GROUP INDEX

General . . . . . . . . . . . . . . . . . . . . . . . . 00
LANCER / Engine. . . . . . . . . . . . . . . . . . . . . . . . . 11
LANCER WAGON Engine Lubrication . . . . . . . . . . . . . . 12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WORKSHOP MANUAL Engine Cooling . . . . . . . . . . . . . . . . . 14
Intake and Exhaust . . . . . . . . . . . . . . 15
Engine Electrical . . . . . . . . . . . . . . . . 16
FOREWORD Engine and Emission Control . . . . . 17
This Workshop manual contains procedures for
service mechanics, including removal, disassembly,
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 21
inspection, adjustment, reassembly and installation. Manual Transmission . . . . . . . . . . . .
Use the following manuals in combination with this
22
manual as required. Automatic Transmission. . . . . . . . . . 23
Front Axle. . . . . . . . . . . . . . . . . . . . . . 26
Rear Axle . . . . . . . . . . . . . . . . . . . . . . 27
TECHNICAL INFORMATION MANUAL
PYME0302 Wheel and Tyre . . . . . . . . . . . . . . . . . 31
PYME0302-A
WORKSHOP MANUAL Power Plant Mount . . . . . . . . . . . . . . 32
CHASSIS GROUP PWME0302
BODY REPAIR MANUAL Front Suspension . . . . . . . . . . . . . . . 33
PBME0302
PBME0302-A Rear Suspension . . . . . . . . . . . . . . . . 34
PARTS CATALOGUE
B606K005A_
Service Brakes. . . . . . . . . . . . . . . . . . 35

All information, illustrations and product descriptions

Parking Brakes . . . . . . . . . . . . . . . . . 36
contained in this manual are current as at the time of Power Steering . . . . . . . . . . . . . . . . . 37
publication. We, however, reserve the right to make
changes at any time without prior notice or obligation. Body . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exterior . . . . . . . . . . . . . . . . . . . . . . . . 51
Interior and Supplemental
Restraint System (SRS) . . . . . . . . . . 52
Chassis Electrical . . . . . . . . . . . . . . . 54
Heater, Air Conditioner and
Ventilation
....... 55
Component Locations. . . . . . . . . . . . 70
Mitsubishi Motors Corporation May 2004
Configration Diagrams . . . . . . . . . . . 80
Circuit Diagrams . . . . . . . . . . . . . . . . 90
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
(1) Improper service or maintenance of any component of the SRS or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).
(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag
modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.
• SRS-ECU, air bag module and clock spring 93°C or more
• Seat belt with pre-tensioner: 90°C or more
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this Manual, and especially its GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of
any component of the SRS or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
 00-1

GROUP 00

GENERAL
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00

GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

NOTES
 11-1

GROUP 11

ENGINE
CONTENTS

ENGINE MECHANICAL <4G1> . . . . . . . . . . . . . . . . . . . . . . . . . 11A

ENGINE OVERHAUL <4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

ENGINE MECHANICAL <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . 11C

ENGINE OVERHAUL <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . 11D

NOTES
 12-1

GROUP 12

ENGINE
LUBRICATION
CONTENTS

GENERAL INFORMATION . . . . . . . . 12-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . 12-3

SERVICE SPECIFICATION . . . . . . . . 12-2 ON-VEHICLE SERVICE . . . . . . . . . . . 12-4

ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-4
LUBRICANT. . . . . . . . . . . . . . . . . . . . 12-2 ENGINE OIL REPLACEMENT . . . . . . . . . . 12-4
ENGINE OIL FILTER REPLACEMENT. . . . 12-4
SEALANT. . . . . . . . . . . . . . . . . . . . . . 12-3 OIL PRESSURE CHECK . . . . . . . . . . . . . . 12-5
12-2 ENGINE LUBRICATION
GENERAL INFORMATION

GENERAL INFORMATION
M1121000100357
The lubrication method is a fully force-fed, full-flow • Avoid contaminating clothes, particularly
filtration type. The engine oil pump is a trochoid type underpants, with oil.
which is driven by the crankshaft <4G1>.The engine • Do not put oily rags in pockets, the use of overalls
oil pump is a gear type which is driven by the without pockets will avoid this.
crankshaft via the balancer timing belt <4G6>. • Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
ENGINE OILS cleaned regularly and kept separate from
Health Warning personal clothing.
• Where there is a risk of eye contact, eye
Prolonged and repeated contact with mineral oil will
protection should be worn, for example, chemical
result in the removal of natural fats from the skin,
goggles or face shields; in addition an eye wash
leading to dryness, irritation and dermatitis. In
facility should be provided.
addition, used engine oil contains potentially harmful
• Obtain first aid treatment immediately for open
contaminants which may cause skin cancer.
cuts and wounds.
Adequate means of skin protection and washing
• Wash regularly with soap and water to ensure all
facilities must be provided.
oil is removed, especially before meals (skin
Recommended Precautions cleansers and nail brushes will help). After
cleaning, the application of preparations
The most effective precaution is to adapt working
containing lanolin to replace the natural skin oils
practices which prevent, as far as practicable, the
is advised.
risk of skin contact with mineral oils, for example by
• Do not use petrol, kerosine, diesel fuel, gas oil,
using enclosed systems for handling used engine oil
thinners or solvents for cleaning skin.
and by degreasing components, where practicable,
• Use barrier creams, applying them before each
before handling them. Other precautions:
work period, to help the removal of oil from the
• Avoid prolonged and repeated contact with oils,
skin after work.
particularly used engine oils.
• If skin disorders develop, obtain medical advice
• Wear protective clothing, including impervious
without delay.
gloves where practicable.

SERVICE SPECIFICATION
M1121000300232

Item Standard value

Oil pressure kPa at idle 29 or more
at 3,500 r/min 294 − 686

LUBRICANT
M1121000400433

Item Specification
Engine oil ACEA classification A1, A2 or A3
Engine oil API classification SG or higher
Engine oil quantity L 4G1 Oil filter 0.3
Total 3.3
4G6 Oil filter 0.3
Total 4.3
 ENGINE LUBRICATION
SEALANT
12-3
SEALANT
M1121000500258

Item Specified sealant Remark

Oil pressure switch 3M ATD Part No. 8660 or equivalent Semi-drying sealant

SPECIAL TOOLS
M1121000600415

Tool Number Name Use

MB991396 Oil filter wrench Removal and installation
of engine oil filter (When
using the engine oil filter
of MD360935)
B991396

MB991828 Oil filter wrench Removal and installation

of engine oil filter (When
using the engine oil filter
of MD348631 and
MD365876)
MB991828

MB991610 Oil filter wrench Removal and installation

of engine oil filter (When
using the engine oil filter
of MD356000)
MB991610

MD998054 Oil pressure switch Removal and installation

wrench of oil pressure switch
12-4 ENGINE LUBRICATION
ON-VEHICLE SERVICE

ON-VEHICLE SERVICE
ENGINE OIL CHECK 4. Install a new engine oil pan drain plug gasket so
M1121000900342 that it faces in the direction shown in the
<4G1> illustration, and then tighten the engine oil pan
drain plug to the specified torque.
Good Tightening torque: 39 ± 5 N⋅m
NOTE: Install the engine oil pan drain plug gasket
Minimum
Maximum so it faces in the direction shown in the illustration.

ACX00892 AC

<4G6>

Good

AC301513

5. Refill with specified quantity of engine oil.

Maximum Minimum
Specified Engine Oil (ACEA and API
classification): ACEA A1, A2 or A3/API SG or
AC205268 AC higher
Total quantity (Includes volume inside engine
1. Pull out the engine oil level gauge slowly and
oil filter):
check that the oil level is in the illustrated range.
3.3 L <4G1>
2. Check that the oil is not excessively dirty, that 4.3 L <4G6>
there is no coolant or petrol mixed in, and that it
has sufficient viscosity. 6. Install the engine oil filler cap.
7. Check engine oil level.
ENGINE OIL REPLACEMENT
M1121001000416 ENGINE OIL FILTER REPLACEMENT
1. Start the engine and allow it to warm up until the M1121001100383

temperature of the coolant reaches 80 °C to 90 1. Start the engine and allow it to warm up until the
°C. temperature of the coolant reaches 80 °C to 90
2. Remove the engine oil filler cap. °C.
2. Remove the engine oil filler cap.
CAUTION
Use care as engine oil could be hot. CAUTION
Use care as engine oil could be hot.
3. Remove the engine oil pan drain plug to drain
engine oil. 3. Remove the engine oil pan drain plug to drain
engine oil.
Engine oil pan
Engine oip pan 4. Remove the under cover.
drain plug

Engine oil
pan side Engine oip pan
drain plug
AC208299 AC
 ENGINE LUBRICATION
ON-VEHICLE SERVICE
12-5
Number Special tool Tightening torque
MB991396 MD348631 Oil filter wrench Approximately 3/4
<4G1>,
MB991828 <4G1> (MB991828) or turn (16 ± 4 N⋅m)
MD365876 equivalent
<4G1>,
MB991610
<4G6> or <4G1>
commercially-
available tool MD360935 Oil filter wrench Approximately 1 turn
<4G1> (MB991396) or (14 ± 2 N⋅m)
equivalent
AC000093 AI
MD136466 Commercially- Approximately 3/4
5. Use the respective tool in the following table to <4G6> available tool turn (17 ± 3 N⋅m)
remove the engine oil filter. MD322508
<4G6>
Number Special tool
MD356000 Oil filter wrench Approximately 3/4
MD348631 <4G1> Oil filter wrench (MB991828)
<4G6> (MB991610) or turn (14 ± 2 N⋅m)
MD365876 <4G1> or equivalent
equivalent
MD360935 <4G1> Oil filter wrench (MB991396) 9. Install the engine oil pan drain plug and refill the
or equivalent engine oil (Refer to P.12-4).
MD136466 <4G6> Commercially- available tool 10.Race the engine 2−3 times, and check to be sure
MD322508 <4G6> that no engine oil leaks from installation section of
the engine oil filter.
MD356000 <4G6> Oil filter wrench (MB991610)
or equivalent
OIL PRESSURE CHECK
6. Clean the filter bracket side mounting surface. M1121002300368

<4G1>

Oil pressure
switch
Oil filter

O-ring
AK101640 AD
AC103250AD

<4G6>
7. Apply a small amount of engine oil to the O-ring of
the new engine oil filter.
Oil filter bracket
8. Once the O-ring of the engine oil filter is touching
the flange, use the respective tool in the following
table to tighten to the specified torque.

Oil pressure switch AK300647AB

1. Check engine oil quantity.

2. Remove the oil pressure switch terminal.
12-6 ENGINE LUBRICATION
ON-VEHICLE SERVICE

CAUTION

MD998054

AKX00295AD

AKX00294 AD
8. Apply the specified sealant to the thread of oil
Since sealant is applied to the thread of oil pressure switch.
pressure switch, take care not to damage the oil Specified sealant: 3M ATD Part No. 8660 or
pressure switch when removing it. equivalent
3. Use the special tool Oil pressure switch wrench
(MD998054) to remove the oil pressure switch. CAUTION
4. Install the oil pressure gauge. MD998054
NOTE: Use an adapter of PT 1/8 thread.
5. Run the engine to warm it.
6. After the engine has been warmed up, check that
oil pressure is within the standard value.
Standard value:
At idle: 29 kPa or more
At 3,500 r/min: 294 − 686 kPa
7. Remove the oil pressure gauge. AKX00294 AD

Do not start the engine within one hour after the

oil pressure switch has been installed.
9. Use the special tool Oil pressure switch wrench
(MD998054) to tighten the oil pressure switch to
the specified torque.
Tightening torque:
<4G1> 19 ± 3 N⋅m (14 ± 2 ft-lb)
<4G6> 10 ± 2 N⋅m (87 ± 17 ft-lb)
10.Install the oil pressure switch terminal.
 13-1

GROUP 13

FUEL
CONTENTS

MULTIPORT FUEL INJECTION (MPI) <4G1> . . . . . . . . . . . . . . 13A

MULTIPORT FUEL INJECTION (MPI) <4G6> . . . . . . . . . . . . . . 13B

FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C

NOTES
 14-1

GROUP 14

ENGINE COOLING
CONTENTS

GENERAL INFORMATION . . . . . . . . 14-2 COOLING FAN MOTOR DRIVE CONTROL

UNIT CHECK. . . . . . . . . . . . . . . . . . . . . . . . 14-23
SERVICE SPECIFICATIONS. . . . . . . 14-2 FAN CONTROL RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24
COOLING FAN MOTOR CHECK . . . . . . . . 14-25
LUBRICANT. . . . . . . . . . . . . . . . . . . . 14-2
THERMOSTAT . . . . . . . . . . . . . . . . . . 14-26
SEALANTS . . . . . . . . . . . . . . . . . . . . 14-3
REMOVAL AND INSTALLATION . . . . . . . . 14-26
SPECIAL TOOLS. . . . . . . . . . . . . . . . 14-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-27

TROUBLESHOOTING . . . . . . . . . . . . 14-5 WATER PUMP . . . . . . . . . . . . . . . . . . 14-29

REMOVAL AND INSTALLATION <4G1> . . 14-29
INSPECTION CHART FOR TROUBLE
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 14-5 REMOVAL AND INSTALLATION <4G6> . . 14-30
INSPECTION PROCEDURE FOR
TROUBLE SYMPTOMS . . . . . . . . . . . . . . . 14-6 WATER HOSE AND WATER PIPE . . 14-31
REMOVAL AND INSTALLATION <4G1> . . 14-31
ON-VEHICLE SERVICE. . . . . . . . . . . 14-22 REMOVAL AND INSTALLATION <4G6> . . 14-33
ENGINE COOLANT LEAK CHECK . . . . . . 14-22 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-34
RADIATOR CAP VALVE OPENING
PRESSURE CHECK. . . . . . . . . . . . . . . . . . 14-22 RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-35
ENGINE COOLANT REPLACEMENT . . . . 14-22 REMOVAL AND INSTALLATION . . . . . . . . 14-35
CONCENTRATION MEASUREMENT . . . . 14-23
14-2 ENGINE COOLING
GENERAL INFORMATION

GENERAL INFORMATION
M1141000100371
The cooling system is designed to keep every part of temperature, the thermostat opens to circulate the
the engine at appropriate temperature in whatever coolant through the radiator as well so that the heat
condition the engine may be operated. The cooling absorbed by the coolant may be radiated into the air.
method is of the water-cooled, pressure forced The water pump is of the centrifugal type and is
circulation type in which the water pump pressurizes driven by the alternator drive belt from the
coolant and circulates it throughout the engine. If the crankshaft. The radiator is the corrugated fin, down
coolant temperature exceeds the prescribed flow type.
Item Specification
Radiator Performance kJ/h 4G13 Standard vehicles 137,720
Vehicles with capacity up radiator 161,288
(option)
4G18 Standard vehicles 161,288
Vehicles with capacity up radiator 181,800
(option)
4G63 181,800
A/T oil cooler Performance kJ/h 5,651

SERVICE SPECIFICATIONS
M1141000300416

Item Standard value Limit

High-pressure valve opening pressure of radiator cap kPa 93 − 123 Minimum 83
Range of coolant antifreeze concentration of radiator % 30 − 60 -
Thermostat Valve opening temperature of 4G1 88 ± 1.5 -
thermostat °C 4G6 82 ± 1.5 -
Full-opening temperature of 4G1 100 -
thermostat °C 4G6 95 -
Valve lift mm 8.5 or more -

LUBRICANT
M1141000400338

Item Specified coolant Quantity L

Engine coolant (including DIAQUEEN SUPER LONG LIFE COOLANT 4G1 5.0
condense tank) or an equivalent 4G6 7.0
 ENGINE COOLING
SEALANTS
14-3
SEALANTS
M1141000500324

Item Specified sealant

Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent
Water pump <4G1>, Thermostat case MITSUBISHI GENUINE Part No.MD970389 or equivalent
<4G6>, Cooling water outlet hose fitting
<4G6>

SPECIAL TOOLS
M1141000600246

Tool Number Name Use

MB991502 MUT-II sub assembly Reading diagnosis code

B991502
14-4 ENGINE COOLING
SPECIAL TOOLS

Tool Number Name Use

MB991955 MUT-III sub assembly Checking the A/T
A A: MB991824 A: Vehicle (Diagnosis display using the
B: MB991827 communication MUT-III)
C: MB991910 interface (V.C.I.)
D: MB991911 B: MUT-III USB cable
MB991824 E: MB991825 C: MUT-III main
B F: MB991826 harness A (Vehicles
with CAN
communication
system)
MB991827 D: MUT-III main
harness B (Vehicles
C
without CAN
DO NOT USE communication
system)
E: MUT-III
MB991910
measurement
D adapter
F: MUT-III trigger
harness

MB991911

MB991825

MB991826

MB991955
 ENGINE COOLING
TROUBLESHOOTING
14-5
Tool Number Name Use
MB991223 Harness set Making voltage and
A
A: MB991219 A: Test harness resistance measurement
B: MB991220 B: LED harness during troubleshooting
C: MB991221 C: LED harness A: Connector pin contact
D: MB991222 adapter pressure inspection
B D: Probe B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester
connection

MB991223 AC

MB991871 LLC changer Coolant refilling

MB991871

TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE
SYMPTOMS
M1141005600360

Trouble symptom Inspection Reference page

procedure No.
Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with 1 P.14-6
A/C)> or A/C condenser fan <4G6> do not operate
Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with 2 P.14-16
A/C)> or A/C condenser fan <4G6> do not change speed or stop
Cooling fan (L.H.) does not operate {When cooling fan (R.H.) 3 P.14-20
<4G1> or A/C condenser fan <4G6> operate} <Vehicles with A/C>
Cooling fan (R.H.) <4G1> or A/C condenser fan <4G6> does not 4 P.14-21
operate {When cooling fan (L.H.) operate} <Vehicles with A/C>
14-6 ENGINE COOLING
TROUBLESHOOTING

INSPECTION PROCEDURE FOR

TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or
A/C Condenser Fan <4G6> do not Operate

Cooling Fan (L.H.) and Cooling Fan (R.H.) or A/C Condenser Fan Drive Circut

ENGINE-ECU <M/T> OR
ENGINE-A/T-ECU <A/T>
FUSIBLE
C-123 LINK No.2
(MU801824)
ENGINE CONTROL
RELAY
B-16X
C-122
(MU803784) 21 C-123 <M/T>
18 C-122 <A/T> R-Y
28
J/C (6)
L B-W
C-12 <LHD>
C-134 <RHD>
A-13 33
(MU802611)
R-Y
1 A-13 <LHD> 8 A-13 <LHD> A-13
C-111 12 C-111 <RHD> 11 C-111 <RHD> (MU802611)

1 2 3 4 5
R-Y
6 7 8 9 10 11 12
4 1
FAN CONTROL C-111
L
RELAY 1 2 3 4 5
A-09X 6 7 8 9 10 11 12

(MU802322) 2 3
L 3
A-18 2
COOLING FAN
MOTOR DRIVE
CONTROL UNIT
B

Wire colour code

B : Black LG : Light green
2 1 A-18-2 2 1 A-18-1 G : Green L : Blue
1 W : White Y : Yellow
COOLING FAN B
MOTOR (R.H.) SB : Sky blue BR : Brown
<4G1 (VEHICLES O : Orange GR : Gray
WITH A/C> R : Red P : Pink V : Violet
OR
A/C CONDENSER COOLING FAN
FAN MOTOR <4G6> MOTOR (L.H.)
AC303577AB
 ENGINE COOLING
TROUBLESHOOTING
14-7
CIRCUIT OPERATION DIAGNOSIS
• The cooling fan motor drive control unit is
powered from fusible link (2).
STEP 1. Check the cooling fan motor (L.H.).
• The engine-ECU <M/T> or engine-A/T-ECU
<Vehicles without A/C>
<A/T> uses input signals from the A/C switch, the Refer to P.14-25.
water temperature sensor unit and the vehicle
speed sensor <M/T> or the output shaft speed Q: Is the cooling fan motor (L.H.) in good condition?
sensor <A/T> to control the speed of the cooling YES : Go to Step 2 .
fan motor (L.H.) and the cooling fan motor (R.H.) NO : Replace the cooling fan motor (L.H.) (Refer
<4G1 (Vehicles with A/C)> or A/C condenser fan to P.14-35). Then go to Step 24 .
motor <4G6>.
• The engine-ECU <M/T> or engine-A/T-ECU STEP 2. Measure the power supply voltage at
<A/T> controls the cooling fan motor drive control cooling fan motor drive control unit connector
unit to activate the cooling fan motor (L.H.) and A-18.
the cooling fan motor (R.H.) <4G1 (Vehicles with
Connector: A-18
A/C)> or A/C condenser fan motor <4G6>.

TECHNICAL DESCRIPTION
• The cause could be a malfunction of the cooling
fan motor drive control unit power supply or earth
circuit.
• If the communication line wiring harness between A-18
the cooling fan motor drive control unit and the 3 2 1

engine-ECU <M/T> or engine-A/T-ECU <A/T> is

AC100293 AD
short-circuited to earth, the cooling fan motor
(L.H.) and the cooling fan motor (R.H.) <4G1 (1) Disconnect cooling fan motor drive control unit
(Vehicles with A/C)> or the A/C condenser fan connector A-18 and measure wiring harness side
motor <4G6> will not rotate. connector.
• The cause could also be a malfunction of the (2) Turn the ignition switch to the "ON" position.
cooling fan motor (L.H.). <Vehicles without A/C>
• The cause could also be a malfunction of imput A-18 Connector
(Component side)
signal from the A/C switch, the water temperature
sensor unit and the vehicle speed sensor <M/T>
or the output shaft speed sensor <A/T> to the
engine-ECU <M/T> or engine-A/T-ECU <A/T>.
• The cause could also be a malfunction of the
cooling fan motor drive control unit or the
engine-ECU <M/T> or engine-A/T-ECU <A/T>.
AC000246AF
TROUBLESHOOTING HINTS
• Malfunction of fusible link (2) (3) Measure the voltage between cooling fan motor
• Malfunction of fan control relay drive control unit connector A-18 terminal 3 and
• Malfunction of cooling fan motor (L.H.) <Vehicles body earth.
without A/C> • The voltage should measure system voltage.
• Malfunction of cooling fan motor drive control unit (4) Turn the ignition switch to the "LOCK" (OFF)
• Malfunction of engine-ECU <M/T> or position.
engine-A/T-ECU <A/T> (5) Connect cooling fan motor drive control unit
• Damaged wiring harness or connector connector A-18.
Q: Is the measured voltage system voltage?
YES : Go to Step 17 .
NO : Go to Step 3 .
14-8 ENGINE COOLING
TROUBLESHOOTING

STEP 3. Check the cooling fan motor drive (1) Disconnect fan control relay connector A-09X
control unit connector A-18. (remove the fan control relay) and measure relay
box side connector.
Connector: A-18 (2) Turn the ignition switch to the "ON" position.

A-09X Connector
(Relay box side)

A-18
3 2 1

AC100293 AD

Q: Is the connector in good condition? AC303511AB

YES : . Go to Step 4 . (3) Measure the voltage between fan control relay
NO : . Repair or replace the connector. Then go to
connector A-09X terminal 4 and body earth.
Step 24 . • The voltage should measure system voltage.
(4) Turn the ignition switch to the "LOCK" (OFF)
STEP 4. Check the fusible link No.2. position.
(5) Connect fan control relay connector A-09X
Relay box
(install the fan control relay).
Q: Is the measured voltage system voltage?
YES : Go to Step 8 .
NO : Go to Step 6 .

STEP 6. Check the fan control relay connector

Fusible link A-09X.
No.2
Connector: A-09X Relay box
AC303509AB

Q: Is the fusible link No.2 in good condition?

YES : . Go to Step 5 .
Fan control relay
NO : . Replace the fusible link No.2. Then go to
Step 24 .

A-09X
STEP 5. Measure the power supply voltage at fan
control relay connector A-09X. AC303510AB
Connector: A-09X Relay box
Q: Is the connector in good condition?
YES : Go to Step 7 .
NO : Repair the connector or replace the relay
Fan control relay box. Then go to Step 24 .

A-09X

AC303510AB
 ENGINE COOLING
TROUBLESHOOTING
14-9
Q: Is the connector in good condition?
STEP 7. Check the harness wire between fusible YES : Go to Step 10 .
link No.2 and fan control relay connector A-09X NO : Repair the connector or replace the relay
terminal 4. box. Then go to Step 24 .
Relay box

STEP 10. Check the harness wire between fan

control relay connector A-09X terminal 2 and
cooling fan motor drive control unit connector
A-18 terminal 3.
Connector: A-09X Relay box

Fusible link
No.2
AC303509AB
Fan control relay

Connector: A-09X Relay box

A-09X

Fan control relay

AC303510AB

Connector: A-18
A-09X

AC303510AB

Q: Is the harness wire in good condition?

YES : . An intermittent malfunction is suspected
A-18
(Refer to GROUP 00 - How to use
3 2 1
troubleshooting P.00-5).
NO : . Repair the damaged harness wire. Then go AC100293 AD
to Step 24 .
Q: Is the harness wire in good condition?
YES : Go to Step 11 .
STEP 8. Check the fan control relay. NO : Repair the damaged harness wire. Then go
Refer to P.14-24. to Step 24 .
Q: Is the fan control relay in good condition?
YES : Go to Step 9 .
NO : Replace the fan control relay. Then go to STEP 11. Measure the terminal voltage at fan
Step 24 . control relay connector A-09X.
Connector: A-09X Relay box

STEP 9. Check the fan control relay connector

A-09X.
Fan control relay
Connector: A-09X Relay box

A-09X
Fan control relay

AC303510AB

A-09X (1) Disconnect fan control relay connector A-09X

(remove the fan control relay) and measure relay
AC303510AB
box side connector.
(2) Turn the ignition switch to the "ON" position.
14-10 ENGINE COOLING
TROUBLESHOOTING

STEP 12. Check the J/C No.6 C-12 <L.H. drive

A-09X Connector vehicles> or C-134 <R.H. drive vehicles>,
(Relay box side) intermediate connector A-13 <L.H. drive
vehicles> C-111 <R.H. drive vehicles> and fan
control relay connector A-09X.
Connector: C-12 <L.H. drive vehicles>

AC303517AB

(3) Measure the voltage between fan control relay C-12

connector A-09X terminal 1 and body earth.
• The voltage should measure system voltage. C-12
(4) Turn the ignition switch to the "LOCK" (OFF)
position. AC303524 AB
(5) Connect fan control relay connector A-09X
(install the fan control relay). Connector: C-134 <R.H. drive vehicles>

Q: Is the measured voltage system voltage?

