A<<
10. 11. 12. 13. 14. 15. 16. 17.
Disassembly steps (Continued) Pinion shaft holder Pinion Washer Side gear Spacer Taper roller bearing Speedometer drive gear Differential case

CENTRE DIFFERENTIAL
22B-39
DISASSEMBLY SERVICE POINTS <<A>> TAPER ROLLER BEARING REMOVAL
>>B<< SPACER / SIDE GEAR / WASHER / PINION / PINION SHAFT HOLDER / PINION SHAFT / LOCK PIN / FRONT OUTPUT SHAFT / SNAP RING / CENTER DIFFERENTIAL FLANGE INSTALLATION
1. Install the spacer on each side gear, then install the side gears into the center differential case. NOTE: When installing new side gears, use spacers of a medium thickness (0.66 0.73 mm).
Washer
MD998801
AK203789AC AK203789
Using the special tool Bearing remover (MD998801), remove the taper roller bearing.
<> TAPER ROLLER BEARING REMOVAL

AK203793AC
MD998801
2. Install a washer on the backside of each pinion. Simultaneously engage all four pinions with the side gears, and install them into position while rotating, then install the pinion shaft holder. 3. Insert the pinion shafts into the pinions.
Differntial case Lock pin
AK203790 AC
Pinion
Using the special tool Bearing remover (MD998801), remove the taper roller bearing.
REASSEMBLY SERVICE POINTS >>A<< TAPER ROLLER BEARING INSTALLATION

MB990936 Spacer
AK204147AC
4. Install the lock pins as indicated in the illustration.
AK203791AC AK203791
Using the special tool installer adapter (MB990936), install the taper roller bearing.
AK203794AC
5. Insert the front output shaft into each side gear, then install the snap ring. 6. Install the spacer on each side gear. Next, install the side gears into the center differential case.
22B-40

CENTRE DIFFERENTIAL
NOTE: When installing new side gears, use spacers of a medium thickness (0.66 0.73 mm).
Match marks
>>C<< TAPER ROLLER BEARING INSTALLATION
MB990936
AK203796AC
AK203792 AC
7. Install the center differential flange on the differential case while aligning the match marks. Secure it temporarily in place using machine screws in four places.
Using the special tool Installer adapter (MB9900936), install the taper roller bearing.
>>D<< CENTER DIFFERENTIAL DRIVE GEAR INSTALLATION
AK203797
8. Measure the backlash between the side gears and pinions. Standard value: 0.025 0.150 mm 9. If the backlash does not fall within the standard value range, select other appropriate spacers, replace the existing spacers with them, and measure the backlash once again. NOTE: Adjust the backlash on each side so that it is equal to the backlash on the other side.
AK204150AC AK204150
1. Apply sealant to the entire threaded part on the bolts. Specified sealant: 3M STUD Locking No. 4170 or equivalent
1 13 7 3 10 6 11 2 14
AK204149AC AK204149
12
5 9 4 8
2. Tighten bolts to the specified torque of 158 7 Nm in the order indicated in the illustration.

TRANSFER
22B-41
TRANSFER
M1222004000095
4 3
AK402153AC
>>D<< >>C<<
1. 2. 3.
Disassembly steps Dust seal guide Oil seal O-ring
>>B<< >>A<<
4. 5.
Disassembly steps (Continued) Oil seal Oil seal
22B-42

TRANSFER
REASSEMBLY SERVICE POINTS >>A<< OIL SEAL INSTALLATION

1. Apply gear oil (Hypoid gear oil API classification GL-5 SAE 90).
2. Using special tool Crankshaft installer (MD999506), press fit the oil seal into the transfer.
>>C<< O-RING INSTALLATION

Install a O-ring to the transfer, and apply gear oil (Hypoid gear oil API classification GL-5 SAE 90) to the O-ring.
MD998800
>>D<< OIL SEAL INSTALLATION

AK501989 AB
MB990936
2. Using special tool Oil seal installer (MD998800), press fit the oil seal into the transfer cover.
>>B<< OIL SEAL INSTALLATION

AK101417 AE
2. Using special tool Installer adapter (MB990936), press fit the oil seal into the transfer.
MD999506
AK302773AB
25-1
GROUP 25
PROPELLER SHAFT
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATION . . . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SEALANT. . . . . . . . . . . . . . . . . . . . . . 25-2 25-2 25-2 25-2 SPECIAL TOOL . . . . . . . . . . . . . . . . . PROPELLER SHAFT . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . .
25-2 25-3
25-3 25-4 25-5
25-2
PROPELLER SHAFT
GENERAL INFORMATION
GENERAL INFORMATION
A 3 way split 4-joint type propeller shaft with centre bearing is used.
M1251000100205
SERVICE SPECIFICATION
M1251000300209
Item Propeller shaft run-out mm
Limit 0.5
LUBRICANTS
M1251000400303
Item Front propeller shaft sleeve yoke LJ assembly
Specified lubricant DIA QUEEN LSD gear oil Repair kit grease
Quantity As required 75 5 g
SEALANT
M1251000500117
Item Rubber packings for LJ assembly
Specified sealant 3M Stud Locking 4170 or equivalent
SPECIAL TOOL
M1251000600192
Tool
Number MD998801
Name Bearing remover
Use Removal of centre bearing assembly
AC106983
PROPELLER SHAFT
PROPELLER SHAFT
25-3
PROPELLER SHAFT
M1251001000364
3 3 2 2
Gear Oil: DIA QUEEN LSD gear oil
2
N
2 1N 4
30 4 Nm 32 2 Nm
30 4 Nm
AC310408 AC
<<A>>
>>A<<
1. 2. 3. 4.
Removal steps Self locking nut Insulator Spacer Propeller shaft assembly
CAUTION Be careful not to bend the joint portion when removing the propeller shaft because this will damage to the joint boot.
Joint boot Rag
REMOVAL SERVICE POINT <<A>> PROPELLER SHAFT ASSEMBLY REMOVAL

1. Make mating marks on the differential companion flange and the propeller shaft assembly.
Joint assembly
Rear propeller shaft

AC101255 AD
2. Insert a rag so as to avoid boot damage, and remove the propeller shaft assembly in a straight and level manner.
25-4
PROPELLER SHAFT
PROPELLER SHAFT
INSTALLATION SERVICE POINT >>A<< PROPELLER SHAFT ASSEMBLY INSTALLATION

CAUTION
INSPECTION
M1251001100219
Oil seal
Check the sleeve yoke and centre yoke for wear, damage or cracks. Check the propeller shaft for bends, twisting or damage. Check the universal joint for smooth operation in all directions. Check the centre bearing for smooth movement.
PROPELLER SHAFT RUNOUT
Transfer
AC211569 AC
Do not damage the oil seal lips on the transfer case. Remove oil and grease from the threads of the mounting bolts and nuts before tightening, or they will loosen. Be careful not to bend the joint portion when removing the propeller shaft, because this will damage the joint boot.
ACX00643AB
Limit: 0.5 mm
PROPELLER SHAFT UNIVERSAL JOINT PLAY CHECK
Mating marks
AC003833 AC
1. If reusing the propeller shaft, align the mating marks of differential companion flange and propeller shaft assembly to install. 2. When installing a new rear propeller shaft assembly, if there is no phase alignment mark on the companion flange at the differential side, assemble while adjusting the hole phases of propeller shaft flange and differential companion flange.
AC501206
1. Hold the tube of propeller shaft by one hand, and apply force by the other hand to the flange yoke or sleeve yoke in rotative direction, axial direction, and perpendicular direction for cheking looseness. 2. If looseness is recognized, replace the propeller shaft with a new one.
PROPELLER SHAFT
PROPELLER SHAFT
25-5

M1251001200249
187 29 Nm
3N
2
34 5 Nm
6 4 1
187 29 Nm
N 12
16 N
14 N 11 N
9 15
7N 8 10
34 5 Nm
13
17
14 11
13 14
15 12 16
14 11
15 12
LJ kit
LJ boot kit
<<A>> <> <<C>> <<A>>
>>E<< >>E<< >>E<< >>D<< >>D<< >>D<<
1. 2. 3. 4. 5. 6. 7. 8. 9.
Disassembly steps Bolt Front propeller shaft assembly Self locking nut Companion flange Centre bearing assembly Bolt Self locking nut Companion flange Centre bearing assembly
<<D>> <<E>>
>>C<< >>B<< >>A<<
10. 11. 12. 13. 14. 15. 16. 17.
Disassembly steps (Continued) Centre propeller shaft Snap ring Boot band LJ assembly Rubber packing LJ boot Washer Rear propeller shaft
AC211583 AC
25-6
Lubrication and Adhesive Points
PROPELLER SHAFT
PROPELLER SHAFT
Rubber mount
Repair kit grease: Quantity: 75 5 g
Adhesive: 3M Stud Locking 4170 or equivalent
AC211584 AC
PROPELLER SHAFT
PROPELLER SHAFT
25-7
DISASSEMBLY SERVICE POINTS <<A>> COMPANION FLANGE REMOVAL

Mating marks
1. Remove the LJ boot from the LJ assembly.
Outer race
Inner race Cage Ball
Circlip
AC101275 AC AC211610 AC
Make mating marks on the companion flange and centre propeller shaft, and then remove the companion flange.
2. Make mating marks on the outer race, cage and inner race, and then remove the circlip, outer race and ball. NOTE: Note the positions of the balls so that they can be reinstalled in their original positions.
Cage Inner race
<>CENTRE BEARING ASSEMBLY REMOVAL

Centre bearing assembly
MD998801
Puller
AC101276 AC
AC101273 AD
Use special tool bearing remover (MD998801) to remove the centre bearing assembly from the centre propeller shaft.
3. Remove the inner race with cage from the centre propeller shaft assembly by using a puller (commercially available). 4. Wipe off the grease and clean the outer race, inner race, cage and balls.
<<C>> BOLT REMOVAL

Make mating marks on the rear propeller shaft, LJ assembly and companion flange, and then remove the bolt.
<<E>> LJ BOOT REMOVAL

When the LJ boot is reused, tape the spline part on the centre propeller shaft and then remove the LJ boot.
<<D>>LJ ASSEMBLY REMOVAL
REASSEMBLY SERVICE POINTS >>A<< LJ BOOT INSTALLATION

1. Install the boot band. 2. Wrap a plastic tape around the spline part on the centre propeller shaft and then install the LJ boot.
LJ assembly
LJ boot
AC101274 AE
25-8
PROPELLER SHAFT
PROPELLER SHAFT
>>B<< LJ ASSEMBLY INSTALLATION

Socket wrench Inner race Outer race
Circlip Cage
AC101277AC AC101280 AC
1. Apply a thin coat of the specified grease to the ball grooves of the inner and outer races. Specified grease: Repair kit grease 2. Assemble the LJ assembly as follows: (1) Assemble the outer race, cage, balls, and inner race with their mating marks aligned. (2) Install the circlip.
6. Lining up the mating marks on the LJ assembly and the centre propeller shaft and using the socket wrench, install the LJ assembly to the centre propeller shaft.
Bolt
LJ boot
AC101281AE
AC101278 AC
3. Apply specified grease to the LJ assembly. Specified grease: Repair kit grease Amount to use: 75 5 g
Rubber packing
7. Using the bolt, align the bolt holes of the LJ boot and the LJ assembly and install LJ boot to the LJ assembly. 8. Install the rubber packing of the companion flange side in the same manner as described in (4) above.
>>C<< BOOT BAND INSTALLATION

CAUTION
Mark
Boot
LJ assembly
AC101279 AE
Vent plug
4. Apply a thin coat of specified adhesive to the groove side of LJ assembly (shown by arrows in the figure) and install the rubber packing. Specified adhesive: 3M Stud Locking 4170 or equivalent 5. Set the groove side of LJ assembly (for packing) toward the LJ boot side and install them.
AC107071AB
Clamp the boot by holding down the lever at a position nearly opposite to the vent groove provided in the LJ boot (at arrow marked position on boot). Be sure to remove grease, if present, from around the vent groove. Grease obstructs the ventilation air passage.
PROPELLER SHAFT
PROPELLER SHAFT
25-9
>>D<< CENTRE BEARING ASSEMBLY/COMPANION FLANGE/SELF-LOCKING NUT INSTALLATION

Centre bearing assembly Companion flange
>>E<<CENTRE BEARING ASSEMBLY/COMPANION FLANGE/SELF-LOCKING NUT INSTALLATION

Companion Dust seal flange Selflocking nut
Rubber mount
Self-locking nut
AC101283 AD
AC101284 AE
1. Set the centre bearing assembly in the direction shown in the figure and install it to the centre propeller shaft. 2. Install, lining up the mating marks on the companion flange and the centre propeller shaft. 3. While tightening the self-locking nut, install the centre bearing assembly with the companion flange.
1. Set the centre bearing assembly in the direction shown in the figure and install it to the centre propeller shaft. 2. Align the mating marks on the companion flange and the centre propeller shaft. 3. While tightening the self-locking nut, install the centre bearing assembly with the companion flange.
NOTES
26-1
GROUP 26
FRONT AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
WHEEL BEARING AXIAL PLAY CHECK . . HUB BOLT REPLACEMENT . . . . . . . . . . .
26-2 26-3 26-3 26-3 26-6

26-6 26-6
FRONT AXLE HUB ASSEMBLY . . . .

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
26-7
26-7 26-9 26-9 26-10
DRIVESHAFT ASSEMBLY. . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . EBJ BOOT (RESIN BOOT) REPLACEMENT
26-11
26-11 26-14 26-16 26-17
26-2
FRONT AXLE
GENERAL INFORMATION
GENERAL INFORMATION
M1261000100444
The front axle consists of front wheel hub assembly, knuckles and driveshafts, and has the following features: The wheel bearing incorporates a unit ball bearing (double-row angular contact ball bearing) for reduced friction. The front wheel hub assembly combines the hub, wheel bearing, and oil seal in a single unit for fewer parts, better rigidity, improved assembly precision, and better structural organization. The driveshaft on wheel side incorporates an EBJ type constant velocity joint.
The driveshaft on the differential side incorporates a TJ type constant velocity joint. ABS rotor for detecting the wheel speed is press-fitted to the EBJ. For environmental protection, a lead-free grease is used on the joints. EBJ:Eight Ball Fixed Joint; The use of the smaller-sized eight balls inside the joint achieves weight saving and compact size compared with a BJ (Birfield Joint). TJ: Tripod Joint
SPECIFICATIONS
Item Wheel bearing Driveshaft Type Joint type Length (joint to joint) diameter mm Outer Inner Left Right Specification Unit ball bearing (Double-row angular contact ball bearing) EBJ TJ 352.5 26 429.5 26
NOTE: The wheel bearing is part of the hub, therefore its size is not listed here.
CONSTRUCTION DIAGRAM
Strut assembly Output shaft TJ (LH) Knuckle Front wheel hub assembly TJ (RH) Driveshaft (RH)
Driveshaft (LH) EBJ ABS rotor Wheel bearing Output shaft
AC211166 AB
FRONT AXLE
26-3
M1261000300460
Item Wheel bearing axial play mm Wheel bearing rotation starting torque Nm Setting of TJ boot length mm Opening dimension of the special tool (MB991561) mm When the EBJ boot band (small) is crimped When the EBJ boot band (large) is crimped Crimped width of the EBJ boot band mm Standard value 85 3 2.9 3.2 2.4 2.8 Limit 0.05 1.03
LUBRICANTS
M1261000400490
Item TJ boot grease EBJ boot grease
Specified lubricant Repair kit grease Repair kit grease
Quantity 145 10 g 100 10 g
SPECIAL TOOLS
M1261000600784
Tool
Number MB990767
Name
Use
Front hub and end Fixing of the hub yoke holder
B990767
MB991618
Hub bolt remover
Removal of the hub bolt
MB991618
MB991897 or MB992011
Ball joint remover
AC106827
Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113)is also used to disconnect knuckle and tie rod end ball joint.
26-4
Tool
A B
FRONT AXLE
SPECIAL TOOLS
Number MB990241 A: MB990242 B: MB990244
Name Axle shaft puller A: Puller shaft B: Puller bar
Use Removal of the driveshaft
MB990241AB
MB991354
Puller body
MB991354
MB990590 A: MB990212 B: MB990211

MB990590
Rear axle shaft oil Removal of the front wheel hub seal remover A: Adapter B: Slide hammer
MB991721
Slide hammer
Removal of the output shaft
MB991721 A
A: MB991017 B: MB990998 C: MB991000
B C AC100320AB
A, B: Front hub remover and installer C: Spacer
Removal of the hub Provisional holding of the wheel bearing Measurement of hub starting torque Measurement of wheel bearing axial play NOTE: MB991000, which belongs to MB990998, should be used as a spacer. Measurement of hub starting torque
MB990685
Torque wrench
MB990326
Preload socket
MB990326
FRONT AXLE
SPECIAL TOOLS
26-5
Use BJ boot (resin boot) band installation
Tool
Number MB991561
Name Boot band crimping tool
MB991561
MB990925
Bearing and oil seal installer set
MB990925
Removal of the wheel bearing Removal and installation of the centre bearing Press-fitting of the dust seal outer, inner O D mm 39.0 45.0 49.5 51.0 54.0 57.0 61.0 63.5 67.5 71.5 75.5 79.0
Tool
MB990925
Type A
Tool number MB990926 MB990927 MB990928 MB990929 MB990930
A Installer adapter Brass bar
MB990931 MB990932 MB990933 MB990934 MB990935 MB990936 MB990937 B C MB990938 MB990939
B Bar (snap-in type)
Tool box
ACX02372 AC
26-6
FRONT AXLE
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
M1261000900268
2. Remove the brake disc.

MB991618 MB990767
CAUTION During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
1. Remove the caliper assembly and suspend it with a wire. 2. Remove the brake disc from the front hub.
AC102439 AC
3. Use the following special tools to remove the hub bolts. Front hub and end yoke holder (MB990767) Hub bolt remover (MB991618)
MB990767
AC102438AD
3. Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction. Limit: 0.05 mm 4. If axial play exceeds the limit, disassemble the front hub assembly and check the parts. 5. Install the brake disc, caliper assembly and tighten the caliper assembly mounting bolts to the specified torque 108 10 Nm.
Plain washer
AC102440AC
HUB BOLT REPLACEMENT

M1261001000332
4. Install the plain washer to the new hub bolt, and install the bolt with a nut. 5. Install the brake disc, caliper assembly and tighten the caliper assembly mounting bolts to the specified torque 108 10 Nm.
CAUTION During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
1. Remove the caliper assembly and suspend it with wire so that it does not fall.
FRONT AXLE
FRONT AXLE HUB ASSEMBLY
26-7

M1261001700740
CAUTION Do not strike the ABS rotors installed to the EBJ outer race of driveshaft against other parts when removing or installing the driveshaft. Otherwise the ABS rotors will be damaged. Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing work. During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe off quickly.
Pre-installation Operation Front Under Cover, Side Under Cover Removal Transmission Oil Draining (Refer to GROUP22A, On-vehicle Service Manual Transmission Oil P.22A-152.) Transfer Oil Draining (Refer to GROUP22A, On-vehicle Service Transfer Oil P.22A-152.) Post-installation Operation Check the dust cover for cracks or damage by pushing it with your finger. Transfer Oil Filling (Refer to GROUP 22A, On-vehicle ServiceTransfer Oil P.22A-152.) Transmission Oil Filling (Refer to GROUP22A, On-vehicle Service Manual Transmission Oil P.22A-152). Front Under Cover, Side Under Cover Installation
11
167 9 Nm
12 10
25 5 Nm
9N
7
108 10 Nm 8.9 1.9 Nm
1N
108 10 Nm 226 29 Nm
2
AC211630 AC
1. <<A>> >>A<< 2. >>A<< 3. 4. <> 5. <<C>> 6. 7.
Removal steps Split pin Driveshaft nut Washer Front ABS sensor Caliper assembly Brake disc Dust cover
<<D>> <<E>>
Removal steps (Continued) 8. Connection for lower arm ball joint 9. Self-locking nut (tie rod end connection) 10. Driveshaft 11. Nut (hub and knuckle to strut connection) 12. Hub and knuckle assembly
26-8
FRONT AXLE
REMOVAL SERVICE POINTS <<A>> DRIVESHAFT NUT REMOVAL

CAUTION Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when driveshaft nut is loosened.
<<D>> SELF-LOCKING NUT (TIE ROD END CONNECTION) REMOVAL

CAUTION Do not remove the nut from ball joint. Loosen it and use the special tool to avoid possible damage to ball joint threads. Hang the special tool with cord to prevent it from falling.
Cord
Nut MB990767
AC102462 AC
MB991897 or MB992011 Bolt Ball joint

AC208247AJ
Use special tool front hub and end yoke holder (MB990767) to fix the hub and remove the driveshaft nut.
<> CALIPER ASSEMBLY REMOVAL

CAUTION During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Secure the removed caliper assembly with wire, etc.
1. Install special tool ball joint remover (MB991897 or MB992011) as shown in the figure.
Bolt Parallel
Knob
Correct
<<C>> BRAKE DISC REMOVAL

Wrong
AC106821AD
Bolts (M81.25)
AC205799AC
If the brake disc is seized, install a M81.25 mm bolts as shown, and remove the disc by tightening the bolts evenly and gradually.
2. Turn the bolt and knob as necessary to make the jaws of special tool parallel, tighten the bolt by hand and confirm that the jaws are still parallel. NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure. 3. Tighten the bolt with a wrench to disconnect the tie rod end.
FRONT AXLE
26-9
<<E>> DRIVESHAFT REMOVAL

MB990242
INSTALLATION SERVICE POINT >>A<< WASHER/ DRIVESHAFT NUT INSTALLATION

CAUTION Before securely tightening the driveshaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearings will be damaged.
Washer
MB990767 MB990244 (Three) MB991354

AC201827 AE
1. Use the following special tools to push out the driveshaft from the hub and knuckle. Puller shaft (MB990242) Puller bar (MB990244) Puller body (MB991354) Front hub and end yoke holder (MB990767)
MB990767
AC102465AD
Driveshaft
1. Be sure to install the driveshaft washer in the specified direction. 2. Using special tool front hub and end yoke holder (MB990767), tighten the driveshaft nut to the specified torque. Tightening torque: 226 29 Nm
AC102551AC
INSPECTION
Check the hub for cracks and spline for wear. Check the knuckle for cracks.
M1261001800286
2. Withdraw the driveshaft from the hub by pulling the bottom of the hub and knuckle towards you. 3. Hang the driveshaft on the vehicle body with a rope.

1
M1261001900261
88 10 Nm
AC211631AC
<<A>>
1. 2.
Disassembly steps Knuckle Front wheel hub assembly
26-10
FRONT AXLE
DISASSEMBLY SERVICE POINTS <<A>> FRONT WHEEL HUB ASSEMBLY REMOVAL

1. If the front wheel hub is seized, remove the knuckle together with front wheel hub and fix them with a vise.
2. Hold the front wheel hub assembly in a vice with a wooden block. 3. Rotate the hub in order to seat the bearing.
MB990326 Wooden block
MB990244
Wooden block MB990685
MB990211
AC206090 AD
MB991354
AC210309AE
2. Use the following special tools to pull out the front wheel hub from the knuckle. Puller bar (MB990244) Puller body (MB991354) Slide hammer (MB990211)
4. Measure the wheel bearing rotation starting torque by using the following special tools. Preload socket (MB990326) Torque wrench (MB990685) Limit: 1.03 Nm 5. If the rotation starting torque is not within the limit range while the nut is tightened to 226 29 Nm, replace the front wheel hub assembly. If there are any signs of binding or tight spots when the wheel bearing turns, replace it.
Wooden block
INSPECTION
M1261002000108
WHEEL BEARING ROTATION STARTING TORQUE AND AXIAL PLAY CHECK

MB991017

AC206091AG
MB991000
AC301927AF
1. Tighten the following special tools to the specified torque. Front hub remover and installer (MB991017) Spacer (MB991000) Tightening torque: 226 29 Nm
6. Measure to determine whether the wheel bearing axial play is within the specified limit or not. Limit: 0.05 mm 7. If the play is not within the limit range while the nut is tightened to 226 29 Nm, replace the front wheel hub assembly.
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-11
DRIVESHAFT ASSEMBLY
M1261003500850
CAUTION Do not strike the ABS rotors installed to the EBJ outer race of driveshaft against other parts when removing or installing the driveshaft. Otherwise the ABS rotors will be damaged.
Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing work. During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe off quickly. Pre-installation Operation Front under cover, side under cover removal Transmission Fluid Draining (Refer to GROUP 22A, On-vehicle service Transmission oil replacement P.22A-152). Transfer Oil Draining (Refer to GROUP 22A, On-vehicle service Transfer oil P.22A-152). Post-installation Operation Check the ball Joint dust cover for cracks or damage by pushing it with your finger. Transfer Oil Filling (Refer to GROUP 22A, On-vehicle service Transfer oil P.22A-152). Transmission Fluid Filling (Refer to GROUP 22A, On-vehicle service Transmission oil replacement P.22A-152). Front Under cover, side under cover Installation
N 12
6 5 10
N
25 5 Nm
9 4
11
N 12
39 5 Nm
3 2 1N 7
39 5 Nm 226 29 Nm
8
108 10 Nm
AC211632 AC
<<A>>
>>B<< >>B<<
1. 2. 3. 4. 5. 6. 7.
Removal steps Split pin Driveshaft nut Washer Front ABS sensor Front ABS sensor harness bracket Brake hose bracket Stabilizer bar link connection
<> <<C>> <<D>> >>A<< >>A<<
Removal steps (Continued) 8. Lower arm ball joint connection 9. Self-locking nut (tie rod end connection) 10. Driveshaft 11. Output shaft 12. Circlip
26-12
FRONT AXLE
DRIVESHAFT ASSEMBLY

CAUTION Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the driveshaft nut is loosened.
Parallel
Bolt
Knob
Correct
Wrong
AC106821AD
MB990767
AC102462 AC
<<C>> DRIVESHAFT REMOVAL <> SELF-LOCKING NUT (TIE ROD END CONNECTION) REMOVAL
CAUTION Do not remove the nut from ball joint. Loosen it and use special tool to avoid possible damage to ball joint threads. Hang special tool with cord to prevent it from falling.
Cord MB990767
MB990244 (Three) MB990242 MB991354

AC102550 AC
Nut

AC208247AJ
1. Use the following special tools to push out the driveshaft from the hub. Puller shaft (MB990242) Puller bar (MB990244) Puller body (MB991354) Front hub and end yoke holder (MB990767)
Drive shaft
AC102551AC
2. Remove the driveshaft from the hub by pulling the bottom of the brake disc towards you.
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-13
CAUTION Do not pull on the driveshaft; doing so will damage the TJ; be sure to use the pry bar. When pulling the driveshaft out from the transmission, be careful that the spline part of the driveshaft does not damage the oil seal.
Transmission
<<D>>OUTPUT SHAFT REMOVAL