YES : . Go to Step 14 .
NO : . Go to Step 12 . C-134

C-134

AC303525 AB

Connector: A-13 <L.H. drive vehicles>

A-13

A-13

AC303526 AB

Connector: C-111 <R.H. drive vehicles>

C-111

C-111
1 2 3 4 5
6 7 8 9 10 11 12
AC303527AB
 ENGINE COOLING
TROUBLESHOOTING
14-11
Relay box
Q: Are these harness wires in good condition?
Connector: A-09X
YES : An intermittent malfunction is suspected
(Refer to GROUP 00 - How to use
troubleshooting P.00-5).
Fan control relay NO : Repair the damaged harness wire. Then go
to Step 24 .

A-09X STEP 14. Check the continuity between fan

control relay connector A-09X and body earth.
AC303510AB
Connector: A-09X Relay box

Q: Are there connectors in good condition?

YES : . Go to Step 13 .
NO : . Repair or replace the connector. Then go to Fan control relay
Step 24 .

STEP 13. Check the harness wire between J/C A-09X

No.6 C-12 terminal 33 <L.H. drive vehicles> or
C-134 terminal 33 <R.H. drive vehicles> and fan AC303510AB
control relay connector A-09X terminal 1.
(1) Disconnect fan control relay connector A-09X
Connector: C-12 <L.H. drive vehicles> (remove the fan control relay) and measure relay
box side connector.

A-09X Connector
(Relay box side)
C-12
C-12

AC303524 AB

Connector: C-134 <R.H. drive vehicles>

AC303533AB

(2) Measure the resistance between fan control relay

C-134 connector A-09X terminal 3 and body earth.
• Continuity exists.
(3) Connect fan control relay connector A-09X
(install the fan control relay).
C-134
Q: Does the continuity exists?
YES : An intermittent malfunction is suspected
AC303525 AB
(Refer to GROUP 00 - How to use
Connector: A-09X Relay box troubleshooting P.00-5).
NO : Go to Step 15 .

Fan control relay

A-09X

AC303510AB
14-12 ENGINE COOLING
TROUBLESHOOTING

STEP 15. Check the fan control relay connector STEP 17. Check the continuity between cooling
A-09X. fan motor drive control unit connector A-18 and
Connector: A-09X Relay box body earth.
Connector: A-18

Fan control relay

A-09X
A-18
3 2 1
AC303510AB

AC100293 AD
Q: Is the connector in good condition?
YES : Go to Step 16 . (1) Disconnect cooling fan motor drive control unit
NO : Repair the connector or replace the relay connector A-18 and measure wiring harness side
box. Then go to Step 24 . connector.

STEP 16. Check the harness wire between fan A-18 Connector
control relay connector A-09X terminal 3 and (Wiring harness side)
body earth.
Connector: A-09X Relay box

Fan control relay

AC303534AB

(2) Measure the resistance between cooling fan

A-09X motor drive control unit connector A-18 terminal 1
and body earth.
AC303510AB
• Continuity exists.
(3) Connect cooling fan motor drive control unit
Q: Is the harness wire in good condition? connector A-18.
YES : An intermittent malfunction is suspected
Q: Dose the continuity exists?
(Refer to GROUP 00 - How to use YES : Go to Step 20 .
troubleshooting P.00-5). NO : Go to Step 18 .
NO : Repair the damaged harness wire. Then go
to Step 24 .
 ENGINE COOLING
TROUBLESHOOTING
14-13

STEP 18. Check the cooling fan motor drive STEP 20. Check the cooling fan motor drive
control unit connector A-18. control unit connector A-18, intermediate
Connector: A-18 connector A-13 <L.H. drive vehicles> or C-111
<R.H. drive vehicles> and engine-ECU connector
C-123 <M/T> or engine-A/T-ECU connector C-122
<A/T>.
Connector: A-18

A-18
3 2 1

AC100293 AD

A-18
Q: Is the connector in good condition?
YES : Go to Step 19 . 3 2 1

NO : Repair or replace the connector. Then go to

AC100293 AD
Step 24 .
Connector: A-13 <L.H. drive vehicles>

STEP 19. Check the harness wire between

cooling fan motor drive control unit connector
A-18 terminal 1 and body earth.
Connector: A-18 A-13

A-13

AC303526 AB

Connector: C-111 <R.H. drive vehicles>

A-18
3 2 1

AC100293 AD

Q: Is the harness wire in good condition?

YES : An intermittent malfunction is suspected C-111
(Refer to GROUP 00 - How to use C-111
troubleshooting P.00-5). 1 2 3 4 5
NO : Repair the damaged harness wire. Then go 6 7 8 9 10 11 12
AC303527AB
to Step 24 .
14-14 ENGINE COOLING
TROUBLESHOOTING

Connector: C-123 <M/T>, C-122 <A/T> STEP 21. Check the harness wire between
Engine-ECU <M/T> or cooling fan motor drive control unit connector
engine-A/T-ECU <A/T> A-18 terminal 2 and engine-ECU connector C-123
terminal 21 <M/T> or engine-A/T-ECU connector
C-122 terminal 18 <A/T>.
Connector: A-18

C-123 <M/T>
or
C-122 <A/T>

A-18
C-123 <M/T>
3 2 1

AC100293 AD

Connector: C-123 <M/T>, C-122 <A/T>

C-122 <A/T>
Engine-ECU <M/T> or
engine-A/T-ECU <A/T>

AC303555AB

Q: Are these connectors in good condition?

YES : Go to Step 21 .
NO : Repair or replace the connector. Then go to C-123 <M/T>
Step 24 . or
C-122 <A/T>

C-123 <M/T>

C-122 <A/T>

AC303555AB

Q: Are these harness wires in good condition?

YES : Go to Step 22 .
NO : Repair the damaged harness wire. Then go
to Step 24 .
 ENGINE COOLING
TROUBLESHOOTING
14-15

STEP 22. Check the cooling fan motor drive (5) Check for the cooling fan operation.
• The cooling fan rotates. (with connector
control unit.
terminal pin 21 <M/T> or 18 <A/T>
Connector: C-123 <M/T>, C-122 <A/T> disconnected)
Engine-ECU <M/T> or • The cooling fan stops. (When connector
engine-A/T-ECU <A/T>
terminal pin 21 <M/T> or 18 <A/T> is
connected to the body earth.)
(6) Turn the ignition switch to the "OFF" position.
(7) Disconnect engine-ECU connector C-123 <M/T>
or engine-A/T-ECU connector C-122 <A/T>, and
push in connector terminal pin 21 <M/T> or 18
C-123 <M/T> <A/T> to disconnect connector.
or
C-122 <A/T> (8) Reconnect the connector with connector terminal
pin still installed.
Q: Does the cooling fan rotate? And when the
C-123 <M/T> connector terminal pin is connected to the body
earth, does the cooling fan stop?
YES : Go to Step 23 .
NO : Replace the cooling fan motor drive control
C-122 <A/T>
unit (Refer to P.14-35). Then go to Step 24 .

STEP 23. MUT-II/III self-diag code

AC303555AB
Check if an MPI system self-diag code is set. (Refer
to GROUP 13A - Trouble shooting P.13A-9) <4G1>
(1) Disconnect engine-ECU connector C-123 <M/T> or (Refer to GROUP 13B - Trouble shooting
or engine-A/T-ECU connector C-122 <A/T>. P.13B-9) <4G6>.
Q: Diagnosis code set?
C-123 connector <M/T> YES : Inspection chart for diagnosis code (Refer
(Harness side connector: ECU side view)
to GROUP 13A - Trouble shooting
P.13A-15) <4G1> or Inspection chart for
diagnosis code (Refer to GROUP 13B -
C-122 connector <A/T> Trouble shooting P.13B-15) <4G6>.
(Harness side connector: ECU side view) NO : Replace the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (Refer to GROUP
13A P.13A-401). Then go to Step 24 .
AC303559 AB

(2) Pull out connector terminal pin 21 <M/T> or 18 STEP 24. Check the symptoms.
<A/T> to disconnect connector.
(3) Reconnect the connector with connector terminal Q: Does the cooling fan motor (L.H.) and the cooling
fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C
pin still removed.
condenser fan motor <4G6> operate correctly?
(4) Turn the ignition switch to the "ON" position. YES : This symptoms is complete.
NO : Return to Step 1 .
14-16 ENGINE COOLING
TROUBLESHOOTING

INSPECTION PROCEDURE 2: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or
A/C Condenser Fan <4G6> do not Change Speed or Stop

COOLING FAN (L.H.) AND COOLING FAN TROUBLESHOOTING HINTS

(R.H.) OR A/C CONDENSER FAN DRIVE • Malfunction of fan control relay
CIRCUIT • Malfunction of cooling fan motor (L.H.) <Vehicles
without A/C>
Refer to P.14-6.
• Malfunction of cooling fan motor drive control unit
CIRCUIT OPERATION • Malfunction of engine-ECU <M/T> or
engine-A/T-ECU <A/T>
Refer to P.14-6.
• Damaged wiring harness or connector
TECHNICAL DESCRIPTION
• If the communication line wiring harness between DIAGNOSIS
the cooling fan motor drive control unit and the
engine-ECU <M/T> or the engine-A/T-ECU
STEP 1. Check the fan control relay.
<A/T> is open, the cooling fan motor (L.H.) and
Refer to P.14-24.
the cooling fan motor (R.H.) <4G1 (Vehicles with
A/C)>, or the A/C condenser fan motor <4G6> Q: Is the fan control relay in good condition?
rotate to prevent the engine from overheating. YES : Go to Step 2 .
• If the system voltage is continuously supplied to NO : Replace the fan control relay. Then go to
the cooling fan motor drive control unit by a fan Step 8 .
motor relay malfunction and a short circuit on the
cooling fan motor drive control unit power supply STEP 2. Check the fan control relay connector
wiring harness, the cooling fan motor (L.H.) and A-09X.
the cooling fan motor (R.H.) <4G1 (Vehicles with
Connector: A-09X Relay box
A/C)>, or the A/C condenser fan motor <4G6>
rotate.
• The cause could also be a malfunction of the
cooling fan motor (L.H.). <Vehicles without A/C> Fan control relay
• The cause could also be a malfunction of input
signal from the A/C switch, the water temperature
sensor unit and the vehicle speed sensor <M/T> A-09X
or the output shaft speed sensor <A/T> to the
engine-ECU <M/T or engine-A/T-ECU <A/T>.
AC303510AB
• The cause could also be a malfunction of the
cooling fan motor drive control unit or the Q: Is the connector in good condition?
engine-ECU <M/T> or engine-A/T-ECU <A/T>. YES : Go to Step 3 .
NO : Repair the connector or replace the relay
box. Then go to Step 8 .
 ENGINE COOLING
TROUBLESHOOTING
14-17

STEP 3. Check the harness wire between fan STEP 4. Check the cooling fan motor drive
control relay connector A-09X terminal 2 and control unit connector A-18, intermediate
cooling fan motor drive control unit connector connector A-13 <L.H. drive vehicles> or C-111
A-18 terminal 3. <R.H. drive vehicles> and engine-ECU connector
Connector: A-09X Relay box C-123 <M/T> or engine-A/T-ECU connector C-122
<A/T>.
Connector: A-18

Fan control relay

A-09X

A-18
AC303510AB
3 2 1

Connector: A-18
AC100293 AD

Connector: A-13 <L.H. drive vehicles>

A-18
A-13
3 2 1

A-13
AC100293 AD

Q: Is the harness wire in good condition? AC303526 AB

YES : Go to Step 4 .
NO : Repair the damaged harness wire. Then go Connector: C-111 <R.H. drive vehicles>
to Step 8 .

C-111

C-111
1 2 3 4 5
6 7 8 9 10 11 12
AC303527AB
14-18 ENGINE COOLING
TROUBLESHOOTING

Connector: C-123 <M/T>, C-122 <A/T> STEP 5. Check the harness wire between cooling
Engine-ECU <M/T> or fan motor drive control unit connector A-18
engine-A/T-ECU <A/T> terminal 2 and engine-ECU connector C-123
terminal 21 <M/T> or engine-A/T-ECU connector
C-122 terminal 18 <A/T>.
Connector: A-18

C-123 <M/T>
or
C-122 <A/T>

A-18
C-123 <M/T>
3 2 1

AC100293 AD

Connector: C-123 <M/T>, C-122 <A/T>

C-122 <A/T>
Engine-ECU <M/T> or
engine-A/T-ECU <A/T>

AC303555AB

Q: Are these connectors in good condition?

YES : Go to Step 5 .
NO : Repair or replace the connector. Then go to C-123 <M/T>
Step 8 . or
C-122 <A/T>

C-123 <M/T>

C-122 <A/T>

AC303555AB

Q: Are these harness wires in good condition?

YES : Go to Step 6 .
NO : Repair the damaged harness wire. Then go
to Step 8 .
 ENGINE COOLING
TROUBLESHOOTING
14-19

STEP 6. Check the cooling fan motor drive (5) Check for the cooling fan operation.
• The cooling fan rotates. (with connector
control unit.
terminal pin 21 <M/T> or 18 <A/T>
Connector: C-123 <M/T>, C-122 <A/T> disconnected)
Engine-ECU <M/T> or • The cooling fan stops. (When connector
engine-A/T-ECU <A/T>
terminal pin 21 <M/T> or 18 <A/T> is
connected to the body earth.)
(6) Turn the ignition switch to the "OFF" position.
(7) Disconnect engine-ECU connector C-123 <M/T>
or engine-A/T-ECU connector C-122 <A/T>, and
push in connector terminal pin 21 <M/T> or 18
C-123 <M/T> <A/T> to disconnect connector.
or
C-122 <A/T> (8) Reconnect the connector with connector terminal
pin still installed.
Q: Does the cooling fan rotate? And when the
C-123 <M/T> connector terminal pin is connected to the body
earth, does the cooling fan stop?
YES : Go to Step 7 .
NO : Replace the cooling fan motor drive control
C-122 <A/T>
unit (Refer to P.14-35). Then go to Step 8 .

STEP 7. MUT-II/III self-diag code

AC303555AB
Check if an MPI system self-diag code is set. (Refer
to GROUP 13A - Trouble shooting P.13A-9) <4G1>
(1) Disconnect engine-ECU connector C-123 <M/T> or (Refer to GROUP 13B - Trouble shooting
or engine-A/T-ECU connector C-122 <A/T>. P.13B-9) <4G6>.
Q: Diagnosis code set?
C-123 connector <M/T> YES : Inspection chart for diagnosis code (Refer
(Harness side connector: ECU side view)
to GROUP 13A - Trouble shooting
P.13A-15) <4G1> or Inspection chart for
diagnosis code (Refer to GROUP 13B -
C-122 connector <A/T> Trouble shooting P.13B-15) <4G6>.
(Harness side connector: ECU side view) NO : Replace the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (Refer to GROUP
13A P.13A-401). Then go to Step 8 .
AC303559 AB

(2) Pull out connector terminal pin 21 <M/T> or 18 STEP 8. Check the symptoms.
<A/T> to disconnect connector.
(3) Reconnect the connector with connector terminal Q: Does the cooling fan motor (L.H.) and the cooling
fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C
pin still removed.
condenser fan motor <4G6> operate correctly?
(4) Turn the ignition switch to the "ON" position. YES : This symptoms is complete.
NO : Return to Step 1 .
14-20 ENGINE COOLING
TROUBLESHOOTING

INSPECTION PROCEDURE 3: Cooling Fan (L.H.) does not Operate {When Cooling Fan (R.H.) <4G1> or
A/C Condenser Fan <4G6> Operate} <Vehicles with A/C>

COOLING FAN (L.H.) AND COOLING FAN STEP 2. Check the cooling fan motor drive
(R.H.) OR A/C CONDENSER FAN DRIVE control unit.
CIRCUIT Refer to P.14-23.
Refer to P.14-6. Q: Is the cooling fan motor drive control unit in good
condition?
CIRCUIT OPERATION YES : Go to Step 3 .
Refer to P.14-6. NO : Replace the cooling fan motor drive control
unit (Refer to P.14-35). Then go to Step 3 .
TECHNICAL DESCRIPTION
The cause could be a malfunction of the cooling fan
STEP 3. Check the symptoms.
motor (L.H.) or cooling fan motor drive control unit.
Q: Do the cooling fan (L.H.) operate (when the cooling
TROUBLESHOOTING HINTS fan (R.H.) <4G1> or A/C condenser fan <4G6>
• Malfunction of cooling fan motor (L.H.) operate)?
YES : This symptoms is complete.
• Malfunction of cooling fan motor drive control unit
NO : Return to Step 1 .

DIAGNOSIS

STEP 1. Check the cooling fan motor (L.H.).

Refer to P.14-25.
Q: Is the cooling fan motor (L.H.) in good condition?
YES : Go to Step 2 .
NO : Replace the cooling fan motor (L.H.) (Refer
to P.14-35). Then go to Step 3 .
 ENGINE COOLING
TROUBLESHOOTING
14-21

INSPECTION PROCEDURE 4: Cooling Fan (R.H.) <4G1> or A/C Condenser Fan <4G6> does not
Operate {When Cooling Fan (L.H.) Operate} <Vehicles with A/C>

COOLING FAN (L.H.) AND COOLING FAN DIAGNOSIS

(R.H.) OR A/C CONDENSER FAN DRIVE
CIRCUIT STEP 1. Check the cooling fan motor (R.H.)
Refer to P.14-6. <4G1> or A/C condenser fan motor <4G6>.
Cooling fan motor (R.H.) check. (Refer to P.14-25)
CIRCUIT OPERATION <4G1>.
Refer to P.14-6. A/C condenser fan motor check. (Refer to GROUP
55 P.55-97) <4G6>.
TECHNICAL DESCRIPTION
Q: Is the cooling fan motor (R.H.) <4G1> or A/C
The cause could be a malfunction of the cooling fan condenser fan motor <4G6> in good condition?
motor (R.H.) <4G1> or A/C condenser fan motor YES : Go to Step 2 .
<4G6> or cooling fan motor drive control unit. NO : Replace the cooling fan motor (R.H.) (Refer
to P.14-35) <4G1> or A/C condenser fan
TROUBLESHOOTING HINTS motor (Refer to GROUP 55 P.55-96)
• Malfunction of cooling fan motor (R.H.) <4G1> or <4G6>. Then go to Step 3 .
A/C condenser fan motor <4G6>
• Malfunction of cooling fan motor drive control unit
STEP 2. Check the cooling fan motor drive
control unit.
Refer to P.14-23.
Q: Is the cooling fan motor drive control unit in good
condition?
YES : Go to Step 3 .
NO : Replace the cooling fan motor drive control
unit (Refer to P.14-35). Then go to Step 3 .

STEP 3. Check the symptoms.

Q: Do the cooling fan (R.H.) <4G1> or A/C condenser
fan <4G6> operate (when the cooling fan (L.H.)
operate)?
YES : This symptoms is complete.
NO : Return to Step 1 .
14-22 ENGINE COOLING
ON-VEHICLE SERVICE

ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK 2. Increase the pressure until the indicator of the
M1141001000300 gauge stops moving.
WARNING Minimum limit: 83 kPa
When pressure testing the cooling system, Standard value: 93 − 123 kPa
slowly release cooling system pressure to
3. Replace the radiator cap if the reading does not
avoid getting burned by hot coolant.
remain at or above the limit.
CAUTION
• Be sure to completely clean away any ENGINE COOLANT REPLACEMENT
moisture from the places checked. M1141001200434

• When the tester is taken out, be careful not to WARNING

spill any coolant. When removing the radiator cap, use care to
• Be careful when installing and removing the avoid contact with hot coolant or steam.
tester and when testing not to deform the Place a shop towel over the cap and turn the
filler neck of the radiator. cap counterclockwise a little to let the
pressure escape through the vinyl tube.
After relieving the steam pressure, remove
Cap adapter the cap by slowly turning it
counterclockwise.
Adapter
1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug
and removing the radiator cap.
<4G1>
Inlet side
ACX01844 AC

1. Check that the coolant level is up to the filler neck.

Install a radiator tester and apply 160 kPa
Cylinder block
pressure, and then check for leakage from the drain plug
radiator hose or connections.
2. If there is leakage, repair or replace the
appropriate part. AC208283 AC

RADIATOR CAP VALVE OPENING <4G6>

PRESSURE CHECK Inlet side
M1141001300389
NOTE: Be sure that the cap is clean before
testing. Rust or other foreign material on the cap
seal will cause an improper reading.

Cylinder block
drain plug
Cap adapter
AC303355 AB

2. Drain the water in the water jacket by unplugging

the drain plug of the cylinder block.
3. Remove the radiator condenser tank and drain
the coolant.
AC211643 AB 4. Drain the coolant then clean the path of the
coolant by injecting water into the radiator from
1. Use a cap adapter to attach the cap to the tester. the radiator cap area.
 ENGINE COOLING
ON-VEHICLE SERVICE
14-23
9. Reinstall the radiator cap.
Cylinder block 10.Start the engine and let it warm up until the
drain plug
thermostat opens.
11.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
12.Remove the radiator cap after the engine has
become cold, and pour in coolant up to the brim.
Reinstall the cap.

AC200625 AC
CAUTION
Do not overfill the radiator condenser tank.
5. Apply the designated sealant to the screw area of 13.Add coolant to the radiator condenser tank
the cylinder block drain plug, and then tighten to between the "F" and "L" mark if necessary.
the standard torque.
Specified sealant: 3M Nut Locking Part CONCENTRATION MEASUREMENT
No.4171 or equivalent M1141001100352
Measure the temperature and specific gravity of the
Tightening torque:
engine coolant to check the antifreeze concentration.
40 ± 5 N⋅m <4G1>
44 ± 5 N⋅m <4G6> Standard value: 30 − 60% (allowable
concentration range)
6. Securely tighten the drain plug of the radiator.
Recommended antifreeze: DIAQUEEN SUPER
7. Reinstall the radiator condenser tank. LONG LIFE COOLANT or equivalent
CAUTION
CAUTION
Do not use alcohol or methanol anti-freeze or any
If the concentration of the anti-freeze is below
engine coolants mixed with alcohol or methanol
30%, the anti-corrosion property will be
anti-freeze. The use of an improper anti-freeze
adversely affected. In addition, if the
can cause corrosion of the aluminium
concentration is above 60%, both the
components.
anti-freezing and engine cooling properties will
MB991871 decrease, affecting the engine adversely. For
these reasons, be sure to maintain the
concentration level within the specified range.

COOLING FAN MOTOR DRIVE CONTROL

UNIT CHECK
M1141006100216
1. Remove the cooling fan motor drive control unit
AIR HOSE connector.
AC303612AB CoolingY1716AU
fan motor
drive control unit
8. By referring to the section on coolant, select an
appropriate concentration for safe operating
temperature within the range of 30 to 60%. Use 3 2 1
special tool LLC changer (MB991871) to refill the
coolant. A convenient mixture is a 50% water and
50% antifreeze solution (freezing point: −31°C).
Recommended antifreeze: DIAQUEEN SUPER
LONG LIFE COOLANT or equivalent
AC103195 AC
Quantity:
5.0 L <4G1> 2. Turn the ignition switch to the "ON" position, and
7.0 L <4G6> measure the voltage between terminal 1 and 3 at
NOTE: For how to use special tool MB991871, the harness side connector.
refer to its manufacturer’s instructions. Standard value: system voltage
14-24 ENGINE COOLING
ON-VEHICLE SERVICE

3. Connect the cooling fan motor drive control unit FAN CONTROL RELAY CONTINUITY
connector, and disconnect the cooling fan motor CHECK
(L.H.) connector. M1141006200280

4. Ensure that the A/C switch is off, and start the

engine and run it at idle. Fan control relay
Cooling fan motor
drive control unit

AC211776

AC303496AB

5. Measure the voltage between the cooling fan

motor drive control unit side connector terminal 1 2 4
and 2. 2
1 3
Standard value: 1V or less 4 3 1
WARNING
Stay clear of the fan when the fan starts
running. AC301712 AB

6. Turn the A/C switch to the "ON" position.

Battery Terminal No.to Continuity test
7. Measure the voltage between the cooling fan voltage be connected to results
motor drive control unit side connector terminal 1 tester
and 2 while the fan is running. The voltage should
repeat the values below. Not applied 4−2 Open circuit
Standard value: Connect 4−2 Less than 2 ohms
1. 1 V or less terminal
No.1 and
2. 8.2 ± 0.7 V
battery (−)
3. System voltage ± 2.6 V
terminal.
8. If the voltage does not repeatedly change as Connect
indicated, replace the cooling fan motor drive terminal
control unit. (Refer to P.14-35). No.3 and
battery (+)
terminal.
 ENGINE COOLING
ON-VEHICLE SERVICE
14-25
COOLING FAN MOTOR CHECK 1. Remove the cooling fan motor connector.
M1141007100060
2. Check to see that the cooling fan motor of the
Cooling fan motor drive control unit radiator turns when applying battery power
between the connector terminal 1 and 2 of the
cooling fan motor. Also check to see that there is
no abnormal sound coming from the cooling fan
2 1 motor at this time.
3. If the cooling fan motor is defective, replace it.
(Refer to P.14-35).
Cooling fan motor
(L.H.) connector
AC303501AB

Cooling fan motor

Cooling fan motor (R.H.) connector
drive control unit <4G1 with A/C>

2 1

AC303502AB
14-26 ENGINE COOLING
THERMOSTAT

THERMOSTAT
REMOVAL AND INSTALLATION
M1141002400442

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).
• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
• Battery Removal and Installation

<4G1>

22 ± 4 N·m

7
6
3

AC203409AC

<4G6>

7 5

1
13 ± 2 N·m
2 6
3 AC301429 AD
 ENGINE COOLING
THERMOSTAT
14-27
Removal steps Removal steps (Continued)
1. Water temperature gauge unit 4. Engine control oxygen sensor
connector <4G6> connector and connector bracket
2. Water temperature sensor unit <4G1>
connector <4G6> 5. Control wiring harness clip <4G6>
<<A>> >B<< 3. Radiator lower hose connection 6. Cooling water inlet hose fitting
>>A<< 7. Thermostat

REMOVAL SERVICE POINT >>B<< RADIATOR LOWER HOSE

<<A>> RADIATOR LOWER HOSE CONNECTION
DISCONNECTION
Projection

Cooling water inlet Mating marks

Mating marks hse fitting
AC200642 AH

AC200641AC
1. Insert radiator lower hose as far as the projection
Make mating marks on the radiator lower hose and of the Cooling water inlet hose fitting.
the hose clamp. Disconnect the radiator lower hose. 2. Align the mating marks on the radiator lower hose
and hose clamp, and then connect the radiator
INSTALLATION SERVICE POINTS lower hose.
>>A<< THERMOSTAT INSTALLATION
INSPECTION
CAUTION M1141002500427

Make absolutely sure that no oil adheres to the THERMOSTAT CHECK

rubber ring of the thermostat. Also do not fold or
scratch the rubber ring during installation.

Jiggle valve

ACX00400AB
Rubber ring
AC000279 AB 1. Immerse the thermostat in water, and heat the
water while stirring. Check the thermostat valve
Install the thermostat so that the jiggle valve is facing opening temperature.
straight up. Be careful not to fold or scratch the
Standard value:
rubber ring.
88 ± 1.5°C <4G1>
82 ± 1.5°C <4G6>
14-28 ENGINE COOLING
THERMOSTAT

2. Check that the amount of valve lift is at the

standard value when the water is at the
full-opening temperature.
NOTE: Measure the valve height when the
thermostat is fully closed, and use this
measurement to compare the valve height when
the thermostat is fully open.
Valve lift
Standard value:
100°C <4G1>
ACX00401AC 95°C <4G6>
Amount of valve lift: 8.5 mm or more
 ENGINE COOLING
WATER PUMP
14-29
WATER PUMP
REMOVAL AND INSTALLATION <4G1>
M1141002700421

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).
• Valve Timing Belt Removal and Installation (Refer to
GROUP 11A P.11A-33).

Bolt specifications

8 × 50 8 × 25

2
1
8 × 30
2 Screw diameter × length mm
23 ± 2 N·m

24 ± 3 N·m

Sealant: Mitsubishi Genuine Part

No. MD970389 or equivalent
14 ± 1 N·m
AC303372 AB

Removal steps
1. Alternator adjusting brace
>>A<< 2. Water pump assembly

INSTALLATION SERVICE POINT 2. Apply a bead of the specified sealant.

>>A<< WATER PUMP ASSEMBLY Specified Sealant: MITSUBISHI GENUINE
INSTALLATION PART No.MD970389 or equivalent
1. Use a gasket scraper or wire brush to completely 3. With the sealant still wet (within 15 minutes after
eliminate all gasket material on the gasket the sealant is applied), install the water pump
mounting surface. assembly. Do not apply the sealant in an area
more than the required.
14-30 ENGINE COOLING
WATER PUMP

REMOVAL AND INSTALLATION <4G6>

M1141002700432

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).
• Valve Timing Belt and Balancer Timing Belt Removal and
Installation (Refer to GROUP 11C P.11C-35).

N4
2
1

22 ± 4 N·m Bolt specifications

8 × 70 8 × 22

2
3N 8 × 14

23 ± 3 N·m 14 ± 1 N·m 8 × 25
8 × 22
Screw diameter × length mm
AC301467AB

Removal steps Removal steps (Continued)

1. Alternator adjusting brace 3. Water pump gasket
2. Water pump assembly >>A<< 4. Cooling water line O-ring

INSTALLATION SERVICE POINT Fit the cooling water line O-ring to the groove in the
water pump inlet pipe. Then lubricate the cooling
>>A<< COOLING WATER LINE O-RING
water line O-ring and the inside of the water pump
INSTALLATION assembly with water, and then insert the water pump
inlet pipe to the water pump assembly.
Water pump assembly

Cooling water
line O-ring

Water pump inlet pipe

AC103005 AF
 ENGINE COOLING
WATER HOSE AND WATER PIPE
14-31
WATER HOSE AND WATER PIPE
REMOVAL AND INSTALLATION <4G1>
M1141003300415

Pre-removal and Post-installation Operation

• Under Cover Removal and Installation
• Engine Coolant Draining and Supplying (Refer to
P.14-22).
• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
• Thermostat Removal and Installation (Refer to P.14-26).

23 ± 4 N·m
3 4

7N 13 N
2
13 ± 2 N·m
6

1 12

N8

9 13 ± 2 N·m

10
5

11
AC203411AC

Removal steps Removal steps (Continued)

1. Water temperature sensor unit 7. Thermostat case gasket
connector >>A<< 8. Cooling water line O-ring
2. Water temperature gauge unit 9. Control wiring harness clamp
connector 10. Throttle body water return hose
3. Control wiring harness and harness 11. Heater water hose connection
bracket 12. Water pump inlet pipe
<<A>> >>B<< 4. Radiator upper hose connection >>A<< 13. Cooling water line O-ring
5. Throttle body water feed hose
6. Thermostat case assembly
14-32 ENGINE COOLING
WATER HOSE AND WATER PIPE

REMOVAL SERVICE POINT >>B<< RADIATOR UPPER HOSE

<<A>> RADIATOR UPPER HOSE CONNECTION
DISCONNECTION
Projection Radiator upper
hose

Mating marks
Mating marks Thermostat case assembly
AC200642 AI

AC200641AC
1. Insert radiator upper hose as far as the projection
After making mating marks on the radiator upper of the thermostat case assembly.
hose and hose clamp, disconnect the radiator upper 2. Align the mating marks on the radiator upper hose
hose. and hose clamp, and then connect the radiator
upper hose.
INSTALLATION SERVICE POINTS
>>A<< COOLING WATER LINE O-RING
INSTALLATION
CAUTION
Water pump or thermostat case

Cooling water
line O-ring

Water pump inlet pipe

AC200644 AD

Do not allow engine oil or other grease to adhere

to the O-ring
Insert the cooling water line O-ring to the water pump
inlet pipe, and coat the outer portion of the cooling
water line O-ring with water or engine coolant.
 ENGINE COOLING
WATER HOSE AND WATER PIPE
14-33
REMOVAL AND INSTALLATION <4G6>
M1141003300426

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Supplying (Refer to
P.14-22).
• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
• Thermostat Removal and Installation (Refer to P.14-26).

N 9
8
9N 13 ± 2 N·m

13 ± 2 N·m
2

23 ± 4 N·m
1 5

5
Ø3 mm

2 Ø3 mm

Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent

AC303471AB

Removal steps Removal steps (Continued)

<<A>> >>C<< 1. Radiator upper hose connection 7. Control wiring harness clamp
>>B<< 2. Cooling water outlet hose fitting 8. Water pump inlet pipe
3. Throttle body water return hose >>A<< 9. Cooling water line O-ring
4. Throttle body water feed hose
>>B<< 5. Thermostat case assembly
6. Heater water hose connection
14-34 ENGINE COOLING
WATER HOSE AND WATER PIPE

REMOVAL SERVICE POINT >>B<< THERMOSTAT CASE

<<A>> RADIATOR UPPER HOSE ASSEMBLY/COOLING WATER OUTLET
DISCONNECTION HOSE FITTING INSTALLATION
1. Use a gasket scraper or wire brush to completely
eliminate all gasket material on the gasket
mounting surface.
2. Apply a bead of the specified sealant.
Specified Sealant: MITSUBISHI GENUINE
PART No.MD970389 or equivalent

Mating marks
3. With the sealant still wet (within 15 minutes after
the sealant is applied), install the thermostat case
assembly or cooling water outlet hose fitting. Do
AC200641AC
not apply the sealant in an area more than the
After making mating marks on the radiator upper required.
hose and hose clamp, disconnect the radiator upper
hose. >>C<< RADIATOR UPPER HOSE
CONNECTION
INSTALLATION SERVICE POINTS
>>A<< COOLING WATER LINE O-RING Projection Radiator upper
INSTALLATION hose

CAUTION
Water pump or thermostat case

Mating marks
Cooling water outlet
O-ring hose fitting AC200642 AJ

1. Insert radiator upper hose as far as the projection

of the cooling water outlet hose fitting.
Water inlet pipe 2. Align the mating marks on the radiator upper hose
AC200644 AC
and hose clamp, and then connect the radiator
Do not allow engine oil or other grease to adhere upper hose.
to the cooling water line O-ring
Insert the cooling water line O-ring to the water pump INSPECTION
M1141003400296
water inlet pipe, and coat the outer portion of the
cooling water line O-ring with water or engine WATER PUMP INLET PIPE AND
coolant. THROTTLE BODY WATER HOSES
CHECK
Check the water pipe and hoses for cracks, damage
and clogs. Replace them if necessary.
 ENGINE COOLING
RADIATOR
14-35
RADIATOR
REMOVAL AND INSTALLATION
M1141001500468

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Supplying (Refer to
P.14-22).
• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).

<4G1 (Vehicles without A/C)>

12 ± 2 N·m

12 ± 2 N·m 2 9
9
3 14
4 5
12

20
10 1
10

15
18
17
6 7
AC303472 AB
14-36 ENGINE COOLING
RADIATOR

<4G1 (Vehicles with A/C)> 12 ± 2 N·m 12

12 ± 2 N·m 2 9
9
14
3 16
5
4
20
15
1
10

8
10

11 19
17
18
6 7
AC303473AB

<4G6> 12 ± 2 N·m

12 ± 2 N·m 2 9 12
9
3 14
4 5 15

1
10 10 20
13

17
6 18
7 AC303474AB

Radiator removal steps Radiator removal steps

1. Drain plug 8. T/M oil cooler line hose connection
2. Radiator cap <A/T>
3. Radiator condenser tank hose 9. Radiator support upper insulator
4. Radiator condenser tank assembly • Radiator and cooling fan motor &
<<A>> >>A<< 5. Radiator upper hose shroud assembly
<<A>> >>A<< 6. Radiator lower hose 10. Radiator support lower insulator
7. Cooling fan motor drive control unit 11. T/M oil cooler line hose <A/T>
connector
 ENGINE COOLING
RADIATOR
14-37
Radiator removal steps Cooling fan motor removal steps
12. Cooling fan motor & shroud (Continued)
assembly 12. Cooling fan motor & shroud
13. A/C condenser fan motor & shroud assembly
assembly <4G6> 15. Cooling fan (L.H.)
14. Radiator assembly 16. Cooling fan (R.H.) <4G1 (Vehicles
Cooling fan motor removal with A/C)>
steps 17. Cooling fan motor drive control unit
3. Radiator condenser tank hose 18. Cooling fan motor (L.H.)
<<A>> >>A<< 5. Radiator upper hose 19. Cooling fan (R.H.) motor <4G1
7. Cooling fan motor drive control unit (Vehicles with A/C)>
connector 20. Cooling fan shroud

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> RADIATOR UPPER >>A<< RADIATOR LOWER
HOSE/RADIATOR LOWER HOSE HOSE/RADIATOR UPPER HOSE
DISCONNECTION CONNECTION

Projection Radiator hose

Mating marks Mating marks

Cooling water hose fitting
AC200641AC or thermostat case assembly AC200642 AK

Make mating marks on the radiator hose and the 1. Insert radiator lower hose as far as the projection
hose clamp. Disconnect the radiator hoses. of the cooling water inlet hose fitting.
2. Insert radiator upper hose as far as the projection
of the thermostat case assembly <4G1> or the
cooling water outlet hose fitting <4G6>.
3. Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
NOTES
 15-1

GROUP 15

INTAKE AND
EXHAUST
CONTENTS

GENERAL INFORMATION . . . . . . . . 15-2 REMOVAL AND INSTALLATION <4G6> . . 15-6

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-7
SERVICE SPECIFICATION . . . . . . . . 15-2
EXHAUST MANIFOLD . . . . . . . . . . . . 15-7
SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-2 REMOVAL AND INSTALLATION <4G1> . . 15-7
REMOVAL AND INSTALLATION <4G6> . . 15-9
AIR CLEANER . . . . . . . . . . . . . . . . . . 15-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-10
REMOVAL AND INSTALLATION . . . . . . . . 15-3
EXHAUST PIPE AND MAIN
INLET MANIFOLD . . . . . . . . . . . . . . . 15-5 MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-11
REMOVAL AND INSTALLATION <4G1> . . 15-5 REMOVAL AND INSTALLATION . . . . . . . . 15-11
15-2 INTAKE AND EXHAUST
GENERAL INFORMATION

GENERAL INFORMATION
M1151000100402
The exhaust pipe is divided into three parts.

SERVICE SPECIFICATION
M1151000300428

Item Standard value Limit

Manifold distortion of the installation surface mm 0.15 or less 0.20

SPECIAL TOOL
M1151000600399

Tool Number Name Use

MD998770 Oxygen sensor wrench Removal and installation of
engine control oxygen sensor
 INTAKE AND EXHAUST
AIR CLEANER
15-3
AIR CLEANER
REMOVAL AND INSTALLATION
M1151002100486

CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
• Avoid any shock or load to these parts when removing and installing them.
• When installing, securely set the air cleaner cover clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws.

<4G1> 4
4.0 ± 1.0 N·m

5
3*

10* 9* 8*
4.0 ± 1.0 N·m
9.0 ± 1.0 N·m

1*

Clamp

12 ± 1 N·m 9.0 ± 1.0 N·m

12 ± 1 N·m
11
AC303618 AB
15-4 INTAKE AND EXHAUST
AIR CLEANER

<4G6> 4
5
4.0 ± 1.0 N·m
3*

10* 9* 8* N 7 6
4.0 ± 1.0 N·m

9.0 ± 1.0 N·m

2

1*

8.8 ± 1.0 N·m

Clamp

12 ± 1 N·m 9.0 ± 1.0 N·m

12 ± 1 N·m
11
AC303619 AB

Removal steps Removal steps (Continued)

1. Air cleaner intake duct 6. Air cleaner air flow sensor <4G6>
2. Air cleaner air flow sensor connector 7. Air cleaner air flow sensor gasket
<4G6> <4G6>
3. Air cleaner assembly <4G1> or Air 8. Air cleaner cover
cleaner and air cleaner air flow sensor 9. Air cleaner element
assembly <4G6> 10. Air cleaner body assembly
4. Rocker cover breather hose 11. Air cleaner bracket
connection
5. Air cleaner to throttle body duct
 INTAKE AND EXHAUST
INLET MANIFOLD
15-5
INLET MANIFOLD
REMOVAL AND INSTALLATION <4G1>
M1151003000749

Pre-removal Operation Post-installation Operation

• Fuel Line Pressure Reduction (Refer to GROUP 13A - • Fuel Delivery Pipe and Fuel Injector Assembly Installation
On-vehicle Service P.13A-389). (Refer to GROUP 13A P.13A-398).
• Engine Coolant Draining (Refer to GROUP 14 - • Throttle Body Assembly Installation (Refer to GROUP
On-vehicle Service P.14-22). 13A P.13A-400).
• Strut Tower Bar Removal (Refer to GROUP 42 P.42-9). • Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
• Throttle Body Assembly Removal (Refer to GROUP 13A • Engine Coolant Supplying (Refer to GROUP 14 -
P.13A-400). On-vehicle Service P.14-22).
• Fuel Delivery Pipe and Fuel Injector Assembly Removal • Accelerator Cable Adjustment (Refer to GROUP 17 -
(Refer to GROUP 13A P.13A-398). On-vehicle Service P.17-2).
• Fuel Leak Check
21 ± 4 N·m
9.0 ± 1.0 N·m
13 7 1
N 14 N2 5.0 ± 1.0 N·m
9 11

8 18 ± 2 N·m

15 10
9.0 ± 1.0 N·m

12 N
18 ± 2 N·m

3
6
5

18 ± 2 N·m

31 ± 3 N·m

49 ± 9 N·m

4
AC303642AB
Removal steps Removal steps (Continued)
1. Inlet manifold absolute pressure 8. Emission control equip hose
sensor connection
2. Engine control pressure sensor 9. Fuel vapour control hose
O-ring connection
3. Engine control detonation sensor 10. Inlet manifold stay
connector 11. Inlet manifold
4. T/M housing front lower cover stay 12. Inlet manifold gasket
(L.H.) 13. EGR valve
5. Battery wiring harness clamp 14. EGR valve gasket
connection 15. Emission vacuum hose & pipe and
6. Inlet manifold stay emission solenoid valve assembly
7. Brake booster vacuum hose
connection
15-6 INTAKE AND EXHAUST
INLET MANIFOLD

REMOVAL AND INSTALLATION <4G6>

M1151003001236

Pre-removal Operation Post-installation Operation

• Fuel Line Pressure Reduction (Refer to GROUP 13A - • Fuel Delivery Pipe and Fuel Injector Assembly Installation
On-vehicle Service P.13A-389). (Refer to GROUP 13B P.13B-334).
• Engine Coolant Draining (Refer to GROUP 14 - • Throttle Body Assembly Installation (Refer to GROUP
On-vehicle Service P.14-22). 13B P.13B-336).
• Strut Tower Bar Removal (Refer to GROUP 42 P.42-9). • Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
• Throttle Body Assembly Removal (Refer to GROUP 13B • Engine Coolant Supplying (Refer to GROUP 14 -
P.13B-336). On-vehicle Service P.14-22).
• Fuel Delivery Pipe and Fuel Injector Assembly Removal • Accelerator Cable Adjustment (Refer to GROUP 17 -
(Refer to GROUP 13B P.13B-334). On-vehicle Service P.17-2).
• Fuel Leak Check

11 ± 1 N·m

12
7
5.0 ± 1.0 N·m

2 9.0 ± 1.0 N·m

20 ± 2 N·m
3 36 ± 6 N·m

5 11 ± 1 N·m
20 ± 2 N·m

4 36 ± 6 N·m

13
36 ± 6 N·m 14 N 1
11 N

13 ± 1 N·m

20 ± 2 N·m
10

N6 8

(Engine oil) 9

31 ± 3 N·m
AC303657AB

Removal steps Removal steps (Continued)

1. Emission control equip hose 4. Engine control detonation sensor
connector connector
2. Brake booster vacuum hose 5. Engine oil level gauge and guide
connection assembly
3. Earth cable connection 6. Engine oil filler O-ring
7. Emission vacuum hose connection
 INTAKE AND EXHAUST
EXHAUST MANIFOLD
15-7
Removal steps (Continued)
8. Battery wiring harness clamp
9. Inlet manifold stay
10. Inlet manifold
11. Inlet manifold gasket
12. Emission vacuum hose & pipe and
emission solenoid valve assembly
13. EGR valve
14. EGR valve gasket

INSPECTION 2. Clogging of the negative pressure (vacuum) outlet

M1151003100616 port, or clogging of the exhaust gas recirculation
Check the following points; replace the part if a passages.
problem is found.
3. Using a straight edge and feeler gauge, check for
Inlet Manifold Check distortion of the cylinder head installation surface.
1. Check for damage or cracking of any part. Standard value: 0.15 mm or less
Limit: 0.20 mm

EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <4G1>
M1151003300568

29 ± 3 N·m

6 3
29 ± 3 N·m

44 ± 5 N·m

N9 17 ± 2 N·m

29 ± 3 N·m

29 ± 3 N·m
4 8
24 ± 4 N·m

N5 7
2N
(Engine oil)

35 ± 6 N·m
1
50 ± 10 N·m AC303662 AB
15-8 INTAKE AND EXHAUST
EXHAUST MANIFOLD

Removal steps Removal steps (Continued)

1. Front exhaust pipe connection 6. Exhaust manifold cover
2. Exhaust pipe gasket 7. Exhaust manifold bracket
<<A>> >>A<< 3. Engine control oxygen sensor (front) 8. Exhaust manifold
4. Engine oil level gauge and guide 9. Exhaust manifold gasket
assembly
5. Engine oil filler O-ring

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> ENGINE CONTROL OXYGEN >>A<< ENGINE CONTROL OXYGEN
SENSOR (FRONT) REMOVAL SENSOR (FRONT) INSTALLATION

MD998770 MD998770

Engine control Engine control

oxygen sensor oxygen sensor
(front) (front)
AC212566AC AC212566AC

Use special tool oxygen sensor wrench (MD998770) Use special tool oxygen sensor wrench (MD998770)
to remove the engine control oxygen sensor (front). to install the engine control oxygen sensor (front).
 INTAKE AND EXHAUST
EXHAUST MANIFOLD
15-9
REMOVAL AND INSTALLATION <4G6>
M1151003300579

Pre-removal and Post-installation Operation

Under cover Removal and Installation

10 N
49 ± 5 N·m
9
29 ± 3 N·m
3
14 ± 1 N·m

29 ± 3 N·m
49 ± 9 N·m 8
44 ± 5 N·m

7
5
6 35 ± 6 N·m 14 ± 1 N·m
49 ± 5 N·m
9.0 ± 2.0 N·m 4
44 ± 5 N·m 2N

1
50 ± 10 N·m AC303680 AB

Removal steps Removal steps (Continued)

1. Front exhaust pipe connection 6. Starter cover
2. Exhaust pipe gasket 7. Starter cover bracket
<<A>> >>A<< 3. Engine control oxygen sensor (front) 8. Engine hanger
4. Exhaust manifold cover 9. Exhaust manifold
5. Exhaust manifold bracket 10. Exhaust manifold gasket
15-10 INTAKE AND EXHAUST
EXHAUST MANIFOLD

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> ENGINE CONTROL OXYGEN >>A<< ENGINE CONTROL OXYGEN
SENSOR (FRONT) REMOVAL SENSOR (FRONT) INSTALLATION

MD998770 MD998770

Engine control Engine control

oxygen sensor oxygen sensor
(front) (front)
AC212566AC AC212566AC

Use special tool oxygen sensor wrench (MD998770) Use special tool oxygen sensor wrench (MD998770)
to remove the engine control oxygen sensor (front). to install the engine control oxygen sensor (front).

INSPECTION 2. Using a straight edge and a feeler gauge, check

M1151003400543 for distortion of the cylinder head installation
Check the following points; replace the part if a surface.
problem is found.
Standard value: 0.15 mm or less
Exhaust Manifold Check Limit: 0.20 mm
1. Check for damage or cracking of any part.
 INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER
15-11
EXHAUST PIPE AND MAIN MUFFLER
REMOVAL AND INSTALLATION
M1151008700301

<4G1> 13 ± 2 N·m 4 13 ± 2 N·m

N 3
45 ± 5 N·m
9 1
2
5 4
N8
6
45 ± 5 N·m

59 ± 10 N·m
7N
50 ± 10 N·m 9 AC303694AB

<4G6> 13 ± 2 N·m 4 13 ± 2 N·m

N 3
45 ± 5 N·m
9 1
2
5 4
N8
6
45 ± 5 N·m

59 ± 10 N·m
7N

50 ± 10 N·m 9 AC303695AB

Exhaust main muffler removal Front exhaust pipe removal

steps steps
1. Exhaust main muffler <<A>> >>A<< 5. Engine control oxygen sensor
3. Exhaust pipe gasket (rear)
4. Exhaust muffler hanger 6. Front exhaust pipe
Centre exhaust pipe removal 7. Exhaust pipe gasket
steps 8. Exhaust pipe gasket
2. Centre exhaust pipe 9. Exhaust muffler hanger
3. Exhaust pipe gasket
7. Exhaust pipe gasket
15-12 INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> ENGINE CONTROL OXYGEN >>A<< ENGINE CONTROL OXYGEN
SENSOR (REAR) REMOVAL SENSOR (REAR) INSTALLATION

MD998770 MD998770

Engine control Engine control

oxygen sensor oxygen sensor
(rear) (rear)
AC212566AD AC212566AD

Use special tool oxygen sensor wrench (MD998770) Use special tool oxygen sensor wrench (MD998770)
to remove the engine control oxygen sensor (rear). to install the engine control oxygen sensor (rear).
 16-1

GROUP 16

ENGINE
ELECTRICAL
CONTENTS

CHARGING SYSTEM . . . . . . . . 16-2 IGNITION SYSTEM . . . . . . . . . 16-30

GENERAL INFORMATION . . . . . . 16-2 GENERAL INFORMATION . . . . . . 16-30

SERVICE SPECIFICATIONS. . . . . 16-3 SERVICE SPECIFICATIONS . . . . . 16-31

SPECIAL TOOL . . . . . . . . . . . . . . . 16-3 SPECIAL TOOL . . . . . . . . . . . . . . . 16-31

ON-VEHICLE SERVICE. . . . . . . . . 16-3 ON-VEHICLE SERVICE . . . . . . . . . 16-32

ALTERNATOR OUTPUT LINE VOLTAGE IGNITION COIL (WITH BUILT-IN
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-3 POWER TRANSISTOR) CHECK . . . . . . 16-32
OUTPUT CURRENT TEST . . . . . . . . . . 16-5 RESISTIVE CORD CHECK . . . . . . . . . . 16-32
REGULATED VOLTAGE TEST . . . . . . . 16-7 SPARK PLUG CHECK AND
WAVEFORM CHECK USING AN CLEANING <4G1> . . . . . . . . . . . . . . . . . 16-32
OSCILLOSCOPE. . . . . . . . . . . . . . . . . . 16-9 SPARK PLUG CHECK AND
CLEANING <4G6> . . . . . . . . . . . . . . . . . 16-33
CAMSHAFT POSITION SENSOR
ALTERNATOR ASSEMBLY . . . . . 16-12 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-33
REMOVAL AND INSTALLATION CRANK ANGLE SENSOR CHECK . . . . 16-33
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12 DETONATION SENSOR CHECK . . . . . 16-33
REMOVAL AND INSTALLATION IGNITION SECONDARY VOLTAGE
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-13 WAVEFORM CHECK USING AN
DISASSEMBLY AND REASSEMBLY . . 16-15 OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-33
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17 IGNITION COIL RELAY CHECK . . . . . . 16-37

STARTING SYSTEM . . . . . . . . . 16-19 IGNITION COIL. . . . . . . . . . . . . . . . 16-38

REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-38
GENERAL INFORMATION . . . . . . 16-19 REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-39

SERVICE SPECIFICATIONS. . . . . 16-20

CAMSHAFT POSITION SENSOR . 16-40
REMOVAL AND INSTALLATION. . . . . . 16-40
STARTER MOTOR ASSEMBLY . . 16-21
REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR 16-41
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21 REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION <4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-41
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22 REMOVAL AND INSTALLATION
STARTER MOTOR ASSEMBLY <4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-23
DISASSEMBLY AND REASSEMBLY . . 16-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-27 DETONATION SENSOR . . . . . . . . 16-43
REMOVAL AND INSTALLATION. . . . . . 16-43
16-2 ENGINE ELECTRICAL
CHARGING SYSTEM

CHARGING SYSTEM
GENERAL INFORMATION
M1161000100522
The charging system uses the alternator output to The average output voltage fluctuates slightly with
keep the battery charged at a constant level under the alternator load condition.
various electrical loads. When the ignition switch is turned on, current flows in
OPERATION the field coil and initial excitation of the field coil
occurs.
Voltage
When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field
Approximately current increases and it falls as the field current
14.4 V decreases. When the battery voltage (alternator "S"
terminal voltage) reaches a regulated voltage of
approximately 14.4 V, the field current is cut off.
Time When the battery voltage drops below the regulated
AKX00183 AC voltage, the voltage regulator regulates the output
Rotation of the excited field coil generates AC voltage to a constant level by controlling the field
voltage in the stator. current.
This alternating current is rectified through diodes to In addition, when the field current is constant, the
DC voltage having a waveform shown in the alternator output voltage rises as the engine speed
illustration. increases.