CAUTION When pulling the output shaft out from the tansaxle, be careful that the spline part of the output shaft does not damage the oil seal.
MB991721
TJ assembly Pry bar

AC100141 AG
Output shaft
AC102556 AC
3. Insert a pry bar between the transmission case and the driveshaft, and then pry and remove the driveshaft from the transmission.
Use special tool slide hammer (MB991721) to remove the output shaft.
CAUTION
INSTALLATION SERVICE POINTS >>A<< OUTPUT SHAFT/DRIVESHAFT INSTALLATION

CAUTION When installing the output shaft or the driveshaft, be careful that the spline part of the output shaft or the driveshaft do not damage the oil seal.
MB991000 MB991017
>>B<< WASHER/DRIVESHAFT NUT INSTALLATION

AC210315 AF
Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the driveshaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using the following special tools. Spacer (MB991000) Front hub remover and installer (MB991017)
Washer
MB990767
AC102465AD
1. Be sure to install the driveshaft washer in the specified direction.
CAUTION Before securely tightening the driveshaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged.
2. Using special tool front hub and end yoke holder (MB990767), tighten the driveshaft nut to the specified torque. Tightening torque: 226 29 Nm
26-14
FRONT AXLE
DRIVESHAFT ASSEMBLY
M1261003700586
CAUTION Be careful not to damage the ABS rotor, which is attached to the EBJ outer race during disassembly and reassembly.
Never disassemble the EBJ assembly except when replacing the EBJ boot.
3 4N 5 6 2N 1N
9 7 8 10 3 4 1 6 4 1 2
4 5 6
Grease for EBJ Grease for TJ
2
TJ boot repair kit TJ repair kit
8
EBJ boot repair kit
10
AC211633 AC
<<A>> <<A>> <>
>>D<< >>D<< >>C<< >>B<< >>A<<
1. 2. 3. 4. 5. 6. 7.
Disassembly steps TJ boot band (large) TJ boot band (small) TJ case Snap ring Spider assembly TJ boot EBJ assembly
TJ: Tripod Joint EBJ:Eight Ball Fixed Joint
Disassembly steps (Continued) 8. EBJ boot band (small) 9. EBJ boot band (large) 10. EBJ boot
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-15
LUBRICATION POINTS
5
Grease: repair kit grease Amount used: 145 10 g
CAUTION
The driveshaft joint uses special grease. Do not mix old and new or different types of grease.
Grease: repair kit grease Amount used: 100 10 g
CAUTION
AC211634 AC
26-16
FRONT AXLE
DRIVESHAFT ASSEMBLY
DISASSEMBLY SERVICE POINTS <<A>> TJ CASE/SPIDER ASSEMBLY REMOVAL

CAUTION Do not disassemble the spider assembly. 1. Wipe off grease from the spider assembly and the inside of the TJ case. 2. Always clean the spider assembly when the grease contains water or foreign material.
>>C<< TJ CASE INSTALLATION

CAUTION The driveshaft joint use special grease. Do not mix old and new or different types of grease.
<> TJ BOOT REMOVAL

1. Wipe off grease from the shaft spline. 2. When reusing the TJ boot, wrap plastic tape around the shaft spline to avoid damaging the boot.
AC102656 AC
REASSEMBLY SERVICE POINTS >>A<< TJ BOOT INSTALLATION

Wrap plastic tape around the shaft spline, and then install the TJ boot band (small) and TJ boot.
After applying the specified grease to the TJ case, insert the driveshaft and apply grease one more time. Specified grease: Repair kit grease Amount to use: 145 10 g NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
>>B<< SPIDER ASSEMBLY 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
>>D<< TJ BOOT BAND (SMALL)/TJ BOOT BAND (LARGE) INSTALLATION
A
AC102657AC
Chamfered side
Set the TJ boot bands at the specified distance in order to adjust the amount of air inside the TJ boot, and then tighten the TJ boot band (small), TJ boot band (large) securely. Standard value (A): 85 3 mm
INSPECTION
AC102654AC
2. Install the spider assembly to the shaft from the direction of the spline chamfered side.
Check the driveshaft for damage, bending or corrosion. Check the driveshaft spline part for wear or damage. Check the spider assembly for roller rotation, wear or corrosion. Check the groove inside TJ case for wear or corrosion.
M1261003800215
FRONT AXLE
DRIVESHAFT ASSEMBLY
26-17
Check the boots for deterioration, damage or cracking.
EBJ BOOT (RESIN BOOT) REPLACEMENT

M1261005200435
<If it is smaller than 2.9 mm> Loosen the adjusting bolt. NOTE: The value of W will change by approximately 0.7 mm for each turn of the adjusting bolt. NOTE: The adjusting bolt should not be turned more than once.
Boot A Boot band (small) B
AC102658
Projection
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.
AC102661AC
6. Position the EBJ boot band (small) so that there is even clearance at either end (A and B).
CAUTION Secure the driveshaft in an upright position and clamp part of the boot band to be crimped securely in the jaws of special tool. Crimp the boot band until special tool touches the stopper.
AC102659
4. Align the centre groove on the EBJ boot small end with the shaft groove.
MB991561 Stopper
MB991561
AC102663 AC
7. Use the special tool to crimp the boot band (small).
C
Adjusting bolt
AC102660 AC
5. Turn the adjusting bolt on special tool boot band crimping tool (MB991561) so that the size of the opening (W) is at the standard value. Standard value (W): 2.9 mm <If it is larger than 2.9 mm> Tighten the adjusting bolt.
AC102662 AD
8. Check that the crimping amount (C) of the boot band is at the standard value. Standard value (C): 2.4 2.8 mm
26-18
FRONT AXLE
DRIVESHAFT ASSEMBLY
Projection D Boot band (large) Boot E
AC102665AC
<If the crimping amount is larger than 2.8 mm > 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 C Example: If C = 2.9 mm, then W = 2.6 mm. <If the crimping amount is smaller than 2.4 mm > 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 C Example: If C = 2.3 mm, then W = 3.2 mm. 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.
13.Position the EBJ boot band (large) so that there is even clearance at either end (D and E). 14.Use the special tool to crimp the EBJ boot band (large) in the same way as in step 7.
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. Specified grease: Repair kit grease Amount to use: 100 10 g
F
AC102666 AD
AC102664 AC
11.Align the centre groove on the EBJ boot big end with the EBJ case groove. 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
15.Check that the crimping amount (F) of the boot band is at the standard value. Standard value (F): 2.4 2.8 mm <If the crimping amount is larger than 2.8 mm > Readjust the value of (W) in step 12 according to the following formula, and then repeat the operation in step 14. W = 5.8 mm F Example: If F = 2.9 mm, then W = 2.9 mm. <If the crimping amount is smaller than 2.4 mm > 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 EBJ boot band. W = 5.8 mm F Example: If F = 2.3 mm, then W = 3.5 mm. 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.
27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SEALANT. . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . .
TROUBLESHOOTING STRATEGY . . . . . . DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . DIAGNOSIS CODE CHART . . . . . . . . . . . . DIAGNOSTIC TROUBLE CODE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . SYMPTOM CHART. . . . . . . . . . . . . . . . . . . INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . DATA LIST REFERENCE TABLE . . . . . . . ACTUATOR TEST REFERENCE TABLE. . CHECK AT 4WD-ECU TERMINAL . . . . . . .
27-2 27-3 27-3 27-3 27-4 27-7

27-7 27-7 27-9 27-11 27-23 27-24 27-25 27-25 27-25
AYC OPERATION CHECK . . . . . . . . . . . . . OIL PRESSURE CHECK . . . . . . . . . . . . . . WHEEL BEARING AXIAL PLAY CHECK . . HUB BOLT REPLACEMENT. . . . . . . . . . . . DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . REMEDY FOR A DISCHARGED BATTERY
27-29 27-29 27-30 27-30 27-31 27-31
REAR AXLE HUB ASSEMBLY . . . . .

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
27-32
27-32 27-33
KNUCKLE . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
27-35
27-35 27-36
DRIVESHAFT ASSEMBLY. . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . .
27-36
27-36 27-39 27-40
ON-VEHICLE SERVICE. . . . . . . . . . .
REAR AXLE TOTAL BACKLASH CHECK . GEAR OIL LEVEL CHECK . . . . . . . . . . . . . GEAR OIL REPLACEMENT . . . . . . . . . . . . FLUID LEVEL CHECK . . . . . . . . . . . . . . . . AYC BLEEDING . . . . . . . . . . . . . . . . . . . . .
27-26
27-26 27-26 27-27 27-27 27-28
DIFFERENTIAL CARRIER ASSEMBLY. . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . . DIFFERENTIAL SUPPORT MEMBER BUSHING REPLACEMENT . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . REMOVAL AND INSTALLATION . . . . . . . . HYDRAULIC UNIT DISPOSAL . . . . . . . . . .
27-43
27-43 27-45 27-46 27-49 27-50
27-2
REAR AXLE
GENERAL INFORMATION
GENERAL INFORMATION
M1271000100382
The rear axle consists of rear wheel hub assembly, knuckles and driveshafts, and has the following features: The wheel bearing is a unit ball bearing (double-row angular contact ball bearing) for reduced friction. The driveshaft has EBJ-TJ constant velocity joints. ABS rotor for detecting the wheel speed is press-fitted to the EBJ.
For environmental protection, lead-free grease is used on the joints. Active Yaw Control (AYC) is adopted to improve the turning performance. AYC incorporates the torque transfer differential and the hydraulic unit. EBJ:Eight Ball Fixed Joint; The use of the smaller-sized eight balls inside the joint achieves weight saving and compact size compared with a BJ (Birfield Joint). TJ: Tripod Joint
SPECIFICATIONS
Item Wheel bearing Type Bearing (OD x ID) mm Driveshaft Type Length (joint to joint) diameter mm Outer Inner Left Right Specification Unit ball bearing (Double-row angular contact ball bearing) 70 40 EBJ TJ 428.5 25 448.5 25
CONSTRUCTION DIAGRAM
TJ BJ Rear hub
Differential carrier
Driveshaft
ABS rotor
AC310259 AB
REAR AXLE
27-3
Hydraulic unit Torque transfer differential

AC311159 AB
M1271000300557
Item Rear axle total backlash mm Wheel bearing rotation starting torque Nm Wheel bearing axial play mm TJ boot assembly dimension mm Pressure generated by AYC hydraulic unit (pressure sensor value) MPa
Standard value 90 3 0.9 1.1
Limit 6 1.0 0.05
LUBRICANTS
M1271000400383
Item AYC Differential Torque transfer mechanism AYC hydraulic piping Torque transfer mechanism oil seal lip Drive shaft EBJ joint Drive shaft TJ joint
Specified lubricant DIA QUEEN LSD gear oil DIA QUEEN ATF-SP III DIA QUEEN ATF-SP III Vaseline Repair kit grease Repair kit grease
Quantity 0.55 0.02 L 0.55 0.6 L 1.0 L As required 80 10 g 135 10 g
SEALANT
M1271000500313
Item Vent plug Differential carrier cover mounting part
Specified sealant 3M ATD Part No.8661 or equivalent
Remark Semi-drying sealant
27-4
REAR AXLE
SPECIAL TOOLS
SPECIAL TOOLS
M1271000600688
Tool
Number MB991502
Use Checking the AYC (Diagnosis display by using the M.U.T.-II)
B991502
MB991824
MB991827
DO NOT USE
MB991910
MB991911
MB991825
M.U.T.-III Checking the AYC (Diagnosis sub-assembly display by using the M.U.T.-III) A: Vehicle Communication Interface (V. C. I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
MB991826 MB991955
MB991529
Diagnosis code check harness
Checking the AYC (Diagnosis display by using the ACD mode indicator lamp)
MB991529
REAR AXLE
SPECIAL TOOLS
27-5
Use
Tool
Number MD998330
Name
Oil pressure gauge Hydraulic pressure measurement
AC103525
MB991705
Hose adapter
MB991705
MB991115
Oil seal installer
Press-fitting of the differential carrier oil seal (Use together with MB990938)
MD998812
Installer cap
Press-fitting of the torque transfer mechanism oil seal
MD998813
Installer 100
MD998829
MB990767
Front hub and end Rear axle hub fixing yoke holder
B990767
MB991618
Hub bolt remover
Removal of the hub bolt
MB991618
27-6
Tool
A B
REAR AXLE
SPECIAL TOOLS
Number MB990241 A: MB990242 B: MB990244
Name Axle shaft puller A: Puller shaft B: Puller bar
Use Removal of the drive shaft
MB990241AB
MB991354
Puller body
MB991354
MB990590 A: MB990212 B: MB990211

MB990590
Rear axle shaft oil seal remover A: Adapter B: Slide hammer Ball joint remover
Removal of the rear wheel hub
MB991897 or MB992011
AC106827
Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113)is also used to disconnect knuckle and tie rod end ball joint. Provisional holding of the wheel bearing Measurement of wheel bearing rotation starting torque Measurement of wheel bearing axial play NOTE: MB991000, which belongs to MB990998, should be used as a spacer. Measurement of the wheel bearing rotation starting torque
A: MB991017 B: MB990998 C: MB991000
B C AC100320AB
A, B: Front hub remover and installer C: Spacer
MB990326
Preload socket
MB990326
MB990685
Torque wrench
MB990641
Lower arm bush (A) remover & installer
Removal and press-fitting of differential support member bushing
MB990641
REAR AXLE
TROUBLESHOOTING
27-7
Use Removal and press-fitting of differential support arm bushing
Tool
Number MB991439
Name Bush remover & installer
MB991439
MB991460
Plug
Prevention of AYC differential gear oil spilling and entry of foreign material
MB990850
End yoke holder
Companion flange fixing
MB990850
A C B
MB990925
MB990925 Bearing and oil A: MB990926 MB990937 seal installer set B: MB990938 A: Installer C: MB990939 adapter B: Bar C: Brass bar
Press-fitting of differential carrier oil seal (Use together with MB991115) For details of each installer, refer to GROUP 26 Special Tools P.26-3.
TROUBLESHOOTING
TROUBLESHOOTING STRATEGY
Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points P.00-5. NOTE: Before starting the troubleshooting procedure, make sure that the following items have been checked. . The correct steering wheel has been installed in the neutral position of the steering column shaft. Tyre and wheel size are correct with correct specifications. Inflation pressure, balance, and wear conditions are okay. Wheel alignment is correct. The engine, suspension, and other parts have not been remodeled so as to affect the AYC system.
M1272003900023
DIAGNOSIS FUNCTION
M1272004000023
READING DIAGNOSIS CODES WHEN USING THE M.U.T.-II/III

Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points P.00-5.
27-8
WHEN USING THE ACD MODE INDICATOR LAMP
1. Turn the ignition switch to the "LOCK" (OFF) position.
REAR AXLE
TROUBLESHOOTING
2. Use special tool diagnosis code check harness (MB991529) to earth terminal number 1 (diagnosis control terminal) of the diagnosis connector. 3. Turn the ignition switch to the "ON" position.
Diagnosis connector
MB991529
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
AC307005 AB
ACD mode indicator lamp
AC306995 AB
4. Read out a diagnosis code by observing how the ACD mode indicator lamp flashes. When the diagnosis code No.24 is set
1.5 secs. 0.5 sec. Illuminated Switched off Pause time 3 secs. Tens signal Place division 2 secs. Units signal ACX01777 AD
Illuminated Switched off ACX01778 AD
When no diagnosis code is set

0.5 sec.
0.25 sec.
5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect special tool diagnosis code check harness (MB991529).
WHEN NOT USING THE M.U.T.-II/III

1. Turn the ignition switch to the "LOCK" (OFF) position. 2. After disconnecting the battery cable from the battery () terminal for 10 seconds or more, reconnect the cable. 3. After the engine has warmed up, rung it at idle for about 15 minutes.
ERASING DIAGNOSIS CODES WHEN USING THE M.U.T.-II/III

Refer to GROUP 00, How to Use Troubleshooting/Inspection Service Points P.00-5.
REAR AXLE
TROUBLESHOOTING
27-9
DIAGNOSIS CODE CHART

Follow the inspection chart that is appropriate for the diagnosis code. Diagnosis code Inspection item Diagnostic content No. 12 Power supply voltage (valve power supply) system Failsafe relay system (inside of 4WD-ECU) Front right wheel speed sensor system Front left wheel speed sensor system Rear right wheel speed sensor system Rear left wheel speed sensor system Wrong size (diameter) tyre Refer to GROUP 22A, Troubleshooting <ACD>P.22A-18 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-19 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-20 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-29 Open circuit or short circuit
M1272004100064
Reference page Refer to GROUP 22A, Troubleshooting <ACD>P.22A-9 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-14 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-14
13
21 22 23 24 25
26
Wheel speed sensor (faulty output signal)
31
Steer sensor (ST-1, ST-2, ST-N) Open circuit or short circuit system Steer sensor (ST-N) system Short circuit Fixing Steer sensor (ST-1, ST-2) system TPS system
32 33 34
Short circuit or output fixing Refer to GROUP 22A, Troubleshooting <ACD>P.22A-33 Open circuit or earth circuit Short circuit Refer to GROUP 22A, Troubleshooting <ACD>P.22A-37 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-41 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-46 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-49
41 42 45
Pressure sensor system
Open circuit or earth circuit
46
Pressure sensor system
Open earth
47
Short circuit
27-10
Diagnosis code No. 51 Inspection item
REAR AXLE
TROUBLESHOOTING
Diagnostic content Open circuit or short circuit
Reference page Refer to GROUP 22A, Troubleshooting <ACD>P.22A-53 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-62 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-68 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-77 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-83 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-88
G sensor (longitudinal) system
52
Defective sensor
56
G sensor (lateral) system
Open circuit or short circuit
57
Defective sensor
61
Stop lamp switch system
Open circuit
62
ACD mode changeover switch
Stuck
63
Parking brake switch system
Short circuit or parking lever Refer to GROUP 22A, not released Troubleshooting <ACD>P.22A-94 Open circuit or defective ABS Open circuit or short circuit Refer to GROUP 22A, Troubleshooting <ACD>P.22A-99 P.27-11 P.27-15 P.27-19 Refer to GROUP 22A, Troubleshooting <ACD>P.22A-105 Open circuit or short circuit Refer to GROUP 22A, Troubleshooting <ACD>P.22A-109
65
ABS monitor system
71 72 73 74
Proportioning valve <AYC> system Direction valve (RH) system Direction valve (LH) system Proportioning valve <ACD> system Electric pump relay system
81
82
Electric pump malfunction or Refer to GROUP 22A, pressure sensor defective Troubleshooting <ACD>P.22A-113 AYC control error ACD control error
84 85
NOTE: . Code No.84 is not a code number output due to malfunction, but a code number output when control for 4WD-ECU to protect the AYC is stopped in excessive driving. AYC control can be recovered by turning the ignition switch to the "ON" position to "OFF" position and to "ON" position. Code No.85 is not a code number output due to malfunction, but a code number output when control for 4WD-ECU to protect the ACD is stopped in excessive driving. ACD control can be recovered by turning the ignition switch to the "ON" position to "OFF" position and to "ON" position.
REAR AXLE
TROUBLESHOOTING
27-11
DIAGNOSTIC TROUBLE CODE PROCEDURES
Code No.71: Proportioning valve <AYC> system
Proportioning valve system/direction valve system circuit 4WD-ECU
1 2 3 4 5 6 7 8 9 10111213 141516171819 202122232425
1 2 3 4 5 6 7 8 9 1011 1213141516171819202122
PROPORTIONING VALVE FOR AYC CONTROL
DIRECTION VALVE (LH)
DIRECTION VALVE (RH)
SB : Sky blue
OPERATION
After processing information of various sensors and switches, the 4WD-ECU calculates the amount of AYC torque movement and direction, and controls the proportioning valve. The current flows from the 4WD-ECU to activate the proportioning valve, which controls oil pressure supplied to the AYC clutches.
DIAGNOSIS CODE SET CONDITIONS

Diagnosis code No.71 is set when the proportioning valve control circuit is open circuited or short-circuited.
PROBABLE CAUSES
Malfunction of the proportioning valve Damaged harness wires and connectors Malfunction of the 4WD-ECU
27-12
DIAGNOSIS
REAR AXLE
TROUBLESHOOTING
STEP 3. Measure the resistance at proportioning valve connector F-25.

Connector: F-25 Hydraulic unit assembly
STEP 1. M.U.T.-II/III data list Set M.U.T.-II/III to data reading mode, and check the data list item. Item 12: Proportioning valve current <AYC> (Refer to Data List Table P.22A-142).
Q: Is the check result normal? YES : This malfunction is intermittent. Refer to
3 2 1
GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope with Intermittent Malfunction P.00-5. NO : Go to Step 2. STEP 2. Measure the resistance at proportioning valve connector F-25.
Harness side F-25 (3-B)

AC310718 AB
Measure the resistance between terminal 2 and earth at the wiring harness side. OK: 2 or less
STEP 4. Connectors check: F-25 proportioning valve connector, F-21 intermediate connector
1 2 3
Connector: F-25
Hydraulic unit assembly
F-25 (3-B)
AC310716 AB
3 2 1
Disconnect the connector, and measure the resistance between terminal 2 and 3 at the proportioning valve side. OK: 4.7 or less
Q: Is the check result normal? YES : Go to Step 3. NO : Replace the hydraulic unit.

AC310718 AB
Connector: F21
1 2 3 4 5 6 7 8
F-21 (8-B)
AC310719AB
Check for the contact with terminals.

REAR AXLE
TROUBLESHOOTING
27-13
STEP 5. Check the harness wires between proportioning valve connector F-25 terminal 2 and intermediate connector F-21 terminal 4 and earth.
3 2 1

AC310718 AB
Connector: F21
1 2 3 4 5 6 7 8
F-21 (8-B)
AC310719AB
Check the earth line for open circuit.

27-14
REAR AXLE
TROUBLESHOOTING
STEP 6. Connectors check: C-25 4WD-ECU connector, C-124, C-134 and F-21 intermediate connectors, and F-25 proportioning valve connector
Connector: C-25 4WD-ECU
1 2 3 4 5 6 7 8 9 1011
C-134 (11-B)
AC310726 AB
C-25 (26-Y)
Connector: F-25
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
AC310721 AB
3 2 1

AC310718 AB
C-124 (25)
1 2 3 4 5 6 7 8 9 10111213 141516171819 202122232425
Connector: F21
AC310722 AB
1 2 3 4 5 6 7 8
F-21 (8-B) C-124 (25)

1 2 3 4 5 6 7 8 9 10111213 141516171819 202122232425
AC310719AB

AC310738 AB
C-134 (11-B)
1 2 3 4 5 6 7 8 9 1011
AC310723 AB
REAR AXLE
TROUBLESHOOTING
27-15
STEP 7. Check the harness between proportioning valve connector F-25 terminal No.3 and 4WD-ECU connector C-25 terminal No.3.
1 2 3
F-25 (3-B)
AC310716 AB
C-25 (26-Y)
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
AC310721 AB
Check the output line for short-circuited or open circuit.

Q: Is the check result normal? YES : Replace the 4WD-ECU. NO : Repair the wiring harness.
Code No.72: Direction valve (RH) system
DIRECTION VALVE (RH) SYSTEM CIRCUIT

Refer to P.27-11.

Diagnosis code No.72 is set when the direction valve (RH) control circuit is open circuited or short-circuited.
OPERATION
After processing information of various sensors and switches, the 4WD-ECU calculates the amount of AYC torque movement and direction, and controls the direction valve (RH). The current flows from the 4WD-ECU to activate the direction valve (RH), which supplies the oil pressure to the AYC right clutch.
PROBABLE CAUSES
Malfunction of the direction valve (RH) Damaged harness wires and connectors Malfunction of the 4WD-ECU
27-16
DIAGNOSIS
REAR AXLE
TROUBLESHOOTING
STEP 3. Measure the resistance at direction valve (RH) connector F-23.

STEP 1. M.U.T.-II/III data list Set M.U.T.-II/III to data reading mode, and check the data list item. Item 59: direction valve (RH) (Refer to Data List Table P.22A-142).
F-23 (2-B)
1 2
GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope with Intermittent Malfunction P.00-5. NO : Go to Step 2. STEP 2. Measure the resistance at direction valve (RH) connector F-23.
AC310740 AB
Measure the resistance between terminal 1 and earth at the direction valve (RH) side OK: 2 or less
STEP 4. Connectors check: F-23 direction valve (RH) connector, F-21 intermediate connector
F-23 (2-B)
1 2
Connector: F-23
AC310740 AB
F-23 (2-B)
1 2
Disconnect the connector, and measure the resistance between terminal 1 and 2 at the direction valve (RH) side. OK: 19 21 or less
Connector: F21
AC310740 AB
1 2 3 4 5 6 7 8
F-21 (8-B)
AC310719AB

REAR AXLE
TROUBLESHOOTING
27-17
STEP 5. Check the harness wires between direction valve (RH) connector F-23 terminal 1 and intermediate connector F-21 and earth.
F-23 (2-B)
1 2
AC310740 AB
Connector: F21
1 2 3 4 5 6 7 8
F-21 (8-B)
AC310719AB

27-18
REAR AXLE
TROUBLESHOOTING
STEP 6. Connectors check: C-25 4WD-ECU connector, C-122, C-134 and F-21 intermediate connectors, and F-23 direction valve (RH) connector
1 2 3 4 5 6 7 8 9 1011
C-134 (11-B)
AC310726 AB
C-25 (26-Y) Connector: F-23

1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
AC310721 AB
F-23 (2-B)
1 2
AC310740 AB
1 2 3 4 5 6 7 8 9 1011 1213141516171819202122
C-122 (22-L)
AC310724 AB
Connector: F21
1 2 3 4 5 6 7 8
F-21 (8-B) C-122 (22-L)

1 2 3 4 5 6 7 8 9 1011 1213141516171819202122
AC310719AB

AC310725 AB
C-134 (11-B)
1 2 3 4 5 6 7 8 9 1011
AC310723 AB
REAR AXLE
TROUBLESHOOTING
27-19
STEP 7. Check the harness between direction valve (RH) connector F-23 terminal No.2 and 4WD-ECU connector C-25 terminal No.14.
F-23 (2-B)
1 2
AC310740 AB
C-25 (26-Y)
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
AC310721 AB

Code No.73: Direction valve (LH) system
DIRECTION VALVE (LH) SYSTEM CIRCUIT

Refer to P.27-11.

Diagnosis code No.73 is set when the direction valve (LH) control circuit is open circuited or short-circuited.
OPERATION
After processing information of various sensors and switches, the 4WD-ECU calculates the amount of AYC torque movement and direction, and controls the direction valve (LH). The current flows from the 4WD-ECU to activate the direction valve (LH), which supplies the oil pressure to the AYC left clutch.
PROBABLE CAUSES
Malfunction of the direction valve (LH) Damaged harness wires and connectors Malfunction of the 4WD-ECU
27-20
DIAGNOSIS
REAR AXLE
TROUBLESHOOTING
STEP 3. Measure the resistance at direction valve (LH) connector F-22.