SYSTEM DIAGRAM

Alternator

Stator coil
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
G

Field coil S
<4G1>
L
+

FR Ignition switch
Battery
Voltage regulator Charge warning light

AK400308 AB

ALTERNATOR SPECIFICATIONS
Item 4G1 4G6
Type Battery voltage sensing
Rated output V/A 12/80 12/110
Voltage regulator Electronic built-in type
 ENGINE ELECTRICAL 16-3
CHARGING SYSTEM

SERVICE SPECIFICATIONS
M1161000300258

Item Standard value Limit

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

SPECIAL TOOL
M1161000600163

Tool Number Name Use

MB991519 Alternator test harness Checking the alternator
("S" terminal voltage)

ON-VEHICLE SERVICE

ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

M1161000900346

Ammeter (clamp-type)

Alternator

Voltmeter (digital-type)

Battery
"B" terminal

AK203361AD

This test determines whether the wiring from the • Drive belt tension
alternator "B" terminal to the battery (+) terminal (Refer to GROUP 11A − On-vehicle Service
(including the fusible line) is in a good condition or <4G1> P.11A-7 or GROUP 11C − On-vehicle
not. Service <4G6> P.11C-7.)
1. Always be sure to check the following before the • Fusible link
test. • Abnormal noise from the alternator while the
• Alternator installation engine is running
16-4 ENGINE ELECTRICAL
CHARGING SYSTEM

2. Turn the ignition switch to the "LOCK" (OFF) Adjust the engine speed by gradually decreasing
position. it until the value displayed on the ammeter is 30
3. Disconnect the negative battery cable. A. Take a reading of the value displayed on the
4. Connect a clamp-type DC test ammeter with a voltmeter at this time.
range of 0 − 120 A to the alternator "B" terminal Limit: maximum 0.3 V
output wire. NOTE: When the alternator output is high and the
NOTE: The way of disconnecting the alternator value displayed on the ammeter does not
output wire and of connecting the ammeter is decrease until 30 A, set the value to 40 A. Read
possibly not found the problem that the output the value displayed on the voltmeter at this time.
current is dropping due to the insufficient When the value range is 40 A, the limit is
connection between terminal "B" and the output maximum 0.4 V.
wire. 11.If the value displayed on the voltmeter is above
5. Connect a digital-type voltmeter between the the limit value, there is probably a malfunction in
alternator "B" terminal and the battery (+) the alternator output wire, so check the wiring
terminal. [Connect the (+) lead of the voltmeter to between the alternator "B" terminal and the
the "B" terminal and the connect the (-) lead of the battery (+) terminal (including fusible link).
voltmeter to the battery (+) cable]. If a terminal is not sufficiently tight or if the
6. Reconnect the negative battery cable. harness has become discolored due to
7. Connect a tachometer or the MUT-II/III (Refer to overheating, repair and then test again.
GROUP 11A − On-vehicle Service − Idle speed 12.After the test, run the engine at idle.
check <4G1> P.11A-11 or GROUP 11C − 13.Turn off all lamps and the ignition switch.
On-vehicle Service − Idle speed check <4G6> 14.Remove the tachometer or the MUT-II/III.
P.11C-11).
15.Disconnect the negative battery cable.
8. Leave the hood open.
16.Disconnect the ammeter and voltmeter.
9. Start the engine.
17.Connect the negative battery cable.
10.With the engine running at 2,500 r/min, turn the
headlamps and other lamps on and off to adjust
the alternator load so that the value displayed on
the ammeter is slightly above 30 A.
 ENGINE ELECTRICAL 16-5
CHARGING SYSTEM

OUTPUT CURRENT TEST

M1161001000368

Load

Ammeter
Voltmeter (clamp-type)

– +

Inition switch Charging indicator

B
FR

Brake warning light L

S
G

Alternator
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
Battery

AK203362 AH

This test determines whether the alternator output CAUTION

current is normal. Never use clips but tighten bolts and nuts to
1. Before the test, always be sure to check the connect the line. Otherwise loose connections
following. (e.g. using clips) will lead to a serious accident
• Alternator installation because of high current.
• Battery (Refer to GROUP 54A − Battery − 4. Connect a clamp-type DC test ammeter with a
On-vehicle Service P.54A-5). range of 0 − 120 A to the alternator "B" terminal
NOTE: The battery should be slightly discharged. output wire.
The load needed by a fully-charged battery is NOTE: The way of disconnecting the alternator
insufficient for an accurate test. output wire and of connecting the ammeter is
• Drive belt tension possibly not found the problem that the output
(Refer to GROUP 11A − On-vehicle Service <4G1> current is dropping due to the insufficient
P.11A-7 or GROUP 11C − On-vehicle Service connection between terminal "B" and the output
<4G6> P.11C-7.) wire.
• Fusible link
5. Connect a voltmeter with a range of 0 − 20 V
• Abnormal noise from the alternator while the
between the alternator "B" terminal and the earth
engine is running.
[Connect the (+) lead of the voltmeter to the "B"
2. Turn the ignition switch to the "LOCK" (OFF) terminal, and then connect the (-) lead of the
position. voltmeter to the earth].
3. Disconnect the negative battery cable. 6. Connect the negative battery cable.
16-6 ENGINE ELECTRICAL
CHARGING SYSTEM

7. Connect a tachometer or the MUT-II/III (Refer to NOTE: .

GROUP 11A − On-vehicle Service − Idle speed • For the nominal current output, refer to the
check <4G1> P.11A-11 or GROUP 11C − Alternator Specifications.
On-vehicle Service − Idle speed check <4G6> • Because the current from the battery will soon
P.11C-11). drop after the engine is started, the above step
8. Leave the hood open. should be carried out as quickly as possible in
order to obtain the maximum current output
9. Check that the reading on the voltmeter is equal value.
to the battery voltage. • The current output value will depend on the
NOTE: If the voltage is 0 V, the cause is probably electrical load and the temperature of the
an open circuit in the wire or fusible link between alternator body.
the alternator "B" terminal and the battery (+) • If the electrical load is small while testing, the
terminal. specified level of current may not be output
10.Turn the light switch on to turn on headlamps and even though the alternator is normal. In such
then start the engine. cases, increase the electrical load by leaving
11.Immediately after setting the headlamps to high the headlamps turned on for some time to
beam and turning the heater blower switch to the discharge the battery or by using the lighting
high revolution position, increase the engine system in another vehicle, and then test again.
speed to 2,500 r/min and read the maximum • The specified level of current also may not be
current output value displayed on the ammeter. output if the temperature of the alternator body
or the ambient temperature is too high. In such
Limit: 70 % of normal current output
cases, cool the alternator and then test again.
12.The reading on the ammeter should be above the
limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
the alternator from the engine and check the
alternator.
13.Run the engine at idle after the test.
14.Turn the ignition switch to the "LOCK" (OFF)
position.
15.Remove the tachometer or the MUT-II/III.
16.Disconnect the negative battery cable.
17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.
 ENGINE ELECTRICAL 16-7
CHARGING SYSTEM

REGULATED VOLTAGE TEST

M1161001100354

Load
Ammeter (clamp-type)

MB991519
Ignition switch
Black

B FR
L Alternator
S
G

Blue
Battery Red Yellow
Engine-ECU <M/T>
Engine-A/T-ECU <A/T>
Voltmeter (digital-type)

AK300727AB

This test determines whether the voltage regulator NOTE: The way of disconnecting the alternator
correctly controlling the alternator output voltage. output wire and of connecting the ammeter is
1. Always be sure to check the following before the possibly not found the problem that the output
test. current is dropping due to the insufficient
• Alternator installation connection between terminal "B" and the output
• Check that the battery installed in the vehicle is wire.
fully charged. 6. Reconnect the negative battery cable.
(Refer to GROUP 54A − Battery − On-vehicle 7. Connect a tachometer or the MUT-II/III (Refer to
Service − Charging P.54A-4). GROUP 11A − On-vehicle Service − Idle speed
• Drive belt tension check <4G1> P.11A-11 or GROUP 11C −
(Refer to GROUP 11A − On-vehicle Service <4G1> On-vehicle Service − Idle speed check <4G6>
P.11A-7 or GROUP 11C − On-vehicle Service P.11C-11).
<4G6> P.11C-7.)
8. Turn the ignition switch to the "ON" position and
• Fusible link
check that the reading on the voltmeter is equal to
• Abnormal noise from the alternator while the
the battery voltage.
engine is running
NOTE: If the voltage is 0 V, the cause is probably
2. Turn the ignition switch to the "LOCK" (OFF)
an open circuit in the wire or fusible link between
position.
the alternator "S" terminal and the battery (+)
3. Disconnect the negative battery cable. terminal.
4. Use the special tool Alternator test harness 9. Turn all lamps and accessories off.
(MB991519) to connect a digital voltmeter
10.Start the engine.
between the alternator "S" terminal and earth
[Connect the (+) lead of the voltmeter to the "S" 11.Increase the engine speed to 2,500 r/min.
terminal, and then connect the (-) lead of the 12.Read the value displayed on the voltmeter when
voltmeter to a secure earth or to the battery (-) the alternator output current alternator becomes
terminal]. 10 A or less.
5. Connect a clamp-type DC test ammeter with a 13.If the voltage reading conforms to the value in the
range of 0 − 120 A to the alternator "B" terminal voltage regulation, then the voltage regulator is
output wire. operating normally.
16-8 ENGINE ELECTRICAL
CHARGING SYSTEM

If the voltage is not within the standard value, 17.Disconnect the negative battery cable.
there is a malfunction of the voltage regulator or of 18.Disconnect the ammeter and voltmeter.
the alternator. 19.Connect the alternator output wire to the
14.After the test, lower the engine speed to the idle alternator "B" terminal.
speed. 20.Remove the special tool, and return the connector
15.Turn the ignition switch to the "LOCK" (OFF) to the original condition.
position. 21.Connect the negative battery cable.
16.Remove the tachometer or the MUT-II/III.
Voltage Regulation Table
Standard value:
Inspection terminal Voltage regulator ambient Voltage V
temperature °C
Terminal "S" −20 14.2 − 15.4
20 13.9 − 14.9
60 13.4 − 14.6
80 13.1 − 14.5
 ENGINE ELECTRICAL 16-9
CHARGING SYSTEM

WAVEFORM CHECK USING AN OSCILLOSCOPE

M1161001200124
MEASUREMENT METHOD Connect the oscilloscope special patterns pick-up to
the alternator "B" terminal.
Alternator

CH1

"B" terminal AK100002 AC

STANDARD WAVEFORM
Observation Conditions
Function Special pattern
Pattern height Variable
Variable knob Adjust while viewing the waveform.
Pattern selector Raster
Engine speed Curb idle speed

(V)

0.4

0.2
Voltage at
alternator 0
"B" terminal
–0.2

–0.4

Time

AKX00189AG

NOTE: (current), and is normal for the alternator. In addition,

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

AKX00190

The voltage waveform of the alternator "B" terminal

can undulate as shown in the illustration. This
waveform is produced when the regulator operates
according to fluctuations in the alternator load
16-10 ENGINE ELECTRICAL
CHARGING SYSTEM

EXAMPLE OF ABNORMAL WAVEFORMS

NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.

Abnormal waveform Problem cause

Example 1 Open diode

AKX00191

Example 2 Short in diode

AKX00192
 ENGINE ELECTRICAL 16-11
CHARGING SYSTEM

Abnormal waveform Problem cause

Example 3 Broken wire in
stator coil

AKX00193

Example 4 Short in stator

coil

AKX00194

Example 5 Open
supplementary
diode

AKX00195

At this time, the charging warning lamp is illuminated.

16-12 ENGINE ELECTRICAL
CHARGING SYSTEM

ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION <4G1>
M1161001400548

Pre-removal Operation Post-installation Operation

• Under Cover Removal • Drive Belt Installation (Refer to GROUP 11A - Crankshaft
• Drive Belt Removal (Refer to GROUP 11A - Crankshaft Pulley P.11A-16).
Pulley P.11A-16). • Drive Belt Tension Adjustment (Refer to GROUP 11A -
On-vehicle Service P.11A-7).
• Under Cover Installation

12 ± 2 N·m
44 ± 10 N·m

2 1

23 ± 2 N·m

24 ± 3 N·m

AC303729AB

Removal steps Removal steps (Continued)

1. Power steering pressure hose 3. Alternator adjusting brace
clamp <<A>> 4. Alternator assembly
2. Alternator connector and terminal

REMOVAL SERVICE POINT

<<A>> ALTERNATOR ASSEMBLY
REMOVAL
Remove the alternator assembly from above the
vehicle.
 ENGINE ELECTRICAL 16-13
CHARGING SYSTEM

REMOVAL AND INSTALLATION <4G6>

M1161001400559

Pre-removal Operation Post-installation Operation

• Under Cover Removal • Air Cleaner Assembly Installation (Refer to GROUP 15
• Strut Tower Bar Removal (Refer to GROUP 42 P.42-9). P.15-3).
• Drive Belt Removal (Refer to GROUP 11C - Crankshaft • Drive Belt Installation (Refer to GROUP 11C - Crankshaft
Pulley P.11C-16). Pulley P.11C-16).
• Air Cleaner Assembly Removal (Refer to GROUP 15 • Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
P.15-3). • Drive Belt Tension Adjustment (Refer to GROUP 11C -
On-vehicle Service P.11C-7).
• Under Cover Installation

1 18 ± 3 N·m

AC303826 AB

Removal steps Removal steps (Continued)

1. Shift cable connection <<A>> 2. shift cable and shift cable bracket
assembly
3. Vehicle speed sensor connector
16-14 ENGINE ELECTRICAL
CHARGING SYSTEM

4
5
6

44 ± 10 N·m

22 ± 4 N·m
23 ± 3 N·m

8
8.8 ± 1.0 N·m
AC303827AB

Removal steps Removal steps (Continued)

4. Battery wiring harness clamp <<B>> 7. Alternator assembly
5. Engine oil pressure switch 8. Water pump pulley
connection 9. Alternator brace
6. Alternator connector

REMOVAL SERVICE POINT <<B>> ALTERNATOR ASSEMBLY

<<A>> SHIFT CABLE AND SHIFT CABLE REMOVAL
BRACKET ASSEMBLY REMOVAL Alternator
Remove the shift cable bracket installation bolt with assemnly
the shift cable installed on the shift cable bracket,
and remove the shift cable and shift cable bracket
assembly from the transmission.

AC302930AB

After removing the alternator assembly installation

bolts and nut, move the alternator assembly to the
transmission side and remove the alternator
assembly upward the engine room through the
clearance between the transmission and the inlet
manifold.
 ENGINE ELECTRICAL 16-15
CHARGING SYSTEM

DISASSEMBLY AND REASSEMBLY

M1161001600166

1
4
3
4.4 ± 1.0 N·m

5
7 6

3.7 ± 0.7 N·m

189 ± 19 N·m
12
10
9

8
14

13

11
3.7 ± 0.7 N·m

AK202845 AE

Disassembly steps Disassembly steps (Continued)

<<A>> 1. Front bracket assembly <<C>> 8. Stator
<<B>> 2. Alternator pulley 9. Plate
>>B<< 3. Rotor <<C>> >>A<< 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Rubber packing
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
16-16 ENGINE ELECTRICAL
CHARGING SYSTEM

DISASSEMBLY SERVICE POINTS CAUTION

<<A>>FRONT BRACKET ASSEMBLY • Use a 180 − 250 W soldering iron, and finish
REMOVAL unsoldering within four seconds. Diodes will
be damaged by heat if unsoldering time is too
long.
• Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the
regulator assembly, undo the soldered points on
the rectifier assembly.
AK202718
REASSEMBLY SERVICE POINTS
CAUTION >>A<<REGULATOR ASSEMBLY
Do not insert the screwdriver blades too deep.
INSTALLATION
Doing so could damage the stator coil.
Insert the blades of screwdrivers between the front
bracket assembly and stator core, and pry and
separate them with the screwdrivers.
Wire
<<B>>ALTERNATOR PULLEY REMOVAL

AK202779 AB

Rear bracket

Brush
AK202714

CAUTION Wire
Perform operation carefully not to damage the
rotor.
Clamp the rotor in a vise with the pulley facing up to AK202830 AB
remove the pulley.
After installing the regulator assembly, insert a piece
of wire through the hole in the rear bracket while
<<C>>STATOR / REGULATOR ASSEMBLY pressing the brush to keep the brush against
REMOVAL movement.
Rectifier Solder NOTE: Holding the brush with the wire facilities
assembly installation of the rotor.

Solder
AK202778 AB
 ENGINE ELECTRICAL 16-17
CHARGING SYSTEM

>>B<< ROTOR INSTALLATION STATOR

Wire

AK202779 AB AK202716

Remove the brush holding wire after the rotor has 1. Check the continuity between coil leads.
been installed.
If there is no continuity, replace the stator.
INSPECTION
M1161001700152

ROTOR

AK202717

2. Check the continuity between coil and core.

AK202735 If there is no continuity, replace the stator.

1. Measure the resistance between the two slip rings

of the rotor coil to check the continuity between
RECTIFIER ASSEBMLY
them.
Replace the rotor if the resistance is not within the
standard value range.
Standard value: 3 − 5 Ω
2. Check the continuity between the slip rings and
core.

AK202803

1. Check the condition of the (+) heat sink by

checking continuity between the (+) heat sink and
each of the stator coil lead connecting terminals.
If continuity is present for both terminals, the
diode is shorted. Replace the rectifier assembly.
AK202736

3. If continuity is present, replace the rotor.

16-18 ENGINE ELECTRICAL
CHARGING SYSTEM

BRUSH

Protrusion
length

AK202802

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

Solder

AK202804

3. Check the condition of the diode trio by testing

continuity of each of the three diodes using a AK202834 AB

circuit tester connected to both sides of the diode.

3. Install a new brush by pushing it into the holder as
Connect in a polarity and then reverse the polarity
shown in the drawing and soldering the lead.
for each test.
If continuity exists or no continuity exists for both
polarities, the diode is defective. Replace the
rectifier assembly if any of the diodes is defective.
 ENGINE ELECTRICAL 16-19
STARTING SYSTEM

STARTING SYSTEM
GENERAL INFORMATION
M1162000100202
If the ignition switch is turned to the "START" When the ignition switch is returned to the "ON"
position, current flows in the pull-in and holding coils position after starting the engine, the starter clutch is
provided inside magnetic switch, attracting the disengaged from the ring gear.
plunger, When the plunger is attracted, the lever An overrunning clutch is provided between the pinion
connected to the plunger is actuated to engage the and the armature shaft, to prevent damage to the
starter clutch. starter.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
SYSTEM DIAGRAM

Holding coil Plunger

Pull-in coil
Lever

B Overrunning clutch

Ignition switch M
Pinion gear
S

+ Armature

Battery

Brush
Yoke

AK202970 AB
16-20 ENGINE ELECTRICAL
STARTING SYSTEM

STARTER MOTOR SPECIFICATIONS

Item 4G1 4G6
Type Reduction drive with planetary Reduction drive with planetary gear
gear
Rated output kW/V 1.2/12 1.4/12
Number of pinion teeth 8 8

SERVICE SPECIFICATIONS
M1162000300068

Item Standard value Limit

Pinion gap mm 0.5 − 2.0 −
Commutator run-out mm − 0.05
Commutator diameter mm 29.4 28.8
Undercut depth mm 0.5 0.2
 ENGINE ELECTRICAL 16-21
STARTING SYSTEM

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION <4G1>
M1162001000628

Pre-removal and Post-installation Operation

• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
• Battery and Battery Tray Removal and Installation

<M/T> 18 ± 3 N·m <A/T>

1 2 12 ± 2 N·m

3
30 ± 3 N·m

4
5

AC303962 AB

Removal steps Removal steps (Continued)

1. Shift cable connection 4. Starter connector and terminal
<<A>> 2. shift cable and shift cable bracket 5. Harness bracket <M/T>
assembly <M/T> 6. Harness bracket <A/T>
<<B>> 3. Shift cable connection <A/T> <<C>> 7. Starter assembly

REMOVAL SERVICE POINT <<B>> SHIFT CABLE CONNECTION

<<A>> SHIFT CABLE AND SHIFT CABLE <A/T> REMOVAL
BRACKET ASSEMBLY <M/T> REMOVAL Disengage the transmission, and remove the shift
Remove the shift cable bracket installation bolt with cable assembly from the transmission.
the shift cable installed on the shift cable bracket,
and remove the shift cable and shift cable bracket <<C>> STARTER ASSEMBLY REMOVAL
assembly from the transmission. Remove the starter assembly from above the
vehicle.
16-22 ENGINE ELECTRICAL
STARTING SYSTEM

REMOVAL AND INSTALLATION <4G6>

M1162001000617

Pre-removal and Post-installation Operation

• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
• Under Cover Removal and Installation

9.0 ± 2.0 N·m

18 ± 3 N·m
4
3
30 ± 3 N·m

49 ± 9 N·m

1
6

AC304005 AB

Removal steps Removal steps (Continued)

1. Starter cover 4. Clutch hose clamp
2. Starter connector and terminal <<A>> 5. Starter assembly
3. Clutch release cylinder connecting 6. Starter cover bracket
bolts

REMOVAL SERVICE POINT

<<A>> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from above the
vehicle.
 ENGINE ELECTRICAL 16-23
STARTING SYSTEM

STARTER MOTOR ASSEMBLY INSPECTION

M1162001100205
PINION GAP ADJUSTMENT
<4G1> Switch

S
B M

Starter Wire
motor Battery AKX00199

AK300648 AB 5. If the pinion gap is out of specification, adjust by

adding or removing gasket(s) between the
<4G6>
magnetic switch and front bracket.
Switch
S MAGNETIC SWITCH PULL-IN TEST
M
B <4G1>
battery

S
Starter Wire
motor B M

AKX01238 AG

1. Disconnect the field coil wire from the M-terminal Starter Wire
of the magnetic switch. motor Battery
2. Connect a 12-volt battery between the S-terminal
AK300649 AB
and M-terminal.
CAUTION <4G6>
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning. S
3. Set the switch to "ON", and the pinion will move M
B
out. Battery

Starter Wire
Stopper motor

AKX01242 AF

1. Disconnect the field coil wire from the M-terminal

of the magnetic switch.
Pinion CAUTION
This test must be performed quickly (in less than
Pinion gap
AKX00198 AC 10 seconds) to prevent the coil from burning.
4. Check the pinion-to-stopper clearance (pinion 2. Connect a 12-volt battery between the S-terminal
gap) with a feeler gauge. and M-terminal.
Standard value: 0.5 − 2.0 mm 3. If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.
16-24 ENGINE ELECTRICAL
STARTING SYSTEM

MAGNETIC SWITCH HOLD-IN TEST FREE RUNNING TEST

<4G1> <4G1>
Carbon-pile rheostat
S S
Wire Ammeter
M
B M B A

V Battery
Starter
Starter motor Voltmeter
motor Battery

AK300650 AB AK300651AB

<4G6> <4G6>
Ammeter
A
S
S Carbon-pile
rheostat
M M B
B
Battery
Battery
Starter V
Starter Wire motor Voltmeter
motor

AKX01244AF AKX01246 AF

1. Disconnect the field coil wire from the M-terminal 1. Place the starter motor in a vise equipped with
of the magnetic switch. soft jaws and connect a fully-charged 12-volt
CAUTION battery to the starter motor as follows:
This test must be performed quickly (in less than 2. Connect a test ammeter (100-ampere scale) and
10 seconds) to prevent the coil from burning. carbon pile rheostat in series between the battery
(+) terminal and starter motor terminal.
2. Connect a 12-volt battery between the S-terminal
and body. 3. Connect a voltmeter (15-volt scale) across the
starter motor.
3. Manually pull out the pinion as far as the pinion
stopper position. 4. Rotate the rheostat to full-resistance position.
4. If the pinion remains out, everything is in order. If 5. Connect the battery cable from the battery (-)
the pinion moves in, the hold-in circuit is open. terminal to the starter motor body.
Replace the magnetic switch. 6. Adjust the rheostat until the battery voltage shown
on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns
smoothly and freely.
Current:
<4G1> maximum 95 Amps
<4G6> maximum 90 Amps
 ENGINE ELECTRICAL 16-25
STARTING SYSTEM

MAGNETIC SWITCH RETURN TEST 1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
<4G1>
CAUTION
S This test must be performed quickly (in less than
Wire
B M 10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal
and body.
Starter WARNING
motor Battery Be careful not to get your fingers caught
when pulling out the pinion.
AK300652 AB
3. Pull the pinion out and release. If the pinion
<4G6> quickly returns to its original position, everything is
operating properly. If it doesn't, replace the
S magnetic switch.
M
B
Battery

Starter Wire
motor

AKX01248 AF
16-26 ENGINE ELECTRICAL
STARTING SYSTEM

DISASSEMBLY AND REASSEMBLY

M1162001200202

11 2
14
12
10

13
20 19

4
1
18
3
16 17

15
5
7

9 AK201881 AG

Disassembly steps Disassembly steps (Continued)

1. Screw 11. Packing B
<<A>> 2. Magnetic switch 12. Plate
3. Screw 13. Planetary gear
4. Bolt 14. Lever
5. Rear bracket <<B>> >>A<< 15. Snap ring
6. Brush holder <<B>> >>A<< 16. Stop ring
7. Rear bearing 17. Overrunning clutch
8. Armature 18. Internal gear
9. Yoke assembly 19. Planetary gear shaft
10. Packing A 20. Front bracket
 ENGINE ELECTRICAL 16-27
STARTING SYSTEM

DISASSEMBLY SERVICE POINTS STARTER MOTOR PARTS CLEANING

<<A>> MAGNETIC SWITCH REMOVAL Never clean in a solvent such starter motor parts
as the magnetic switch, brush holder, and
armature. If they are soaked in a solvent, their
S terminal insulation could be impaired. When these parts
B terminal require cleaning, wipe off contamination with
M terminal cloth.
1. Never soak the drive unit in a solvent. If it is
washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.
AK201882AC

CAUTION REASSEMBLY SERVICE POINTS

Do not clamp the yoke assembly with a vise. >>A<< STOP RING/SNAP RING
Disconnect the lead from the M terminal of the INSTALLATION
magnetic switch.

<<B>> SNAP RING/STOP RING REMOVAL

Socket wrench
Overrunning Stop ring
clutch
Stop ring
Stop ring Pinion Gear
Overrunning
clutch
Snap ring AK202911 AB

Use a suitable puller to pull the stop ring until it gets

over the snap ring.
AK100883AC

1. Apply a long socket wrench of an appropriate size INSPECTION

M1162001300157
to the stop ring and strike the wrench to drive out COMMUTATOR
the stop ring toward the pinion gear side.

Snap ring
Snap ring
pliers Pinion gear

Overrunning
clutch

AK202712
AK202791 AB

1. Support the armature with a pair of V block and

2. Remove the snap ring with snap ring pliers, then
turn it to measure the runout of the surface not
remove the stop ring and overrunning clutch. rubbed by the brushes using a dial gauge.
Standard value: 0.05 mm or less
Limit: 0.1 mm
16-28 ENGINE ELECTRICAL
STARTING SYSTEM

OVERRUNNING CLUTCH

Free

AK202715 Lock

AK202710 AB
2. Measure the diameter of the commutator.
Standard value: 29.4 mm 1. Make sure that the pinion cannot be turned
Limit: 28.8 mm counterclockwise and can be turned clockwise
freely.
2. Check the pinion for abnormal ware and damage.
Segment Undercut
Mica BRUSHES

AK202711 AB Brush
height
3. Measure the depth of the undercut between
segments.
Standard value: 0.5 mm
AK202846 AB
Limit: 0.2 mm
1. Check the commutator contacting surface of each
BRUSH HOLDER brush for abnormal roughness. Also check the
height of the brush. Replace the brush holder if
the height is lower than the limit.
Limit: 7.0 mm
2. When the contact surface of the brush is rectified
or the brush holder is replaced, recondition the
contact surface with sandpaper wrapped around
the commutator.

ARMATURE COIL
AK201187 1. Check the armature coil for short circuit as
Push the brush into the brush holder to make sure follows:
that the spring is working on the brush.
If the spring is not working, replace the brush holder.
 ENGINE ELECTRICAL 16-29
STARTING SYSTEM

Growler
MAGNETIC SWITCH

AK202733 AB
M terminal

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

M terminal

AK202892 AB

2. Contact fusion check

AK202734
• Check that there is no continuity between the B
4. Check the insulation between commutator terminal and M terminal.
segments and armature coils. The armature coils • If there is continuity, replace the magnetic switch.
are properly insulated if no continuity is present.

B terminal

M terminal

AK202893 AB

AK202713
3. Switch contact check
5. Check continuity between a segment and another. • Push the indicated end of the magnetic switch
There is no open circuit in the tested coil if there is with a strong force to close the internal contacts.
continuity. Without releasing the switch end, check that
there is continuity between the B terminal and M
terminal.
• If there is no continuity, replace the magnetic
switch.
16-30 ENGINE ELECTRICAL
IGNITION SYSTEM

IGNITION SYSTEM
GENERAL INFORMATION
M1163000100294
This system is equipped with two ignition coils (A and The engine-ECU <M/T> or engine-A/T-ECU <A/T>
B) with built-in power transistors for the No. 1 and turns the two power transistors inside the ignition
No. 4 cylinders and the No. 2 and No. 3 cylinders coils alternately on and off. This causes the primary
respectively. currents in the ignition coils to be alternately
Interruption of the primary current flowing in the interrupted and allowed to flow to fire the cylinders in
primary side of ignition coil A generates a high the order 1-3-4-2.
voltage in the secondary side of ignition coil A. The The engine-ECU <M/T> or engine-A/T-ECU <A/T>
high voltage thus generated is applied to the spark determines which ignition coil should be controlled
plugs of No. 1 and No. 4 cylinders to generate by means of the signals from the camshaft position
sparks. At the time that the sparks are generated at sensor which is incorporated in the camshaft and
both spark plugs, if one cylinder is at the from the crank angle sensor which is incorporated in
compression stroke, the other cylinder is at the the crankshaft. It also detects the crankshaft position
exhaust stroke, so that ignition of the compressed in order to provide ignition at the most appropriate
air/fuel mixture occurs only for the cylinder which is timing in response to the engine operation
at the compression stroke. conditions. It also detects the crankshaft position in
In the same way, when the primary current flowing in order to provide ignition at the most appropriate
ignition coil B is interrupted, the high voltage thus timing in response to the engine operation
generated is applied to the spark plugs of No. 2 and conditions.
No. 3 cylinders. When the engine is cold or operated at high
altitudes, the ignition timing is slightly advanced to
provide optimum performance.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce
output torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM

MAP sensor <4G1>

Air flow sensor

<4G6>
Ignition
Intake air temperatur
sensor switch
Ignition coil B Ignition coil A
Engine coolant
temperature sensor Engine-ECU
<M/T>
Camshaft position Engine-A/T-
sensor
ECU <A/T>
Battery
Crank angle sensor

Spark plug
Barometric pressure
sonsor <4G6>

Detonatoin sensor Cylinder No. 2 3 4 1

Ignition switch-ST

AK101074 AG
 ENGINE ELECTRICAL 16-31
IGNITION SYSTEM

IGNITION COIL SPECIFICATION

Item Specification
Type Molded 2-coil

SPARK PLUG SPECIFICATIONS

Items 4G1 4G66
NGK BKR6E-11 IGR6A11
DENSO K20PR-U11 −
CHAMPION RC8YC4 −

SERVICE SPECIFICATIONS
M1163000300180

IGNITION COIL
Item Standard value
Secondary coil resistance kΩ 8.5 − 11.5

SPARK PLUG
Items Standard value Limit
Spark plug gap mm 4G1 1.0 − 1.1 −
4G6 1.0 − 1.1 1.3

RESISTIVE CORD
Item Standard value Limit
Resistance kΩ − Maximum 19

SPECIAL TOOL
M1163000600288

Tool Number Name Use

MD998773 Detonation sensor Detonation sensor
wrench removal and installation
16-32 ENGINE ELECTRICAL
IGNITION SYSTEM

ON-VEHICLE SERVICE RESISTIVE CORD CHECK

M1163001400124

IGNITION COIL (WITH BUILT-IN POWER

TRANSISTOR) CHECK
M1163001200324
Check by the following procedure, and replace if
there is a malfunction.
SECONDARY COIL RESISTANCE CHECK

AKX00382

Measure the resistance of the all spark plug cables.

1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Maximum 19 kΩ

AKX01264 SPARK PLUG CHECK AND CLEANING

Measure the resistance between the high-voltage <4G1>
terminals of the ignition coil. M1163004300342

Standard value: 8.5 − 11.5 kΩ CAUTION

When pulling off the spark plug cable from the
PRIMARY COIL AND POWER plug always hold the cable cap, not the cable.
TRANSISTOR CONTINUITY CHECK 1. Remove the spark plug cables.
NOTE: . 2. Remove the spark plugs.
•

3. Check for burned out electrode or damaged

insulator. Check for even burning.
1.5 V 4. Remove carbon deposits with wire brush or plug
cleaner. Remove sand from plug screw with
compressed air.
– + 1 2 3
Plug gap gauge

Measurement
AKX01265AD
direction

An analogue-type circuit tester should be used.

• Connect the negative (-) prove of the circuit tester
to terminal No. 1.
CAUTION
This test must be performed quickly (in less than AKX01272AG
10 seconds) to prevent coil from burning and
power transistor from breakage. 5. Use a plug gap gauge to check that the plug gap
is within the standard value range.
1.5 V power supply Continuity between 1 −
between 2 − 3 2 Standard value: 1.0 − 1.1 mm
When current is flowing Continuity If the plug gap is not within the standard value
range, adjust by bending the earth electrode.
When current is not
flowing No continuity CAUTION
Be careful not to allow foreign matter in
cylinders.
6. Clean the engine plug holes.
7. Install the spark plugs.
 ENGINE ELECTRICAL 16-33
IGNITION SYSTEM

SPARK PLUG CHECK AND CLEANING CRANK ANGLE SENSOR CHECK

M1163004500272
<4G6> Check the crank angle sensor circuit if self-diagnosis
M1163004300353
code No. P0335 is shown.
CAUTION
(Refer to GROUP 13A − Troubleshooting −
When pulling off the spark plug cable from the
Inspection chart for diagnosis code <4G1> P.13A-15
plug always hold the cable cap, not the cable.
or GROUP 13B − Troubleshooting − Inspection chart
1. Remove the spark plug cables. for diagnosis code <4G6> P.13B-15 ).
2. Remove the spark plugs.
CAUTION DETONATION SENSOR CHECK
M1163002900047
• Do not attempt to adjust the gap of the iridium Check the detonation sensor circuit if self-diagnosis
plug. code No. P0325 is shown.
• Always use a plug cleaner and finish cleaning (Refer to GROUP 13A − Troubleshooting −
within 20 seconds. Do not use wire brushes. Inspection chart for diagnosis code <4G1> P.13A-15
Otherwise, the iridium and platinum tip may or GROUP 13B − Troubleshooting − Inspection chart
be damaged. for diagnosis code <4G6> P.13B-15).

IGNITION SECONDARY VOLTAGE

WAVEFORM CHECK USING AN
OSCILLOSCOPE
M1163001700170
Iridium
tip MEASUREMENT METHOD
1. Clamp the secondary pickup around the spark
Platinum
tip plug cable.
NOTE: .
AKX00383AL
• The peak ignition voltage will be reversed
3. Check the plug gap and replace if the limit is when the spark plug cables No. 2 and No. 4,
exceeded. or No. 1 and No. 3 cylinders are clamped.
• Because of the two-cylinder simultaneous
Standard value: 1.0 − 1.1 mm ignition system, the waveforms for two
Limit: 1.3 mm cylinders in each group appear during
CAUTION waveform observation (No. 1 cylinder - No. 4
Be careful not to allow foreign matter in cylinder, No. 2 cylinder - No. 3 cylinder).
cylinders. However, waveform observation is only
4. Clean the engine plug holes. applicable for the cylinder with the spark plug
cable clamped by the secondary pickup.
5. Install the spark plugs.
• Identifying which cylinder waveform is
displayed can be difficult. For reference,
CAMSHAFT POSITION SENSOR CHECK remember that the waveform of the cylinder
M1163004400219
Check the camshaft position sensor circuit if attached to the secondary pickup will be
self-diagnosis code No. P0340 is shown. displayed as stable.
(Refer to GROUP 13A − Troubleshooting − 2. Clamp the spark plug cable with the trigger
Inspection chart for diagnosis code <4G1> P.13A-15 pickup.
or GROUP 13B − Troubleshooting − Inspection chart
NOTE: Clamp the trigger pickup to the same
for diagnosis code <4G6> P.13B-15 ).
spark plug cable clamped by the secondary
pickup.
16-34 ENGINE ELECTRICAL
IGNITION SYSTEM

STANDARD WAVEFORM

Observation Conditions
Function Secondary
Pattern height High (or Low)
Pattern selector Raster
Engine revolutions Curb idle speed

Spark line (point A)

kV

Ignition voltage
(point D)

Secondary
ignition voltage
wave pattern
Wave dampling reduction section (point B)

Dwell section

Point C

Time

AKX00278AD

Observation Conditions (The only change from above condition is the pattern selector.)
Pattern selector Display
 ENGINE ELECTRICAL 16-35
IGNITION SYSTEM

kV

NO. 2 cylinder
NO. 1 cylinder NO. 3 cylinder NO. 4 cylinder ignition noise
ignition noise

Secondary ignition
voltage wave pattern Time
0
2 Newtral section

AKX01275 AC

WAVEFORM OBSERVATION POINTS

Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).
Spark line Plug gap Condition of Compression Concentration Ignition Spark plug
electrode force of air mixture timing cable
Length Long Small Normal Low Rich Advanced Leak
Short Large Large wear High Lean Retarded High
resistance
Height High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
Slope Large Plug is fouled − − − −
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil and condenser
3 or more Normal
Except above Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations Coil
5 − 6 or higher Normal
Except above Abnormal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentration Ignition Spark plug
voltage electrode force of air mixture timing cable
High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
16-36 ENGINE ELECTRICAL
IGNITION SYSTEM

EXAMPLES OF ABNORMAL Example 3

WAVEFORMS • Wave characteristics
Spark line is low and long, and is sloping.
However, there is almost no spark line
distortion.
• Cause of problem
Spark plug gap is fouled.

AKX00280

Example 1
• Wave characteristics
Spark line is high and short.
• Cause of problem AKX00283

Spark plug gap is too large.

Example 4
• Wave characteristics
Spark line is high and short.
Difficult to distinguish between this and abnormal
waveform example 1.
• Cause of problem
Spark plug cable is nearly falling off (Causing a
dual ignition).

AKX00281

Example 2
• Wave characteristics
Spark line is low and long, and is sloping.
Also, the second half of the spark line is distorted.
This could be a result of misfiring.
• Cause of problem
Spark plug gap is too small. AKX00284

Example 5
• Wave characteristics
No waves in wave damping section.
• Cause of problem
Layer short in ignition coil.

AKX00282
 ENGINE ELECTRICAL 16-37
IGNITION SYSTEM

IGNITION COIL RELAY CHECK Battery Terminal No.to Continuity test

M1163006500018
voltage be connected to results
tester
Not applied 1−4 Open circuit
Ignition coil relay
Connect 1−4 Less than 2 ohms
terminal
No.2 and
battery (+)
Battery terminal.
Connect
terminal
No.3 and
AC301727
battery (−)
terminal.

1
4
2 3

AC304311AB
16-38 ENGINE ELECTRICAL
IGNITION SYSTEM

IGNITION COIL
REMOVAL AND INSTALLATION <4G1>
M1163004000404

10 ± 2 N·m

1
3
10 ± 2 N·m
4

2
4

25 ± 5 N·m

AC303965AB

Removal steps Removal steps (Continued)

1. Ignition coil connector 4. Ignition coil
2. Spark plug cable 5. Spark plug
3. Accelerator cable support clamp
<RHD>
 ENGINE ELECTRICAL 16-39
IGNITION SYSTEM

REMOVAL AND INSTALLATION <4G6>

M1163004000415

10 ± 2 N·m
3.0 ± 0.5 N·m

1 2
4
4
3
2
3
5
25 ± 4 N·m

AC301786 AB

Removal steps Removal steps (Continued)

1. Rocker cover centre cover 4. Ignition coil
2. Ignition coil connector 5. Spark plug
3. Spark plug cable
16-40 ENGINE ELECTRICAL
IGNITION SYSTEM

CAMSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION
M1163003400443

<4G1>
1
8.8 ± 1.0 N·m

N3

AC303970AB

<4G6>

2
1

3N 8.8 ± 1.0 N·m

AC301556 AC

Removal steps Removal steps (Continued)

1. Camshaft position sensor 2. Camshaft position sensor
connector 3. O-ring
 ENGINE ELECTRICAL 16-41
IGNITION SYSTEM

CRANKSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION <4G1>
M1163003500439

Pre-removal and Post-installation Operation

• Valve Timing Belt Removal and Installation (Refer to
GROUP 11A P.11A-33).

11 ± 1 N·m

8.8 ± 1.0 N·m

AC208380AB

Removal steps
1. Engine crank angle sensor
2. Crank angle sensor connector
bracket
16-42 ENGINE ELECTRICAL
IGNITION SYSTEM

REMOVAL AND INSTALLATION <4G6>

M1163003500440

Pre-removal and Post-installation Operation

• Valve Timing Belt Removal and Installation (Refer to
GROUP 11C P.11C-35).

3.0 ± 0.5 N·m

22 ± 4 N·m
6

7
1

8.8 ± 1.0 N·m

2
9
22 ± 4 N·m
4

3
8
8.8 ± 1.0 N·m

49 ± 9 N·m 5 49 ± 9 N·m

AC301612 AC

Removal steps Removal steps (Continued)

1. Power steering pressure switch 6. Rocker cover centre cover
connector 7. Engine crankshaft position sensor
2. A/C compressor connector connector
3. A/C compressor connector clamp 8. Engine crankshaft position sensor
<<A>> 4. Power steering oil pump assembly 9. Crankshaft position sensor
5. Power steering oil pump bracket connector bracket

REMOVAL SERVICE POINT

<<A>> POWER STEERING OIL PUMP
ASSEMBLY REMOVAL
Remove the power steering oil pump assembly from
the bracket with the hose attached.
NOTE: Place the removed power steering oil pump
assembly in a place where it will not be a hindrance
when removing and installing and secure it with a
cord or wire.
 ENGINE ELECTRICAL 16-43
IGNITION SYSTEM

DETONATION SENSOR
REMOVAL AND INSTALLATION
M1163002800556

CAUTION
Do not drop or hit the detonation sensor against other components. Internal damage may result, and
the detonation sensor will need to be replaced.

<4G1> Cylinder block

(Intake side)

1
23 ± 2 N·m

AC303971 AB

<4G6>
Inlet manifold

23 ± 2 N·m
AC303972 AB

Removal steps
1. Engine control detonation sensor
connector
<<A>> >>A<< 2. Engine control detonation sensor
16-44 ENGINE ELECTRICAL
IGNITION SYSTEM

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> ENGINE CONTROL DETONATION >>A<< ENGINE DETONATION SENSOR
SENSOR REMOVAL INSTALLATION
Engine control Engine control
detonation detonation
sensor sensor

MD998773 MD998773

AC100807AD AC100807AD

Use special tool detonation sensor wrench Use special tool detonation sensor wrench
(MD998773) to remove the engine control detonation (MD998773) to tighten the engine control detonation
sensor. sensor to the specified torque.
 17-1

GROUP 17

ENGINE AND
EMISSION
CONTROL
CONTENTS

ENGINE CONTROL . . . . . . . . . . 17-2 COMPONENT LOCATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . . 17-9
POSITIVE CRANKCASE VENTILATION
GENERAL INFORMATION . . . . . . 17-2 SYSTEM CHECK . . . . . . . . . . . . . . . . . . 17-9
POSITIVE CRANKCASE VENTILATION
(PCV) VALVE CHECK . . . . . . . . . . . . . . 17-9
SERVICE SPECIFICATIONS. . . . . 17-2
EVAPORATIVE EMISSION CONTROL
ON-VEHICLE SERVICE. . . . . . . . . 17-2 SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-9
ACCEL CABLE CHECK AND GENERAL INFORMATION (EVAPORATIVE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 17-2 EMISSION CONTROL SYSTEM) . . . . . 17-9
COMPONENT LOCATION (EVAPORATIVE
EMISSION CONTROL SYSTEM) . . . . . 17-10
ACCELERATOR CABLE AND PURGE CONTROL SYSTEM CHECK. . 17-10
PEDAL . . . . . . . . . . . . . . . . . . . . . . 17-3 PURGE PORT VACUUM CHECK . . . . . 17-11
PURGE CONTROL SOLENOID VALVE
REMOVAL AND INSTALLATION . . . . . 17-3 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-11
FUEL VAPOUR CANISTER REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . 17-12
EMISSION CONTROL MPI . . . . 17-5
EXHAUST GAS RECIRCULATION
GENERAL INFORMATION . . . . . . 17-5
(EGR) SYSTEM . . . . . . . . . . . . . . . 17-13
GENERAL INFORMATION
EMISSION CONTROL DEVICE (EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-13
REFERENCE TABLE . . . . . . . . . . 17-5 COMPONENT LOCATION
(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-14
EGR SYSTEM CHECK . . . . . . . . . . . . . 17-15
SERVICE SPECIFICATION(S) . . . 17-5 EGR VALVE CHECK . . . . . . . . . . . . . . . 17-15
EGR PORT VACUUM CHECK <4G1>. . 17-16
EGR CONTROL SOLENOID VALVE
VACUUM HOSE. . . . . . . . . . . . . . . 17-6 CHECK <4G1> . . . . . . . . . . . . . . . . . . . . 17-16
VACUUM HOSE PIPING DIAGRAM . . . 17-6 EGR CONTROL SOLENOID VALVE
VACUUM CIRCUIT DIAGRAM . . . . . . . 17-7 CHECK <4G6> . . . . . . . . . . . . . . . . . . . . 17-17
VACUUM HOSE CHECK. . . . . . . . . . . . 17-8 EXHAUST GAS RECIRCULATION (EGR)
VACUUM HOSE INSTALLATION . . . . . 17-8 VALVE REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . 17-18
CRANKCASE EMISSION CONTROL
SYSTEM. . . . . . . . . . . . . . . . . . . . . 17-8 CATALYTIC CONVERTER . . . . . . 17-18
GENERAL INFORMATION (CRANKCASE REMOVAL AND INSTALLATION. . . . . . 17-18
EMISSION CONTROL SYSTEM) . . . . . 17-8
17-2 ENGINE AND EMISSION CONTROL
ENGINE CONTROL

ENGINE CONTROL
GENERAL INFORMATION
M1171000100277
A cable-type accelerator mechanical
suspended-type pedal has been adopted.

SERVICE SPECIFICATIONS
M1171000300088

Item Standard value

Accel cable play mm 1.0 − 2.0
Engine idle speed r/min 4G1 750 ± 50
4G6 750 ± 100

ON-VEHICLE SERVICE <4G1>

Adjusting bolts
ACCEL CABLE CHECK AND Plate

ADJUSTMENT
M1171000900314
1. Turn A/C and lights OFF. Inspect and adjust at no
load.
2. Warm engine until stabilized at idle.
Accel cable
3. Confirm idle speed is at standard value.
Standard value: AC207966 AC

750 ± 50 r/min <4G1>

<4G6>
750 ± 100 r/min <4G6> Adjusting bolts

4. Stop engine. [ignition switch: LOCK (OFF)

position].
5. Confirm there are no sharp bends in the Plate
accelerator cable.
6. Check the inner cable for correct slack.
Standard value: 1.0 − 2.0 mm Accel cable
7. If there is too much slack or no slack, adjust play AC301055 AC
by the following procedures.
(1) Loosen the adjusting bolts to release the
cable.
(2) Move the plate until the inner cable play is at
the standard value, and then tighten the
adjusting bolts.
(3) After adjusting, check that the throttle lever is
touching the stopper.
 ENGINE AND EMISSION CONTROL 17-3
ENGINE CONTROL

ACCELERATOR CABLE AND PEDAL

REMOVAL AND INSTALLATION
M1171001200341

Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-2).

<L.H. drive vehicles> 5.0 ± 1.0 N·m

12 ± 2 N·m
10
9
1
7 7
5N
4

8
13
12 N
<R.H. drive vehicles> 6 Y1060AU
5.0 ± 1.0 N·m 11
3

2 1

12 ± 2 N·m 9
7
11
10
6
N5
4 12 N
7 8

Y1059AU
13 AC304070AB

Accelerator cable assembly Accelerator pedal assembly

removal steps removal steps
1. Inner cable connection (Accelerator 1. Inner cable connection (Accelerator
pedal side) pedal side)
2. Inner cable connection (Throttle body 4. Accelerator pedal assembly
side) 5. Accelerator control equip nut
3. Accelerator cable assembly 6. Accelerator pedal arm and
accelerator pedal pad assembly
17-4 ENGINE AND EMISSION CONTROL
ENGINE CONTROL

Accelerator pedal assembly Accelerator pedal assembly

removal steps (Continued) removal steps (Continued)
7. Accelerator control equip bushing 10. Accelerator pedal arm bracket
8. Accelerator pedal arm return spring 11. Accelerator pedal arm
9. Accelerator pedal arm stopper >>A<< 12. Accelerator pedal pad
13. Accelerator pedal arm stopper

INSTALLATION SERVICE POINT

>>A<< ACCEL PEDAL PAD
INSTALLATION
CAUTION
To prevent damages to the accelerator pedal pad,
warm the thumb area of the accelerator pedal
pad with a dryer, etc. prior to assembling it.
NOTE: If it is difficult to assemble, apply soapy water
to the thumb area to enhance the assembling
process.
 ENGINE AND EMISSION CONTROL 17-5
EMISSION CONTROL <MPI>

EMISSION CONTROL <MPI>

GENERAL INFORMATION • Crankcase emission control system
M1173000100370 • Evaporative emission control system
The emission control system consists of the following • Exhaust emission control system
subsystems:
Items Name Specification
Crankcase emission control Positive crankcase ventilation Variable flow type
system (PCV) valve (Purpose: HC reduction)
Evaporative emission control Canister Equipped
system Purge control solenoid valve Duty cycle type solenoid valve
(Purpose: HC reduction)
Exhaust emission control system Air-fuel ratio control device - MPI Oxygen sensor feedback type
system (Purpose: CO, HC, NOx reduction)
Exhaust gas recirculation system Equipped
• EGR valve Single type
• EGR control solenoid valve Duty cycle type solenoid valve
(Purpose: NOx reduction)
Catalytic converter Monolith type
(Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE

REFERENCE TABLE
M1173006600135

Related parts Crankcase Evaporative Air/fuel ratio Catalytic Exhaust gas

emission emission control converter recirculation
control control system system
system system
PCV valve ×
Purge control solenoid valve ×
MPI system component × ×
Catalytic converter ×
EGR valve ×
EGR control solenoid valve ×

SERVICE SPECIFICATION(S)
M1173000300288

Items Standard value

Purge control solenoid valve coil resistance (at 20°C) Ω 30 − 34
EGR control solenoid valve coil resistance (at 20°C) Ω 29 − 35
17-6 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
M1173000900417

<4G1>

Air cleaner

Air

To Fuel pressure From

fuel tank regulator fuel pump

EGR valve
Canister
Oxygen sensor
(front)

Catalytic EGR control Purge control

converter solenoid valve solenoid valve

Oxygen sensor (rear)

Catalytic
converter

AK300964 AB

<4G6>
Air cleaner

Air

Fuel pressure
To regulator From
fuel tank fuel pump

PCV valve
EGR valve
Oxygen sensor Canister
(front)

EGR control
solenoid valve Purge control
Catalytic solenoid valve
converter
Oxygen sensor (rear)

Catalytic
converter

AK204364AC
 ENGINE AND EMISSION CONTROL 17-7
EMISSION CONTROL <MPI>

VACUUM CIRCUIT DIAGRAM

M1173007100263

<4G1>
Intake manifold Throttle body

To From
combustion air
chamber cleaner

L G
R
Fuel
pressure
regulator

Y R Canister
Vacuum hose colour G
B: Black
G: Green EGR B
R: Red G control
Y: Yellow EGR solenoid Purge
L: Blue valve valve control
solenoid
valve
AK300765 AB

<4G6>
Intake manifold Throttle body

To From
combustion air
chamber cleaner

L W
R
Fuel
pressure
regulator
G
Y B Canister
Vacuum hose colour EGR
B: Black control
G: Green solenoid B B
R: Red valve Purge
W: White EGR
valve control
Y: Yellow solenoid
L: Blue valve
AK300766 AB
17-8 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

VACUUM HOSE CHECK CRANKCASE EMISSION CONTROL

M1173007300159
1. Using the piping diagram as a guide, check to be SYSTEM
sure that the vacuum hoses are correctly
connected. GENERAL INFORMATION (CRANKCASE
2. Check the connection condition of the vacuum EMISSION CONTROL SYSTEM)
M1173005000237
hoses, (removed, loose, etc.) and check to be
The crankcase emission control system prevents
sure that there are no bends or damage.
blow-by gases from escaping inside the crankcase
into the atmosphere.
VACUUM HOSE INSTALLATION Fresh air is sent from the air cleaner into the
M1173007200107
1. When connecting the vacuum hoses, they should crankcase through the breather hose.
be securely inserted onto the nipples. The air becomes mixed with the blow-by gases
2. Connect the hoses correctly, using the vacuum inside the crankcase.
hose piping diagram as a guide. The blow-by gas inside the crankcase is drawn into
the intake manifold through the positive crankcase
ventilation (PCV) valve.
The PCV valve lifts the plunger according to the
intake manifold vacuum so as to regulate the flow of
blow-by gas properly.
In other words, the blow-by gas flow is regulated
during low load engine operation to maintain engine
stability, while the flow is increased during high load
operation to improve the ventilation performance.