STEP 1. M.U.T.-II/III data list Set M.U.T.-II/III to data reading mode, and check the data list item. Item 60: direction valve (LH) (Refer to Data List Table P.22A-142).
1 2
GROUP 00, How to Use Troubleshooting/Inspection Service Points How to Cope with Intermittent Malfunction P.00-5. NO : Go to Step 2. STEP 2. Measure the resistance at direction valve (LH) connector F-22.
F-22 (2-B)
AC310739 AB
Measure the resistance between terminal 1 and earth at the direction valve (LH) side OK: 2 or less
STEP 4. Connectors check: F-22 direction valve (LH) connector, F-21 intermediate connector
Connector: F-22
1 2
F-22 (2-B)
AC310739 AB
Disconnect the connector, and measure the resistance between terminal 1 and 2 at the direction valve (LH) side. OK: 19 21 or less
Connector: F21
1 2
F-22 (2-B)
AC310739 AB
1 2 3 4 5 6 7 8
F-21 (8-B)
AC310719AB

REAR AXLE
TROUBLESHOOTING
27-21
STEP 5. Check the harness wires between direction valve (LH) connector F-22 terminal 1 and intermediate connector F-21 and body earth.
1 2
F-22 (2-B)
AC310739 AB
Connector: F21
1 2 3 4 5 6 7 8
F-21 (8-B)
AC310719AB

27-22
REAR AXLE
TROUBLESHOOTING
STEP 6. Connectors check: C-25 4WD-ECU connector, C-122, C-134 and F-21 intermediate connectors, and F-22 direction valve (LH) connector
1 2 3 4 5 6 7 8 9 1011
C-134 (11-B)
AC310726 AB
C-25 (26-Y)
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
Connector: F21
AC310721 AB
1 2 3 4 5 6 7 8
F-21 (8-B) C-122 (22-L)

AC310724 AB
AC310719AB
Connector: F-22
1 2 3 4 5 6 7 8 9 1011 1213141516171819202122
1 2
F-22 (2-B)
AC310739 AB

C-122 (22-L)
1 2 3 4 5 6 7 8 9 1011 1213141516171819202122
AC310725 AB
C-134 (11-B)
1 2 3 4 5 6 7 8 9 1011
AC310723 AB
REAR AXLE
TROUBLESHOOTING
27-23
STEP 7. Check the harness between direction valve (LH) connector F-22 terminal No.2 and 4WD-ECU connector C-25 terminal No.15.
1 2
F-22 (2-B)
AC310739 AB
C-25 (26-Y)
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
AC310721 AB

SYMPTOM CHART
M1272004200027
Trouble symptom Communication with the M.U.T.-II/III is not possible Communication between the M.U.T.-II/III and 4WD-ECU is not possible Three ACD mode indicator lamps do not light up when the ignition key is turned to "ON" position (engine stopped). Three ACD mode indicator lamps remain lit up after the engine has started. AYC is inoperative. Unable to start or accelerate on slippery road surface. Rear tyres are noisy during low-speed cornering. Vehicle skews. Noise is produced from the torque transfer differential during turning.
Inspection procedure No. 1 2 3 4 5 6 7
Reference page Refer to GROUP 22A, TroubleshootingS ymptom chart P.22A-118.
P.27-24 P.27-24 P.27-25
27-24
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
REAR AXLE
TROUBLESHOOTING
INSPECTION PROCEDURE 5: AYC is inoperative. Unable to start or accelerate on slippery road surfaces.

The hydraulic oil level is probably low, there is an oil leak, the hydraulic unit is defective, or the torque transfer differential is defective.
STEP 3. AYC operation check Check the AYC operation (Refer to P.27-29).
Q: Does a malfunction take place again? YES : Go to Step 4. NO : The procedure is complete.
POSSIBLE CAUSES
Low hydraulic oil level Oil leak Malfunction of the hydraulic unit Malfunction of the torque transfer differential
STEP 4. Oil pump pressure test Measure the oil pump pressure of the hydraulic unit. (Refer to P.27-29).
DIAGNOSIS
STEP 1.Gear oil level check Check the gear oil level of AYC differential part and torque transfer mechanism part (Refer to P.27-26).
Q: Is the check result normal? YES : Go to Step 2. NO : After checking for oil leakage, repair it and
STEP 5. AYC bleeding Bleed the AYC system (Refer to P.27-28).

Q: Does a malfunction take place again? YES : Replace the hydraulic unit (Refer to
refill the gear oil (Refer to P.27-26). STEP 2. Fluid level check Check the fluid level (Refer to P.27-27).
Q: Is the check result normal? YES : Go to Step 3. NO : After checking the hydraulic pressure line
P.27-49).
NO : Go to Step 6.
STEP 6. Hydraulic pressure line check Check the hydraulic pressure line for entry of foreign matter.
Q: Is there foreign matter trapped in the hydraulic pressure line? YES : Remove the foreign matter in the hydraulic
for fluid leakage, repair it and refill the fluid (Refer to P.27-27).
pressure line.
NO : Replace the torque transfer differential.
INSPECTION PROCEDURE 6: Rear tyres are noisy during low-speed cornering. Vehicle skews.

The hydraulic unit or the torque transfer differential is probably defective.
DIAGNOSIS
STEP 1. Fluid level check Check the fluid level (Refer to P.27-27).
Q: Is the check result normal? YES : Go to Step 2. NO : After checking the hydraulic pressure line
POSSIBLE CAUSES
Malfunction of the hydraulic unit Malfunction of the torque transfer differential
for fluid leakage, repair it and refill the fluid (Refer to P.27-27).
REAR AXLE
TROUBLESHOOTING
27-25
STEP 2. AYC operation check Check the AYC operation (Refer to P.27-29).
Q: Does a malfunction take place again? YES : Go to Step 3. NO : The procedure is complete.
STEP 4. AYC bleeding Bleed the AYC system (Refer to P.27-28).

Q: Does a malfunction take place again? YES : Replace the hydraulic unit (Refer to
P.27-49).
NO : Go to Step 5.
STEP 3. Oil pump pressure test Measure the oil pump pressure of the hydraulic unit. (Refer to P.27-29).
STEP 5. Hydraulic pressure line check Check the hydraulic pressure line for entry of foreign matter.
Q: Is there foreign matter trapped in the hydraulic pressure line? YES : Remove the foreign matter in the hydraulic
pressure line.
INSPECTION PROCEDURE 7: Noise is produced from the torque transfer differential during turning

The torque transfer differential is probably defective.
POSSIBLE CAUSES
Malfunction of the torque transfer differential
DIAGNOSIS
STEP 1. M.U.T.-II/III actuator test (1) Replace the torque transfer gear oil (Refer to P.27-26). (2) Set M.U.T.-II/III to actuator test mode, and drive the vehicle in straight with the speed 20 km/h or less and with the steering wheel on neutral position. (3) Test the following items for 5 times respectively. Item 06: Clutch operation (left) Item 07: Clutch operation (right) OK: Noise is not produced.
Q: Is the check result normal? YES : The procedure is complete and replace the
STEP 2. M.U.T.-II/III actuator test Test again the following items for 5 times respectively with the same condition described in STEP 2. Item 06: Clutch operation (left) Item 07: Clutch operation (right) OK: Noise is not produced.
Q: Is the check result normal? YES : The procedure is complete and replace the
torque transfer gear oil (Refer to P.27-26).

DATA LIST REFERENCE TABLE

Refer to GROUP 22A, Data list reference table P.22A-142.
M1272004300024
ACTUATOR TEST REFERENCE TABLE

Refer to GROUP 22A, Actuator test reference table P.22A-145.
M1272005200020
CHECK AT 4WD-ECU TERMINAL

Refer to GROUP 22A, Check at 4WD-ECU terminal P.22A-146.
M1272004500028
torque transfer gear oil (Refer to P.27-26). NO : Go to Step 2.
27-26
REAR AXLE
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK
M1271001200252
1. Remove the filler plug.
1. Park the vehicle on a flat, level surface. 2. Move the transmission gearshift lever to the neutral position. Apply the parking brake and jack up the vehicle.
Mating marks Upper limit Lower limit
Gear oil
6 mm
AC102739 AF
ACX00962 AC
3. Turn the propeller shaft clockwise as far as it will go. Make the mating marks on the companion flange and on the differential carrier.
2. Check that the gear oil level is within the specified range from the bottom end of the filler plug hole. 3. If the gear oil level exceeds the standard value, add the specified gear oil up to the bottom end of the filler plug hole. Specified gear oil: DIA QUEEN LSD gear oil 4. Fit the filler plug and tighten it to the specified torque. Tightening torque: 49 10 Nm
TORQUE TRANSFER MECHANISM PART

Filler plug
ACX00964AC
4. Turn the propeller shaft counterclockwise as far as it will go, and measure the amount of distance between the mating marks. Limit: 6 mm 5. If the backlash exceeds the limit value, replace the differential carrier assembly.
AC310750AB
1. Remove the filler plug.
GEAR OIL LEVEL CHECK

M1272001200330
Gear oil
DIFFERENTIAL PART
Upper limit Lower limit
6 mm
AC102739 AF
Filler plug
2. Check that the gear oil level is within the specified range from the bottom end of the filler plug hole.
AC310749 AB
REAR AXLE
ON-VEHICLE SERVICE
27-27
Filler plug
3. If the gear oil level exceeds the standard value, add the specified gear oil up to the bottom end of the filler plug hole. Specified gear oil: DIA QUEEN ATF-SP III 4. Fit the filler plug and tighten it to the specified torque. Tightening torque: 49 10 Nm
GEAR OIL REPLACEMENT

M1272004600133
Drain plug
DIFFERENTIAL PART
AC310750 AC
1. Remove the drain plug to discharge the gear oil. 2. Fit the drain plug and tighten it to the specified torque. Tightening torque: 49 10 Nm 3. Remove the filler plug.
Filler plug Drain plug
AC310749 AC
Oil suction gun (General service tool)
1. Remove the drain plug to discharge the gear oil. 2. Fit the drain plug and tighten it to the specified torque. Tightening torque: 49 10 Nm
AC310751AB
Gear oil
Upper limit Lower limit
4. Using the oil suction gun (general service tool), between the body and differential support arm, apply the specified gear oil up to the under of the filler plug hall. Amount to use: 0.55 0.6 L Specified gear oil: DIA QUEEN ATF-SP III
AC102739 AF
6 mm
3. Remove the filler plug and add the specified gear oil up to the bottom end of the filler plug hole. Specified gear oil: DIA QUEEN LSD gear oil Amount to use: 0.55 0.02 L 4. Fit the filler plug and tighten it to the specified torque. Tightening torque: 49 10 Nm
5. Fit the filler plug and tighten it to the specified torque. Tightening torque: 49 10 Nm
FLUID LEVEL CHECK

M1272004700022
1. Remove the maintenance lid located in the luggage compartment. 2. <Not using M.U.T.-II/III> If the vehicle has been run, leave it for 90 min. or more in an ordinary temperature (10 30C) to allow the accumulator internal pressure to drop. NOTE: If the ambient temperature is 10C or less, allow more time to leave the vehicle to stand idle. 3. <Using M.U.T.-II/III>
27-28
REAR AXLE
ON-VEHICLE SERVICE
CAUTION Turn the ignition switch to the "LOCK (OFF)" position before connecting or disconnecting the M.U.T.-II/III.
4. Set M.U.T.-II/III to 16 pin diagnostic connector. Turn the ignition switch to the "ON" position, operate M.U.T.-II/III to drive (item 03: directional valve) forcibly, release the pressure in the accumulator. NOTE: . To drive (oil level check mode) forcibly, turn the directional valve of the hydraulic unit 20 turns from side to side, release the differential automatically. Drive can also be cleared forcibly using the clear key of M.U.T.-II/III. If the function has been stopped by fail safe, the hydraulic unit cannot be cleared forcibly.
Diagnosis connector
AC100188 AN
AC310678
5. Check that the fluid level in the oil reservoir is in the range between MAX and MIN. 6. If the fluid level is lower than MIN, add the specified fluid. Specified fluid: DIA QUEEN ATF-SP III 7. Reinstall the maintenance lid.
2. Set the M.U.T.-II/III to the 16-pin diagnosis connector. 3. Turn the ignition switch to the "ON" position. 4. Set the steering wheel in the straight-ahead position. 5. Operating the M.U.T.-II/III, drive the hydraulic unit (item No.02) forcibly. NOTE: . Drive the bleeding mode forcibly for 5 minutes, release the operation automatically. Drive can also be cleared forcibly using the Clear key of M.U.T.-II/III. If the function has been stopped by fail safe, the hydraulic unit cannot be cleared forcibly.
AYC BLEEDING
M1272004800029
Bleeder screw Vinyl hose

AC310754 AB
1. Lift up the vehicle.
6. Remove the cap of the left bleeder screw on the torque transfer differential and connect a vinyl hose. 7. Gradually turn the steering wheel clockwise from the straight-ahead position. At this time, loosen the left bleeder screw and check that fluid is discharged with air.
REAR AXLE
ON-VEHICLE SERVICE
27-29
CAUTION While the system is being bled of air, add fluid as necessary to ensure that it is left in the oil reservoir during the entire procedure.
8. After air has been completely discharged, tighten bleeder screw and turn the steering wheel in the straight-ahead position. 9. Repeat steps 6 and 7 two to three times until no air bubbles are recognized in the fluid that comes out. Then, tighten the bleeder screw to the specified torque. Tightening torque: 9 1 Nm 10.Perform steps 5 through 8 for the right bleeder screw. Note, however, that the steering wheel should be turned counterclockwise. 11.When removing the hydraulic unit, bleed the fluid line in ACD side (Refer to GROUP 22A On-vehicle Service P.22A-153).
CAUTION If the system is not completely bled of air, the hydraulic unit could generate noise, degrading pump durability.
12.After the system has been completely bled of air, check for the fluid level (Refer to P.27-27).
AYC OPERATION CHECK

M1272004900026
1. Lift up the vehicles.
NOTE: . Set the steering wheel to the neutral position. When turning the steering wheel, AYC operates continually (operation sound from the torque transfer differential), but it is not system fault. In this case, set the steering wheel to the neutral position, and perform the following operations in order to stop the ACD. Release the clutch. Set the gear to "Neutral". Stop the engine. 5. Operate the M.U.T.-II/III, drive the torque transfer differential by the actuator test (item No.06 and 07) forcibly. NOTE: . Drive the clutch operating mode forcibly for 1 minute, release the operation automatically. Drive can also be cleared forcibly using the Clear key of M.U.T.-II/III. If the hydraulic unit function has been stopped by fail-safe, the torque transfer differential cannot be forcibly driven. 6. Operating the M.U.T.-II/III by data list (item No.07 and 08), check the condition of the wheel speed below. <Driving actuator test item No.06 forcibly> The left rear wheel is faster 2 km/h than right rear wheel. <Driving actuator test item No.07 forcibly> The right rear wheel is faster 2 km/h than left rear wheel. NOTE: If the above are not satisfied, check the oil pressure as the system may be faulty.
OIL PRESSURE CHECK

M1272005000037
1. Lift up the vehicles.
Diagnosis connector
AC100188 AN
2. Set the M.U.T.-II/III to the 16-pin diagnosis connector. 3. Start the engine. 4. Set the gear to the 2nd gear or above, operate M.U.T.-II/III, and check from the data list (Item No.09) that the wheel speed is within 10 km/h to 20 km/h.
Diagnosis connector
AC100188 AN
27-30
2. Set the M.U.T.-II/III to the 16-pin diagnosis connector. 3. Turn the ignition switch to "ON" position.
MB991705
REAR AXLE
ON-VEHICLE SERVICE
10.Supply the specified fluid up to the MAX level of the oil reservoir, and bleed. Specified fluid: DIA QUEEN ATF-SP III Amount to use: 1.0 L
WHEEL BEARING AXIAL PLAY CHECK

M1271000900515
1. Remove the caliper assembly, and suspend the caliper assembly with a wire and remove the brake disc.
MD998330
AC310756 AB
4. Disconnect the hydraulic unit and the hydraulic unit hose assembly, connect the special tool to L port, put the lid to R port or connect the hydraulic unit hose assembly disconnected from L port to R port. Hose adaptor (MB991705) Oil pressure gauge (MD998330) 5. Operating the M.U.T.-II/III, drive the hydraulic unit forcibly (actuator test item No.02). NOTE: . Drive the operation check mode of the clutch left side for 1 minute, release the operation automatically. Drive can also be cleared forcibly using the Clear key of M.U.T.-II/III. If the function has been stopped by fail safe, the hydraulic unit cannot be cleared forcibly.
AC206092AC
2. Fit the dial gauge as shown in the diagram and move the hub in the axial direction to measure the play. Limit: 0.05 mm 3. If the play exceeds the limit, the driveshaft nut should be tightened to the specified torque and check the axial play again. Tightening torque: 225 25 Nm 4. Replace the rear hub assembly if adjustment cannot be made to within the limit. 5. Install the brake disc and caliper assembly, and tighten the caliper assembly mounting bolts to the specified torque. Tightening torque: 54 5 Nm
CAUTION While the oil pressure is checked, add fluid as necessary to ensure that it is left in the oil reservoir during the entire procedure.
6. Check that the generated oil pressure of the hydraulic unit satisfies the standard value. Standard value: 0.9 1.1 MPa 7. Check the oil pressure of the clutch right side following step 4 through 6. Connect the special tool to R port, put the lid to L port or hydraulic unit hose assembly disconnected from R port to L port, use the M.U.T.-II/III to drive actuator test item No.07 (operation check mode of clutch right side) forcibly. 8. If the measured value exceeds the standard value, replace the hydraulic unit. 9. Connect the hydraulic unit and the hydraulic unit hose assembly, and connect the torque transfer differential and hydraulic unit hose assembly, tighten the flare nut in specified torque. Tightening torque: 21 3 Nm
HUB BOLT REPLACEMENT
M1271001000195
1. Remove the brake caliper and brake disc.

MB991618 MB990767
AC001182 AB
2. Use the following special tools to remove the hub bolts. Front hub and end yoke holder (MB990767) Hub bolt remover (MB991618)
REAR AXLE
ON-VEHICLE SERVICE
27-31
NOTE: To retain a space for removing the hub bolts, remove near the retainer spring mounting position.
MB990767 Plain washer
2. Remove the differential carrier oil seal.

MD998829
MD998812 MD998813
AC310759AB
AC001183 AB
3. Install the plain washer to the new hub bolt, and install the bolt with a nut.
DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT

M1272001300133
DIFFERENTIAL PART
1. Remove the driveshaft from the differential carrier. (Refer to P.27-36). 2. Remove the differential carrier oil seal.
3. Use the following special tools to press-fit a new oil seal. Installer cap (MD998812) Installer 100 (MD998813) Installer adaptor (MD998829) 4. Apply specified grease to the oil seal lip and driveshaft oil seal seating area. Specified grease: Vaseline 5. Replace the driveshaft circlip with a new one, and install the driveshaft to the differential carrier. (Refer to P.27-36).
REMEDY FOR A DISCHARGED BATTERY

M1272005100023
MB990938 Battery fuse assembly Battery cable for AYC MB991115

AC102740 AC
3. Use the following special tools to press-fit a new oil seal. Installer bar (MB990938) Oil seal installer (MB991115) 4. Apply multi-purpose grease to the oil seal lip and driveshaft oil seal seating area. 5. Replace the driveshaft circlip with a new one, and install the driveshaft to the differential carrier. (Refer to P.27-36).
AC310768 AB

1. Remove the driveshaft from the differential carrier. (Refer to P.27-36).
When the engine is started using a booster cable where the battery has completely run down and you attempt to start the vehicle without waiting for the battery to recover a certain charge, the engine can misfire and you just cannot start to move it. In such cases, charge the battery sufficiently; or, remove the AYC battery cable from the battery fuse assembly to make AYC inactive before attempting to start the vehicles. When the battery cable is removed, the ACD mode indicator lamp lights up. After the battery has been recharged, fit the battery cable back again and start the engine to ensure that the ACD mode indicator lamp is off.
27-32
REAR AXLE
REAR AXLE HUB ASSEMBLY

M1271002000466
CAUTION Do not strike the ABS rotors installed to the EBJ outer race of driveshaft against other parts when removing or installing the driveshaft. Otherwise the ABS rotors will be damaged.
Be careful not to strike the pole piece at the tip of the rear ABS sensor with tools during servicing work. During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. Pre-installation Operation Gear Oil Draining (Refer to P.27-26). Post-installation Operation Gear Oil Filling (Refer to P.27-26). Parking Brake Lever Stroke Adjustment (Refer to GROUP 36, Onvehicle Service Parking Brake Lever Stroke Check P.36-3).
11
54 5 Nm
5 2 3
4
118 19 Nm
12 10
225 25 Nm
1N 7 8
71 7 Nm
9
AC211950 AC
1. <<A>> >>A<< 2. >>A<< 3. 4. <> 5. 6.
Removal steps Split pin Driveshaft nut Washer Rear ABS sensor Caliper assembly Brake disc <<C>>
7.
8. 9. 10. 11. 12.
Removal steps (Continued) Parking brake shoe and lining assembly (Refer to GROUP 36, Parking brake lining and drum P.36-6). Clip Parking brake cable connection Rear driveshaft assembly Rear wheel hub assembly Backing plate
REAR AXLE
27-33

CAUTION Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the driveshaft nut is loosened.
INSTALLATION SERVICE POINT >>A<< WASHER/ DRIVESHAFT NUT INSTALLATION

CAUTION Before securely tightening the driveshaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearings will be damaged.
Washer
MB990767
AC205988AB
MB990767
AC205992AC

1. Be sure to install the driveshaft washer in the specified direction. 2. Using special tool front hub and end yoke holder (MB990767), tighten the driveshaft nut to the specified torque. Tightening torque: 225 25 Nm
INSPECTION
M1271002100300
<<C>> REAR WHEEL HUB REMOVAL

If the rear wheel hub is seized, remove the rear wheel hub as follows. 1. Remove the knuckle with rear wheel hub and fix them with a vise (Refer to P.27-35).
WHEEL BEARING ROTATION STARTING TORQUE AND AXIAL PLAY CHECK

MB991000 MB991017
MB990244
MB991354
AC212015 AB
MB990211
AC207000AB
2. Use the following special tools to pull out the rear wheel hub from the knuckle. Puller bar (MB990244) Puller body (MB991354) Slide hammer (MB990211)
1. Tighten the following special tools to the specified torque. Front hub remover and installer (MB991017) Spacer (MB991000) Tightening torque: 225 25 Nm 2. Rotate the rear hub in order to seat the bearing.
27-34
REAR AXLE
Wooden block MB990685
5. If the rotation starting torque is not within the limit range while the nut is tightened to 225 25 Nm, replace the front wheel bearing assembly. If there are any signs of binding or tight spots when the wheel bearing turns, replace it.
Wooden block
AC206090 AD
3. Hold the rear wheel hub assembly with wooden blocks. 4. Measure the wheel bearing rotation starting torque by using the following special tools. Preload socket (MB990326) Torque wrench (MB990685) Limit: 1.0 Nm

AC206091AG
6. Measure to determine whether the wheel bearing axial play is within the specified limit or not. Limit: 0.05 mm 7. If the play is not within the limit range while the nut is tightened to 225 25 Nm, replace the rear wheel hub assembly.
REAR AXLE
KNUCKLE
27-35
KNUCKLE
M1271003000265
CAUTION Be careful not to strike the pole piece at the tip of the rear ABS sensor with tools during servicing work.
During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly. *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
Pre-removal Operation Rear Wheel Hub Assembly Removal (Refer to P.27-32). Post-installation Operation Check the ball joint dust cover for cracks or damage by pushing it with your finger. Rear Wheel Hub Assembly Installation (Refer to P.27-32).
81 6 Nm
1
81 6 Nm
5N
6
N
81 6 Nm*
N4
N3
88 10 Nm*
AC211951AB
<<A>>
1. 2. 3.
Removal steps Rear ABS sensor Self-locking nut (trailing arm connection) Self-locking nut (lower arm connection)
<<A>> <<A>>
4. 5. 6.
Removal steps (Continued) Self-locking nut (toe control arm connection) Self-locking nut (upper arm connection) Knuckle
27-36
REAR AXLE
DRIVESHAFT ASSEMBLY
REMOVAL SERVICE POINT <<A>>SELF-LOCKING NUT (TRAILING ARM, TOE CONTROL ARM AND UPPER ARM CONNECTION) REMOVAL
CAUTION Do not remove the nut from ball joint. Loosen it and use the special tool to avoid possible damage to ball joint threads. Hang the special tool with cord to prevent them from falling.
Cord
Bolt Parallel
Knob
Correct
Wrong
AC106821AD
Nut

AC208247AJ
2. After turning the bolt and knob to adjust the arms of special tool in parallel, tighten the bolt by hand and confirm that the arms are parallel. NOTE: When adjusting the arms in parallel, turn the knob so that it is at right angles to the arms. 3. Tighten the bolt with a wrench to disconnect the ball joint and remove the self-locking nut.
INSPECTION
Check the knuckle for wear or cracks.
M1271003100154
DRIVESHAFT ASSEMBLY
M1271003300266
CAUTION Do not strike the ABS rotors installed to the EBJ outer race of driveshaft against other parts when removing or installing the driveshaft. The ABS rotors will be damaged.
Be careful not to strike the pole piece at the tip of the rear ABS sensor with tools during servicing work. During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe it off quickly. Pre-installation Operation Gear Oil Draining (Refer to P.27-26). Centre Exhaust Pipe Removal (Refer to GROUP15, Exhaust Pipe and Main Muffler P.15-13). Post-installation Operation Check the dust cover for cracks or damage by pushing it with your finger. Centre Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Gear Oil Filling (Refer to P.27-26). Parking Brake Lever Stroke Adjustment (Refer to GROUP 36, On-vehicle Service Parking Brake Lever Stroke Check and Adjustment P.36-3). Rear Wheel Alignment Check and Adjustment (Refer to GROUP34, On-vehicle ServiceRear Wheel Alignment Check and Adjustment P.34-4).
REAR AXLE
DRIVESHAFT ASSEMBLY
27-37
5
14 N
4
54 5 Nm
7
81 6 Nm
13 8
N 10
225 25 Nm
2N
N 12
81 6 Nm*
N 11
88 10 Nm*
3 6
N1
9
Removal steps Split pin Driveshaft nut Washer Rear ABS sensor Caliper assembly Brake disc Parking brake shoe and lining assembly (Refer to GROUP 36, Parking brake lining and drum P.36-6).
AC211952 AB
1. <<A>> >>B<< 2. >>B<< 3. 4. <> 5. 6. 7.
<<C>> <<C>> <<C>>
8. 9. 10. 11. 12.
<<D>> >>A<< 13. 14.
Removal steps (Continued) Clip Parking brake cable connection Self-locking nut (trailing arm connection) Self-locking nut (lower arm connection) Self-locking nut (toe control arm connection) Driveshaft Circlip

CAUTION Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage to wheel bearing before tightening driveshaft nut fully.
MB990767
AC205988AB
27-38
REAR AXLE
DRIVESHAFT ASSEMBLY

NOTE: When adjusting the arms in parallel, turn the knob so that it is at right angles to the arms. 3. Tighten the bolt with a wrench to disconnect the ball joint and remove the self-locking nut.
<<D>> DRIVESHAFT REMOVAL

MB990242 MB990244 (Three)
<<C>>SELF-LOCKING NUT (TRAILING ARM, LOWER ARM AND TOE CONTROL ARM CONNECTION) REMOVAL
CAUTION Do not remove the nut from ball joint. Loosen it and use the special tool to avoid possible damage to ball joint threads. Hang the special tool with cord to prevent them from falling.
Cord
MB990767
MB991354
AC205989 AB
Nut

AC208247AJ
1. Use the following special tools to push out the driveshaft from the hub. Puller shaft (MB990242) Puller bar (MB990244) Puller body (MB991354) Front hub and end yoke holder (MB990767)
Bolt Parallel
CAUTION Do not pull on the driveshaft. Doing so will damage the TJ. Be sure to use the pry bar. When pulling the driveshaft out from the differential carrier, be careful that the spline part of the driveshaft does not damage the oil seal.
Differential carrier
Knob
Correct TJ assembly Wrong Pry bar

AC106821AD AC102552 AE
2. After turning the bolt and knob to adjust the arms of special tool in parallel, tighten the bolt by hand and confirm that the arms are parallel.
2. Remove the driveshaft from the differential carrier by using a pry bar.
REAR AXLE
DRIVESHAFT ASSEMBLY
27-39
CAUTION
MB991017
>>B<< WASHER/DRIVESHAFT NUT INSTALLATION

CAUTION Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage to wheel bearing before tightening the driveshaft nut fully.
Washer
AC212015 AB
MB991000
Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the driveshaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using the following special tools. Front hub remover and installer (MB991017) Spacer (MB991000)
MB990767
AC205992 AB
INSTALLATION SERVICE POINTS >>A<< DRIVESHAFT INSTALLATION

CAUTION When installing the driveshaft, be careful that the spline part of the driveshaft does not damage the oil seal.
1. Assemble the driveshaft washer in the illustrated direction. 2. Tighten the driveshaft nut to the specified torque with special tool front hub and end yoke holder (MB990767). Tightening torque: 225 25 Nm
INSPECTION
Check the driveshaft for damage, bending or corrosion. Check the driveshaft spline part for wear or damage. Check the boots for deterioration, damage or cracking. Check the dust cover for damage or deterioration.
M1271003400081
27-40
REAR AXLE
DRIVESHAFT ASSEMBLY
M1271003500204
CAUTION Be careful not to damage the ABS rotor, which is attached to the EBJ outer race during disassembly and reassembly.
Never disassemble the EBJ assembly except when replacing the EBJ boot.
5N
N4
1N 7 2N
3 6
8N 10 11
N9
1 9 8 10 11
6 7 1 2
EBJ repair kit
TJ repair kit
5 1 2 8 10 9
7 1 2
Grease for TJ
Grease for EBJ
EBJ boot repair kit
TJ boot repair kit

AC201162 AC
Disassembly steps >>C<< 1. TJ boot band (large) >>C<< 2. TJ boot band (small) <<A>> >>B<< 3. TJ case 4. Circlip 5. Snap ring <<A>> >>B<< 6. Spider assembly
<> >>A<< 7. 8. 9. <> >>A<< 10. 11.
Disassembly steps (Continued) TJ boot EBJ boot band (large) EBJ boot band (small) EBJ boot EBJ assembly
REAR AXLE
DRIVESHAFT ASSEMBLY
27-41
LUIBRICATION POINTS
GREASE: REPAIR KIT GREASE AMOUNT USED: 135 10 g
GREASE: REPAIR KIT GREASE AMOUNT USED: 80 10 g
CAUTION
CAUTION
AC103560AE
27-42
REAR AXLE
DRIVESHAFT ASSEMBLY
DISASSEMBLY SERVICE POINTS <<A>> TJ CASE/SPIDER ASSEMBLY REMOVAL

CAUTION Do not disassemble the spider assembly.
1. Wipe off grease from the TJ case and spider assembly. 2. If there is water or foreign material in the wiped grease, be sure to clean the spider assembly.
>>B<< SPIDER ASSEMBLY/TJ CASE INSTALLATION

CAUTION Do not mix old and new or different types of grease, as special grease is used in the joint.
<> TJ BOOT/EBJ BOOT REMOVAL
AC102656 AC
Plastic tape
ACX02368AB
After applying the specified grease to the TJ case, insert the driveshaft and apply grease again. Specified grease: Repair kit grease Amount to use: 135 10 g NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
1. Wipe off grease from the shaft spline part. 2. Wrap plastic tape around the spline part on the TJ side of the driveshaft so that TJ and EBJ boots are not damaged when they are removed.
>>C<< TJ BOOT BAND(SMALL)/TJ BOOT BAND(LARGE) INSTALLATION
REASSEMBLY SERVICE POINTS >>A<< EBJ BOOT/TJ BOOT INSTALLATION

Wrap plastic tape around the spline part on the TJ side of the driveshaft, and then install EBJ and TJ boots.
A
AC102657AC
Set the TJ boot bands at the specified distance in order to adjust the amount of air inside the TJ boot, and then tighten the TJ boot band(large) and TJ boot band(small) securely. Standard value (A): 90 3 mm
REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-43

M1272002000522
Pre-removal Operation Hydraulic Piping Fluid Draining Differential Gear Oil Draining (Refer to P.27-27). Lower Arm Assembly Removal (Refer to GROUP 34, Lower Arm Assembly and Assist Link P.34-12 ). Rear Stabilizer Bar Removal (Refer to GROUP 34, Stabilizer Bar P.34-20). Driveshaft Removal (Refer to P.27-36).
Post-installation Operation Driveshaft Installation (Refer to P.27-36). Rear Stabilizer Bar Installation (Refer to GROUP 34, Stabilizer Bar P.34-20). Lower Arm Assembly Installation (Refer to GROUP 34, Lower Arm Assembly and Assist Link P.34-12 ). Differential Gear Oil Filling (Refer to P.27-27). Hydraulic Piping Fluid Filling (Refer to P.27-27). Hydraulic Piping Bleeding (Refer to P.27-28).
1
21 3 Nm
6 5 7
120 10 Nm 12 2 Nm 88 10 Nm
8 8N
N3
88 10 Nm
12 10 11
88 10 Nm
44 10 Nm
4
32 2 Nm
88 10 Nm 88 10 Nm
AC310800AC
Removal steps 1. Hydraulic unit hose assembly connection <<A>> >>C<< 2. Propeller shaft connection (Refer to GROUP 25, Propeller shaft P.25-3). 3. Differential support member mounting nut <> >>B<< 4. Rear crossmember and differential carrier assembly 5. Differential support member
Removal steps (Continued) >>A<< 6. Upper stopper >>A<< 7. Lower stopper 8. Differential support arm mounting nut 9. Differential support arm 10. Differential mount bracket 11. Differential mount bracket 12. Differential carrier assembly
27-44
REAR AXLE
REMOVAL SERVICE POINTS <<A>> PROPELLER SHAFT DISCONNECTION

Mating marks
Install the lower and upper stopper as shown in the illustration.
>>B<< REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY INSTALLATION
Front of vehicle
AC003833 AC
4 5
1. Make mating marks on the differential companion flange and the propeller shaft assembly. 2. Suspend the removed propeller shaft from the body with a wire to prevent bending.
AC212040 AC
<> REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY REMOVAL

1. Using a jack, support the differential carrier from its underside. 2. Remove the rear crossmember mounting bolts and remove the differential carrier, where it is attached to the rear crossmember, from the vehicle.
Tighten the rear crossmember mounting bolts in the numerical order shown. NOTE: To ensure both good installation accuracy and ease of installation, the rear crossmember mounting holes have different diameters between front and rear. This is the reason for specifying the tightening sequence of the mounting bolts. No. 1, 2, 3 4 5 Bolt type Flange bolt (with washer) Bolt size (Thread dia. length) mm 12 105
INSTALLATION SERVICE POINTS >>A<< LOWER STOPPER/UPPER STOPPER INSTALLATION

Upper stopper
Bolt (with spring 12 152 washer and washer) Flange bolt (with washer) 12 80
>>C<< PROPELLER SHAFT INSTALLATION

Align the mating marks of differential companion flange and propeller shaft assembly.
Lower stopper
AC310796 AB
REAR AXLE
27-45
DIFFERENTIAL SUPPORT MEMBER BUSHING REPLACEMENT

M1272001400107
<DIFFERENTIAL SUPPORT ARM>

MB991439 Differential support arm
<DIFFERENTIAL MOUNT BRACKET>

Bushing
Bushing
MB990641
AC212059AB
Differential mount bracket
1. Use special tool bush remover and installer (MB991439) to remove the bushing.
MB991439
Bushing
Differential support arm
Hollow
AC212041 AB
1. Use special tool lower arm bush (A) remover and installer (MB990641) to remove or install the bushing. 2. Press-fit the bushing with its hollow portion facing in the direction shown. 3. Press-fit the bushing until the bushing outer case end face is flush with the differential mount bracket.
Hollow
AC212042 AB
2. Press-fit the bushing with its marks facing in the direction shown. 3. Press-fit the bushing until the bushing outer case end face is flush with the differential support arm.
27-46
REAR AXLE
M1272008200018
N N 13
5
N4
49 10 Nm
14
186 29 Nm
10 9
N 11
9 1 Nm
N8
3
N4
49 10 Nm
12 N
N
2 1
49 10 Nm
5 1 Nm
AC310833 AB
1. 2. 3. 4. 5. 6. 7.
Disassembly steps Drain plug Packing Filler plug Gasket Vent plug Bleeder screw Cover
<<A>> >>C<< 8. 9. 10. 11. >>B<< 12. >>A<< 13. 14.
Disassembly steps (Continued) Self-locking nut Washer Companion flange Oil seal Oil seal Oil seal Differential carrier assembly
REAR AXLE
27-47
Lubrication and Adhesive Points
Grease: Vaseline
Sealant: 3M ATD Part No.8661 or equivalent
Sealant: 3M ATD Part No.8661 or equivalent

AC301834 AB
27-48
REAR AXLE
DISASSEMBLY SERVICE POINTS <<A>> SELF-LOCKING NUT REMOVAL
>>B<< OIL SEAL PRESS-FITTING
MB990938
MB991115 MB990850
AC310763AB AC102740 AC
Use special tool end yoke holder (MB990850) to hold the companion flange, and then remove the companion flange self-locking nut.
REASSEMBLY SERVICE POINTS >>A<< OIL SEAL PRESS-FITTING

MD998829
1. Use the following special tools to press-fit the oil seal. Installer bar (MB990938) Oil seal installer (MB991115) 2. Apply multi-purpose grease to the oil seal lip and driveshaft oil seal seating area.
>>C<< SELF-LOCKING NUT INSTALLATION
MB990850 MD998812 MD998813

AC310759AB
1. Use the following special tools to press-fit the oil seal. Installer cap (MD998812) Installer 100 (MD998813) Installer adaptor (MD998829) 2. Apply specified grease to the oil seal lip and driveshaft oil seal seating area. Specified grease: Vaseline
AC310764 AB
Tighten the companion flange self-locking nut to the specified torque while holding the companion flange with special tool end yoke holder (MB990850). Tightening torque: 186 29 Nm
REAR AXLE
27-49

M1272005400035
CAUTION When connecting the return hose and suction hose, do not apply lubricant.
No foreign matter should be allowed in the hydraulic piping and joints.
Pre-removal Operation Trunk Room Side Trim Removal (Refer to GROUP 52ATrims P.52A-10). Hydraulic Piping Fluid Draining Post-installation Operation Hydraulic Piping Fluid Filling (Refer to P.27-27). Hydraulic Piping Bleeding (Refer to P.27-28). Trunk Room Side Trim Installation (Refer to GROUP 52ATrims P.52A-10).
34 5 Nm* 26 4 Nm**
12 2 Nm 18 2 Nm
9
12 2 Nm
4 11
24 4 Nm
3 10 8 6 2
12 2 Nm 21 3 Nm
12 2 Nm 34 5 Nm* 26 4 Nm**
7 1
NOTE: *: Thread is not lubricated **: Thread is lubricated 12 2 Nm
5
7. <<A>> 8. 9. >>A<< 10. 11.
18 2 Nm
AC310846 AC
1. 2. 3. 4. 5. >>B<< 6.
Removal steps Dust guard Reservoir hose assembly and hydraulic unit connection Hydraulic unit hose assembly and hydraulic unit connection Transfer connector assembly and hydraulic unit connection Hydraulic unit bracket assembly mounting bolt Hydraulic unit assembly
Removal steps (Continued) Hydraulic unit bracket Stabilizer bar to differential support arm connection (Refer to GROUP 34, Stabilizer bar P.34-20). Differential support arm (Refer to P.27-43). Hydraulic unit hose assembly Transfer connector assembly Reservoir hose assembly Oil reservoir
27-50
REAR AXLE
REMOVAL SERVICE POINTS <<A>> HYDRAULIC UNIT HOSE ASSEMBLY REMOVAL

Pipe
Insert the reservoir hose assembly to the positioning spool.
>>B<< HYDRAULIC UNIT ASSEMBLY INSTALLATION
Hook Hose
AC310847AB
Rear floor side member
1. Disconnect the hydraulic unit side pipe and hose.

Hydraulic unit hose assembly
AC310851AB
Hook the hydraulic unit assembly hook to the rear floor side member and tighten the hydraulic unit assembly mounting bolt.
HYDRAULIC UNIT DISPOSAL

M1272008300026
Differential support arm

AC310848AB
2. Pull down the differential support arm, remove the hydraulic unit hose assembly.
INSTALLATION SERVICE POINTS >>A<< RESERVOIR HOSE ASSEMBLY INSTALLATION

Nipple Positioning spool Reservoir hose assembly
CAUTION The hydraulic unit has its accumulator filled with a high-pressure gas. Never throw it into a fire. Also, never attempt to disassemble, press, weld or melt it. When drilling a hole in the accumulator, be sure to wear safety goggles since drill chips may blow out together with the gas.
AC310849 AB
AC310850 AB
When discarding the hydraulic unit, drill a hole in the accumulator at the illustrated position beforehand in order to release the inside gas.
37-1
GROUP 37
POWER STEERING
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . LUBRICANTS . . . . . . . . . . . . . . . . . . SEALANTS . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
STEERING WHEEL FREE PLAY CHECK . STEERING ANGLE CHECK . . . . . . . . . . . . TIE ROD END BALL JOINT TURNING TORQUE CHECK . . . . . . . . . . . . . . . . . . . . STATIONARY STEERING EFFORT CHECK STEERING WHEEL RETURN TO CENTRE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE BELT TENSION CHECK. . . . . . . . . FLUID LEVEL CHECK . . . . . . . . . . . . . . . . FLUID REPLACEMENT . . . . . . . . . . . . . . . POWER STEERING SYSTEM AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP PRESSURE TEST . . . . . . . . . . POWER STEERING PRESSURE SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIE ROD END BALL JOINT DUST COVER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37-2 37-4 37-4 37-5 37-5 37-7

37-7 37-8 37-8 37-9 37-9 37-9 37-9 37-10 37-10 37-11 37-11 37-12
STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING MECHANISM CHECK
37-12
STEERING WHEEL*. . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
37-13
37-13
STEERING COLUMN SHAFT ASSEMBLY* . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . .
37-15
37-15 37-17
POWER STEERING GEAR BOX AND LINKAGE* . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . TIE ROD END BALL JOINT DUST COVER REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
37-18
37-18 37-21 37-22 37-30
POWER STEERING OIL PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . . DISASSEMBLY AND REASSEMBLY . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
37-31
37-31 37-32 37-32
POWER STEERING HOSES*. . . . . . .

37-33
37-33
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative). Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).
37-2
POWER STEERING
GENERAL INFORMATION
GENERAL INFORMATION
M1372000100434
Power steering has been adopted in all vehicles to make the steering system easier to handle.
FEATURES
The system has been equipped with the MOMO leather 3-spoke-type steering wheel with built-in SRS air bag.
A steering column with a shock absorbing mechanism and a tilt steering mechanism has been adopted. Integral-type rack and pinion gear with high rigidity and excellent response has been adopted. A variable capacity pump has been adopted to reduce power losses and improve fuel economy. Improved the cooling efficiency of power steering fluid by adopting a cooler tube to the fluid line.
SPECIFICATIONS
Item Steering wheel Type Outside diameter mm Maximum number of turns Steering column Power steering type Oil pump Type Basic delivery rate cm3/rev. Relief pressure MPa Reservoir type Pressure switch Steering gear Type Stroke ratio (Rack stroke/Steering wheel maximum turning radius) Rack stroke mm Column mechanism Specification MOMO leather-wrapped 3-spoke type 365 2.1 Tilt steering Integral type Variable capacity type (vane pump) 9.6 8.3 9.0 Separate type Equipped Rack and pinion 68.61 146
POWER STEERING
GENERAL INFORMATION
37-3
CONSTRUCTION DIAGRAM LH drive vehicles

Steering wheel
Steering column and shaft Reservoir tank Suction hose Return hose Pressure hose
Oil pump assembly
Cooler tube Steering gear and linkage

AC310660AB
RH drive vehicles
Steering wheel
Steering column and shaft Reservoir tank Suction hose Return hose Pressure hose
Steering gear and linkage Oil pump assembly
Cooler tube
AC310702 AC
37-4
POWER STEERING
M1372000300502
Item Steering wheel free play mm Steering angle Toe-in Tie rod end ball joint turning torque Nm Stationary steering effort N [Fluctuation allowance N] Oil pump pressure Oil pump relief pressure MPa (750 100 r/min). Pressure under no-load conditions Steering gear retention hydraulic pressure Oil pressure switch operating pressure MPa Total pinion torque Nm OFF ON ON OFF Total rotation torque Torque variation Tie rod swing resistance N [Tie rod swing torque Nm] With engine running With engine stopped Inner wheel Outer wheel (reference)
Standard value 10 or less 3145' 130' 2715' 02 1.0 3.0 32 or less [6.0 or less] 8.3 9.0 0.2 0.8 8.3 9.0 1.8 2.4 1.0 2.4 0.8 1.8 0.49 or less 8 27 [1.5 4.9]
Limit 30
Opening dimension of special tool boot band crimping tool (MB991561) 2.9 mm Band crimped width mm 2.4 2.8
LUBRICANTS
M1372000400435
Item Power steering fluid Steering gear Bearing O-ring and seal ring Oil seal Special tool (MB991214) Bellows Tie rod end ball joint Pinion and valve assembly Rock assembly Oil pump O-ring
Specified lubricant
Quantity
ATF DEXRON III or DEXRON II Approximately 1.0 L ATF DEXRON III or DEXRON II As required
Silicon grease
As required
Multipurpose grease SAE J310, As required NLGI No.2 or equivalent Repair kit grease As required
ATF DEXRON III or DEXRON II As required
POWER STEERING
SEALANTS
37-5
M1372000500357
SEALANTS
Item Steering shaft cover assembly bolt hole on the toeboard Steering gear End plug Rack support cover Specified sealant 3M ATD Part No.8513 or equivalent 3M ATD Part No.8661 or equivalent
SPECIAL TOOLS
M1372000600677
Tool
Number MB991897 or MB992011
Name Ball joint remover
Use Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113) is also available to disconnect knuckle and tie rod end ball joint. Tie rod end ball joint turning torque check
AC106827
MB990326
Preload socket
MB990326
MB991548
Power steering oil pressure gauge adapter (Pump side)
Oil pump pressure test
MB991548
MB991549
Power steering oil pressure gauge adapter (Hose side)
MB991549
MB990662
Power steering oil pressure gauge
MB990662
MB990784
Ornament remover Cover removal
MB990784
37-6
Tool Number MB991006
POWER STEERING
SPECIAL TOOLS
Name Preload socket
Use Steering gear total pinion torque check and adjustment
MB991006
MB991621
Piston driver
Rack support cover removal Rack support adjustment
MB991621
MB990925
Bearing and oil seal installer set
MB990925
Lower bearing removal Oil seal and bearing installation MB990927, MB990938, MB990939 (For details, refer to GROUP 26, Special Tools P.26-3). Needle bearing removal
MB991120
Needle bearing puller
MB991120
MB991199
Oil seal and bearing installer
Oil seal installation
MB991199 AB
MB991197
Bar (long type)
Oil seal installation
MB991197
MB991202
Oil seal and bearing installer
Needle bearing installation Lower bearing installation
MB991202
MB991214
Oil seal protector
Rack installation
MB991212
POWER STEERING
ON-VEHICLE SERVICE
37-7
Use Oil seal and bearing installation
Tool
Number MB991203
Name Oil seal and bearing installer
MB991203
MB991317
Seal ring installer
Seal rings installation
MB991317
MB990941
Torque tube bearing installer
Lower oil seal installation
MB990941
MB991561
Boot band crimping Bellows band installation tool
MB991561
MB990776
Front axle base
Tie rod end ball joint dust cover installation
MB990776
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK
M1372001000311
1. With the engine running (hydraulic operation), set the front wheels straight ahead.
2. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions. Limit: 30 mm 3. When the play exceeds the limit, check for the play on the steering shaft and steering linkage connection. Correct or replace. 4. If the free play still exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Load 5 N towards the steering wheel circumference and check the play. Standard value (steering wheel play with the engine stopped): 10 mm or less
ACX01122AB
37-8
POWER STEERING
ON-VEHICLE SERVICE
5. If the play exceeds the standard value, remove the steering gear (Refer to P.37-18) and check the total pinion torque (Refer to P.37-22).
TIE ROD END BALL JOINT TURNING TORQUE CHECK

M1372001500565
STEERING ANGLE CHECK

M1372001100460
CAUTION Do not remove the tie rod end nut from the ball joint. Loosen it and use special tool to avoid possible damage to the ball joint threads. Hang special tool with cord to prevent it from falling.
Cord
AC000756AB
Nut
1. Place the front wheel on a turning radius gauge and measure the steering angle. Standard value: Inner wheels Outer wheels (reference) 3145' 130' 2715'
Ball joint
MB991897 or MB992011 Bolt

AC208247AJ
2. When the steering angle is not within the standard value, the toe-in is probably incorrect. Adjust the toe-in as follows. Standard value: 0 2 mm
Lock nut Clip
Bolt Parallel
Knob
Correct
Wrong
AC106821AD
AC006074 AD
3. Loosen the lock nut, and unclip the bellows clip. 4. Adjust the toe-in by turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. 5. Tighten the lock nut to the specified torque, and tighten the bellows by the clip. Tightening torque: 52 2 Nm 6. Recheck the steering angle.
MB990326
ACX01129 AB
POWER STEERING
ON-VEHICLE SERVICE
37-9
4. Move the ball joint stud several times and install the nut on the stud. Using special tool preload socket (MB990326), measure the ball joint turning torque. Standard value: 1.0 3.0 Nm 5. If the turning torque exceeds the standard value, replace the tie rod end. 6. If the turning torque is under the standard value, check the ball joint for axial play or ratcheting. If no axial play or ratcheting, the ball joint can be re-used.
STEERING WHEEL RETURN TO CENTRE CHECK

Conduct a road test: 1. Make both gradual and sudden turns and check the steering wheel return.
M1372001800317
70
70
CAUTION Always use a new ball joint nut as it is a self-locking nut.

7. Install the tie rod end to the knuckle, then tighten a new self-locking nut to the specified torque. Tightening torque: 25 5 Nm
ACX01130AB
STATIONARY STEERING EFFORT CHECK

M1372001700440
1. With the vehicle stopped on a flat and paved surface, turn the steering wheel to the straight ahead position. 2. Start the engine and set the it to 1,000 100 r/min.
2. At a vehicle speed of approximately 35 km/h, turn the steering wheel 90, hold a few seconds, then release. If the steering wheel then returns 70 or more, the return can be judged satisfactory. NOTE: There will be a momentary feeling or "heaviness" when the wheel is turned quickly, but this is not abnormal (Oil pump discharge amount is especially apt to be insufficient during idling).
DRIVE BELT TENSION CHECK

Refer to GROUP 11A, On-vehicle Service Drive Belt Tension Check P.11A-7.
M1372001900358
FLUID LEVEL CHECK

M1372002000370
ACX01122AB
3. Attach a spring balance to the outer circumference of the steering wheel and measure the steering force required to turn the steering wheel from the straight ahead position to the left and right (within a range of 0.9 turns). Also check to be sure that there is no significant change in the required steering effort. Standard value: Steering effort: 32 N or less Fluctuation allowance: 6.0 N or less 4. If the measured value exceeds the standard value, check and adjust the related parts.
1. Park the vehicle on a flat, level surface. 2. Start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 60C. 3. With the engine running, turn the wheel all the way to the left and right several times.
Fluid level change: Within 5 mm
With engine running
With engine stopped

ACX01131AC
37-10
POWER STEERING
ON-VEHICLE SERVICE
4. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the change of the fluid level is 5 mm or more, air bleeding should be done.
FLUID REPLACEMENT
M1372002100430
CAUTION Perform air bleeding only while cranking the engine. If air bleeding is performed while the engine is running, air could enter the fluid. During air bleeding, refill the steering fluid supply so that the level never falls below the "MIN" mark on the oil reservoir.
3. Turn the steering wheel all the way to the left and right five or six times while using the starter motor to crank the engine intermittently several times (for 15 to 20 seconds). 4. Connect the ignition coil connectors (Refer to GROUP 16, Ignition Coil P.16-34). 5. Start the engine (idling). 6. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir. 7. Confirm that the fluid is not milky, and that the level is between "MAX" and "MIN" marks. 8. Confirm that there is very little change in the fluid level when the steering wheel is turned left and right.
1. Raise and support the front wheels.