SYSTEM DIAGRAM

Air cleaner

Air

Ventilation hose Breather hose

PCV valve

AK204365AB
 ENGINE AND EMISSION CONTROL 17-9
EMISSION CONTROL <MPI>

COMPONENT LOCATION (CRANKCASE POSITIVE CRANKCASE VENTILATION

EMISSION CONTROL SYSTEM) (PCV) VALVE CHECK
M1173007400208 M1173001200187

<4G1>

PCV valve

PCV valve

AK300767AB AK100010 AC

<4G6> 1. Insert a thin rod into the PCV valve from the side
shown in the illustration (rocker cover installation
side), and move the rod back and forth to check
that the plunger moves.
2. If the plunger does not move, there is a clogging
in the PCV valve. In this case, clean or replace
the PCV valve.

PCV valve EVAPORATIVE EMISSION CONTROL

AK204366AC
SYSTEM
POSITIVE CRANKCASE VENTILATION GENERAL INFORMATION (EVAPORATIVE
SYSTEM CHECK EMISSION CONTROL SYSTEM)
M1173001100179 M1173005100405
1. Remove the ventilation hose from the PCV valve. The evaporative emission control system prevents
2. Remove the PCV valve from the rocker cover. fuel vapours generated in the fuel tank from escaping
3. Reinstall the PCV valve at the ventilation hose. into the atmosphere.
4. Start the engine and run at idle. Fuel vapours from the fuel tank flow through the fuel
tank pressure control valve and vapour pipe/hose to
be stored temporarily in the canister.
PCV valve When driving the vehicle, fuel vapours stored in the
canister flow through the purge solenoid and purge
port and go into the intake manifold to be sent to the
combustion chamber.
When the engine coolant temperature is low or when
the intake air quantity is small (when the engine is at
idle, for example), the engine control unit turns the
purge solenoid off to shut off the fuel vapour flow to
AKX00336 AD the intake manifold.
This does not only insure the driveability when the
5. Place a finger at the opening of the PCV valve engine is cold or running under low load but also
and check that vacuum of the intake manifold is stabilize the emission level.
felt.
NOTE: At this moment, the plunger in the PCV
valve moves back and forth.
6. If vacuum is not felt, clean the PCV valve or
replace it.
17-10 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

SYSTEM DIAGRAM

Throttle body

Engine-ECU <4G1-M/T, 4G6>,

Engine-A/T-ECU <4G1-A/T>
Canister
From
fuel Manifold absolute pressure
tank (MAP) sensor <4G1>
OFF
Air flow sensor <4G6>
Purge
control Engine coolant
ON solenoid temperature sensor
valve Control
relay Intake air
temperature sensor
Barometric pressure
Battery sensor <4G6>

AK204367AC

COMPONENT LOCATION (EVAPORATIVE PURGE CONTROL SYSTEM CHECK

M1173001400299
EMISSION CONTROL SYSTEM)
M1173007500216 <4G1>
<4G1> Vacuum hose

Plug
Purge control AK300771 AB
solenoid valve
AK300769 AB
<4G6> Vacuum hose
<4G6>

Plug

Purge control AK300772AB

solenoid valve
AK300770 AB
 ENGINE AND EMISSION CONTROL 17-11
EMISSION CONTROL <MPI>

1. Disconnect the vacuum hose (red stripe) from

throttle body and connect it to a hand vacuum
pump.
2. Plug the nipple from which the vacuum hose was
removed. Vac-
3. When the engine is cold or hot, apply a vacuum of uum
53 kPa, and check the condition of the vacuum.
When engine is cold Engine speed (r/min)
(Engine coolant temperature: 40°C or less)
AK100011AC
Engine condition Normal condition
At idle Vacuum is maintained. 3. Start the engine.
3,000 r/min 4. Check that a fairly constant negative pressure is
generated regardless of the engine speed.
When engine is hot 5. If no negative pressure is generated, the port is
(Engine coolant temperature: 80°C or higher) probably blocked and should be cleaned.
Engine condition Normal condition
At idle Vacuum is maintained. PURGE CONTROL SOLENOID VALVE
3,000 r/min (within 3 Vacuum will leak. CHECK
M1173001700193
minutes after engine
NOTE: When disconnecting the vacuum hose,
starts)
always make a mark so that it can be reconnected at
original position.
PURGE PORT VACUUM CHECK
M1173001500177
A
<4G1> Vacuum hose

Plug

Battery
AK100012 AC

AK300773 AB

<4G6>
Vacuum hose
Plug

AK100013

AK300774 AB 1. Disconnect the vacuum hose from the solenoid

valve.
1. Disconnect the vacuum hose (red stripe) from the
2. Disconnect the harness connector.
throttle body and connect a hand vacuum pump to
the nipple. 3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
2. Plug the vacuum hose (red stripe).
17-12 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

4. Check airtightness by applying a vacuum with Battery voltage Normal condition

voltage applied directly from the battery to the
purge control solenoid valve and without applying Applied Vacuum leaks
voltage. Not applied Vacuum maintained
5. Measure the resistance between the terminals of
the solenoid valve.
Standard value: 30 − 34 Ω (at 20°C)

FUEL VAPOUR CANISTER REMOVAL

AND INSTALLATION
M1173004200153

Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).

3
2

4
1 8
5

AC208253AD

Removal steps Removal steps (Continued)

1. Emission vacuum hose connection 5. Fuel vapour control line clamp
2. Fuel vapour control line hose 6. Fuel vapour canister
3. Fuel vapour control check valve 7. Fuel high-pressure hose clamp
4. Fuel vapour control line hose 8. Fuel vapour canister bracket
 ENGINE AND EMISSION CONTROL 17-13
EMISSION CONTROL <MPI>

EXHAUST GAS RECIRCULATION The EGR flow rate is controlled by the EGR valve so
as not to decrease the driveability.
(EGR) SYSTEM
OPERATION
GENERAL INFORMATION (EGR SYSTEM)
M1173005200327 The EGR valve is being closed and does not
The exhaust gas recirculation (EGR) system lowers recirculate exhaust gases under one of the following
the nitrogen oxide (NOx) emission level. conditions.
When the air/fuel mixture combustion temperature is Otherwise, the EGR valve is opened and recirculates
high, a large quantity of nitrogen oxides (NOx) is exhaust gases.
generated in the combustion chamber. • The engine coolant temperature is low.
Therefore, this system recirculates part of emission • The engine is at idle.
gas from the exhaust port of the cylinder head to the • The throttle valve is widely opened.
combustion chamber through the intake manifold to
decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.

SYSTEM DIAGRAM
<4G1>

EGR
control
solenoid
valve
Engine-ECU <M/T>,
OFF Engine-A/T-ECU <A/T>
EGR valve
Manifold absolute
ON pressure (MAP) sensor

Control Engine coolant

relay temperature sensor

Battery Crank angle sensor

AK300775 AB
17-14 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

<4G6>

EGR
control
Solenoid
valve

OFF
Engine-ECU
EGR valve
ON Barometric pressure
sensor

Air flow sensor

Control
relay
Engine coolant
temperature sensor

Battery Crank angle sensor

AK302349 AB

COMPONENT LOCATION (EGR SYSTEM) <4G1>

M1173007600224

<4G1>
EGR control
solenoid valve

EGR valve

AK300777AB

AK300776AB <4G6>
EGR valve
<4G6>

EGR control
solenoid valve
AK300779AB

AK300778 AB
 ENGINE AND EMISSION CONTROL 17-15
EMISSION CONTROL <MPI>

EGR SYSTEM CHECK <4G1>

M1173002600348

<4G1>

Green stripe

Green stripe
Three-way
terminal
EGR valve

AK300782 AB
EGR valve
AK300780 AB <4G6>
Green stripe
<4G6>
Three-way
terminal

Green stripe
EGR valve

EGR valve
AK300783AB

AK300781AB 4. Connect the hand vacuum pump to the EGR

valve nipple.
1. Disconnect the vacuum hose (Green stripe) from
5. Check whether the engine stalls or the idling is
the EGR valve, and then connect a hand vacuum
unstable when a vacuum of 30 kPa or higher is
pump via the three-way terminal.
applied during idling.
2. When the engine is hot or cold, check the
condition of vacuum by racing the engine. EGR VALVE CHECK
M1173002800223
When engine is cold
1. Remove the EGR valve and inspect for sticking,
(Engine coolant temperature: 20°C or less)
carbon deposits, etc. If found, clean with a
Throttle valve Normal vacuum condition suitable solvent so that the valve seats correctly.
Open quickly No vacuum will generate (the 2. Connect a hand vacuum pump to the EGR valve.
same as barometric pressure.)
3. Apply 67 kPa of vacuum, and check that the
When engine is hot vacuum is maintained.
(Engine coolant temperature: 80°C or higher)
Throttle valve Normal vacuum condition
Open quickly It will momentarily rise over 13
kPa
3. Disconnect the three-way terminal.

AKX00348

4. Apply a vacuum and check the passage of air by

blowing through one side of the EGR passage.
Vacuum Passage of air
5.3 kPa or less Air is not blown out
27 kPa or more Air is blown out
17-16 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

5. Replace the gasket, and tighten to the specified 1. Disconnect the vacuum hose (White stripe) from
torque. the throttle body EGR vacuum nipple and connect
Tightening torque: a hand vacuum pump to the nipple.
<4G1> 21 ± 4 N⋅m 2. Plug the vacuum hose (White stripe).
<4G6> 20 ± 2 N⋅m

EGR PORT VACUUM CHECK <4G1>

M1173002900167

Vac-
uum

Engine speed (r/min)

AK100011AC
Green strip
3. Start the engine.
4. Check that a fairly constant negative is generated
AK300784AB regardless of the engine speed.
1. Disconnect the vacuum hose (Green stripe) from 5. If no negative pressure is generated, the port is
the throttle body EGR vacuum nipple and connect probably blocked and should be cleaned.
a hand vacuum pump to the nipple.
2. Plug the vacuum hose (Green stripe).
EGR CONTROL SOLENOID VALVE
CHECK <4G1>
M1173003100238
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.
Vac-
uum A

Engine speed (r/min)

AK201224AB
B
3. Start the engine and check that, after raising the
engine speed by racing the engine, purge vacuum
raises according to engine speed. Battery
AKX00351AE
NOTE: If there is a problem with change in
vacuum, the throttle body purge port may be 1. Disconnect the vacuum hose from the solenoid
clogged and require cleaning. valve.
2. Disconnect the harness connector.
EGR PORT VACUUM CHECK <4G6>
M1173002900156 3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
White stripe 4. Check air tightness by applying a vacuum with
voltage applied directly from the battery to the
EGR control solenoid valve and without applying
voltage.
Battery voltage Normal condition
Applied Vacuum leaks
Not applied Vacuum maintained
AK300786AB
 ENGINE AND EMISSION CONTROL 17-17
EMISSION CONTROL <MPI>

1. Disconnect the vacuum hose from the solenoid

valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
4. Check air tightness by applying a vacuum with
voltage applied directly from the battery to the
EGR control solenoid valve and without applying
voltage.
AKX00352
Battery B nipple Normal condition
5. Measure the resistance between the terminals of voltage condition
the solenoid valve. Not applied Open Vacuum
Standard value: 29 − 35 Ω (at 20°C) maintained
Applied Open Vacuum leaks
EGR CONTROL SOLENOID VALVE
Closed Vacuum
CHECK <4G6> maintained
M1173003100249
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.
A

C AK100016

Battery 5. Measure the resistance between the terminals of

the solenoid valve.
AK201251AB
Standard value: 29 − 35 Ω (at 20°C)
17-18 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

EXHAUST GAS RECIRCULATION (EGR)

VALVE REMOVAL AND INSTALLATION
M1173010500175

Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).

<4G1> 21 ± 4 N·m
3N
1

AC208130 AC

<4G6> 1
2 19 ± 3 N·m

3N

AC301219AC

Removal steps Removal steps (Continued)

1. Emission vacuum hose connection 2. EGR valve
3. EGR valve gasket

CATALYTIC CONVERTER
REMOVAL AND INSTALLATION
M1173003900386
Refer to GROUP 15 - Exhaust Pipe and Main Muffler P.15-11.
 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
 23-1

GROUP 23

AUTOMATIC
TRANSMISSION
CONTENTS

AUTOMATIC TRANSMISSION (FF) . . . . . . . . . . . . . . . . . . . . . . 23A

AUTOMATIC TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . 23B

NOTES
 26-1

GROUP 26

FRONT AXLE
CONTENTS

GENERAL INFORMATION . . . . . . . . 26-2 FRONT AXLE HUB ASSEMBLY . . . . 26-8

REMOVAL AND INSTALLATION . . . . . . . . 26-8
SERVICE SPECIFICATIONS. . . . . . . 26-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-11
DISASSEMBLY AND REASSEMBLY . . . . . 26-11
LUBRICANTS . . . . . . . . . . . . . . . . . . 26-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-13

SPECIAL TOOLS. . . . . . . . . . . . . . . . 26-4 DRIVE SHAFT ASSEMBLY . . . . . . . . 26-14

REMOVAL AND INSTALLATION . . . . . . . . 26-14
ON-VEHICLE SERVICE. . . . . . . . . . . 26-7 DISASSEMBLY AND REASSEMBLY . . . . . 26-18
WHEEL BEARING AXIAL PLAY CHECK . . 26-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 26-21
HUB BOLT REPLACEMENT . . . . . . . . . . . 26-7 BJ BOOT (RESIN BOOT)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 26-21
26-2 FRONT AXLE
GENERAL INFORMATION

GENERAL INFORMATION
M1261000100347
The front axle consists of front hubs, knuckles, wheel • The dynamic damper has been mounted on the
bearings and driveshafts, and has the following driveshaft to reduce differential gear noise.
features: • ABS rotor for detecting the wheel speed is
• The wheel bearing is a double-row angular press-fitted to the BJ.
contact ball bearing which incorporates the oil NOTE: .
seals and is highly resistant to thrust loads. • TJ: Tripod Joint
• The driveshaft incorporates BJ-TJ type constant • BJ: Birfield Joint
velocity joints with high transmission efficiency for
low vibration and noise.

SPECIFICATIONS
Item 1.3L, 1.6L 2.0L
Wheel bearing Type Double-row angular contact ball bearing
Bearing (OD x ID) mm 80 x 40 80 x 40
Driveshaft Joint type Outer BJ BJ
Inner TJ TJ
Length (joint to joint) × LH 375.9 × 23.2 375.9 × 23.2
diameter mm RH 699 × 23.2 (1.6L-M/T), 700 × 23.2
703.2 × 22 (1.3L-M/T,
1.6L-A/T)

CONSTRUCTION DIAGRAM

Strut assembly

Knuckle TJ (LH)
Drive shaft (LH)

Front hub

TJ (RH) Dynamic damper

Dynamic damper

BJ
ABS rotor
Wheel bearing Drive shaft (RH)

AC303569 AB
 FRONT AXLE
SERVICE SPECIFICATIONS
26-3
SERVICE SPECIFICATIONS
M1261000300396

Item Standard value Limit

Wheel bearing axial play mm − 0.05
Hub starting torque N⋅m − 1.8
Protruding length of stabilizer bar mounting bolt mm 22 ± 1.5 −
Setting of TJ boot length mm 1.3L-RH, 1.6L-A/T-RH 85 ± 3 −
1.3L-LH, 1.6L-M/T, 90 ± 3 −
1.6L-A/T-LH, 2.0L
Opening dimension of the When the BJ boot band 2.9 −
special tool (MB991561) mm (small) is crimped
When the BJ boot band 2.9 −
(large) is crimped
Crimped width of the BJ boot band mm 2.4 − 2.8 −

LUBRICANTS
M1261000400382

Item Specified lubricant Quantity

TJ boot grease Repair kit grease 1.3L-LH, 1.6L-LH, 2.0L-LH 120 ± 10 g
1.3L-RH, 1.6L-A/T-RH 110 ± 10 g
1.6L-M/T-RH 120 ± 10 g
2.0L-RH 105 ± 10 g
BJ boot grease Repair kit grease 95 ± 10 g
26-4 FRONT AXLE
SPECIAL TOOLS

SPECIAL TOOLS
M1261000600375

Tool Number Name Use

MB990767 End yoke holder Fixing of the hub

B990767

MB991618 Hub bolt remover Removal of the hub bolt

MB991618

MB991897 Ball joint remover 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
AC106827
ball joint.
A MB990241 Axle shaft puller Removal of the drive shaft
A: MB990242 A: Puller shaft
B B: MB990244 B: Puller bar

MB990241AB

MB991354 Puller body

MB991354

MB991056 or Knuckle arm • Removal of the hub

MB991355 bridge • Removal of the wheel bearing

A A: MB991017 A, B: Front hub • Removal of the hub

B: MB990998 remover and • Provisional holding of the wheel
C: MB991000 installer bearing
B C: Spacer • Measurement of hub starting torque
C • Measurement of wheel bearing axial
AC100320AB
play
NOTE: MB991000, which belongs to
MB990998, should be used as a
spacer.
 FRONT AXLE
SPECIAL TOOLS
26-5
Tool Number Name Use
MB990685 Torque wrench Measurement of hub starting torque

MB990326 Preload socket

MB990326

MB990810 Side bearing • Removal of the centre bearing

puller bracket
• Removal of the wheel bearing inner
race (outside)
MB990810

MB991460 Plug Prevention of transmission fluid drain

and of entry of foreign objects

MB991561 Boot band BJ boot (resin boot) band installation

crimping tool

MB991561

MB990925 Bearing and oil • Removal of the wheel bearing

seal installer set • Removal and installation of the
centre bearing
• Press-fitting of the dust seal outer,
inner
MB990925

MB990890 Rear suspension • Installation of the wheel bearing

bushing base • Press-fitting of the dust seal outer,
inner

MB990890

MB990883 Rear suspension Installation of the wheel bearing

bushing arbor

MB990883
26-6 FRONT AXLE
SPECIAL TOOLS

Tool Type Tool number O D mm

MB990925
A MB990926 39.0
MB990927 45.0
MB990928 49.5
MB990929 51.0
MB990930 54.0
A
Installer adapter MB990931 57.0
MB990932 61.0
C Brass bar MB990933 63.5
MB990934 67.5

B
MB990935 71.5
Bar (snap-in type) MB990936 75.5
MB990937 79.0
B MB990938 −
C MB990939 −

Tool box
ACX02372 AC
 FRONT AXLE
ON-VEHICLE SERVICE
26-7
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK MB991618
M1261000900224
1. Remove the caliper assembly and suspend it with
a wire.
2. Remove the brake disc from the front hub.

Hub bolt

AC302114 AD

3. Use special tool hub bolt remover (MB991618) to

remove the hub bolts.

AC209503AC

3. Attach a dial gauge as shown in the illustration, MB990767

and then measure the axial play while moving the
hub in the axial direction. Plain
washer
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 AC104588 AC

tighten the caliper assembly mounting bolts to the 4. Install the plain washer to the new hub bolt, and
specified torque 100 ± 10 N⋅m. install the bolt with a nut while holding the hub
with special tool end yoke holder (MB990767).
HUB BOLT REPLACEMENT 5. Install the brake disc, caliper assembly and
M1261001000291
1. Remove the caliper assembly and suspend it with tighten the caliper assembly mounting bolts to the
wire so that it does not fall. specified torque 100 ± 10 N⋅m.
2. Remove the brake disc.
26-8 FRONT AXLE
FRONT AXLE HUB ASSEMBLY

FRONT AXLE HUB ASSEMBLY

REMOVAL AND INSTALLATION
M1261001700353

CAUTION
• Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when
removing or installing the drive shaft. 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.
Post-installation Operation
• Check the dust cover for cracks or damage by pushing it
with your finger.

N 6

25 ± 5 N·m
7

8 12 13 10 N

167 ± 9 N·m 1

7
3
11
245 ± 29 N·m
5

4N
7

100 ± 10 N·m

108 ± 10 N·m
2 9

AC209505AC

Removal steps Removal steps (Continued)

1. Front ABS sensor 8. Collar
<<A>> 2. Caliper assembly 9. Lower arm connecting bolt
<<B>> 3. Brake disc <<D>> 10. Self-locking nut (tie rod end
<<C>> >>B<< 4. Drive shaft nut connection)
>>B<< 5. Washer <<E>> 11. Drive shaft
>>A<< 6. Self-locking nut (stabilizer bar 12. Nut (hub and knuckle to strut
connection) connection)
>>A<< 7. Stabilizer rubber 13. Hub and knuckle
 FRONT AXLE
FRONT AXLE HUB ASSEMBLY
26-9
REMOVAL SERVICE POINTS <<D>> SELF-LOCKING NUT (TIE ROD
<<A>> CALIPER ASSEMBLY REMOVAL END CONNECTION) REMOVAL
Secure the removed caliper assembly with wire, etc. CAUTION
• Do not remove the nut from ball joint. Loosen
<<B>> BRAKE DISC REMOVAL 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

BOLT
(M8×1.25) Nut MB991897

AC209507AC

If the brake disc is seized, install M8x1.25-mm bolts

Bolt
as shown, and remove the disc by tightening the Ball joint AC208247AD
bolts evenly and gradually.
1. Install special tool ball joint remover (MB991897)
<<C>> DRIVE SHAFT NUT REMOVAL as shown in the figure.
CAUTION
Do not apply pressure to wheel bearing by the Bolt
vehicle weight to avoid possible damage when
drive shaft nut is loosened. Parallel

Knob Correct

Wrong AC106821AB

2. Turn the bolt and knob as necessary to make the

MB990767 jaws of special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
AC102462 AC
NOTE: When adjusting the jaws in parallel, make
Use special tool end yoke holder (MB990767) to fix sure the knob is in the position shown in the
the hub and remove the drive shaft nut. figure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.
26-10 FRONT AXLE
FRONT AXLE HUB ASSEMBLY

<<E>> DRIVE SHAFT REMOVAL INSTALLATION SERVICE POINT

<Comfort>
>>A<< STABILIZER
RUBBER/SELF-LOCKING NUT
(STABILIZER BAR CONNECTION)
INSTALLATION
MB990767

MB990241
AC100128AD

<Sport>
MB990244
(Three)

MB990767 AC210393 AC

Install the stabilizer rubber and collar as shown in the

figure, and tighten the self-locking nut so that the
MB991354 protruding length of the stabilizer bar mounting bolt
MB990242 protruding part meets its standard value (A).
AC303949 AC Standard value (A): 22 ± 1.5 mm

1. Use the following special tools to push out the

drive shaft from the hub and knuckle. >>B<< WASHER/ DRIVE SHAFT NUT
• Axle shaft puller (MB990241) INSTALLATION
• Puller shaft (MB990242) CAUTION
• Puller bar (MB990244) Before securely tightening the drive shaft nuts,
• Puller body (MB991354) make sure there is no load on the wheel
• End yoke holder (MB990767) bearings. Otherwise the wheel bearings will be
damaged.

Washer

Drive shaft

AC102551AC MB990767
AC102465AD
2. Withdraw the drive shaft from the hub by pulling
the bottom of the hub and knuckle towards you. 1. Be sure to install the drive shaft washer in the
3. Hang the drive shaft on the vehicle body with a specified direction.
rope. 2. Using special tool end yoke holder (MB990767),
tighten the drive shaft nut to the specified torque.
Tightening torque: 245 ± 29 N⋅m
 FRONT AXLE
FRONT AXLE HUB ASSEMBLY
26-11
INSPECTION NOTE: If the meshing of the wheel bearing outer
M1261001800242 race and the knuckle, or of the wheel bearing
• Check the hub for cracks and spline for wear. inner race and the hub, is loose, replace the
• Check the knuckle for cracks. bearing or damaged parts.
• Check for defective bearing.