Return hose
Vinyl hose
AC211746 AC
2. Disconnect the return hose connection, and then connect a vinyl hose to the return hose, and drain the fluid into a container. 3. Disconnect the ignition coil connectors (Refer to GROUP 16, Ignition Coil P.16-34). 4. While operating the starter motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid. 5. Connect the return hose securely, and then secure with the clip. 6. Fill the oil reservoir with specified fluid up to between "MAX" and "MIN" marks, and then bleed the air. Specified fluid: ATF DEXRON III or DEXRON II
CAUTION If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled. If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control valve, and this condition could cause reduce the life of the power steering components.
Fluid level change: Within 5 mm
POWER STEERING SYSTEM AIR BLEEDING

Perform air bleeding procedure as necessary after replacing the steering gear or the steering fluid lines. 1. Raise and support the front wheels. 2. Disconnect the ignition coil connectors (Refer to GROUP 16, Ignition Coil P.16-34).
M1372002200426
With engine running
With engine stopped

ACX01131AC
9. Confirm that the change in the fluid level is no more than 5 mm when the engine is stopped and when it is running. 10.If the change of the fluid level is 5 mm or more, the air has not been completely bled from the system. The air bleeding procedure must be repeated.
POWER STEERING
ON-VEHICLE SERVICE
37-11
OIL PUMP PRESSURE TEST

M1372002300401
Temperature gauge
Pressure gauge (MB990662)
Shut-off valve (fully closed)
Oil reservoir Adapter (MB991548)
7. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering gear, so check these parts and repair as necessary. 8. Turn the steering wheel all the way to the left or right; then check whether or not the retention hydraulic pressure is the standard value. Standard value: 8.3 9.0 MPa 9. If not the standard value, overhaul the steering gear. Remeasure fluid pressure. 10. Remove the special tools, and then tighten the pressure hose to the specified torque. Tightening torque: 18 3 Nm 11. Bleed the system (Refer to P.37-10).
Oil pump
Adapter (MB991549)
POWER STEERING PRESSURE SWITCH CHECK

M1372007200421
ACX01133 AB
Adapter (MB991548) Temperature gauge
Shut-off valve Pressure gauge (MB990662)
1. Disconnect the pressure hose from the oil pump, and then connect the following special tools. Power steering oil pressure gauge (MB990662) Power steering oil pressure gauge adapter (pump side) (MB991548) Power steering oil pressure gauge adapter (hose side) (MB991549) 2. Bleed air, then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 60C. 3. Start the engine and idle it at 1,000 100 r/min.
Oil pump Adapter (MB991549)
Oil reservoir
CAUTION The pressure gauge shut-off valve must not remain closed for more than 10 seconds. 4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the standard value range. Open it again immediately after checking the pressure. Standard value: 8.3 9.0 MPa
5. If it is not within the standard value, replace the oil pump. 6. Check whether or not the hydraulic pressure is the standard value when no-load conditions are created by fully opening the shut-off valve of the pressure gauge. Standard value: 0.2 0.8 MPa
ACX01134 AB
1. Disconnect the pressure hose from the oil pump, and then connect the following special tools. Power steering oil pressure gauge (MB990662) Power steering oil pressure gauge adapter (pump side) (MB991548) Power steering oil pressure gauge adapter (hose side) (MB991549) 2. Bleed air, and then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 60C. 3. The engine should be idling.
37-12
POWER STEERING
ON-VEHICLE SERVICE
4. Disconnect the connector for the oil pressure switch, and place an ohmmeter at the switch. 5. Gradually close the shut-off valve of the pressure gauge and increase the hydraulic pressure, then check whether or not the hydraulic pressure that activates the switch is the standard value. Standard value: 1.8 2.4 MPa 6. Gradually open the shut-off valve and reduce the hydraulic pressure; then check whether or not the hydraulic pressure that deactivates the switch is the standard value. Standard value: 1.0 2.4 MPa 7. Remove the special tools, and then tighten the pressure hose to the specified torque. Tightening torque: 18 3 Nm 8. Bleed the system (Refer to P.37-10).
WARNING If the vehicle continues to be driven after
the collision absorbing mechanism has operated, the steering column shaft may be damaged while it is in use. If there is a slack in the one-way capsule, do not attempt to repair it but replace the steering column shaft assembly.
Inspection Procedure
1. Remove the lower and upper column covers.
CAUTION Do not release the tilt lever until the steering column has been installed to complete this inspection procedure.
2. Ensure that the tilt lever is in the lock position. NOTE: If not, place the tilt lever in the lock position.
TIE ROD END BALL JOINT DUST COVER CHECK

M1372008600262
1. Press the dust cover with your finger to check whether the dust cover is cracked or damaged. 2. If the dust cover is cracked or damaged, replace the tie rod end. NOTE: If the dust cover is cracked or damaged, the ball joint could be damaged.
Steering column assembly
STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING MECHANISM CHECK

If a collision accident occurs or severe impact is applied on the steering wheel, the collision energy absorbing mechanism may have operated. Once the mechanism has operated, it will be inoperative even it has suffered no apparent damage. Determine if the steering column shaft can be reused by the following procedure. If the collision energy absorbing mechanism has already operated, replace the steering column shaft assembly. If any excessive radial free play on the steering wheel is found with the tilt lever in the lock position, always check the steering shaft assembly.
M1372013500090
Steering column mounting bolt
AC304673 AB
3. Loosen the two steering column mounting bolts (upper) by two turns.
AC304673 AC304673
One way capsule
AC304672 AC304923 AB
POWER STEERING
STEERING WHEEL
37-13
4. Hold the one way capsule as shown, and then try to lock them. If there is a slack in either of the capsules, replace the steering column shaft assembly. NOTE: When installing a new steering column shaft assembly, place the tilt lever in the lock position, if it is not in place.
CAUTION Be careful that nothing is pinched between the one-way capsules and the body. Do not release the tilt lever until the steering column has been installed to complete this inspection procedure.
5. If no problem is found during the inspection, tighten the steering column mounting bolts to the specified torque. Tightening torque: 12 2 Nm
STEERING WHEEL
M1372011400279
WARNING Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-3) and Air Bag Module and Clock Spring (P.52B-110). When removing and installing the steering wheel, do not let it bump against the air bag module.
Post-installation Operation Checking Steering Wheel Position with Wheels Straight Ahead
50 5 Nm
AC211760AD
<<A>> <>
Removal steps 1. Cover 2. Steering wheel and air bag module assembly
37-14
REMOVAL SERVICE POINTS <<A>> COVER REMOVAL
POWER STEERING
STEERING WHEEL
1. By sliding section A of the clock spring connector as shown in the illustration in the arrow direction, disconnect the connector.
Hexagonal bit socket
MB990784
AC211761AB
Insert special tool ornament remover (MB990784) at the indicated position to remove the cover. NOTE: The special tool can be inserted through the notch behind the area shown.
AC211762 AC
<> STEERING WHEEL AND AIR BAG MODULE ASSEMBLY REMOVAL
2. Loosen the bolt completely. Then, remove the steering wheel and air bag module assembly. NOTE: Use a hexagonal bit socket or a hexagonal wrench having an effective length of 75 mm or more in the hexagonal section and the diameter of 8 mm or more.
Steering wheel
AC304700
Air bag module connector
A
AC105823 AC305145AB
POWER STEERING
STEERING COLUMN SHAFT ASSEMBLY
37-15

M1372003100091
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Service Precautions (P.52B-3) and Air Bag Module and Clock Spring (P.52B-110).
Pre-removal Operation Steering Wheel and Air bag Module Assembly Removal (Refer to P.37-13). Under Cover Removal (Refer to GROUP 52A, Instrument Panel P.52A-2). Post-installation Operation Under Cover Installation (Refer to GROUP 52A, Instrument Panel P.52A-2). Steering Wheel and Air bag Module Assembly Installation (Refer to P.37-13).
WARNING
2
Section A - A
2.5 0.5 Nm A (mounting screw)
3 2
A
Tab
1 5
Section B - B B B Toe board 12 2 Nm B B
1 4 6
18 2 Nm
6
Specified sealant: 3M ATD Part No.8513 or equivalent
5.0 1.0 Nm
AC310967AB
Removal steps 1. Lower column cover 2. Upper column cover 3. Clock spring and column switch assembly (Refer to GROUP 52B, Drivers, Front Passengers Air Bag Modules and Clock Spring P.52B-110).
Removal steps (Continued) 4. Shaft cover <<A>> >>A<< 5. Steering column shaft assembly 6. Cover assembly
37-16
POWER STEERING
REMOVAL SERVICE POINT <<A>> STEERING COLUMN SHAFT ASSEMBLY REMOVAL

CAUTION The tilt lever should be held in the lock position until the steering column shaft is installed to the vehicle. If the steering column is removed with the tilt lever released, or the tilt lever is released after the steering column shaft was removed from the vehicle, the steering column can not be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged.
1. Ensure that the tilt lever is in the lock position, and remove the steering column mounting bolts.
INSTALLATION SERVICE POINT >>A<< STEERING COLUMN SHAFT ASSEMBLY INSTALLATION

CAUTION When reusing the steering column, do not release the tilt lever until the steering column shaft has been installed. When the steering column is replaced, do not release the tilt lever until it has been installed. Do not remove the tilt lever fixing band until the installation has completed. When installing the steering column, do not leave it fixed temporarily at only one point and make sure the column shaft is not shaken strongly. If you fail to do, the collision absorbing mechanism at the column shaft mounting location may be damaged.
3
Clip Steering column shaft 1 4 Tilt lever 2
AC210969AD
2. Pinch the steering column shaft clip with pliers, and pull up the shaft towards the direction shown to disengage the steering column shaft assembly.
AC209383AG
Ensure that the tilt lever is in the lock position, and install the steering column. Tighten the four bolts in the order shown by hand, and then tighten them to the specified torque in the order shown. Tightening torque: 12 2 Nm
POWER STEERING
37-17

M1372015000079
1 2
AC210967AD
<<A>> >>A<< 1. >>A<< 2.
Disassembly steps Special bolt Steering lock bracket
>>A<< 3. 4.
Disassembly steps (Continued) Steering lock cylinder assembly Steering column shaft assembly
DISASSEMBLY SERVICE POINT <<A>> SPECIAL BOLT REMOVAL

Reverse screw tap Special bolt Steering lock bracket
REASSEMBLY SERVICE POINT >>A<< STEERING LOCK CYLINDER ASSEMBLY/STEERING LOCK BRACKET/SPECIAL BOLT INSTALLATION
CAUTION The steering lock bracket and bolts must be replaced with new ones when the steering lock is installed. 1. When installing the steering lock cylinder assembly and steering lock bracket to the column tube, temporarily install the steering lock in alignment with the column boss.
Steering lock cylinder
ACX01138AB
1. Drill in the special bolt a hole deep enough for the tap to stand. 2. Remove the special bolt with a left-hand tap.
37-18
POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE
ACX01139 AB
2. After checking that the lock works properly, tighten the special bolts until the head twists off.

M1372010900505
Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-3) and Air Bag Module and Clock Spring (P.52B-110). Centre the front wheels. Failure to do so may damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
CAUTION During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Front Axle Crossmember Bar, Front Suspension Centremember, Engine Rear Roll Stopper Rod and Bracket Assembly Removal (Refer to GROUP 32, Engine Rear Roll Stopper, Centremember P.32-7). Lower Arm Removal (Refer to GROUP 33, Lower Arm Assembly P.33-10). Stabilizer Bar Removal (Refer to GROUP 33, Stabilizer Bar P.33-14). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Steering Wheel Air Bag Module Assembly, Clock spring Removal (Refer to P.37-13). Power Steering Fluid Draining (Refer to P.37-10). Post-installation Operation Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Stabilizer Bar Installation (Refer to GROUP 33, Stabilizer Bar P.33-14). Lower Arm Installation (Refer to GROUP 33, Lower Arm Assembly P.33-10). Front Axle Crossmember Bar, Front Suspension Centremember, Engine Rear Roll Stopper Rod and Bracket Assembly Installation (Refer to GROUP 32, Engine Rear Roll Stopper, Centremember P.32-7). Steering Wheel Air Bag Module Assembly Installation (Refer to P.37-13). Power Steering Fluid Supplying (Refer to P.37-10). Power Steering Fluid Line Bleeding (Refer to P.37-10). Press the dust cover with a finger to check whether the dust cover cracked or damaged. Checking Steering Wheel Position with Wheels Straight Ahead. Front Wheel Alignment Check and Adjustment (Refer to P.37-8). Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2).
WARNING
POWER STEERING
<LH drive vehicles> 12 2 Nm
37-19
10100AU 10104AU AC210547
8
59 10 Nm
5
70 10 Nm
7 1 4
15 3 Nm 18 2 Nm
3 9 2 6
12 2 Nm
11
10
AC310933 AB
Removal steps 1. Steering shaft assembly and gear box connecting bolt. >>A<< 2. Joint cover grommet 3. Return hose 4. Return tube 5. O-ring
6. 7. 8. 9. 10. 11.
Removal steps (Continued) Return tube Eye bolt Pressure hose assembly Clamp Front axle No.1 crossmember Steering gear and linkage
37-20
<RH drive vehicles>
POWER STEERING
10101AU AC304919 AC210547
15 3 Nm
2 4 5 3
70 10 Nm
18 2 Nm
6
59 10 Nm
7
AC310934 AB
Removal steps 1. Steering shaft assembly and gear box connecting bolt. >>A<< 2. Joint cover grommet 3. Return hose connection 4. Return tube 5. Pressure hose connection
Removal steps (Continued) 6. Clamp 7. Front axle No.1 crossmember 8. Steering gear and linkage
POWER STEERING
37-21
INSTALLATION SERVICE POINT >>A<< JOINT COVER GROMMET INSTALLATION

Joint cover grommet A B
NOTE: Remove the bellows from the rack housing before measuring. NOTE: Measure the total rotation torque by turning the special tool left and right 180 from the neutral position. 2. If the standard values are not met, adjust the pinion total rotation torque. 3. In case the adjustment is impossible, disassemble and check the components, and repair if necessary.
Steering gear
AC304922 AB
TIE ROD SWING RESISTANCE CHECK

1. Give 10 hard swings to the tie rod.
Align the joint cover grommet notch (arrow A) with the steering gear lug (arrow B), and then install the steering joint cover to the steering gear.
INSPECTION
M1372011000323
STEERING GEAR TOTAL PINION TORQUE CHECK

CAUTION When holding the steering gear in a vice, secure its mounting positions. If it is secured in any other place, the gear housing may become deformed or damaged.
AC000997
2. Measure the tie rod swing resistance [tie rod swing torque] with a spring balance. Standard value: 8 27 N [1.5 4.9 Nm] 3. If the measured value exceeds the standard value, replace the tie rod. 4. If the measured value is below the standard value, the tie rod can be re-used if it swings smoothly without excessive play.
MB991006
TIE ROD END BALL JOINT DUST COVER CHECK

AC000996 AC
1. Using special tool preload socket (MB991006), rotate the pinion gear at the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque. Standard value: Total rotation torque 0.8 1.8 Nm Torque fluctuation 0.49 Nm or less
1. Check the dust cover for cracks or damage by pushing it with your finger. 2. If the dust cover is cracked or damaged, replace the tie rod end (Refer to P.37-22). NOTE: Cracks or damage of the dust cover may damage the ball joint. If it is damaged during service work, replace the dust cover (Refer to P.37-30).
37-22
<LH drive vehicles>
POWER STEERING
M1372011100290
Flare nut 22 4 Nm
35 1 36 2 6 16 5 7 9 8 10
88 10 Nm
24 23 22 18 20 21 19 34 13 59 10 Nm 12
13 3 Nm
23 21 19 8
Repair kit grease
52 2 Nm
33 17
15 14
23 2 Nm -30
11 8
25 4 Nm 59 10 Nm
11 35 17 31 29 28 32
Steering gear seal kit
11
26 27
25 28 29 31 30
32
AC311001AB
>>O<< 1. 2. 3. 4. >>N<< 5. >>N<< 6. 7. >>M<< 8. 9. >>L<< 10. >>L<< 11. >>K<< >>J<< 12. <<A>> >>J<< 13. 14. 15. >>I<< 16. 17.
Disassembly steps Gear mounting rubber Gear housing mounting bushing Feed pipe O-ring Lock nut Tie rod end Clip Bellows band Bellows Tie rod Tab washer Total pinion torque adjustment Lock nut Rack support cover Support spring Rack support End plug Lock nut
<> <> <<C>> <<D>> <<D>> <<E>> <<F>> <<F>> <<F>> <<F>> <<F>> <<C>> <<G>> <<H>> <>
18. >>H<< 19. 20. >>G<< 21. >>F<< 22. >>F<< 23. 24. >>E<< 25. 26. >>D<< 27. >>D<< 28. 29. >>C<< 30. 31. 32. >>B<< 33. >>B<< 34. >>A<< 35. 36.
Disassembly steps (Continued) Valve housing assembly Lower oil seal Pinion and valve assembly Seal ring Upper bearing Upper oil seal Valve housing Circlip Rack stopper Rack bushing Oil seal O-ring Rack assembly Seal ring O-ring Lower bearing Needle bearing Oil seal Gear housing
POWER STEERING
37-23
<RH drive vehicles>

Flare nut 13 3 Nm
24 23 18 22
22 4 Nm
3 21 19 20 4 34 2 4 4 35 15 14 12 13
59 10 Nm
23 21 19
Repair kit grease
11 8
1 36
25 4 Nm
33 17
8 35 11 17 31 29 28 32
Steering gear seal kit
59 10 Nm
16 30 31 32 27 29 28
23 2 Nm
-30 52 2 Nm
26 25
11
10 8 9 7 5 6
AC311005 AB
88 10 Nm
>>O<< 1. 2. 3. 4. >>N<< 5. >>N<< 6. 7. >>M<< 8. 9. >>L<< 10. >>L<< 11. >>K<< >>J<< 12. <<A>> >>J<< 13. 14. 15. >>I<< 16. 17.
Disassembly steps Gear mounting rubber Gear housing mounting bushing Feed pipe O-ring Lock nut Tie rod end Clip Bellows band Bellows Tie rod Tab washer Total pinion torque adjustment Lock nut Rack support cover Support spring Rack support End plug Lock nut
<> <> <<C>> <<D>> <<D>> <<E>> <<F>> <<F>> <<F>> <<F>> <<F>> <<C>>
>>H<< >>G<< >>F<< >>F<< >>E<< >>D<< >>D<< >>C<<
<<G>> >>B<< <<H>> >>B<< <> >>A<<
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.
Disassembly steps (Continued) Valve housing assembly Lower oil seal Pinion and valve assembly Seal ring Upper bearing Upper oil seal Valve housing Circlip Rack stopper Rack bushing Oil seal O-ring Rack assembly Seal ring O-ring Lower bearing Needle bearing Oil seal Gear housing
37-24
POWER STEERING
LUBRICATION AND SEALING POINTS
Fluid: ATF DXRON III or DEXRON II
Grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent
Grease: Repair kit grease Fluid: ATF DXRON III or DEXRON II Sealant: 3M ATD Part No. 8661 or equivalent
AC200119 AC
Grease: Silicone grease
Grease: Repair kit grease Fluid: ATF DXRON III or DEXRON II
POWER STEERING
37-25
DISASSEMBLY SERVICE POINTS <<A>> RACK SUPPORT COVER REMOVAL
<<D>> UPPER BEARING/UPPER OIL SEAL REMOVAL
MB991621
AC103692 AF
Socket
ACX01145AC
Using the following special tool piston driver (MB991621), remove the rack support cover from the steering gear.
Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.
<<E>> CIRCLIP REMOVAL

CAUTION If the rack stopper is first turned anticlockwise, the circlip will get caught in the slot in the housing and the rack stopper will not turn.
Rack stopper
<> LOWER OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL
Circlip
ACX01143AB
Using a plastic hammer, gently tap the pinion to remove it.
ACX01146 AB
<<C>> SEAL RING REMOVAL

CAUTION When cutting the seal ring, be careful not to damage the pinion and valve assembly or the rack.
1. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing. 2. Turn the rack stopper anticlockwise to remove the circlip.
<<F>> RACK STOPPER/RACK BUSHING/OIL SEAL/O-RING/RACK ASSEMBLY REMOVAL
ACX01144 AB
Cut the seal ring and remove it from the pinion and valve assembly or the rack.
ACX01147 AB
37-26
POWER STEERING
1. Pull out the rack slowly. Take out the rack stopper and the rack bushing at the same time.
Use special tool needle bearing puller (MB991120) to remove the needle bearing from the valve housing.
CAUTION Do not damage the oil seal press fitting surface.
<> OIL SEAL REMOVAL

CAUTION Be careful not to damage the inner surface of the rack cylinder of the gear housing.
Rack bushing
Gear housing Pipe or similar tool
ACX01148 AB
Oil seal
2. Partially bend the oil seal and remove it from the rack bushing.
AC100259 AB
<<G>> LOWER BEARING REMOVAL

MB990939 Valve housing
Use a piece of pipe or similar tool to remove the oil seal from the gear housing.
REASSEMBLY SERVICE POINTS >>A<< OIL SEAL INSTALLATION

1. Apply a coating of ATF DEXRON III or DEXRON II to the both sides of the oil seal.
Lower bearing
Gear housing
ACX01149 AC
MB991199 MB991197
Use a brass bar or special tool brass bar (MB990939) to remove the lower bearing from the valve housing.
Oil seal
AC100260 AF
<<H>> NEEDLE BEARING REMOVAL

CAUTION Do not open special tool excessively to prevent damaging housing interior.
2. Using the following special tools, press the oil seal into the rack housing. Bar (long type) (MB991197) Oil seal installer (MB991199)
MB991120
>>B<< NEEDLE BEARING/LOWER BEARING INSTALLATION

Needle bearing
Valve housing
1. Apply ATF DEXRON III or DEXRON II to housing and bearing press fitting surface.
ACX01150 AB
POWER STEERING
37-27
CAUTION Press-fit straight. The valve housing is aluminium, and may become deformed if press-fit on an angle.
MB990938 Needle bearing MB990938 MB991202
4. Align the centre of the oil seal with the rack to prevent the retainer spring from slipping. Slowly insert the rack from power cylinder side.
>>D<< OIL SEAL/RACK BUSHING INSTALLATION
MB991202
Lower bearing
MB990927 Oil seal O-ring
ACX01153 AE
2. Press fit needle bearing/lower bearing with the following special tools. Bar (snap-in type) (MB990938) Oil seal and bearing installer (MB991202)
Rack bushing
ACX01156 AE
>>C<< RACK ASSEMBLY INSTALLATION

CAUTION Do not close the vent hole in the rack with grease.
Vent hole
1. Apply ATF DEXRON III or DEXRON II to the outer surface of the oil seal. Using special tool installer adapter (MB990927), press in the oil seal until it is flush with the bushing end face.
Rack
Plastic tape Rack bushing

AC100261AC
Seal ring and O-ring

ACX01154 AB
1. Apply a coating of repair kit grease to the rack teeth face.
2. Apply ATF DEXRON III or DEXRON II to the oil seal inner surface and the O-ring. 3. Wrap the rack end with plastic tape, and push the rack bushing onto the rack.
>>E<< CIRCLIP INSTALLATION

Oil seal
CAUTION Insert the circlip to the rack stopper hole while turning the rack stopper clockwise.
Circlip MB991214
ACX01155 AH
Circlip
2. Cover rack serrations with the following special tool oil seal protector (MB991214). 3. Apply ATF DEXRON III or DEXRON II to special tool, and to the outer surface of the seal ring and the O-ring.
Slot Slot
ACX01158 AB
37-28
POWER STEERING
Insert the circlip to the rack stopper hole through cylinder hole. Turn the rack stopper clockwise and insert the circlip firmly.
>>H<< LOWER OIL SEAL INSTALLATION

CAUTION
Approximately 1 mm Oil seal Housing MB990941
>>F<< UPPER OIL SEAL/UPPER BEARING INSTALLATION

MB990938 MB990938
ACX01161 AC
MB991203 Oil seal
MB991203 Bearing ACX01159AC
Apply a coating of ATF DEXRON III or DEXRON II to the outside of the upper oil seal/upper bearing. Using the following special tools, press the upper oil seal/upper bearing into the valve housing. Bar (snap-in type) (MB990938) Oil seal and bearing installer (MB991203)
To eliminate a seal malfunction at the valve housing alignment surface, the upper surface of the oil seal should project outward approximately 1 mm from the housing edge surface. Using special tool torque tube bearing installer (MB990941), press the oil seal into the valve housing.
>>I<< END PLUG INSTALLATION

End plug
>>G<< SEAL RINGS INSTALLATION
End plug
MB991317
ACX01162 AB
ACX01160 AB
Because the seal rings expand after installation, tighten after installing by using special tool seal ring installer (MB991317) to compress the rings, or press down by hand.
1. Apply specified sealant to the threaded part of the end plug. Specified sealant: 3M ATD Part No.8661 or equivalent 2. Secure the threaded portion of the end plug at two places by using a punch.
>>J<< RACK SUPPORT COVER/LOCK NUT INSTALLATION

1. Position the rack at its centre. 2. Apply specified sealant to the threaded part of the rack support cover. Specified sealant: 3M ATD Part No.8661 or equivalent
POWER STEERING
37-29
2. If the total pinion torque or the change in torque is outside the standard value, move the rack support cover 0 30, and adjust the pinion torque again.
>>L<< TAB WASHER/TIE ROD INSTALLATION

MB991621
AC100273 AF
3. Use the following special tool piston driver (MB991621) to tighten the rack support cover to 23 2 Nm. 4. Turn the rack support cover 30 anticlockwise. 5. Use the special tool to hold the rack support cover, and then tighten the lock nut to 59 10 Nm.
ACX01163 AB
>>K<< TOTAL PINION TORQUE ADJUSTMENT

CAUTION Be sure there is no ratcheting or catching when operating the rack towards the shaft. Measure the total pinion torque through the whole stroke of the rack.
After installing the tie rod to the rack, fold tab washer end (two locations) to tie rod notch.
>>M<< BELLOWS BAND INSTALLATION

MB991561 Stopper W
MB991006 Adjusting bolt

ACX01164 AB
AC100274AB
1. Using special tool preload socket (MB991006), rotate the pinion shaft at the rate of one rotation in 4 to 6 seconds to check the total pinion torque and the change in torque. Standard value: Total pinion torque: 0.8 1.8 Nm Torque fluctuation: 0.49 Nm or less
1. Turn the adjusting bolt of special tool boot band crimping tool (MB991561) to adjust the opening dimension (W) to the standard value. NOTE: The dimension (W) is adjusted by approximately 0.7 mm per one turn. NOTE: Do not turn the adjusting bolt more than one turn. Standard value (W): 2.9 mm <When more than 2.9 mm>: Screw in the adjusting bolt. <When less than 2.9 mm>: Loosen the adjusting bolt.
CAUTION When adjusting, set at the highest value of the standard value range. NOTE: If the total pinion toque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary.
37-30
POWER STEERING
CAUTION Hold the rack housing, and use special tool to crimp the bellows band securely. Crimp the bellows band until special tool touches the stopper.
MB991561
>>N<< TIE ROD END/LOCK NUT INSTALLATION

Edge of bellows assembly groove Lock nut
184 mm
AC001011AO
ACX01165 AB
2. Use special tool boot band crimping tool (MB991561) to crimp the bellows band.
Screw in the tie rod end to achieve the right and left length as illustrated. Lock with the lock nut. NOTE: The lock nuts must be tightened securely only after the steering gear is installed to the vehicle and toe-in is adjusted.
>>O<< GEAR MOUNTING RUBBER INSTALLATION

220 mm
ACX01166 AB
3. Check that crimped width (A) is within the standard value. Standard value (A): 2.4 2.8 mm <When more than 2.8 mm>: Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2). W = 5.5 mm A [Example: if (A) is 2.9 mm, (W) is 2.6 mm.] <When less than 2.4 mm>: Remove the bellows band, readjust the dimension (W) of step (1) to the value calculated by the following equation, and use a new bellows band to repeat steps (2) to (3). W = 5.5 mm A [Example: if (A) is 2.3 mm, (W) is 3.2 mm.]
AC100275AB
Install the gear mounting rubber to the rack housing so that the distance is as shown in the illustration.
TIE ROD END BALL JOINT DUST COVER REPLACEMENT M1372008200327

If the dust cover is damaged accidentally during service work, replace the dust cover as follows:
MB990776
AC001012AB
1. Apply specified grease to the lip and inside of the dust cover. Specified grease: Multipurpose grease SAE J310, NLGI No.2 or equivalent
POWER STEERING
POWER STEERING OIL PUMP ASSEMBLY
37-31
2. Drive in the dust cover with special tool front axle base (MB990776) until it is fully seated.
3. Check the dust cover for cracks or damage by pushing it with your finger.

M1372005200470
Pre-removal Operation Power Steering Fluid Draining (Refer to P.37-10).
Post-installation Operation Power Steering Fluid Supplying and Bleeding (Refer to P.37-10). Drive Belt Tension Check (Refer to GROUP 11A, On-vehicle Service Drive Belt Tension Check P.11A-7).
3 4
18 3 Nm
5N
5N 6 1
22 4 Nm
22 4 Nm* 22 4 Nm
40 5 Nm*
40 5 Nm
AC211828 AE
1. 2. >>B<< 3. >>B<< 4. >>A<< 5.
Removal steps Pressure switch connector Drive belt (Refer to GROUP 11A,Crankshaft Pulley P.11A-15). Suction hose connection Pressure hose connection O-ring
6. 7. 8.
Removal steps (Continued) Heat protector Oil pump assembly Power steering pump bracket
37-32
POWER STEERING
INSTALLATION SERVICE POINTS >>A<< O-RING INSTALLATION

1 2
>>B<< PRESSURE HOSE ASSEMBLY/SUCTION HOSE REMOVAL

Suction hose
Marking
Pressure hose assembly Notch
AC311013 AB
No. 1 2
ID Width mm 11.0 1.9 13.0 1.9
AC211830 AC
Install the pressure hose assembly and suction hose as illustrated.

M1372005400418
39 5 Nm
21 3 Nm
1 2
: Automatic transmission fluid DEXRON or DEXRON II
AC211831AC
1. 2. 3. 4.
Removal steps Suction connector O-ring Connector Gasket
INSPECTION
Check the drive belt for cracks. Check the pulley for uneven rotation.
M1372005500277
POWER STEERING
POWER STEERING HOSES
37-33
POWER STEERING HOSES

M1372005700828
Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-3) and Air Bag Module and Clock Spring (P.52B-110). Centre the front wheels. Failure to do so may damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
CAUTION During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal and Post-installation Operation Power Steering Fluid Draining and Refilling (Refer to P.37-10) and Bleeding (Refer to P.37-10).
WARNING
<LH drive vehicles>

18 3 Nm 12 2 Nm 12 2 Nm
5
12 2 Nm
12 13 17
12 2 Nm 15 3 Nm
11
59 10 Nm
16 1 6 4 2
12 2 Nm Crossmember
10 14 7
18 2 Nm
15
3
12 2 Nm 167 9 Nm
18
8
52 7 Nm* 49 10 Nm
AC211825 AC
1. >>B<< 2.
Removal steps Oil reservoir Suction hose
3. 4.
Removal steps (Continued) Return hose Return hose
37-34
5. 6.
POWER STEERING
POWER STEERING HOSES Removal steps (Continued) Return hose Strut tower bar (Refer to GROUP 42, Strut tower bar P.42-9). Return hose Clock spring (Refer to GROUP 52B, Drivers, Front Passengers Air Bag Modules and Clock Spring P.52B-110). Crossmember Bar (Refer to GROUP 33, Crossmember Bar P.33-17). Centremember (Refer to GROUP 32, Engine Roll Stopper Centremember P.32-7). Front exhaust pipe (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). 7. 8. 9. Removal steps (Continued) Steering gear and joint connecting bolt Rear roll stopper connecting bolt Rear roll stopper (Refer to GROUP 32, Engine Roll Stopper Centremember P.32-7). Eye bolt Gasket Pressure hose assembly O-ring Return hose Return tube Return tube O-ring Front bumper (Refer to GROUP 51, Front Bumper Assembly P.51-2). Intercooler (Refer to GROUP 15, Intercooler P.15-6). Cooler tube assembly
<<A>>
10. 11. >>B<< 12. >>A<< 13. 14. 15. <<A>> 16. 17. 18.
<RH drive vehicles>

12 2 Nm 12 2 Nm 18 3 Nm
11
12 2 Nm
5 12
12 2 Nm 59 10 Nm
1 4 2
6 14
15 3 Nm
13
10
9 7
18 2 Nm
Crossmember
3
12 2 Nm
167 9 Nm
8 15
49 10 Nm 52 7 Nm*
AC310935AB
1. >>B<< 2.
Removal steps Oil reservoir Suction hose
3. 4.
Removal steps (Continued) Return hose Return hose
POWER STEERING
POWER STEERING HOSES 5. 6. Removal steps (Continued) Return hose Strut tower bar (Refer to GROUP 42, Strut tower bar P.42-9). Return hose Clock spring (Refer to GROUP 52B, Drivers, Front Passengers Air Bag Modules and Clock Spring P.52B-110). Crossmember Bar (Refer to GROUP 33, Crossmember Bar P.33-17). Centremember (Refer to GROUP 32, Engine Roll Stopper Centremember P.32-7). Front exhaust pipe (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). 7. 8. <<A>> 9. 10. >>B<< 11. >>A<< 12. <<A>> 13. 14. 15.
37-35
Removal steps (Continued) Steering gear and joint connecting bolt Rear roll stopper connecting bolt Eye bolt Gasket Pressure hose assembly O-ring Return tube O-ring Front bumper (Refer to GROUP 51, Front Bumper Assembly P.51-2). Intercooler (Refer to GROUP 15, Intercooler P.15-6). Cooler tube assembly
REMOVAL SERVICE POINT <<A>> EYE BOLT/RETURN TUBE REMOVAL

1. Loosen the crossmember mounting bolts and nuts, and lower the crossmember to a position so that the eye bolts or return tube at the steering gear side can be removed. NOTE: In this case, do not remove the crossmember mounting bolts and nuts. 2. Remove the eye bolts or return tube.
No. 1 2
ID Width mm 11.0 1.9 13.0 1.9
>>B<< PRESSURE HOSE ASSEMBLY/SUCTION HOSE REMOVAL

Suction hose
INSTALLATION SERVICE POINTS >>A<< O-RING INSTALLATION

1 2
Marking
Pressure hose assembly Notch
AC211830 AC
Install the pressure hose assembly and suction hose as illustrated.
AC311013 AB
NOTES
11A-1
GROUP 11A
ENGINE MECHANICAL
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATIONS. . . . . . . SEALANTS . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE. . . . . . . . . . .
DRIVE BELT TENSION CHECK. . . . . . . . . AUTO-TENSIONER CHECK . . . . . . . . . . . IGNITION TIMING CHECK . . . . . . . . . . . . . IDLE SPEED CHECK . . . . . . . . . . . . . . . . . IDLE MIXTURE CHECK . . . . . . . . . . . . . . . COMPRESSION PRESSURE CHECK. . . . MANIFOLD VACUUM CHECK . . . . . . . . . . LASH ADJUSTER CHECK . . . . . . . . . . . . .
11A-2 11A-2 11A-3 11A-3 11A-7

11A-7 11A-7 11A-9 11A-10 11A-11 11A-11 11A-12 11A-13
CAMSHAFT AND VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-17

REMOVAL AND INSTALLATION . . . . . . . . 11A-17
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A-26

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-26 11A-28
CRANKSHAFT OIL SEAL . . . . . . . . . 11A-29

CYLINDER HEAD GASKET . . . . . . . . 11A-31

TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-36

REMOVAL AND INSTALLATION . . . . . . . . INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-36 11A-44
CRANKSHAFT PULLEY . . . . . . . . . .
11A-15
11A-15
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-46

11A-2
ENGINE MECHANICAL
GENERAL INFORMATION
GENERAL INFORMATION
M1111000100914
Item Total displacement mL Bore Stroke mm Compression ratio Compression chamber Camshaft arrangement Number of valve Valve timing Intake Exhaust Intake opening Intake closing Exhaust opening Exhaust closing Fuel system Rocker arm Auto-lash adjuster
4G63 1,997 85 88 8.8 Pentroof DOHC 8 8 BTDC 0 30 ABDC 80 50 BBDC 58 ATDC 18 Electronically controlled multipoint fuel injection Roller type Equipped
M1112000300609
Item Drive belt tension
Standard value Vibration frequency Hz 110 144 (Reference) Tension N (Reference) 245 412 5 BTDC 3
Limit
Basic ignition timing Ignition timing Idle speed r/min CO contents % HC contents ppm Compression pressure kPa-r/min Compression pressure difference of all cylinders kPa Inlet manifold vacuum kPa Cylinder head bolt nominal length mm Balancer timing belt tension (When adjusted) Deflection mm Balancer timing belt tension (When replaced) Deflection mm Balancer timing belt tension (When checked) Deflection mm Timing belt tensioner adjuster rod protrusion amount mm Timing belt tensioner adjuster rod movement mm
Approximately 5 BTDC 800 100 0.5 or less 100 or less 1,000 250 57 57 5 10 3.8 4.5 Within 1 640 250 Maximum 98 Minimum 60 99.4
ENGINE MECHANICAL
SEALANTS
11A-3
M1112000500313
SEALANTS
Item Cylinder head Camshaft position sensor support Rocker cover Camshaft end seal Rocker cover gasket Engine oil pan 3M ATD Part No.8660 or equivalent MITSUBISHI GENUINE PART MD970389 or equivalent Specified Sealant MITSUBISHI GENUINE PART MD970389 or equivalent Remark Semi-drying sealant
SPECIAL TOOLS
M1112000600882
Tool
Number MB991502
Use Drive belt tension check Checking the ignition timing Checking the idle speed
B991502
11A-4
Tool
A
ENGINE MECHANICAL
SPECIAL TOOLS
Number MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826
Name M.U.T.-III sub assembly A: Vehicle communication interface (V.C.I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A (Vehicles with CAN communication system) D: M.U.T.-III main harness B (Vehicles without CAN communication system) E: M.U.T.-III measurement adapter F: M.U.T.-III trigger harness
Use Drive belt tension check Checking the ignition timing Checking the idle speed
MB991824
MB991827
DO NOT USE
MB991910
CAUTION If you connect M.U.T.-III main harness A to a vehicle without CAN communication system to use the M.U.T.-III, a pulse signal may interfere with the simulated vehicle speed lines, thus causing the M.U.T.-III inoperative. Therefore, use the M.U.T.-III main harness B (MB991911) instead.
MB991911
MB991825
MB991826 MB991955
MB991668
Belt tension meter set
Drive belt tension check (used together with M.U.T.-II or M.U.T.-III)
B991668
MD998772
Valve spring compressor
Compressing valve spring
MD998772
MD998737
Valve stem seal installer
Valve stem seal installation
ENGINE MECHANICAL
SPECIAL TOOLS
11A-5
Use Camshaft oil seal installation
Tool
Number MD998713
Name Camshaft oil seal installer
D998713
MD998727
Oil pan FIPG cutter
Oil pan removal
D998727
MD998781
Flywheel stopper
Supporting the flywheel
D998781
MB990938
Installer bar
Crankshaft rear oil seal installation
MD998776
Crankshaft rear oil seal installer
D998776
MD998285
Crankshaft front oil seal guide
Crankshaft front oil seal installation
D998285
MD998375
Crankshaft front oil seal installer
MB991654
Cylinder head bolt wrench (12)
Removal and installation of cylinder head bolt
B991654
11A-6
Tool Number MD998738
ENGINE MECHANICAL
SPECIAL TOOLS
Name Adjusting bolt
Use Supporting the timing belt tensioner arm and timing belt tensioner adjuster
D998738
MB991367
Special spanner
Holding the crankshaft camshaft drive sprocket
B991367
MB991385
Pin
B991385
MD998767
Tensioner wrench
Valve timing belt tension adjustment
D998767
MB991454
Engine hanger balancer
B991454
MB991895
Engine hanger
When the engine hanger is used: Supporting the engine assembly during removal and installation of the transmission assembly NOTE: Special tool MB991454 is a part of engine hanger attachment set MB991453.
Z203830
Slide bracket (HI)
F D B C
B991928
MB991928 A: MB991929 B: MB991930 E C: MB991931 D: MB991932 E: MB991933 F: MB991934
Engine hanger A: Joint (50) 2 B: Joint (90) 2 C: Joint (140) 2 D: Foot (standard) 4 E: Foot (short) 2 F: Chain and hook assembly
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-7
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
M1111003100612
CAUTION Check the drive belt tension after turning the crankshaft clockwise one turn or more.
4. If there are any problems in the procedure 1 or 3, replace the auto-tensioner.(Refer to P.11A-36). 5. Install the drive belt.(Refer to P.11A-15).
FUNCTION CHECK
You can verify if the auto-tensioner is defective or not by checking the drive belt tension.
When using the M.U.T.-II

A
1. Check the drive belt tension. (Refer to P.11A-7). 2. Measure the drive belt tension vibration frequency by the following procedures:
CAUTION
Indicator mark
AC211616AB
1. Make sure that the indicator mark is within the area marked with A in the illustration. 2. If the mark is out of the area, replace the drive belt. (Refer to P.11A-15). NOTE: The drive belt tension check is not necessary as auto-tensioner is adopted.
16-pin
AUTO-TENSIONER CHECK
M1111003000284
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-15).
Y1848AU
M.U.T.-II
MB991668
AC211432 AB
AC211619
3. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto tensioner. Turn the auto-tensioner to the left and right to check and see that there is no threading.
To prevent damage to the M.U.T.-II, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the M.U.T.-II. (1) Connect special tool belt tension meter set (MB991668) to the M.U.T.-II. (2) Connect the M.U.T.-II to the diagnosis connector. (3) Turn the ignition switch to "ON" position, and select "BELT TENSION" on the menu screen.
11A-8

ENGINE MECHANICAL
ON-VEHICLE SERVICE
CAUTION The temperature of the surface of the belt should be as close to normal temperature as possible. Do not allow any contaminants such as water or oil to get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle's engine is running.
Power steering oil pump pulley MB991668 Water pump pulley 15 15
10 20 mm
3. If not within the standard value, replace the auto-tensioner. (Refer to P.11A-36).
When using the V.C.I.

1. Check the drive belt tension. (Refer to P.11A-7). 2. Measure the drive belt tension vibration frequency by the following procedures:
CAUTION
16-pin
MB991911
Gentry tap with your finger

AC102806AB
(4) Hold special tool belt tension meter set (MB991668) to the middle of the drive belt between the pulleys (at the place indicated by arrow), approximately 10 20 mm away from the rear surface of the belt so that it is perpendicular to the belt (within an angle of 15 degree). (5) Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and measure that the vibration frequency of the belt is within the standard value. Standard value: 110 144 Hz
MB991668 MB991824
AC211433 AB
To prevent damage to special tool V.C.I. (MB991824), always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting special tool V.C.I. (MB991824). (1) Connect special tool belt tension meter set (MB991668) to special tool V.C.I. (MB991824). (2) Connect special tool M.U.T.-III main harness B (MB991911) to special tool V.C.I. (MB991824). (3) Connect special tool M.U.T.-III main harness B (MB991911) to the diagnosis connector. (4) Turn the ignition switch to "ON" position, and select "Belt Tension" on the menu screen.
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-9
Power steering oil pump pulley
CAUTION The temperature of the surface of the belt should be as close to normal temperature as possible. Do not allow any contaminants such as water or oil to get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle's engine is running.
Power steering oil pump pulley MB991668 Water pump pulley 15 15
10 20 mm
Belt tension gauge
Water pump pulley
AC102807AB
2. Use a belt tension gauge in the middle of the belt between the pulleys (at the place indicated by the arrow) to measure that the belt tension is within the standard value. Standard value: 245 412 N 3. If not within the standard value, replace the auto-tensioner. (Refer to P.11A-36).
IGNITION TIMING CHECK

M1111001701332
Steering shaft 16-Pin

Gentry tap with your finger
AC102806AB
(5) Hold special tool belt tension meter set (MB991668) to the middle of the drive belt between the pulleys (at the place indicated by arrow), approximately 10 20 mm away from the rear surface of the belt so that it is perpendicular to the belt (within an angle of 15 degree). (6) Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and measure that the vibration frequency of the belt is within the standard value. Standard value: 110 144 Hz 3. If not within the standard value, replace the auto-tensioner. (Refer to P.11A-36).
MB991502
AC304777AC
16-PIN
MB991911 MB991824
When using a tension gauge

1. Check the drive belt tension. (Refer to P.11A-7).
MB991827
AC211686 AB
11A-10
ENGINE MECHANICAL
ON-VEHICLE SERVICE
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to the "LOCK" (OFF) position and then connect the M.U.T.-II/III to the diagnosis connector. 3. Connect a timing light. 4. Start the engine and let it run at idle. 5. Use the M.U.T.-II/III to measure engine idle speed and check that it is within the standard value. Standard value: 800 100 r/min 6. Select No. 17 of the M.U.T.-II/III Actuator test. 7. Check that basic ignition timing is within the standard value. Standard value: 5 BTDC 3 8. If the basic ignition timing is outside the standard value, inspect the MPI system (Refer to GROUP 13A Troubleshooting Inspection chart for diagnosis code P.13A-17).
IDLE SPEED CHECK

M1111003501215
MB991502
AC304777AC
16-PIN
CAUTION If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. 9. Press the M.U.T.-II/III clear key (Select a forced driving cancel mode) to release the Actuator test. 10.Check that ignition timing is at the standard value. Standard value: approximately 5 BTDC NOTE: . The ignition timing may fluctuate within 7. This is normal. In higher altitude, the ignition timing is more advanced than the standard value by approximately 5. 11.Remove the timing light. 12.Turn the ignition switch to the "LOCK" (OFF) position and then remove the M.U.T.-II/III.
MB991911 MB991824
MB991827
AC211686 AB
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position and then connect the M.U.T.-II/III to the diagnosis connector. 3. Connect a timing light. 4. Start the engine and let it run at idle. 5. Check that ignition timing is at the standard value. Standard value: approximately 5 BTDC 6. Check the idle speed. Standard value: 800 100 r/min NOTE: . The idle speed is controlled automatically by the idle speed control system. When using the M.U.T.-II/III, select item No. 22 and take a reading of the idle speed.
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-11
7. If the idle speed is outside the standard value, inspect the MPI system (Refer to GROUP 13A Troubleshooting Inspection chart for diagnosis code P.13A-17). 8. Remove the timing light. 9. Turn the ignition switch to the "LOCK" (OFF) position and then remove the M.U.T.-II/III.
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, check the following items: Diagnosis output Closed-loop control (when the closed-loop control is normal, the output signal of the oxygen sensor changes between 0 400 mV and 600 1,000 mV at idle.) Fuel pressure Injector Ignition coil, spark plug cable, spark plug EGR control system Evaporative emission control system Compression pressure NOTE: Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items. 10.Remove the timing light. 11.Turn the ignition switch to the "LOCK" (OFF) position and then remove the M.U.T.-II/III.
IDLE MIXTURE CHECK

M1111002100471
MB991502
AC304777AC
16-PIN
COMPRESSION PRESSURE CHECK

M1111002601402
MB991911 MB991824
Crank angle sensor connector
AK304215AB
MB991827
AC211686 AB
Compression gauge
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position and then connect the M.U.T.-II/III to the diagnosis connector. 3. Connect a timing light. 4. Start the engine and let it run at idle. 5. Check that ignition timing is at the standard value. Standard value: approximately 5 BTDC 6. Run the engine at 2,500 r/min for 2 minutes.
AK304216AB
1. Before inspection, set the vehicle to the pre-inspection condition.
11A-12
ENGINE MECHANICAL
ON-VEHICLE SERVICE
2. Disconnect the ignition coils and spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crank angle sensor connector. NOTE: Doing this will prevent the engine-ECU from carrying out ignition and fuel injection.
MANIFOLD VACUUM CHECK

M1111002701034
CAUTION Keep away from the spark plug hole when cranking. If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous. 5. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. 6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 r/min): 1,000 kPa
Limit (at engine speed of 250 r/min): Minimum 640 kPa 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Maximum 98 kPa 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps from 6 to 8. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression dose not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10.Connect the crank angle sensor connector. 11.Install the spark plugs. 12.Install the ignition coils and spark plug cables. 13.Use the M.U.T.-II/III to erase the diagnosis codes. NOTE: This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.
MB991502
AC304777AC
16-PIN
MB991911 MB991824
MB991827
AC211686 AB
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to "LOCK" (OFF) position. 3. Connect the M.U.T.-II/III to the diagnosis connector.
Vacuum gauge
Fuel pressure control solenoid valve

AK304217AB
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-13
4. Attach a three-way joint to the vacuum hose between the fuel pressure control solenoid valve and the inlet manifold, and connect a vacuum gauge. 5. Start the engine and check that idle speed is within the standard valve. Standard value: 800 100 r/min 6. Check the inlet manifold vacuum. Limit: Minimum 60 kPa 7. Turn off the ignition switch. 8. Remove the vacuum gauge and the three-way joint, and then connect the vacuum hose. 9. Remove the M.U.T.-II/III.
1. Start the engine. 2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise dose not occur immediately after the engine is started, or if it dose not change in accordance with the engine speed, the problem is not being caused by the lash adjusters, so check for some other cause of the problem. Moreover, if the noise dose not change in accordance with the engine speed, the cause of the problem is probably not with the engine (In these cases, the lash adjusters are normal). 3. While the engine is idling, check that the noise level does not change when the engine load is varied. If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings (In such cases, the lash adjusters are normal). 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters (Refer to GROUP 11B Rocker Arms and Camshaft Rocker Arms and Camshaft Inspection P.11B-39). If not improved, go to step 5. 5. Bleed air from the lash adjusters (Refer to P.11A-13). 6. If the noise has not disappeared even after the air bleeding, clean the lash adjusters (Refer to GROUP 11B Rocker Arms and Camshaft Rocker Arms and Camshaft Inspection P.11B-39).
LASH ADJUSTER CHECK

If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and dose not stop, carry out the following check. NOTE: . If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high-pressure chamber. If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters. The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load. Because of this, if the noise dose not occur immediately after the engine is started, if it dose not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick.
M1111002900585
<LASH ADJUSTER AIR BLEEDING>
Good Max Min.