DISASSEMBLY AND REASSEMBLY

M1261001900205

2
<Sport>

N 1
<Comfort>

N 4

3 2
AC303659AB

Disassembly steps Assembly steps

1. Snap ring 5. Knuckle
<<A>> 2. Hub >>A<< 4. Wheel bearing
3. Dust cover 1. Snap ring
<<B>> 4. Wheel bearing 3. Dust cover
5. Knuckle 2. Hub
>>B<< • Hub starting torque check
>>C<< • Wheel bearing axial play check
26-12 FRONT AXLE
FRONT AXLE HUB ASSEMBLY

DISASSEMBLY SERVICE POINTS 1. Crush the oil seal in two places so that the tabs of
<<A>> HUB REMOVAL the special tool will be caught on the wheel
bearing inner race (outside).
CAUTION
When the hub has been removed, always replace
CAUTION
the wheel bearing with a new part because wheel
When removing the inner race (outside) from the
bearing frictional surface will be damaged when
hub, be careful not to let the hub drop.
removing the hub.
MB990810

MB991017 MB991056 or
MB991355

Tighten the nut

with the bolt
secured Inner race
MB991000
(outside) AC102509 AC
AC100130AB

Use the following special tools to pull out the hub 2. Remove the wheel bearing inner race (outside)
from the knuckle. from the front hub by using special tool side
• Knuckle arm bridge (MB991056 or MB991355) bearing puller (MB990810).
• Front hub remover and Installer (MB991017)
• Spacer (MB991000) MB990938

<<B>> WHEEL BEARING REMOVAL Inner race

(outside) MB990935
Inner race
(outside)

MB991056 or MB991355 AC102510 AC

3. Install the inner race (outside) that was removed

Outer oil seal
from the hub to the wheel bearing, and then use
the following special tools to remove the wheel
AC102508 AC
bearing.
• Installer bar (MB990938)
• Installer adapter (MB990935)
• Knuckle arm bridge (MB991056 or MB991355)
 FRONT AXLE
FRONT AXLE HUB ASSEMBLY
26-13
REASSEMBLY SERVICE POINTS
MB990685
>>A<< WHEEL BEARING INSTALLATION
1. Fill the wheel bearing with multipurpose grease.
2. Apply a thin coating of multipurpose grease to the
knuckle and bearing contact surfaces.
CAUTION
Press the outer race when pressing-in the wheel MB990326
bearing. Otherwise the wheel bearing will be
damaged. AC100136 AB

MB990883
3. Measure the hub starting torque by using the
following special tools.
MB990890 • Torque wrench (MB990685)
• Preload socket (MB990326)
Limit: 1.8 N⋅m
4. The starting torque must be within the limit and
the hub rotation must be smooth.

AC102511 AC
>>C<< WHEEL BEARING AXIAL PLAY
3. Press-in the bearing by using the following special CHECK
tools.
MB991000
• Rear suspension bushing arbor (MB990883)
• Rear suspension bushing base (MB990890)
245 ± 29 N·m
>>B<< HUB STARTING TORQUE CHECK Tighten the nut
with the bolt
secured

MB991017
MB991000 MB991017

AC100137AB

1. Measure to determine whether the wheel bearing

245 ± 29 N·m axial play is within the limit or not by using the
Tighten the nut following special tools.
with the bolt secured
• Front hub remover and installer (MB991017)
AC210929AC • Spacer (MB991000)
1. Tighten the following special tools to the specified Limit: 0.05 mm
torque, and then press-in the hub into the knuckle. 2. If the play is not within the limit range while the nut
• Front hub remover and installer (MB991017) is tightened to 245 ± 29 N⋅m, the bearing, hub
• Spacer (MB991000) and/or knuckle have probably not been installed
2. Rotate the hub in order to seat the bearing. correctly. Replace the bearing and re-install.

INSPECTION
M1261002000078
• Check the front hub and brake disc mounting
surfaces for galling and contamination.
• Check the knuckle inner surface for galling and
cracks.
26-14 FRONT AXLE
DRIVE SHAFT ASSEMBLY

DRIVE SHAFT ASSEMBLY

REMOVAL AND INSTALLATION
M1261003500399

CAUTION
• Do not strike the ABS rotors installed to the BJ outer race of drive shaft against other parts when
removing or installing the drive shaft. 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.

Pre-installation Operation Post-installation Operation

• Transmission Fluid Draining (Refer to GROUP • Front Exhaust Pipe Installation (Refer to
22A, On-vehicle Service − Transmission Oil GROUP 15, Exhaust Pipe and Muffler
Replacement P.22A-8). P.15-11).
• Front Exhaust Pipe Removal (Refer to GROUP • Check the Ball Joint Dust Cover for cracks or
15, Exhaust Pipe and Muffler P.15-11). damage by pushing it with your finger.
• Transmission Fluid Filling (Refer to GROUP
22A, On-vehicle Service − Transmission Oil
Replacement P.22A-8).

12 N N 6

7 4 5 25 ± 5 N·m
10 N
3
11

8 245 ± 29 N·m
7
2
1N

9 108 ± 10 N·m

AC303689AB

Removal steps Removal steps (Continued)

<<A>> >>C<< 1. Drive shaft nut 8. Collar
>>C<< 2. Washer 9. Lower arm connecting bolt
3. Front ABS sensor <<B>> 10. Self-locking nut (tie rod end
4. Front ABS sensor bracket connection)
5. Brake hose bracket <<C>> >>A<< 11. Drive shaft
>>B<< 6. Self-locking nut (stabilizer bar 12. Circlip
connection)
>>B<< 7. Stabilizer rubber
 FRONT AXLE
DRIVE SHAFT ASSEMBLY
26-15
REMOVAL SERVICE POINTS 2. Turn the bolt and knob as necessary to make the
<<A>> DRIVE SHAFT NUT REMOVAL jaws of special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
CAUTION
NOTE: When adjusting the jaws in parallel, make
Do not apply pressure to the wheel bearing by sure the knob is in the position shown in the
the vehicle weight to avoid possible damage figure.
when the drive shaft nut is loosened.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.

<<C>> DRIVE SHAFT REMOVAL

<Comfort>

MB990767
MB990767
AC102462 AC

Use special tool end yoke holder (MB990767) to fix

the hub and remove the drive shaft nut.
MB990241
AC100128AD
<<B>> SELF-LOCKING NUT (TIE ROD
END CONNECTION) REMOVAL <Sport>
CAUTION
• Do not remove the nut from ball joint. Loosen MB990767
it and use special tool to avoid possible
damage to ball joint threads.
• Hang special tool with cord to prevent it from
MB990244
falling.
(Three)
Cord MB990242 MB991354
AC102550 AE

1. Use the following special tools to push out the

drive shaft from the hub.
Nut MB991897 • Axle shaft puller (MB990241)
• Puller shaft (MB990242)
• Puller bar (MB990244)
Bolt • Puller body (MB991354)
Ball joint AC208247AD
• End yoke holder (MB990767)

1. Install special tool ball joint remover (MB991897)

as shown in the figure.

Bolt Drive shaft

Parallel

Knob Correct AC102551AC

2. Remove the drive shaft from the hub by pulling

Wrong the bottom of the brake disc towards you.
AC106821AB
26-16 FRONT AXLE
DRIVE SHAFT ASSEMBLY

CAUTION 4. Use special tool plug (MB991460) to prevent the

• Do not pull on the drive shaft; doing so will entry of foreign material into the transmission
damage the TJ; be sure to use the pry bar. case.
• When pulling the drive shaft out from the CAUTION
transmission, be careful that the spline part of
the drive shaft does not damage the oil seal.
MB991000
Transmission
MB991017

TJ assembly AC102555 AC

Pry bar Do not apply pressure to the wheel bearing by

AC100141 AG
the vehicle weight to avoid possible damage
3. Insert a pry bar between the transmission case when the drive shaft is removed. If, however,
and the drive shaft, and then pry and remove the vehicle weight must be applied to the bearing in
drive shaft from the transmission. moving the vehicle, temporarily secure the wheel
bearing by using the following special tools.
• Spacer (MB991000)
• Front hub remover and installer (MB991017)

MB991460
AC102554 AC
 FRONT AXLE
DRIVE SHAFT ASSEMBLY
26-17
INSTALLATION SERVICE POINTS >>C<< WASHER/DRIVE SHAFT NUT
>>A<< DRIVE SHAFT INSTALLATION INSTALLATION
CAUTION
When installing the drive shaft, be careful that Washer
the spline part of the drive shaft does not
damage the oil seal.

>>B<< STABILIZER
RUBBER/SELF-LOCKING NUT
(STABILIZER BAR CONNECTION) MB990767
INSTALLATION AC102465AD

1. Be sure to install the drive shaft washer in the

A
specified direction.
CAUTION
Before securely tightening the drive shaft nuts,
make sure there is no load on the wheel
bearings. Otherwise the wheel bearing will be
damaged.
2. Using special tool end yoke holder (MB990767),
AC210393 AC
tighten the drive shaft nut to the specified torque.
Install the stabilizer rubber and collar as shown in the Tightening torque: 245 ± 29 N⋅m
figure, and tighten the self-locking nut so that the
protruding length of the stabilizer bar mounting bolt
protruding part meets its standard value (A).
Standard value (A): 22 ± 1.5 mm
26-18 FRONT AXLE
DRIVE SHAFT ASSEMBLY

DISASSEMBLY AND REASSEMBLY

M1261003700456

CAUTION
• Be careful not to damage the ABS rotor, which is attached to the BJ outer race during disassembly
and reassembly.
• Never disassemble the BJ assembly except when replacing the BJ boot.

N 4
3

5N 6
7
1N
2N

9
N 8 13

10

N 11
N 12

4 1 4
4
5 7
8 11 7 1
12 1
5 13
2 3 5
6
2 2
Grease for TJ
Grease for BJ

BJ boot repair kit TJ repair kit TJ boot repair kit

AC303692 AB

Disassembly steps Disassembly steps (Continued)

>>D<< 1. TJ boot band (large) 10. BJ assembly
>>D<< 2. TJ boot band (small) 11. BJ boot band (small)
<<A>> >>C<< 3. TJ case 12. BJ boot band (large)
4. Circlip 13. BJ boot
5. Snap ring NOTE: .
<<A>> >>B<< 6. Spider assembly • TJ: Tripod Joint
<<B>> >>A<< 7. TJ boot • BJ: Birfield Joint
>>A<< 8. Damper band
>>A<< 9. Dynamic damper
 FRONT AXLE
DRIVE SHAFT ASSEMBLY
26-19
LUBRICATION POINTS

Grease: repair kit grease

Amount used: <1.3L-LH, 1.6L-LH,
2.0L-LH>: 120 ± 10 g
<1.3L-RH, 1.6L-A/T-RH>: 110 ± 10 g
<1.6L-M/T-RH>: 120 ± 10 g
<2.0L-RH>: 105 ± 10 g
CAUTION
The drive shaft joint uses special
grease. Do not mix old and new or
different types of grease.

Grease: repair kit grease

Amount used: 95 ± 10 g

CAUTION
The drive shaft joint uses special
grease. Do not mix old and new or
different types of grease.
AC303700 AB

DISASSEMBLY SERVICE POINTS 2. Always clean the spider assembly when the
<<A>> TJ CASE/SPIDER ASSEMBLY grease contains water or foreign material.
REMOVAL
<<B>> TJ BOOT REMOVAL
CAUTION
1. Wipe off grease from the shaft spline.
Do not disassemble the spider assembly.
2. When reusing the TJ boot, wrap plastic tape
1. Wipe off grease from the spider assembly and the
around the shaft spline to avoid damaging the
inside of the TJ case.
boot.
26-20 FRONT AXLE
DRIVE SHAFT ASSEMBLY

REASSEMBLY SERVICE POINTS >>C<< TJ CASE INSTALLATION

>>A<< DYNAMIC DAMPER/DAMPER CAUTION
BAND/TJ BOOT INSTALLATION The drive shaft joint use special grease. Do not
mix old and new or different types of grease.
CAUTION
There should be no grease adhered to the rubber
part of the dynamic damper.

AC102656 AC

After applying the specified grease to the TJ case,

AC101695 AC
insert the drive shaft and apply grease one more
time.
1. Install the dynamic damper in the position (L) Specified grease: Repair kit grease
shown in the figure . Amount to use:
L: 230 ± 3 mm <LH>, 415 ± 3 mm <RH> <1.3L-LH, 1.6-LH, 2.0-LH>: 120 ± 10 g
2. Secure the damper bands. <1.3L-RH, 1.6L-A/T-RH>: 110 ± 10 g
<1.6L-M/T-RH>: 120 ± 10 g
3. Wrap plastic tape around the shaft spline, and
<2.0L-RH>: 105 ± 10 g
then install the TJ boot band (small) and TJ boot.
NOTE: The grease in the repair kit should be divided
in half for use, respectively, at the joint and inside the
>>B<< SPIDER ASSEMBLY boot.
INSTALLATION
CAUTION >>D<< TJ BOOT BAND (SMALL)/TJ BOOT
• The drive shaft joint use special grease. Do BAND (LARGE) INSTALLATION
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 A

AC102657AC

Chamfered Set the TJ boot bands at the specified distance in

side
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):
<1.3L-RH, 1.6L-A/T-RH>: 85 ± 3 mm
<1.3L-LH, 1.6L-M/T, 1.6L-A/T-LH, 2.0L>: 90 ± 3
AC102654AC mm
2. Install the spider assembly to the shaft from the
direction of the spline chamfered side.
 FRONT AXLE
DRIVE SHAFT ASSEMBLY
26-21
INSPECTION 4. Align the centre groove on the BJ boot small end
M1261003800130 with the shaft groove.
• Check the drive shaft for damage, bending or
corrosion. MB991561
• Check the drive shaft spline part for wear or
Stopper
damage.
• Check the spider assembly for roller rotation,
wear or corrosion.
• Check the groove inside TJ case for wear or W
corrosion.
• Check the dynamic damper for damage or
cracking. Adjusting bolt
• Check the boots for deterioration, damage or AC102660 AC

cracking.
5. Turn the adjusting bolt on special tool boot band
crimping tool (MB991561) so that the size of the
BJ BOOT (RESIN BOOT) REPLACEMENT
M1261005200361 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.
<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
AC102658
more than once.
1. Remove the boot bands (large and small). Boot
NOTE: The boot bands cannot be re-used.
2. Remove the BJ boot. A
3. Wrap a plastic tape around the shaft spline, and
Boot band
assemble the boot band and BJ boot. (small)

Projection AC102661AC

6. Position the BJ boot band (small) so that there is

even clearance at either end (A and B).

AC102659
26-22 FRONT AXLE
DRIVE SHAFT ASSEMBLY

CAUTION CAUTION
• Secure the drive shaft in an upright position The drive shaft joint uses special grease. Do not
and clamp part of the boot band to be crimped mix old and new or different types of grease.
securely in the jaws of special tool. 10.Fill the inside of the boot with the specified
• Crimp the boot band until special tool amount of the specified grease.
touches the stopper.
Specified grease: Repair kit grease
Amount to use: 95 ± 10 g

MB991561
AC102663 AC

7. Use the special tool to crimp the boot band AC102664 AC

(small).
11.Align the centre groove on the BJ boot big end
with the BJ case groove.
12.Follow the same procedure as in step 5 to adjust
C the size of the opening (W) on the special tool so
that it is at the standard value.
Standard value (W): 2.9 mm

Projection

AC102662 AD D

8. Check that the crimping amount (C) of the boot Boot band
band is at the standard value. (large)
Standard value (C): 2.4 − 2.8 mm
E
<If the crimping amount is larger than 2.8 mm > Boot
Readjust the value of (W) in step 5 according
AC102665AC
to the following formula, and then repeat the
operation in step 7. 13.Position the BJ boot band (large) so that there is
W = 5.5 mm − C even clearance at either end (D and E).
Example: If C = 2.9 mm, then W = 2.6 mm. 14.Use the special tool to crimp the BJ boot band
<If the crimping amount is smaller than 2.4 (large) in the same way as in step 7.
mm >
Remove the BJ 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 BJ 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 F
AC102666 AD
steps 6 to 8, using a new boot band.
15.Check that the crimping amount (F) of the boot
band is at the standard value.
 FRONT AXLE
DRIVE SHAFT ASSEMBLY
26-23
Standard value (F): 2.4 − 2.8 mm 16.Check that the boot band is not sticking out past
<If the crimping amount is larger than 2.8 mm > the place where it has been installed. If the boot
Readjust the value of (W) in step 12 band is sticking out, remove it and then repeat
according to the following formula, and then steps 13 to 15, using a new boot band.
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 BJ boot band, readjust the value
of (W) in step 12 according to the following
formula, and then repeat the operations in
steps 13 and 14 using a new BJ boot band.
W = 5.8 mm − F
Example: If F = 2.3 mm, then W = 3.5 mm.
NOTES
 27-1

GROUP 27

REAR AXLE
CONTENTS

GENERAL INFORMATION . . . . . . . . 27-2 ON-VEHICLE SERVICE . . . . . . . . . . . 27-4

WHEEL BEARING AXIAL PLAY CHECK . . 27-4
SERVICE SPECIFICATIONS. . . . . . . 27-2 REAR HUB ROTARY-SLIDING
RESISTANCE CHECK . . . . . . . . . . . . . . . . 27-4
SEALANT. . . . . . . . . . . . . . . . . . . . . . 27-2 HUB BOLT REPLACEMENT. . . . . . . . . . . . 27-4

SPECIAL TOOLS. . . . . . . . . . . . . . . . 27-3 REAR AXLE HUB ASSEMBLY . . . . . 27-5

REMOVAL AND INSTALLATION . . . . . . . . 27-5
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27-6
27-2 REAR AXLE
GENERAL INFORMATION

GENERAL INFORMATION
M1271000100304
The rear axle has the following features: • ABS rotor for detecting the wheel speeds is
• The wheel bearing is a unit ball bearing press-fitted to the rear hub in vehicles with ABS.
(double-row angular contact ball bearing) which
incorporates the oil seals and is highly resistant
to a thrust load.
CONSTRUCTION DIAGRAM

Oil seal
Rear hub

Trailing arm spindle

Wheel bearing

ABS rotor

AC300617AB

SERVICE SPECIFICATIONS
M1271000300483

Item Limit
Wheel bearing axial play mm 0.05
Rear hub rotary-sliding resistance N 19

SEALANT
M1271000500261

Item Specified sealant Remark

Hub cap 3M ATD Part No.8663 or equivalent Semi-drying sealant
 REAR AXLE
SPECIAL TOOLS
27-3
SPECIAL TOOLS
M1271000600495

Tool Number Name Use

MB990767 End yoke holder Hub fixing

B990767

MB991618 Hub bolt remover Hub bolt removal

MB991618

MD998801 Remover Removal of ABS rotor

MD998812 Installer cap

MD998813 Installer 100

MD998815 Installer adapter

27-4 REAR AXLE
ON-VEHICLE SERVICE

ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK 3. Wind a rope around the hub bolt and turn the hub
M1271000900452 by pulling at a 90° angle with a spring balance.
1. Remove the caliper assembly, and suspend the Measure to determine whether or not the
caliper assembly with a wire and remove the rotary-sliding resistance of the rear hub is at the
brake disc. limit value.
Limit: 19 N
4. If limit value is exceeded, loosen the self-locking
nut and then tighten it to the specified torque and
check the rear hub rotary sliding resistance again.
Tightening torque: 175 ± 25 N⋅m
5. Replace the rear hub assembly if an adjustment
cannot be made to within the limit.

AC303736 AB HUB BOLT REPLACEMENT

M1271001000258
2. Check the bearing's axial play. Place a dial gauge 1. Remove the caliper assembly and suspend it with
against the hub surface; then move the hub in the wire so that it does not fall.
axial direction and check whether or not there is 2. Remove the brake disc.
axial play.
MB991618
Limit: 0.05 mm
3. If the play exceeds the limit, the self-locking nut
should be tightened to the specified torque and
check the axial play again.
Tightening torque: 175 ± 25 N⋅m
Hub bolt
4. Replace the rear hub assembly if an adjustment
cannot be made to within the limit.

REAR HUB ROTARY-SLIDING AC302114 AD

RESISTANCE CHECK 3. Use special tool hub bolt remover (MB991618) to

M1271001100244 remove the hub bolts.
1. Remove the caliper assembly, and suspend the
caliper assembly with a wire and remove the
brake disc.
2. Turn the hub a few times to seat the bearing. MB990767

Plain
washer

AC104588 AC

4. Install the plain washer to the new hub bolt, and

install the bolt with a nut while holding the hub
AC303737
with special tool end yoke holder (MB990767).
5. Install the brake disc, caliper assembly and
tighten the caliper assembly mounting bolts to the
specified torque 60 ± 5 N⋅m.
 REAR AXLE
REAR AXLE HUB ASSEMBLY
27-5
REAR AXLE HUB ASSEMBLY
REMOVAL AND INSTALLATION
M1271002000381

CAUTION
• Care must be taken not to scratch or damage the teeth of the ABS rotor. The ABS rotor must never
be dropped. If the teeth of the ABS rotor are chipped, resulting in a deformation of the ABS rotor,
it will not be able to accurately detect the wheel rotation speed, and the system will not function
normally.
• The rear hub assembly should not be dismantled. When removing the rear hub assembly, the
wheel bearing inner race may be left at the spindle side. In this case, always replace the rear hub
assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play.

<SPORT>
1 6 5
2
60 ± 5 N·m

<COMFORT>

6 3

5
3
2 N 4
Semi-drying sealant: 175 ± 25 N·m
3M ATD Part No. 8663 or
equivalent
AC304175 AB

Removal steps Removal steps (Continued)

<<A>> 1. Caliper assembly <<B>> >>B<< 4. Self-locking nut
2. Brake disc 5. Rear hub assembly
3. Hub cap <<C>> >>A<< 6. ABS rotor
27-6 REAR AXLE
REAR AXLE HUB ASSEMBLY

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

<<A>> CALIPER ASSEMBLY REMOVAL >>A<< ABS ROTOR INSTALLATION
Secure the removed caliper assembly with wire, etc. CAUTION
When installing, take care not to deform the ABS
<<B>> SELF-LOCKING NUT REMOVAL rotor.
CAUTION Iron piece
ABS rotor

Rear hub
assembly

Iron piece
AC102209AC

AC303738 Press-fit the ABS rotor to the rear hub assembly.

Do not apply the vehicle weight to the wheel
bearing while loosening the self-locking nut, or >>B<< SELF-LOCKING NUT
the wheel bearing will be damaged. INSTALLATION
CAUTION
<<C>> ABS ROTOR REMOVAL
175 ± 25 N·m

MD998812

MD998813

ABS rotor AC303739 AB

MD998815 Before securely tightening the self-locking nuts,

MD998801 make sure there is no load on the wheel
bearings. Otherwise the wheel bearing will be
damaged.
Tighten the self-locking nut to the specified torque.

INSPECTION
M1271002100258
• Check the rear hub assembly for crack or
damage.
Rear hub assembly
AC210936 AC
• Check the oil seal of the rear hub assembly for
crack or damage.
Use the following special tools to press out ABS rotor • Check the ABS rotor for chipped teeth.
from the rear hub assembly.
• Remover (MD998801)
• Installer cap (MD998812)
• Installer100 (MD998813)
• Installer adapter (MD998815)
 31-1

GROUP 31

WHEEL AND TYRE

CONTENTS

GENERAL INFORMATION . . . . . . . . 31-2 ON-VEHICLE SERVICE . . . . . . . . . . . 31-7

TYRE INFLATION PRESSURE CHECK . . . 31-7
SERVICE SPECIFICATIONS. . . . . . . 31-2 TYRE WEAR CHECK . . . . . . . . . . . . . . . . . 31-7
WHEEL RUNOUT CHECK . . . . . . . . . . . . . 31-7
TROUBLESHOOTING . . . . . . . . . . . . 31-3
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 31-3 WHEEL AND TYRE . . . . . . . . . . . . . . 31-7
WHEEL BALANCE ACCURACY . . . . . . . . 31-4 INSTALLATION SERVICE POINT . . . . . . . 31-7
31-2 WHEEL AND TYRE
GENERAL INFORMATION

GENERAL INFORMATION
M1311000100220
The wheels and tyres of the following specifications
have been established.
SPECIFICATIONS
ROAD WHEEL AND TYRE
Item Comfort Sport
Wheel Type Steel type or Aluminium type* Aluminium type
Size 15 × 6JJ 16 × 6JJ
Amount of wheel offset mm 46 46
PCD mm 114.3 114.3
Tyre Size 195/60R15 88H 195/50R16 84V
SPARE WHEEL AND TYRE
Item Comfort Sport
Spare Type Steel type Steel type
wheel Size 16 × 4T or 15 × 6JJ* 16 × 4T or 16 × 6JJ*
Amount of wheel offset mm 46 40 or 46*
PCD mm 114.3 114.3
Spare tyre Size T125/70D16 96M or T125/70D16 96M or
195/60R15 88H* 195/50R16 84V*
NOTE: .
• The * mark indicates optional item.
• PCD (Pitch Circle Diameter) indicates the pitch circle diameter of the wheel installation holes.

SERVICE SPECIFICATIONS
M1311000300398

ITEM LIMIT
Tread depth of tyre mm Minimum 1.6
Wheel runout Radial runout mm 1.0 or less
<Aluminium wheel> Lateral runout mm 1.0 or less
Wheel runout Radial runout mm 1.2 or less
<Steel wheel> Lateral runout mm 1.2 or less
 WHEEL AND TYRE
TROUBLESHOOTING
31-3
TROUBLESHOOTING
DIAGNOSIS
M1311000700385

Symptom Probable cause Remedy Reference page

Rapid wear Under-inflation Adjust the tyre For tyre inflation
at shoulders or lack of pressure. pressure, refer to
rotation the label on the
driver's side centre
pillar.
ACX00923AB
ACX00924 AB

Rapid wear Over-inflation

at centre or lack of
rotation

ACX00925AB
ACX00926AB

Cracked Under-inflation Adjust the tyre For tyre inflation

treads pressure. pressure, refer to
the label on the
driver's side centre
pillar.
ACX00927AB

Wear on one Excessive Check the camber. <Front>

side camber Refer to GROUP
33, On-vehicle
service − Front
wheel alignment
ACX00928 AB
check and
ACX00929 AB adjustment P.33-5.
<Rear>
Feathered Incorrect toe-in Adjust the toe-in. Refer to GROUP
edge 34, On-vehicle
service − Rear
wheel alignment
check and
ACX00930AB adjustment P.34-5.
ACX00931AB

Bald spots Unbalanced Balance the wheels. P.31-4

wheel

ACX00932AB
ACX00933 AB
31-4 WHEEL AND TYRE
TROUBLESHOOTING

Symptom Probable cause Remedy Reference page

Scalloped Lack of rotation of tyres or worn Rotate the tyres, and <Front>
wear or out-of-alignment suspension check the front or Refer to GROUP
rear suspension 33, On-vehicle
alignments. service − Front
wheel alignment
ACX00934
check and
adjustment P.33-5.
<Rear>
Refer to GROUP
34, On-vehicle
service − Rear
wheel alignment
check and
adjustment P.34-5.