AKX00328 AE
1. Check the engine oil and replenish or replace the oil if necessary.
11A-14
ENGINE MECHANICAL
ON-VEHICLE SERVICE
Drive pattern for air breeding Gradually open Close the throttle valve the throttle valve Approximately 3,000 r/min Idle speed 15 s 15 s
NOTE: . If there is an only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage. If the amount of oil is greater than normal, then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil. If the oil is degenerated, air and oil will not separate easily in oil, and the amount of air mixed into the oil will increase.
Once
AKX00330AE
High-pressure chamber
AK100001AC
If the air which has been mixed in with the oil

due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve close. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal.
2. Run the engine at idle for 1 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration above and check if the abnormal noise disappears (The noise should normally disappear after 10 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters). 4. After the noise has disappeared, repeat the drive pattern shown in the illustration above a further 5 times. 5. Run the engine at idle for 1 3 minutes and check that the noise has disappeared.
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-15
CRANKSHAFT PULLEY
M1112001600573
CAUTION If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Side Cover Removal Post-installation Operation Drive Belt Tension Check (Refer to P.11A-7). Side Cover Installation Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2).
2 1
25 4 Nm
AC210941AB
<<A>>
1. 2.
Removal steps Drive belt Crank shaft damper pulley
11A-16
REMOVAL SERVICE POINT <<A>> DRIVE BELT REMOVAL
ENGINE MECHANICAL
CRANKSHAFT PULLEY
2. Rotate the auto-tensioner anti-clockwise and align hole A with hole B.
The following operations will be needed due to the introduction of the serpentine drive system with the drive belt auto-tensioner.
Autotensioner
CAUTION To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
Autotensioner Hole B Hole A

AC210996 AB
L-shaped hexagon wrench
1. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto-tensioner.
AC210998AB
3. Insert an L-shaped hexagon wrench, etc. into the hole to fix and then remove the drive belt.
ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
11A-17

M1112006601076
*Remove and assemble the marked parts in each cylinder unit.
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Side Cover Removal Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service Engine Coolant Replacement P.14-15). Air Duct Removal (Refer to GROUP 15, Air Cleaner P.15-5). Air Pipe C Removal (Refer to GROUP 15, Intercooler P.15-6). Accelerator Cable Removal (Refer to GROUP 17, Accelerator Cable and Pedal P.17-3). <LH drive vehicles> Valve Timing Belt Removal (Refer to P.11A-36). Post-installation Operation Valve Timing Belt Installation (Refer to P.11A-36). Accelerator Cable Installation (Refer to GROUP 17, Accelerator Cable and Pedal P.17-3). <LH drive vehicles> Air Pipe C Installation (Refer to GROUP 15, Intercooler P.15-6). Air Duct Installation (Refer to GROUP 15, Air Cleaner P.15-5). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service Engine Coolant Replacement P.14-15). Drive Belt Tension Check (Refer to P.11A-7). Side Cover Installation Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2). Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service Accelerator Cable Check and Adjustment P.17-2). <LH drive vehicles>
11A-18
ENGINE MECHANICAL
4
3.0 0.5 Nm
11 1 Nm
7
11 1 Nm
15
3.0 0.5 Nm
14
11 1 Nm
8 9 16 18 N 12 10 17 N
5.0 1.0 Nm 11 1 Nm
6
8.8 1.0 Nm
5 1 2
N
13 11
AC504945AB
>>O<< >>O<<
1. 2. 3. 4. 5. 6. 7. 8. 9.
Removal steps Oil feeder control valve connector <<A>> Oil feeder control valve O-ring Rocker cover centre cover Spark plug cables and ignition coils (Refer to GROUP 16, Ignition Coil P.16-34). Oxygen sensor (Front) connector Crank angle sensor connector Control wiring harness connection Rocker cover PCV hose Rocker cover breather hose
>>N<<
>>M<<
Removal steps (Continued) 10. Radiator upper hose connection 11. Camshaft position sensor connector (exhaust side) 12. Camshaft position sensor connector (inlet side) 13. Earth terminal 14. Control wiring harness connection 15. Vacuum hose and pipe assembly 16. Rocker cover 17. Spark plug hose gaskets 18. Rocker cover gasket
ENGINE MECHANICAL
11A-19
10 2 Nm
Apply engine oil to all moving parts before installation.
22 4 Nm
26 43 45
20 1 Nm
23 25
14 1 Nm
24 N
19
41 46 32 34 30 35
44 42
22 21
10 2 Nm
20 N
22 4 Nm 14 1 Nm
40 31 38
65 5 Nm
33
39 29
37 36
32 2 Nm 89 9 Nm
28 N 27
AC406533AC
>>L<< >>J<<
>>K<< <> >>J<< >>I<< >>G<< >>F<<
Removal steps 19. Camshaft position sensor support cover 20. Camshaft position sensor support cover gasket 21. Camshaft position sensing cylinder (exhaust side) 22. Camshaft position sensor support 23. Camshaft position sensor support cover 24. Camshaft position sensor support cover gasket 25. Camshaft position sensing cylinder (inlet side) 26. Camshaft position sensor support 27. Camshaft sprocket (exhaust side) 28. Camshaft oil seal 29. Camshaft bearing cap, front
>>F<< >>F<< >>F<< >>F<< >>F<< >>E<< <> >>H<< >>G<< >>F<< >>F<< >>F<< >>F<< >>F<< >>F<< >>E<<
30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.
Removal steps (Continued) Camshaft bearing cap, rear Camshaft bearing cap, No.2 Camshaft bearing cap, No.5 Camshaft bearing cap, No.3 Camshaft bearing cap, No.4 Exhaust camshaft Camshaft sprocket cap Washer Camshaft sprocket (inlet side) Camshaft oil seal Camshaft bearing cap, front Camshaft bearing cap, rear Camshaft bearing cap, No.2 Camshaft bearing cap, No.5 Camshaft bearing cap, No.3 Camshaft bearing cap, No.4 Inlet camshaft
11A-20
47
ENGINE MECHANICAL
25 4 Nm
11 1 Nm
51* 52* 53* N 54*
48 50
49
51* 52* 53* 55* N

AC406534 AC
>>D<<
47. 48. 49. 50.
Removal steps Rocker arms Rocker arm lash adjusters Oil delivery body Spark plugs
<<C>>
>>C<< >>B<< >>A<< >>A<<
51. 52. 53. 54. 55.
Removal steps (Continued) Valve spring retainer locks Valve spring retainers Valve springs Inlet valve stem seals Exhaust valve stem seals
REMOVAL SERVICE POINTS <<A>> RADIATOR UPPER HOSE DISCONNECTION
<> CAMSHAFT SPROCKETS REMOVAL
Mating marks
AC200641AB
AC407095AC
Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.
1. Hold the hexagon part of the camshaft with a wrench. 2. Loosen the camshaft sprocket mounting bolts and remove the camshaft sprocket.
ENGINE MECHANICAL
11A-21
<<C>> VALVE SPRING RETAINER LOCKS REMOVAL

CAUTION When removing valve spring retainer locks, leave the piston of each cylinder in the TDC (Top Dead Centre) position. The valve may fall into the cylinder if the piston is not properly in the TDC position.
2. Use the special tool to fill a new valve stem seal in the valve guide using the valve stem area as a guide.
Grey Grey green
MD998772
Inlet side
Exhaust side
AC201542AB
NOTE: Check the valve stem seal colour to identify the inlet side or exhaust side.
>>B<< VALVE SPRINGS INSTALLATION

AC201799 AB
Use special tool valve spring compressor (MD998772) to compress the valve spring, remove the valve spring retainer locks.
Rocker arm side
INSTALLATION SERVICE POINTS >>A<< EXHAUST VALVE STEM SEALS/INLET VALVE STEM SEALS INSTALLATION
1. Apply a small amount of engine oil to the valve stem seals.
Small end
AC211159AB
The small end of the valve spring should face the rocker arm.
CAUTION Valve stem seals cannot be reused. The special tool valve stem seal installer (MD998737) must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide.
MD998737 Valve Valve stem seal Valve guide
AC308920AB
>>C<< VALVE SPRING RETAINER LOCKS INSTALLATION
MD998772
AC201799 AB
Use special tool valve spring compressor (MD998772) to compress the valve spring in the same manner as removal.
11A-22
ENGINE MECHANICAL
>>D<< ROCKER ARM LASH ADJUSTERS INSTALLATION

CAUTION If the rocker arm lash adjuster is reused, always clean and check it before installation. (Refer to GROUP 11B, Rocker Arms and Camshaft Inspection P.11B-39).
1. Set the dowel pin of the camshaft to the position as shown in the illustration.
E4
Engine front
Bearing cap No. Identification of inlet side and exhaust side

AC201460AB
>>E<< EXHAUST CAMSHAFT/INLET CAMSHAFT INSTALLATION

1. Remove sealant remained on the cylinder head. 2. Apply engine oil to the cam and the journal of the camshaft.
CAUTION Do not install wrong camshaft on the side of inlet or exhaust. The exhaust camshaft has a slit at the rear surface.
Engine front <Inlet side> Slit
2. Since the shape of camshaft bearing caps No.2 5 is identical, check the identification marks so that the bearing cap No., inlet side, or exhaust side is installed in the direction shown in the illustration. Identification mark (engraved on the front and bearing caps No.2 5) I: Inlet side E: Exhaust side
Engine front
<Exhaust side> Slit

AC407425AC
3. Install the camshaft to the cylinder head.
>>F<< CAMSHAFT BEARING CAPS, NO. 4/CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT BEARING CAPS, NO. 5/CAMSHAFT BEARING CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/CAMSHAFT BEARING CAPS, FRONT INSTALLATION
Approximately 4 Dowel pin
AC201461AC
3. Apply sealant to the positions (8 areas) of the upper side of the cylinder head as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
Inlet side
Exhaust side
AC201459AC
ENGINE MECHANICAL
<Inlet side> Front marking
11A-23
1. Apply engine oil to the entire inner diameter of the oil seal lip. 2. Use special tool camshaft oil seal installer (MD998713) to press-fit the oil seals.
Engine front
>>H<< CAMSHAFT SPROCKET (INLET SIDE) INSTALLATION

Engine front AC406643AE
(Engine oil)
<Exhaust side> Front marking Engine front Camshaft sprocket

AC500123AC
AC406642AF
4. Position the camshaft bearing caps, rear in the direction as shown in the illustration for installation. 5. Check the identification marks on the camshaft bearing caps, front so that inlet side and exhaust side is installed in the same way as that of bearing caps No.2 5. 6. Tighten the bearing cap mounting bolts increasing the pressure in 2 to 3 times and finally tighten to the specified torque. Tightening torque: 20 1 Nm 7. Ensure that the rocker arms are installed properly. NOTE: Remove an excess sealant completely.
1. Apply engine oil to the tip of the camshaft and the camshaft installation side of the camshaft sprocket. 2. Align the dowel pin hole of the camshaft sprocket with the dowel pin of the camshaft, and install the camshaft sprocket to the camshaft. 3. While holding the hexagonal area of the camshaft with a wrench, check that the camshaft sprocket does not turn. NOTE: This is necessary, because you cannot confirm that the camshaft dowel pin is inserted into the pin hole.
Engine front (Engine oil)
>>G<< CAMSHAFT OIL SEALS INSTALLATION

Camshaft sprocket
AC504842AB
4. Apply the engine oil to the threads and the face of the camshaft sprocket mounting bolt. Then fix the camshaft with a wrench in the same way as removal and tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 65 5 Nm
MD998713
AC102323AB
11A-24
ENGINE MECHANICAL
>>I<< CAMSHAFT SPROCKET (EXHAUST SIDE) INSTALLATION
3. Install the camshaft position sensor support to the cylinder head.
CAUTION Wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.
4. Tighten the camshaft position sensor support mounting bolts to the specified torque. Tightening torque: 14 1 Nm
AC407095AC
1. Hold the hexagon part of the camshaft with a wrench in the same manner as removal. 2. Tighten the camshaft sprocket mounting bolts to the specified torque. Tightening torque: 89 9 Nm
>>K<< CAMSHAFT POSITION SENSING CYLINDER (INLET SIDE) INSTALLATION

(4 1') Dowel pin
>>J<< CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION

1. Remove sealant from the camshaft position sensor support and cylinder head surfaces.
<Exhaust side>
Vane
AC406644AE
1. Set the dowel pin of the inlet camshaft to the position (No.1 cylinder at compression TDC) as shown in the illustration. 2. Tighten the camshaft position sensing cylinder mounting bolts to the specified torque. Tightening torque: 22 4 Nm
3 mm
AC201463AC
<Inlet side>
>>L<< CAMSHAFT POSITION SENSING CYLINDER (EXHAUST SIDE) INSTALLATION

Approximately 45 Vane (small) Dowel pin
3 mm
AC406663AC
Vane (large)
AC201464AB
2. Apply the sealant to the camshaft position sensor support flange in a continuous bead as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the camshaft position sensor support within 15 minutes after applying liquid gasket.
1. Set the dowel pin of the exhaust camshaft to the position (No.1 cylinder at compression TDC) as shown in the illustration. NOTE: Use the force of the exhaust valve spring to rotate anti-clockwise.
ENGINE MECHANICAL
11A-25
2. Install the vane (small) of the camshaft position sensing cylinder at an angle of approximately 45 degrees to the position of the dowel pin of the exhaust camshaft. 3. Tighten the camshaft position sensing cylinder mounting bolts to the specified torque. Tightening torque: 22 4 Nm
1. Insert each hose until it contacts the projection on the water outlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then secure the radiator hose.
>>O<< O-RING/OIL FEEDER CONTROL VALVE INSTALLATION

CAUTION Never re-use the O-ring.
>>M<< ROCKER COVER INSTALLATION

Engine front
Tape
AC201469AC
AC504840AB
1. Apply sealant to the positions of the rocker cover gasket (8 areas) as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent 2. Install the rocker cover to the cylinder head. 3. Tighten the rocker cover mounting bolts to the specified torque. Tightening torque: 3.5 0.5 Nm
Before installing O-ring, wind the tape with the soft adhesion (sealing tape) around the oil passages cut-out area of engine oil control valve to prevent the damage. If the O-ring is damaged, it can be the cause of oil leak. 1. Apply a small amount of engine oil to the O-ring and then install it to the oil control valve. 2. Assemble the engine oil control valve to the cylinder head. 3. Tighten the engine oil control valve mounting bolt to the specified torque. Tightening torque: 11 1 Nm
>>N<< RADIATOR UPPER HOSE CONNECTION

Projection
Water outlet fitting
Mating marks
AC200642 AB
11A-26
ENGINE MECHANICAL
OIL PAN
OIL PAN
M1112002801409
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Engine Oil Draining (Refer to GROUP 12, On-vehicle Service Engine Oil Replacement P.12-3). Front Axle Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-7). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Starter Assembly Removal (Refer to GROUP 16, Starter Motor Assembly P.16-20).
Post-installation Operation Starter Assembly Installation (Refer to GROUP 16, Starter Motor Assembly P.16-20). Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Front Axle Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-7). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service Engine Oil Replacement P.12-3). Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2).
4N 3
9.0 1.0 Nm
13
N
22 4 Nm
2N
14 1 Nm
N
42 2 Nm 8.8 1.0 Nm
9 8
N 11
7
9.0 3.0 Nm 26 5 Nm <Bolt, washer assembled> 9.0 1.0 Nm <Flange bolt> 10 2 Nm
AC310566 AB
5.0 1.0 Nm
6
39 5 Nm
10
9.0 3.0 Nm
12
1. 2. 3. 4. >>C<< 5. 6. 7.
Removal steps Flywheel housing front lower cover Gasket Oil return tube Oil return tube gasket Oil return tube gasket Engine oil level sensor connector Engine oil level sensor
8. 9. 10. >>B<< 11. <<A>> >>A<< 12. 13.
Removal steps (Continued) Engine oil cooler return hose Engine oil cooler tube gaskets Engine oil pan drain plug Engine oil pan drain plug gasket Engine oil pan Cylinder block baffle plate
ENGINE MECHANICAL
OIL PAN
11A-27
REMOVAL SERVICE POINT <<A>> ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.
CAUTION
B Groove portion 4 mm Bolt hole portion
AC211002 AB
AC301325 AB
MD998727
MD998727
2. Apply a bead of the sealant to the cylinder block mating surface of the engine oil pan as shown. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent NOTE: Install the engine oil pan within 15 minutes after applying sealant. 3. Assemble the engine oil pan to the cylinder block.
CAUTION Wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during this time.
AC102324 AB
Do not use special tool oil pan FIPG cutter (MD998727) in area A of the engine oil pan. Using the special tool in area A may cause deformation of the front case because the front case is made of aluminium. 2. Tap the special tool into the range (B) between the cylinder block and the engine oil pan, and then slide the tool sideways. NOTE: If any sounding parts interfere with the removal, there is no need to use the special tool. 3. Remove the engine oil pan.
M6 8 mm
AC211004 AB
INSTALLATION SERVICE POINTS >>A<< ENGINE OIL PAN INSTALLATION

1. Remove old sealant from the engine oil pan and cylinder block surfaces.
4. Tighten the engine oil pan mounting bolts to the specified torque. Be careful when installing, as the oil pan mounting bolts (indicated in the illustration) have different lengths from the other bolts. Tightening torque: 9.0 3.0 Nm
11A-28
ENGINE MECHANICAL
OIL PAN
>>B<< ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION
>>C<< OIL RETURN TUBE GASKET INSTALLATION
Engine oil pan side
Convex part
AC102325 AE
AC211005 AB
Replace the gasket with a new gasket. Install the new gasket in the direction shown in the illustration.
The oil return tube gasket should be replaced with a new one. Set the convex part to the position as shown in the illustration for installation. NOTE: There is no specific direction indicated for installing the turbocharger side of the oil return tube gasket.
INSPECTION
Check the engine oil pan for cracks. Check the engine oil pan sealant-coated surface for damage and deformation.
M1112002900265
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-29
CRANKSHAFT OIL SEAL

M1112003100444
132 5 Nm
3 3 6
2 1
(Lip section) Engine oil
(Lip section)
AC210943AB
>>D<< >>C<< 1. 2. 3.
Crankshaft front oil seal removal steps Valve timing belt, balancer timing belt (Refer to P.11A-36). Crankshaft balancer shaft drive sprocket Crankshaft key Crankshaft front oil seal
<<A>> >>B<< >>A<< 4. 5. 6.
Crankshaft front oil seal removal steps Transfer assembly (Refer to GROUP 22A, Transfer Assembly P.22A-160). Transmission assembly (Refer to GROUP 22A, Transmission Assembly P.22A-163). Flywheel bolts Flywheel assembly Crankshaft rear oil seal
11A-30
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
REMOVAL SERVICE POINT <<A>> FLYWHEEL BOLTS REMOVAL
1. Use special tool flywheel stopper (MD998781) to secure the flywheel in the same manner as removal. 2. Tighten the flywheel mounting bolts to the specified torque. Tightening torque: 132 5 Nm
>>C<< CRANKSHAFT FRONT OIL SEAL INSTALLATION

MD998781
AC211171AB
Crankshaft
MD998375
1. Use special tool flywheel stopper (MD998781) to secure the flywheel. 2. Remove the flywheel mounting bolts.
(Engine oil)
INSTALLATION SERVICE POINTS >>A<< CRANKSHAFT REAR OIL SEAL INSTALLATION

Oil seal
MD998285 (Oil applied to the circumference)
Oil seal
AC102329AC
MB990938 (Engine oil)
1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip. 2. Apply a small amount of engine oil to the outer diameter of special tool crankshaft front oil seal guide (MD998285) and install it to the crankshaft. 3. Use special tool crankshaft front oil seal installer (MD998375) to press-fit the oil seal.
MD998776
Crankshaft
AC102328 AB
>>D<< CRANKSHAFT BALANCER SHAFT DRIVE SPROCKET INSTALLATION

: Clean : Clean and degrease
1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip. 2. Use the following special tools to press-fit the oil seal. Installer bar (MB990938) Crankshaft rear oil seal installer (MD998776)
Crankshaft
>>B<< FLYWHEEL BOLTS INSTALLATION
Front case MD998781

AC211171AB
Crankshaft balancershaft drive sprocket
Engine front
AC211222 AB
ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-31
1. Clean or degrease the front case, the crankshaft and the crankshaft balancer shaft drive sprocket as shown. NOTE: Also clean the degreased surfaces. 2. Install the crankshaft balancer shaft drive sprocket in the direction shown in the illustration.

M1112004001744
Pre-removal Operation Fuel Line Pressure Reduction [Refer to GROUP 13A, On-vehicle Service Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) P.13A-398]. Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Side Cover Removal Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service Engine Coolant Replacement P.14-15). Engine Oil Draining (Refer to GROUP 12, On-vehicle Service Engine Oil Replacement P.12-3). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Air Cleaner Assembly Removal (Refer to GROUP 15, Air Cleaner P.15-5). Air Hose E, Air Pipe C and Air Hose D Removal (Refer to GROUP 15, Intercooler P.15-6). Battery Removal Accelerator Cable Removal (Refer to GROUP 17, Accelerator Cable and Pedal P.17-3). Rocker Cover Centre Cover Removal (Refer to P.11A-17). Radiator Assembly Removal (Refer to GROUP 14, Radiator P.14-24). Front Axle Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-7). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Starter Assembly Removal (Refer to GROUP 16, Starter Motor Assembly P.16-20). Valve Timing Belt Removal (Refer to P.11A-36). Post-installation Operation Valve Timing Belt Installation (Refer to P.11A-36). Starter Assembly Installation (Refer to GROUP 16, Starter Motor Assembly P.16-20). Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Front Axle Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-7). Radiator Assembly Installation (Refer to GROUP 14, Radiator P.14-24). Rocker Cover Centre Cover Installation (Refer to P.11A-17). Accelerator Cable Installation (Refer to GROUP 17, Accelerator Cable and Pedal P.17-3). Battery Installation Air Hose E, Air Pipe C and Air Hose D Installation (Refer to GROUP 15, Intercooler P.15-6). Air Cleaner Assembly Installation (Refer to GROUP 15, Air Cleaner P.15-5). Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar P.42-9). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service Engine Oil Replacement P.12-3). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service Engine Coolant Replacement P.14-15). Drive Belt Tension Check (Refer to P.11A-7). Side Cover Installation Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2). Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service Accelerator Cable Check and Adjustment P.17-2). Fuel Leak Check
11A-32
ENGINE MECHANICAL
4 3
5.0 1.0 Nm
6
9.0 1.0 Nm
5.0 1.0 Nm
13 1 Nm
(Engine oil)
7
AC310567 AB
1. 2. 3. 4.
Removal steps Control wiring harness connection Earth cable connection EGR solenoid valve connector EGR solenoid valve and bracket assembly
5. 6. 7. 8.
Removal steps (Continued) Brake booster vacuum hose connection Oil level gauge and guide assembly O-ring Purge hose connection
ENGINE MECHANICAL
11A-33
27 28
5.0 1.0 Nm
26
25
20 2 Nm <Cold engine> 78 2 Nm to 0 Nm to 20 2 Nm to +90 to +90
29 N
(Engine oil)
30 31
(Engine oil)
11 10
31 3 Nm 42 2 Nm 11 1 Nm
24
12
N
16 14 13 17 18
N
30 3 Nm
15 N
N 32
35 6 Nm
22 N
30 3 Nm
19
21
9.0 1.0 Nm
23
N 20
14 1 Nm
AC407431AC
>>E<<
>>D<<
9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Removal steps Alternator brace bolt Battery wiring harness connection Inlet manifold stay Eye bolt Gasket Eye bolt Gasket Oil feeder control valve pipe Filter Oil pipe joint Gasket Gasket Oil return tube Oil return tube gasket Oil return tube gasket
24.
>>C<< <<A>> >>C<< >>B<< >>A<<
25. 26. 27. 28. 29. 30. 31. 32.
Removal steps (Continued) Turbocharger bracket Water outlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe P.14-22). Rocker cover (Refer to P.11A-17). Water return hose connection Heater hose connection Fuel return line hose connection Fuel high-pressure hose connection O-ring Cylinder head bolts Cylinder head assembly Cylinder head gasket
11A-34
REMOVAL SERVICE POINT <<A>> CYLINDER HEAD BOLTS REMOVAL
ENGINE MECHANICAL
2. Assemble to the cylinder block so the cylinder head gasket identification mark "63" is at the top surface and on the exhaust side.
>>B<< CYLINDER HEAD BOLTS INSTALLATION

(Engine oil) MB991654
A Engine front
AC102537AB
10
1. Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolt with a new one. Limit (A): 99.4 mm 2. Apply a small amount of engine oil to the thread of the bolts and to the washers.
AC201623AB
Using special tool cylinder head bolt wrench (MB991654), loosen the cylinder head bolts in two or three steps in the order shown in the illustration. NOTE: If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it by using a magnet.
MB991654
INSTALLATION SERVICE POINTS >>A<< CYLINDER HEAD GASKET INSTALLATION

CAUTION Do not allow any foreign materials to get into the coolant passages, oil passages and cylinder. 1. Remove the gasket from the cylinder head and cylinder block.
8
Engine front
10
AC201625 AB
Identification mark "63" Exhaust side

AC107217AC
3. Use special tool cylinder head bolt wrench (MB991654) to tighten the cylinder head bolts as follows: (1) Tighten the cylinder head bolts to 78 2 Nm in the order shown. (2) Loosen the bolts fully in the reverse order of that shown.
ENGINE MECHANICAL
11A-35
(3) Tighten the cylinder head bolts to 20 2 Nm in the order shown.

Step (4) 90 Step (5) 90
Paint marking
Paint marking
AC102331AB
2. Turning the fuel high-pressure hose to the right and left, install it onto the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel high-pressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly. 4. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 1.0 Nm
(4) Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown.
>>D<< OIL RETURN TUBE GASKET INSTALLATION
CAUTION The bolt is not tightened sufficiently if the bolt is tightened less than 90 degree angle. (5) Tighten the bolt an additional 90 degree angle as shown. Then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head are aligned. (6) If tightening the bolt 90 degree angle results in moving the paint mark on the bolt past the paint mark on the cylinder head, remove the bolt and start over from step 1.
Convex part
AC211005 AB
>>C<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION Do not let any engine oil get into the delivery pipe.
1. Apply a small amount of new engine oil to the O-ring.
The oil return tube gasket should be replaced with a new one. Set the convex part to the position shown in the illustration. NOTE: There is no specific direction indicated for installing the turbocharger side of the oil return tube gasket.
>>E<< EYE BOLT INSTALLATION

CAUTION When tightening the eye bolt, hold the oil pipe joint with a spanner so that it does not rotate with the eye bolt.
11A-36
ENGINE MECHANICAL
TIMING BELT
TIMING BELT
M1112004301400
Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Side Cover Removal Crankshaft Shaft Damper Pulley Removal (Refer to P.11A-15). Front Axle Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-7). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Post-installation Operation Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Front Axle Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-7). Crankshaft Shaft Damper Pulley Installation (Refer to P.11A-15). Drive Belt Tension Check (Refer to P.11A-7). Side Cover Installation Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2).
21 4 Nm
9
48 5 Nm 12 2 Nm 11 1 Nm
10
8.8 1.0 Nm
3
23 3 Nm
5 6
44 10 Nm
7 4
24 4 Nm 11 1 Nm 9.0 1.0 Nm
79 5 Nm
AC406655AC
1. 2. 3. 4. 5. 6.
Removal steps Power steering pressure hose connection Timing belt upper cover Water pump pulley Idler pulley Auto-tensioner Timing belt lower cover
>>G<< <<A>> >>F<< >>E<< >>D<<
Removal steps (Continued) Engine mounting insulator (Refer to GROUP 32, Engine Mount P.32-4). Valve timing belt tension adjustment 7. Valve timing belt 8. Timing belt tensioner pulley 9. Timing belt tensioner arm 10. Timing belt tensioner adjuster
ENGINE MECHANICAL
TIMING BELT
11A-37
12 2 Nm 22 4 Nm
12
15
35 6 Nm
11 20 19
19 3 Nm
22 4 Nm
13
(Engine oil) 49 9 Nm
40 5 Nm
14 17
167 Nm
49 9 Nm
18
16
8.8 1.0 Nm
AC211076 AD
<>
Removal steps 11. Power steering pressure switch connector 12. Power steering oil pump heat protector 13. Power steering oil pump, bracket and reservoir assembly 14. Power steering oil pump bracket
<<C>>
>>C<< >>C<< >>B<< >>A<< >>A<<
15. 16. 17. 18. 19. 20.
<<D>>
Removal steps (Continued) Timing belt Idler pulley Crank angle sensor Crankshaft camshaft drive sprocket Crankshaft angle sensing blade Balancer timing belt tension adjustment Balancer timing belt tensioner Balancer timing belt
REMOVAL SERVICE POINTS <<A>> VALVE TIMING BELT REMOVAL

CAUTION Never turn the crankshaft anti-clockwise.
Timing mark
1. Turn the crankshaft clockwise, align each timing mark to set No.1 cylinder to TDC of its compression stroke.
MD998738
Timing belt under cover

AC102487AC AC211534AB
2. Remove the timing belt under cover rubber plug and then set the special tool adjusting bolt (MD998738).
11A-38
Timing belt tensioner arm
ENGINE MECHANICAL
TIMING BELT
CAUTION For reinstallation of the valve timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.
MD998738
6. After removal of the special tool, loosen the timing belt tensioner pulley mounting bolt and remove the valve timing belt.
AC107289 AB
3. Screw in the special tool until it comes in contact with the timing belt tensioner arm.
<> POWER STEERING OIL PUMP, BRACKET AND RESERVOIR ASSEMBLY REMOVAL
With the hose installed, remove the power steering oil pump assembly from the bracket. NOTE: Secure the removed power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the balancer timing belt.
CAUTION The special tool can be gradually installed at a rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the special tool may bend.
<<C>> CRANKSHAFT CAMSHAFT DRIVE SPROCKET REMOVAL

Crankshaft camshaft drive sprocket MB991385
AC102775AB
MB991367
4. Gradually screw in the special tool. Then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjustor cylinder set hole B.
Timing belt tensioner pulley mounting bolt Wire or pin
AC102332AB
1. Use the following special tools to support the crankshaft camshaft drive sprocket. Special spanner (MB991367) Pin (MB991385) 2. Loosen the crankshaft pulley centre bolt and remove the crankshaft camshaft drive sprocket.
<<D>> BALANCER TIMING BELT REMOVAL

AC107185AC
5. Insert a wire or pin in the set hole.
CAUTION For reinstallation of the balancer timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.
ENGINE MECHANICAL
TIMING BELT
11A-39
INSTALLATION SERVICE POINTS >>A<< BALANCER TIMING BELT/BALANCER TIMING BELT TENSIONER INSTALLATION
Balancershaft sprocket Belt tension side Timing mark
>>B<< BALANCER TIMING BELT TENSION ADJUSTMENT

CAUTION When tightening the mounting bolts, ensure that the tensioner does not rotate with the bolts. Allowing it to rotate with the bolts can cause excessive tension of the belt.
Belt tension side
Timing mark
AC102689AB
1. Ensure that the crankshaft balancershaft drive sprocket timing marks and balancershaft sprocket timing marks are aligned. 2. Install the balancer timing belt on the crankshaft balancershaft drive sprocket and balancershaft sprocket. There should be no slack on the tension side.
Centre of the mounting bolt
AC102691AB
1. With your fingers, lift the balancer timing belt tensioner in the direction of the arrow. Apply pressure of 3.0 0.4 Nm to the balancer timing belt. Tighten the assembling bolt to the standard torque. Then, fix the balancer timing belt tensioner. Tightening torque: 19 3 Nm
Balancershaft sprocket
Timing mark Centre of the pulley

AC102690 AB
Timing mark
3. Assemble and temporarily fix the centre of the pulley of the balancer timing belt tensioner so that it is at the top left from the centre of the assembling bolt, and the pulley flange is at the front-side of the engine. 4. Adjust the balancer timing belt tension.
AC102689AC
2. Turn the crankshaft clockwise two turns to set No.1 cylinder to TDC of its compression stroke and check that the sprocket timing marks are aligned.
Approximately 100 N
Deflection
AC102693AB
11A-40
ENGINE MECHANICAL
TIMING BELT
3. Apply a pressure of approximately 100N at the centre (arrow area) between the sprocket as shown, then inspect whether the belt deflection is within the standard value. Standard value: At adjustment: 5 7 mm At replacement: 5 7 mm 4. If not within the standard value, adjust the belt tension again.
4. Apply some engine oil to the crankshaft pulley centre bolt bearing surface and screw.
Crankshaft camshaft drive sprocket
MB991385
MB991367
>>C<< CRANKSHAFT ANGLE SENSING BLADE/CRANKSHAFT CAMSHAFT DRIVE SPROCKET INSTALLATION

: Clean : Clean and degrease : Apply engine oil Crankshaft pulley centre bolt Crankshaft camshaft drive sprocket Crankshaft
AC102332AB
5. Use the following special tool as during removal to support the crankshaft camshaft drive sprocket. Special spanner (MB991367) Pin (MB991385) 6. Tighten the crankshaft pulley centre bolts to the specified torque. Tightening torque: 167 Nm
>>D<< TIMING BELT TENSIONER ADJUSTER INSTALLATION

1. Install according to the following procedures when the timing belt tensioner adjuster rod is fully extended.
CAUTION If the compression is too fast, the procedure may damage the rod.
Crankshaft pulley washer Engine front A Crankshaft angle sensing blade
AC211535AC
1. Clean or degrease the crankshaft, the crankshaft angle sensing blade, the crankshaft camshaft drive sprocket and crankshaft pulley washer as shown. NOTE: Also clean the degreased surfaces. 2. Install the crankshaft angle sensing blade and crankshaft camshaft drive sprocket in the direction shown. 3. Place the larger chamfer side of the crank shaft pulley washer in the direction shown and then assemble on the crankshaft pulley centre bolt.
AC102334AB
(1) Slowly compress the timing belt tensioner adjuster rod using a press or vice, then align the set hole A of the rod with set hole B of the timing belt tensioner adjuster cylinder.
ENGINE MECHANICAL
TIMING BELT
Wire or pin
11A-41
>>F<< VALVE TIMING BELT INSTALLATION

Timing mark
AC102335AC
(2) Insert a wire or pin into the aligned set hole. NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt tensioner adjuster is set with a pin. 2. Assemble the timing belt tensioner adjuster to the engine, then tighten the assembling bolt to the standard torque. Do not remove the wire or pin until the tension of the valve timing belt is adjusted. Tightening torque: 23 3 Nm
Camshaft sprocket Crankshaft camshaft drive sprocket
Engine oil pump sprocket
Timing mark Timing mark

AC504874AB
>>E<< TIMING BELT TENSIONER PULLEY INSTALLATION
1. Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket.
Plug
Timing belt tensioner pulley hole

AC102336AB
60 mm or more
Temporarily tighten the timing belt tensioner pulley as shown.
Starter 8 mm Balancer shaft
AC211545 AB
11A-42
ENGINE MECHANICAL
TIMING BELT
2. After aligning the timing marks of the engine oil pump sprocket, remove the cylinder block plug and insert a Phillips screw driver with a shaft diameter of 8 mm through the plug hole to check that the shaft of the screw driver can be inserted for 60 mm or more. If the screw driver makes contact with the balancer shaft and can be inserted for only 20 25 mm, turn the engine oil pump sprocket for one round and align timing marks again to check that screw driver can be inserted for 60 mm or more. Do not take the screw driver out before completing installation of the valve timing belt. 3. Install the valve timing belt as follows:
Inlet side camshaft sprocket Exhaust side camshaft sprocket
Timing mark
AC211559AB
(3) Use two wrenches to align the timing mark on the rocker cover with that on the camshaft sprocket. Pass the valve timing belt around the inlet-side camshaft sprocket.
Timing belt idler pulley Timing belt tensioner pulley
Paper clip
AC211560 AB
(4) Hold the valve timing belt with paper clamps. (5) Pass the valve timing belt around the timing belt tensioner pulley.
Engine oil pump sprocket
Crankshaft camshaft drive sprocket
AC407000AC
(1) Pass the valve timing belt around the crankshaft camshaft drive sprocket, the engine oil pump sprocket and the timing belt idler pulley in that order.
CAUTION Install the valve timing belt. Then apply reverse rotation (anti-clockwise rotation) pressure to the cam shaft sprocket. Re-check to see that each timing mark is aligned while the tension side of the belt is tight. (6) Remove the two paper clamps.
Paper clip
MD998767
AC102694 AB
AC211558AB
(2) Pass the valve timing belt around the exhaust-side camshaft sprocket, and hold the valve timing belt with paper clamps.
4. Turn the timing belt tensioner in the direction shown using special tool tensioner wrench (MD998767) to apply tension to the valve timing belt. Then pre-tighten the timing belt tensioner pulley. 5. Check that the timing marks are aligned.
ENGINE MECHANICAL
TIMING BELT
11A-43
3. Turn the crankshaft 1/4 turn anti-clockwise. 4. Turn the crankshaft in the clockwise direction until you align each timing mark to set No.1 cylinder to TDC of its compression stroke. 5. Loosen the timing belt tensioner pulley mounting bolt.
Screw driver Plug
CAUTION When tightening the mounting bolts, ensure that the timing belt tensioner pulley does not rotate with the bolts. Allowing it to rotate with the bolts can cause deficient tension of the belt.
MD998767
AC211564AB
AC102695AB
6. Remove the Phillips screw driver inserted in Step 2 above, then assemble the cylinder block plug. 7. Tighten the cylinder block plug to the specified torque. Tightening torque: 30 3 Nm 8. Adjust the valve timing belt tension.
6. With special tool tensioner wrench (MD998767) and torque wrench, apply tension torque 3.5 Nm, and tighten the timing belt tensioner pulley mounting bolt to the specified torque. Tightening torque: 48 5 Nm
>>G<< VALVE TIMING BELT TENSION ADJUSTMENT

MD998738
Wire or pin
AC102776AD

AC211534AB
7. Remove wire or pin inserted to timing belt tensioner.
1. Set special tool adjusting bolt (MD998738) when removing the valve timing belt.
MD998738
CAUTION Always screw in the special tool by hand. Use of a spanner or other tools may damage the wire or pin inserted in the timing belt tensioner adjuster.
2. Gradually screw in the special tool until the wire or pin inserted in the timing belt tensioner adjuster lightly moves.

AC211534AB
11A-44
ENGINE MECHANICAL
TIMING BELT
8. Remove special tool adjusting bolt (MD998738), and install the rubber plug to the timing belt under cover. 9. Rotate the crankshaft clockwise two turns, and leave it for about 15 minutes.
CAUTION Always check the tightening torque of the crank shaft pulley centre bolt when turning the crack shaft pulley centre bolt anti-clockwise. Re-tighten if it is loose.
Timing mark
Wire or pin
AC102776AD
Camshaft sprocket Crankshaft camshaft drive sprocket Engine oil pump sprocket Timing mark Timing mark
10.Insert wire or pin removed in Step 7 again, and ensure that it can be pulled out easily. When wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin.
AC407000 AD
12.Check again that the timing marks on sprockets are aligned.

Timing belt tensioner adjuster
AC102338AB
INSPECTION
M1112004400493
If the projection of timing belt tensioner adjuster rod is within the standard value, appropriate tension is applied. Standard value (A): 3.8 4.5 mm 11.If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt tension.
TIMING BELT TENSIONER ADJUSTER CHECK

1. Check for oil leak from seal, and replace it if leak is detected. 2. Check for wear or damage at the top of the rod. Replace it, if required.
ENGINE MECHANICAL
TIMING BELT
Movement
11A-45
98 196 N
BALANCER TIMING BELT TENSION CHECK

Check the balancer timing belt tension as follows:
B
Approximately 100 N
Rod
Timing belt tensioner adjuster

AC102339AB
Deflection
3. Hold the timing belt tensioner adjuster by hand, and press the top end of the rod onto the metal (e.g. cylinder block) under a pressure of 98 196 N to measure the movement of the rod. Standard value: Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A B: Movement 4. If the measured value is out of the standard value, replace the timing belt tensioner adjuster.
AC102693AB
1. Apply a pressure of approximately 100N at the centre (arrow area) between the sprocket as shown then inspect whether the deflection is within the standard value. Standard value: 5 10 mm 2. If not within the standard value, adjust the belt tension. (Refer to P.11A-36).
11A-46
ENGINE MECHANICAL
ENGINE ASSEMBLY
ENGINE ASSEMBLY
M1112001002317
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine weight applied on the vehicle body.
Pre-removal Operation Fuel Line Pressure Reduction [Refer to GROUP 13A, On-vehicle Service Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) P.13A-398]. Hood Removal (Refer to GROUP 42, Hood P.42-4). Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Side Cover Removal Engine Oil Draining (Refer to GROUP 12, On-vehicle Service Engine Oil Replacement P.12-3). Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service Engine Coolant Replacement P.14-15). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Air Cleaner Assembly Removal (Refer to GROUP 15, Air Cleaner P.15-5). Air Pipe C, Air Pipe B and Air Hose A Removal (Refer to GROUP 15, Intercooler P.15-6). Battery and Battery Tray Removal Accelerator Cable Removal (Refer to GROUP 17, Accelerator Cable and Pedal P.17-3). Rocker Cover Centre Cover Removal (Refer to P.11A-17). Radiator Assembly Removal (Refer to GROUP 14, Radiator P.14-24). Front Axle Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-7). Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Air Outlet Fitting Removal (Refer to GROUP 15, Exhaust Manifold and Turbocharger P.15-10). Post-installation Operation Air Outlet Fitting Installation (Refer to GROUP 15, Exhaust Manifold and Turbocharger P.15-10). Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-13). Front Axle Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper and Centermember P.32-7). Radiator Assembly Installation (Refer to GROUP 14, Radiator P.14-24). Rocker Cover Centre Cover Installation (Refer to P.11A-17). Accelerator Cable Installation (Refer to GROUP 17, Accelerator Cable and Pedal P.17-3). Battery and Battery Tray Installation Air Pipe C, Air Pipe B and Air Hose A Installation (Refer to GROUP 15, Intercooler P.15-6). Air Cleaner Assembly Installation (Refer to GROUP 15, Air Cleaner P.15-5). Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar P.42-9). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service Engine Coolant Replacement P.14-15). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service Engine Oil Replacement P.12-3). Drive Belt Tension Check (Refer to P.11A-7). Side Cover Installation Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2). Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service Accelerator Cable Check and Adjustment P.17-2). Hood Installation (Refer to GROUP 42, Hood P.42-4). Fuel Leak Check
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-47
5.0 1.0 Nm
2
26 5 Nm 14 3 Nm
3
5.0 1.0 Nm
5.0 1.0 Nm
4
11 1 Nm
AC310569 AB
1. 2. 3.
Removal steps Control wiring harness connection Earth cable connection Battery wiring harness connection
4. <<A>> 5.
Removal steps (Continued) Turbocharger wastegate actuator bolts Drive belt
11A-48
ENGINE MECHANICAL
ENGINE ASSEMBLY
17 18 6
19
5.0 1.0 Nm
20 N
(Engine oil)
67 7 Nm* 12 2 Nm
7
22 4 Nm
21
98 10 Nm*
14 N
8 9
22 4 Nm
16 22
10
40 5 Nm
42 2 Nm
13
15
42 2 Nm
12
6. 7. 8. 9. <> <> 10. 11. 12. 13. 14. Removal steps Brake booster vacuum hose connection Purge hose connection Power steering pressure switch connector Power steering oil pump heat protector Power steering oil pump, bracket and reservoir assembly A/C compressor connector A/C compressor and clutch assembly Engine oil cooler feed hose connection Engine oil cooler tube gaskets 15. 16. 17. 18. 19. 20.
11
AC211078 AC
>>D<< >>D<<
<<C>> <<D>> <<E>>
>>C<< >>B<< >>A<<
21. 22.
Removal steps (Continued) Engine oil cooler return hose connection Engine oil cooler tube gaskets Heater water hoses connection Fuel return line hose connection Fuel high-pressure hose connection O-ring Transfer assembly (Refer to GROUP 22A, Transfer Assembly P.22A-160). Transmission assembly Engine mounting insulator and cushion stoppers assembly Engine assembly
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-49
REMOVAL SERVICE POINTS <<A>> DRIVE BELT REMOVAL

The following operations will be needed due to the introduction of the serpentine drive system with the drive belt auto-tensioner.
Autotensioner
NOTE: Secure the removed power steering oil pump assembly, and A/C compressor and clutch assembly with cord or rope at a position where they will not interfere with the removal of the engine assembly.
<<C>> TRANSMISSION ASSEMBLY REMOVAL
Hole B Hole A
AC210996 AB
1. Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto-tensioner. 2. Rotate the auto-tensioner anti-clockwise and align hole A with hole B.
AC107630AB
CAUTION To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
1. Pre-tighten the 2 bolts on the car to assemble the radiator support upper insulator to set the special tools engine hanger (MB991895) or engine hanger (MB991928). 2. Remove the transmission assembly. (Refer to GROUP 22A Transmission Assembly P.22A-163).
<<D>> ENGINE MOUNTING INSULATOR AND CUSHION STOPPERS ASSEMBLY REMOVAL

Autotensioner L-shaped hexagon wrench
1. Support the engine with a garage jack. 2. Remove the following special tool.
MB991895
AC210998AB
3. Insert an L-shaped hexagon wrench, etc. into the hole to fix and then remove the drive belt.
<> POWER STEERING OIL PUMP, BRACKET AND RESERVOIR ASSEMBLY/ A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL
With the hose installed, remove the power steering oil pump assembly, and A/C compressor and clutch assembly from the bracket.
MB991454
AC209097AB
(1) <Special tool engine hanger (MB991895) is used> Remove special tool MB991895.
11A-50
MB991928
ENGINE MECHANICAL
ENGINE ASSEMBLY
INSTALLATION SERVICE POINTS >>A<< ENGINE ASSEMBLY INSTALLATION

MB991454
Slide bracket (HI) MB991454 MB991932

AC209108AB
MB991930
(2) <Special tool engine hanger (MB991928) is used> Remove the base hanger and the following tool. Slide bracket (HI) Foot (standard) (MB991932) Joint (90) (MB991930)
AC100954 AB
Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.
MB991454
>>B<< ENGINE MOUNTING INSULATOR AND CUSHION STOPPERS ASSEMBLY INSTALLATION

Engine side Engine side
F R
AC100954 AB
3. Hold the engine assembly with a chain block, etc. 4. Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine assembly is no longer being applied to the engine mounting insulator. 5. Loosen the engine mounting insulator mounting nuts and bolt. Remove the engine mounting insulator and cushion stopper assembly.
<Vehicle rear view>
Engine mounting cushion stopper
<Vehicle front view>

AC210426 AC
<<E>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.
1. Arrow marks on the engine mounting cushion stopper should face the shown direction. NOTE: Disregard F and R stamped as a shared part. 2. Place a garage jack against the engine oil pan with a piece of wood in between. Install the engine mounting insulator and cushion stoppers while adjusting the position of the engine. 3. Support the engine assembly with a garage jack. 4. Remove the chain block. 5. Use the following special tool as during removal to support the engine.
ENGINE MECHANICAL
ENGINE ASSEMBLY
MB991895
11A-51
>>C<< TRANSMISSION ASSEMBLY INSTALLATION

1. Install the transmission assembly. (Refer to GROUP 22A Transmission Assembly P.22A-163).
MB991454
AC209097AB
(1) <Special tool engine hanger (MB991895) is used> Set special tool MB991895.
Slide bracket (HI) Front side
AC107630AB
2. Remove from the car the 2 bolts, to assemble the radiator support upper insulator.
Joint (90) (MB991930) Foot (Standard) (MB991932)
>>D<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

AC209516AB
(2) <Special tool engine hanger (MB991928) is used> a. Set the following parts to the base hanger. Slide bracket (HI) Foot (standard) (MB991932) Joint (90) (MB991930)
MB991928
CAUTION Do not let any engine oil get into the delivery pipe.
1. Apply a small amount of new engine oil to the O-ring. 2. Turning the fuel high-pressure hose to the right and left, install it to the delivery pipe, being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel high-pressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly. 4. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 1.0 Nm
Slide bracket (HI) MB991454 MB991932

AC209108AB
MB991930
b. Set special tool MB991928.
NOTES
12-1
GROUP 12
ENGINE LUBRICATION
CONTENTS
GENERAL INFORMATION . . . . . . . . SERVICE SPECIFICATION . . . . . . . . LUBRICANT. . . . . . . . . . . . . . . . . . . . SEALANT. . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . . 12-2 12-2 12-2 12-3 12-3 ON-VEHICLE SERVICE . . . . . . . . . . .
ENGINE OIL CHECK . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT . . . . . . . . . . ENGINE OIL FILTER REPLACEMENT. . . . OIL PRESSURE CHECK . . . . . . . . . . . . . .
12-3
12-3 12-3 12-4 12-4
ENGINE OIL COOLER . . . . . . . . . . . .

12-6
12-6
12-2
ENGINE LUBRICATION
GENERAL INFORMATION
GENERAL INFORMATION
M1121000100454
The lubrication method is a fully force-fed, full-flow filtration type. The engine oil pump is a gear type which is driven by the crankshaft via the timing belt.
ENGINE OILS HEALTH WARNING

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
RECOMMENDED PRECAUTIONS
The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them. Other precautions: Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable.
Avoid contaminating clothes, particularly underpants, with oil. Do not put oily rags in pockets, the use of overalls without pockets will avoid this. Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separate from personal clothing. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Obtain First Aid treatment immediately for open cuts and wounds. Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. If skin disorders develop, obtain medical advice without delay.
SERVICE SPECIFICATION
M1121000300265
Item Oil pressure kPa at idle at 3,500 r/min
Standard value 29 or more 294 686
LUBRICANT
M1121000400897
Item Engine oil ACEA classification Engine oil API classification Engine oil quantity L Oil filter Oil cooler Total
Specification A1, A2 or A3 SG or higher 0.3 0.5 5.3
ENGINE LUBRICATION
SEALANT
12-3
M1121000500269
SEALANT
Item Oil pressure switch Specified sealant 3M ATD Part No. 8660 or equivalent Remark Semi-drying sealant
SPECIAL TOOLS
M1121000600664
Tool
Number MD998012
Name Oil pressure switch wrench
Use Removal and installation of oil pressure switch
ON-VEHICLE SERVICE
ENGINE OIL CHECK
M1121000900438
Drain plug gasket Good Maximum Minimum Oil pan side
AC210335AB ACX00892AB
1. Pull out the engine oil level gauge slowly and check that the oil level is in the illustrated range. 2. Check that the oil is not excessively dirty, that there is no coolant or petrol mixed in, and that it has sufficient viscosity.
4. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque. Tightening torque: 39 5 Nm
ENGINE OIL REPLACEMENT

M1121001000922
1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80C to 90C.
Use care as oil could be hot.

2. Remove the engine oil filler cap. 3. Remove the drain plug to drain oil.
AC504927AB
WARNING
5. Refill with specified quantity of engine oil. Specified Engine Oil (ACEA and API classification): ACEA A1, A2 or A3/API SG or higher Total quantity (Includes volume inside oil filter and oil cooler): 5.3 L
12-4
ENGINE LUBRICATION
ON-VEHICLE SERVICE
NOTE: SAE 5W-30 engine oil can be used to improve engine startability in very cold weather areas where the lowest atmospheric temperature is below the range shown in the illustration. In this case, use engine oil conforming to the following classification: . ACEA classification: For service A3 API classification: For service SG or higher 6. Install the engine oil filler cap. 7. Check oil level.
Tightening torque: Approximately 3/4 turn (14 2 Nm) 9. Install the side cover. 10.Install the drain plug and refill engine oil. (Refer to Engine Oil Replacement P.12-3). 11.Rev the engine a few times, and check to be sure that no engine oil leaks from the installation area of the oil filter.
OIL PRESSURE CHECK

M1121002300829
ENGINE OIL FILTER REPLACEMENT

M1121001100468
1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80C to 90C.
Engine front Oil pressure switch
Use care as oil could be hot.

2. Remove the engine oil filler cap. 3. Remove the drain plug to drain oil. 4. Remove the side cover.
Commerciallyavailable tool
WARNING
Oil filter
AK501835 AB
1. Check engine oil quantity.
CAUTION
MD998012
ACX00395 AD
5. Use the commercially-available tool to remove the engine oil filter. 6. Clean the filter bracket side mounting surface and ensure the old O-ring has been removed.
AKX00294 AF
O-ring
ACX00396 AB
7. Apply a small amount of engine oil to the O-ring of the new oil filter. 8. Where the oil filter O-ring touches the oil pan flange, tighten the oil filter to the specified torque using the commercially-available tool.
Since sealant is applied to the thread of oil pressure switch, take care not to damage the oil pressure switch when removing it. 2. Use the special tool Oil pressure switch wrench (MD998012) to remove the oil pressure switch. NOTE: Remove the terminal of oil pressure switch where the special tool oil pressure wrench (MD998012) is not fitted. 3. Install the oil pressure gauge. NOTE: Use an adapter of PT 1/8 thread. 4. Run the engine to warm it. 5. After the engine has been warmed up, check that oil pressure is within the standard value. Standard value: At idle: 29 kPa or more At 3,500 r/min: 294 686 kPa 6. Remove the oil pressure gauge.
ENGINE LUBRICATION
ON-VEHICLE SERVICE
12-5
CAUTION
MD998012
AKX00295AD
7. Apply the specified sealant to the thread of oil pressure switch. Specified sealant: 3M ATD Part No. 8660 or equivalent
AKX00294 AF
Do not start the engine within one hour after the oil pressure switch has been installed. 8. Use the special tool oil pressure switch wrench (MD998012) to tighten the oil pressure switch to the specified torque. Tightening torque: 10 2 Nm
12-6
ENGINE LUBRICATION
ENGINE OIL COOLER
ENGINE OIL COOLER

M1121001300127
Pre-removal Operation Engine Oil Draining (Refer to P.12-3). Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-2). Side Cover Removal Post-installation Operation Side Cover Installation Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-2). Engine Oil Refilling (Refer to P.12-3).
2
12 2 Nm
3 8
12 2 Nm
5N
42 2 Nm
1N 6 1N
7 4
12 2 Nm
42 2 Nm
AC310319AB
1. 2. 3. 4.
Removal steps Engine oil cooler tube gaskets Engine oil cooler, bracket and hose assembly Engine oil cooler brackets Engine oil cooler feed hose
5. 6. 7. 8.
Removal steps (Continued) Engine oil cooler tube gaskets Engine oil cooler return hose Engine oil cooler tube gaskets Engine oil cooler

2001 Mitsubishi Lancer Evo IX.

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2001 Mitsubishi Lancer Evo IX.

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SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

INPUT SIGNAL PROCEDURES

Connectors: C-214, C-217 <LHD> Junction block (front view)

C-217 C-214 Harness side

C-217 Harness side

the door switches and the ETACS-ECU.

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

DOOR SWITCH (FRONT: LH)

DOOR SWITCH (REAR: LH)

DOOR SWITCH (REAR: RH)

DOOR SWITCH (FRONT: RH)

COMMENTS ON TROUBLE SYMPTOM

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

OK: The M.U.T.-II/III sounds or the voltmeter needle fluctuates.

switch (front: RH) signal is not received P.54B-244."

Connector: D-01 <RHD>

Connectors: D-08, D-11, D-18 <RHD>

D-08 Harness side

D-11 Harness side

D-18 Harness side

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

Step 4. Check the door switch. Refer to GROUP 42 Door P.42-27.

Junction block side

Connector: D-01 <RHD>

Connectors: D-08, D-11, D-18 <RHD>

D-08 Harness side

D-11 Harness side

D-18 Harness side

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

Connectors: C-214, C-217 Junction block (front view) <RHD>

C-214 Harness side

C-217 Harness side

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

DOOR LOCK ACTUATOR (FRONT: LH)

COMMENTS ON TROUBLE SYMPTOM

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

Harness side E-04(B)

Harness side E-04(B)

Connector E-04 (Harness side)

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

Harness side E-04(B) Harness side

Front door (LH)

Harness side E-04(B)

Step 5. Connector check: C-227 ETACS-ECU connector

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

DOOR LOCK ACTUATOR (FRONT: RH)

COMMENTS ON TROUBLE SYMPTOM

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

Connector E-15 (Harness side)

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

Step 5. Connector check: C-227 ETACS-ECU connector

Connector: E-15 <RHD>

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

VEHICLE SPEED SENSOR

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

Vehicle Speed Signal Input Circuit <RHD> ETACS-ECU

VEHICLE SPEED SENSOR

COMMENTS ON TROUBLE SYMPTOM

GROUP 54A Combination meter P.54A-34).

SMART WIRING SYSTEM (SWS) NOT USING SWS MONITOR

Connector: C-228 <RHD>

Junction block (rear view)

Connector: C-228 <RHD>