WHEEL BALANCE ACCURACY PROCEDURE <Balancing Tips>

M1311001700247
1. Confirm that the balancer's cone and the wheel
PURPOSE mounting cone are undamaged and free of dirt
This section contains tips and procedures for and rust.
achieving accurate wheel balance. Steering wheel
2. On this vehicle, the wheel's centre hole on the
vibration and/or body shake can result if any of these
hub side has a chamfered edge. Use a
procedures are not carefully observed.
back-mounting cone on your wheel balancer to
1. Wheels and tyres must be properly mounted on a centre the wheel on the balancer shaft.
balancer in order to achieve correct balance.
3. Install a wheel mounting cone. The appropriate
Centring the wheel on the shaft of the balancer is
size cone for this vehicle is 67.0 mm.
essential for proper mounting.
4. Before balancing the wheel, remove any wheel
2. Off-the-car wheel balancers must be calibrated
weights from both sides. Also check both sides for
periodically to ensure good balancing results. An
any damage.
inaccurately calibrated balancer could cause
unnecessary replacement of tyres, shocks, 5. When installing wheel weights, hammer them at a
suspension components, or steering components. straight (not diagonal) angle.
Check your balancer's calibration approximately
every 100 balances. Your wheel balancer's
instruction manual should include calibration
procedures. If the calibration procedures specifically
for your balancer are missing, use the generic steps
in this section for zero calibration, static balance, and
dynamic balance checks. The wheel balancer
calibration checks are also described in the
flowchart. (Refer to P.31-6).
 WHEEL AND TYRE
TROUBLESHOOTING
31-5

Clamping cup
Hub/shaft assembly

Wing nut

Spring plate
Wheel mounting cone AC305700AB

Standard passenger car wheel

<Confirming Proper Balance> • If the imbalance is more than 5g, the balancer
1. After balancing the wheel, loosen the wing nut requires calibration. Contact the balancer
and turn the wheel 180° against the balancer's manufacturer for calibration by their repair
hub. Then re-tighten the wing nut and check the representative.
balance again. Repeat wheel balance if 4. <<Static Balance Check>>
necessary. Attach a 5g weight to the outer rim. Recheck the
2. Turn the wheel again 180° against the balancer's balancer. The balancer should detect 5 ± 2g of
hub. If the wheel becomes out-of-balance each imbalance 170 to 190° away from the 5g weight.
time it is turned against the balancer's hub, the • If the imbalance is within specification, the static
wheel balancer may require calibration. balance calibration is correct. Go to Step 5 to
check the dynamic balance.
<Wheel Balancer Calibration Checks> • If the imbalance is out of specification, the
1. Mount an undamaged original-equipment alloy balancer requires calibration. Contact the
rim and tyre assembly (wheel) onto your balancer manufacturer for calibration by their
off-the-car wheel balancer. Balance the wheel. repair representative.
2. <<Zero Calibration Check>> 5. <<Dynamic Balance Check>>
Loosen the balancer wing nut, rotate the wheel a Attach a 5g weight to the inner rim at 180°
half-turn (180°), and retighten the nut. Recheck opposite the 5g weight that was added in Step 4.
the balance. Recheck the balance. The balancer should detect
• If the imbalance is 5g or less, the zero calibration 5 ± 2g of imbalance 170 to 190° away from both
is OK. Rebalance the wheel, then go to Step 4 to the inner and outer 5g weights.
check static balance. • If the imbalance is within specification, the
• If the imbalance is more than 5g, go to Step 3. dynamic balance calibration is correct. The
balancer calibration checks are complete.
3. Loosen the balancer wing nut, rotate the wheel
• If the imbalance is out of specification, the
1/4 turn (90°), and retighten the nut. Recheck the
balancer requires calibration. Contact the
wheel balance.
balancer manufacturer for calibration by their
• If the imbalance is 5g or less, the wheel may not
repair representative.
be centred on the balancer, or the balancing
cones, the cup, and/or wing nut are damaged,
dirty, or inappropriate for the wheel. You may
need to refer to the balancer manufacturer's
instructions to verify the correct attachments.
After making the necessary corrections, recheck
the wheel balance. If OK, then go to Step 4.
31-6 WHEEL AND TYRE
TROUBLESHOOTING

WHEEL BALANCER CALIBRATION

CHECKING FLOW CHART

Balance wheel.

ZERO CALIBRATION
Rotate wheel 1/2 turn. CHECK

Imbalance = 5g (0.18oz) or less Imbalance = more than 5g (0.18oz)

Rebalance wheel.
Rotate wheel 1/4 turn.

Imbalance = 5g (0.18oz) or less Imbalance = more than 5g (0.18oz)

Verify wheel is properly centred.

Verify cones, cup, and wing nut are clean,
undamaged, and appropriate for wheel.
Make necessary corrections, then recheck
wheel balance.

Attach a 5-g (0.18-oz) weight to the outer rim. STATIC BALANCE

Is the imbalance 5 ± 2g (0.18 ± 0.06oz) at 170 – 190 CHECK
degrees away from the 5-g (0.18-oz) weight?

YES NO

DYNAMIC BALANCE
Attach a 5-g (0.18-oz) weight to the inner rim at 180
CHECK
degrees opposite the weight on the outer rim.
Is the imbalance 5 ± 2g (0.18 ± 0.06oz) at 170 – 190
degrees away from both 5-g (0.18-oz) weights?

YES NO

Balancer does not require Balancer requires calibration.

calibration. Contact balancer manufacturer.

AC000040 AB
 WHEEL AND TYRE
ON-VEHICLE SERVICE
31-7
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK WHEEL RUNOUT CHECK
M1311000900312 M1311001100353
NOTE: For information on tyre inflation pressure,
refer to the label attached to the centre pillar on the
driver's side.
Radial
TYRE WEAR CHECK
M1311001000334
Measure the tread depth of the tyres.
Minimum limit: 1.6 mm
If the remaining tread depth is less than the minimum
limit, replace the tyre. Lateral
ACX00651AB
NOTE: When the tread depth of the tyres is reduced Jack up the vehicle so that the wheels are clear of
to 1.6 mm or less, wear indicators will appear. the floor. While slowly turning the wheel, measure
wheel runout with a dial indicator.
Limit:
Item Steel wheel Aluminium
wheel
Radial runout mm 1.2 1.0
Lateral runout 1.2 1.0
mm
If wheel runout exceeds the limit, replace the wheel.

WHEEL AND TYRE

INSTALLATION SERVICE POINT Tightening torque: 98 ± 10 N⋅m
M1311001300294
Tighten the wheel nuts to the specified torque.
NOTES
 32-1

GROUP 32

POWER PLANT
MOUNT
CONTENTS

GENERAL INFORMATION . . . . . . . . 32-2 TRANSMISSION MOUNTING . . . . . . 32-5

REMOVAL AND INSTALLATION . . . . . . . . 32-5
SERVICE SPECIFICATION . . . . . . . . 32-3
ENGINE ROLL STOPPER,
SPECIAL TOOL . . . . . . . . . . . . . . . . . 32-3 CENTERMEMBER . . . . . . . . . . . . . . . 32-7
REMOVAL AND INSTALLATION . . . . . . . . 32-7
ENGINE MOUNTING . . . . . . . . . . . . . 32-4
REMOVAL AND INSTALLATION . . . . . . . . 32-4 CROSSMEMBER . . . . . . . . . . . . . . . . 32-8
REMOVAL AND INSTALLATION . . . . . . . . 32-8
32-2 POWER PLANT MOUNT
GENERAL INFORMATION

GENERAL INFORMATION
M1321000100340
The engine mounting system employs the inertial • The fore-and-aft, liquid-filled engine mount of
axis four-point suspension method, which is field cylinder type is adopted to reduce engine shake
proven. for improved riding comfort.
• The optimised locations of the front and rear roll
mounts well distribute their loads thereby
reducing engine idling vibrations.

CONSTRUCTION DIAGRAM

Transmission mounting
body side bracket

Engine front
mounting bracket

Y0290AU

Engine rear roll stopper bracket

Engine front roll stopper bracket

AC107318
AC303563AB
 POWER PLANT MOUNT
SERVICE SPECIFICATION
32-3
SERVICE SPECIFICATION
M1321000300333

Item Standard value

Protruding length of stabilizer link thread part mm 22 ± 1.5

SPECIAL TOOL
M1321000600378

Tool Number Name Use

MB991897 Ball joint remover Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113) is also
available to disconnect knuckle and
AC106827
tie rod end ball joint.
32-4 POWER PLANT MOUNT
ENGINE MOUNTING

ENGINE MOUNTING
REMOVAL AND INSTALLATION
M1321001100440

CAUTION
*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal Operation
Raise the engine and transmission assembly until its weight
is not applied to the insulator, and support it securely.

<4G1> <4G6>
12 ± 2 N·m
44 ± 10 N·m* 67 ± 7 N·m*

2N 44 ± 10 N·m*
1

67 ± 7 N·m*

2N

3
3

AC303999 AC303968
AC304304AB

Removal steps Removal steps (Continued)

1. Pressure hose clamp <4G6> 2. Self-locking nuts
3. Engine front mounting bracket
 POWER PLANT MOUNT
TRANSMISSION MOUNTING
32-5
TRANSMISSION MOUNTING
REMOVAL AND INSTALLATION
M1321001400430

CAUTION
*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal Operation Post-installation Operation
• Raise the engine and transmission assembly until its • Engine Rear Roll Stopper Bracket Installation (Refer to
weight is not applied to the insulator, and support it P.32-7).
securely. • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Battery and Battery tray Removal P.15-3).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Battery and Battery tray Installation
P.15-3).
• Engine Rear Roll Stopper Bracket Removal (Refer to
P.32-7).

<M/T> <A/T>

80 ± 7 N·m*
80 ± 7 N·m*

47 ± 7 N·m*
47 ± 7 N·m*

2 2

2 2
1 1

AC303988 AC303989
AC304258AB

Removal steps
1. Transmission mounting body side
bracket
>>A<< 2. Transmission mounting stopper
32-6 POWER PLANT MOUNT
TRANSMISSION MOUNTING

INSTALLATION SERVICE POINT Install the transmission mounting stopper so that its
arrow points upward.
>>A<< TRANSMISSION MOUNTING
STOPPER INSTALLATION
Engine side

Transmission
mounting body
side bracket

Transmission
mounting
stopper
AC200645 AB
 POWER PLANT MOUNT
ENGINE ROLL STOPPER, CENTERMEMBER
32-7
ENGINE ROLL STOPPER, CENTERMEMBER
REMOVAL AND INSTALLATION
M1321002300287

CAUTION
*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal and Post-installation Operation
Under Cover Removal and Installation

11 ± 1 N·m 45 ± 5 N·m*

69 ± 10 N·m
5

<4G1> <4G6>
45 ± 5 N·m* 7
6
45 ± 5 N·m*
1 3 52 ± 7 N·m* 52 ± 7 N·m*
2

52 ± 7 N·m*
3 1

4 69 ± 10 N·m
69 ± 10 N·m
AC303978
AC304309AB

Engine front roll stopper bracket Engine rear roll stopper bracket
and centermember removal removal steps
steps 5. Engine rear roll stopper bracket
1. Engine front roll stopper bracket connecting bolt
connecting bolt 6. Transmission case rear roll stopper
• Centermember and engine front roll bracket
stopper bracket assembly 7. Engine rear roll stopper bracket
>>B<< 2. Engine mounting cushion stopper
<4G6>
>>A<< 3. Engine front roll stopper bracket
4. Centermember
32-8 POWER PLANT MOUNT
CROSSMEMBER

INSTALLATION SERVICE POINTS

>>A<< ENGINE FRONT ROLL STOPPER >>B<< ENGINE MOUNTING CUSHION
BRACKET INSTALLATION STOPPER INSTALLATION <4G6>
Engine mounting
cushion stopper
Hole

Hole

Front of vehicle Front of vehicle

AC005918AC AC304315AB

Install the engine front roll stopper bracket so that its Install the engine mounting cushion stopper as
hole points towards the front side of the vehicle. shown.

CROSSMEMBER
REMOVAL AND INSTALLATION
M1321003200368

CAUTION
• Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions P.52B-5, Air bag Module and Clock Spring P.52B-210. Also, set the front
wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this,
the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.
• *1: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
• *2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in the unladen condition.
Pre-removal Operation Post-installation Operation
• Centermember Removal (Refer to P.32-7). • Front Exhaust Pipe Installation (Refer to GROUP 15,
• Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler P.15-11).
Exhaust Pipe and Main Muffler P.15-11). • Centermember Installation (Refer to P.32-7).
• Steering Wheel Air Bag Module Assembly Removal • Clock Spring Centring (Refer to GROUP 52B, Air Bag
(Refer to GROUP 37, Steering Wheel P.37-17). Modules and Clock Spring P.52B-210).
• Power Steering Fluid Draining (Refer to GROUP 37, • Steering Wheel Air Bag Module Assembly Installation
On-vehicle Service P.37-13). (Refer to GROUP 37, Steering Wheel P.37-17).
• Power Steering Fluid Supplying (Refer to GROUP 37,
On-vehicle Service P.37-13).
• Power Steering Fluid Line Bleeding (Refer to GROUP 37,
On-vehicle Service P.37-13).
• 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
GROUP 33, On-vehicle Service P.33-5).
 POWER PLANT MOUNT
CROSSMEMBER
32-9
<L.H. drive vehicles>

12 ± 2 N·m 5
10
18 ± 2 N·m

70 ± 10 N·m 4
11 N
12 57 ± 7 N·m

45 ± 5 N·m* 1 8 9
70 ± 10 N·m

6 14 13 N
16
25 ± 4 N·m
21 ± 4 N·m

15

21 ± 4 N·m

7
52 ± 7 N·m* 1
2N 108 ± 10 N·m

3
17

1
186 ± 10 N·m* 2
167 ± 9 N·m
49 ± 10 N·m
AC304000 AB

Removal steps Removal steps (Continued)

1. Lower arm and knuckle connection 9. Eye bolt
>>B<< 2. Self-locking nut 10. Pressure hose connection
3. Lower arm assembly 11. Gasket
4. Shaft cover 12. Clamp
5. Steering shaft assembly and gear 13. Self-locking nut
box connecting bolt <<A>> 14. Tie rod end and knuckle connection
6. Engine rear roll stopper bracket <<B>> • Crossmember assembly
connection bolt >>A<< 15. Stabilizer bar
7. Engine rear roll stopper bracket 16. Steering gear and linkage
8. Return hose connection 17. Crossmember
32-10 POWER PLANT MOUNT
CROSSMEMBER

<R.H. drive vehicles>

8
57 ± 7 N·m
9
18 ± 2 N·m
5 7
4 5.0 ± 1.0 N·m

70 ± 10 N·m
N 6
45 ± 5 N·m*¹
11 25 ± 4 N·m
15 N 10

12 14

21 ± 4 N·m

2N
13
52 ± 7 N·m*¹

16
108 ± 10 N·m

186 ± 10 N·m*²
167 ± 9 N·m
49 ± 10 N·m

AC101614 AE

Removal steps Removal steps (Continued)

1. Lower arm and knuckle connection 10. Self-locking nut
>>B<< 2. Self-locking nut <<A>> 11. Tie rod end and knuckle connection
3. Lower arm assembly 12. Engine rear roll stopper bracket
4. Eye bolt connection bolt
5. Pressure hose connection <<B>> • Crossmember assembly
6. Gasket 13. Engine rear roll stopper bracket
7. Return hose connection >>A<< 14. Stabilizer bar
8. Shaft cover 15. Steering gear and linkage
9. Steering shaft assembly and gear 16. Crossmember
box connecting bolt
 POWER PLANT MOUNT
CROSSMEMBER
32-11
REMOVAL SERVICE POINTS <<B>> CROSSMEMBER ASSEMBLY
<<A>> TIE ROD END AND KNUCKLE REMOVAL
DISCONNECTION
CAUTION
• Do not remove the nut from ball joint. Loosen Piece of wood
it and use special tool to avoid possible
damage to ball joint threads.
• Hang special tool with a cord to prevent it
from falling.

Cord Transmission
jack AC102600 AD

1. Use a transmission jack to hold the crossmember,

and then remove the crossmember mounting nuts
Nut MB991897 and bolts.
2. Lower the crossmember with the engine rear roll
stopper bracket, the stabilizer bar, the return tube,
and the steering gear.
Bolt
Ball joint AC208247AD INSTALLATION SERVICE POINTS
1. Install the special tool ball joint remover >>A<< STABILIZER
(MB991897) as shown in the figure. BAR/BUSHING/FIXTURE INSTALLATION
Outside of Approximately
Bolt vehicle 10 mm

Identification
Parallel mark

Knob Good

Bushing (LH) Fixture (LH)

Bad AC106821AB AC006141AD

2. Turn the bolt and knob as necessary to make the Align the stabilizer bar identification mark with the
jaws of the special tool parallel, tighten the bolt by right end of the bushing (LH).
hand and confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make
>>B<< SELF-LOCKING NUT
sure the knob is in the position shown in the INSTALLATION
figure.
3. Tighten the bolt with a wrench to disconnect the A
tie rod end.

AC101741AC

Tighten the self-locking nut until the stabilizer link

thread part protruding length meets the standard
value.
Standard value (A): 22 ± 1.5 mm
NOTES
 33-1

GROUP 33

FRONT
SUSPENSION
CONTENTS

GENERAL INFORMATION . . . . . . . . 33-2 STRUT ASSEMBLY . . . . . . . . . . . . . . 33-7

REMOVAL AND INSTALLATION . . . . . . . . 33-7
SERVICE SPECIFICATIONS. . . . . . . 33-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-7
DISASSEMBLY AND REASSEMBLY . . . . . 33-8
LUBRICANT. . . . . . . . . . . . . . . . . . . . 33-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-10

SPECIAL TOOLS. . . . . . . . . . . . . . . . 33-4 LOWER ARM . . . . . . . . . . . . . . . . . . . 33-11

REMOVAL AND INSTALLATION . . . . . . . . 33-11
ON-VEHICLE SERVICE. . . . . . . . . . . 33-5 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-12
FRONT WHEEL ALIGNMENT CHECK LOWER ARM BALL JOINT COVER
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 33-5 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-12
LOWER ARM BALL JOINT AXIAL PLAY LOWER ARM BUSHING (REAR)
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-13
LOWER ARM BALL JOINT COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6 STABILIZER BAR* . . . . . . . . . . . . . . . 33-14
REMOVAL AND INSTALLATION . . . . . . . . 33-14
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 33-17

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
paassenger (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 (*).
33-2 FRONT SUSPENSION
GENERAL INFORMATION

GENERAL INFORMATION
M1332000100407
The front suspension is a McPherson strut with coil
spring. The shock absorber is gas-filled hydraulic
double-acting type.

CONSTRUCTION DIAGRAM

<Sport>
Strut damper

<Comfort>

Stabilizer bar Coil spring Strut damper

AC304022

Strut cover

Strut (shock absorber)

Lower arm assembly

Front axle No.1

crossmember

AC304023
AC304754 AB

SPECIFICATIONS
COIL SPRING
Item Sedan Wagon
Comfort Sport Comfort Sport
Wire diameter mm 13 13 13 <1600-M/T> 14
14 1600-A/T, 13 <1600>*
2000>
14 <2000>*
Average diameter mm 160 160 160 160
Free length mm 330 321 330 <1600-M/T> 314 <1600>
338 <1600-A/T> 321 <2000>
338 <2000> 330 <1600>*
338 <2000>*
NOTE: .
• The*mark indicates optional item.
 FRONT SUSPENSION 33-3
SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
M1332000300586

Item Standard value

Toe-in At the centre of tyre tread mm 1±2
Toe-angle (per wheel) 0°03' ± 06'
Toe-out angle on turns (inner wheel when outer wheel at 20°) 21°42' ± 1°30'
Steering angle Inner wheel Comfort 39°30' ± 1°30'
Sport (LH drive vehicles) 33°40' +1°00'/-2°00'
Sport (RH drive vehicles) 37°00' +1°00'/-2°00'
Outer wheel (reference) Comfort 32°30'
Sport (LH drive vehicles) 28°46'
Sport (RH drive vehicles) 30°00'
Camber Comfort 0°05' ± 30'*
Sport -0°05' ± 30'*
Caster Comfort 2°45' ± 30'*
Sport 2°55' ± 30'*
Kingpin inclination Comfort 12°30' ± 1°30'
Sport 12°40' ± 1°30'
Lower arm ball joint rotation starting torque N⋅m 0 − 3.9
Protruding length of stabilizer link thread part mm 22 ± 1.5

NOTE: *: difference between right and left wheels must be less than 30'

LUBRICANT
M1332000400152

Item Specified lubricant Quantity

Lower arm ball joint Lip portion of ball joint cover Multipurpose grease SAE J310, As required
Inside of ball joint cover NLGI No.2 or equivalent
33-4 FRONT SUSPENSION
SPECIAL TOOLS

SPECIAL TOOLS
M1332000600297

Tool Number Name Use

MB991004 Wheel alignment gauge Wheel alignment
attachment measurement <Vehicles
with aluminium wheels>

MB991004

A: MB991237 A: Spring compressor Coil spring compression

B: MB991238 body
A B: Arm set

B MB991237

A MB991680 Wrench set Strut assembly

B A: MB991681 A: Wrench disassembly and
B: MB991682 B: Socket reassembly
MB991680

MB991006 Preload socket Lower arm ball joint

rotation starting torque
check

MB991006

MB990800 Ball joint remover and Lower arm ball joint cover
installer installation

MB990800
 FRONT SUSPENSION 33-5
ON-VEHICLE SERVICE

Tool Number Name Use

MB990883 Rear suspension bushing Lower arm bushing (rear)
arbor removal and press-fitting

MB990883

MB990972 Torsion bar bushing

remover base

MB990971

MB990887 Ring

MB990890 Rear suspension bushing

base

MB990890

MB991897 Ball joint remover Knuckle and tie rod end

ball joint disconnection
NOTE: Steering linkage
puller (MB990635 or
AC106827 MB991113) is also
available to disconnect
knuckle and tie rod end
ball joint.

ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND Lock nut
ADJUSTMENT
M1331000900682
Clip
Measure wheel alignment with alignment equipment
on a level surface. The front suspension, steering
system, wheels, and tyres should be serviced to
normal condition before measuring wheel alignment.
TOE-IN
Standard value:
at the centre of tyre tread: 1 ± 2 mm AC006074 AD

Toe angle (per wheel): 0°03' ± 06' 1. Adjust the toe-in by undoing the clip and lock nut,
and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions).
33-6 FRONT SUSPENSION
ON-VEHICLE SERVICE

NOTE: The toe will move out as the left NOTE: *: difference between right and left wheels
turnbuckle is turned toward the front of the vehicle must be less than 30'
and the right turnbuckle is turned toward the rear NOTE: Camber and caster are preset at the factory
of the vehicle. and cannot be adjusted.
2. Install the clip and tighten the lock nut to the CAUTION
specified torque. Never subject the wheel bearings to the vehicle
Tightening torque: 40 ± 5 N⋅m load when the driveshaft nuts are loosened.
3. Confirm that the toe-in is at the standard value. NOTE:
4. Use a turning radius gauge to check that the
MB991004
steering angle is at the standard value.
STEERING ANGLE
Standard value:
Inner Comfort 39°30' ± 1°30'
wheels Sport (LH drive 33°40' +1°00'/-2°00'
vehicles)
Sport (RH drive 37°00' +1°00'/-2°00' AC001079 AB
vehicles)
For vehicles with aluminium wheels, attach the
Outer Comfort 32°30' camber/caster/kingpin gauge to the driveshaft by
wheels Sport (LH drive 28°46' using special tool wheel alignment gauge attachment
(reference) vehicles) (MB991004). Tighten the special tool to the same
torque 245 ± 29 N⋅m as the driveshaft nut.
Sport (RH drive 30°00'
vehicles)
LOWER ARM BALL JOINT AXIAL PLAY
TOE-OUT ANGLE ON TURNS CHECK
M1332011300074
To check the steering linkage, especially after the 1. Raise the vehicle.
vehicle has been involved in an accident or if an 2. Remove the stabilizer link from the lower arm.
accident is presumed, it is advisable to check the
toe-out angle on turns in addition to the wheel 3. Move the lower arm up and down with your hands
alignment. to check for an excessive play in the axial
Conduct this test on the left turn as well as on the direction of the ball joint. If there is an excessive
right turn. play, replace the lower arm assembly.
Standard value: LOWER ARM BALL JOINT COVER
Item Specification CHECK
M1332008600321
Toe-out angle on turns (inner 21°42' ± 1°30' 1. Press the lower arm ball joint cover with your
wheel when outer wheel at 20°) finger to check that there are no cracks or
damage in the lower arm ball joint cover.
CAMBER, CASTER AND KINGPIN 2. If the lower arm ball joint cover is cracked or
damaged, replace the lower arm assembly.
INCLINATION
NOTE: If the lower arm ball joint cover is cracked
Standard value:
or damaged, it is possible that there may also be
Item Comfort Sport damage to the ball joint.
Camber 0°05' ± 30'* -0°05' ± 30'*
Caster 2°45' ± 30'* 2°55' ± 30'*
Kingpin 12°30' ± 1°30' 12°40' ± 1°30'
inclination
 FRONT SUSPENSION 33-7
STRUT ASSEMBLY

STRUT ASSEMBLY
REMOVAL AND INSTALLATION
M1332001100325

Post-installation Operation
• Front Wheel Alignment Adjustment (Refer to P.33-5.)

N 4

44 ± 5 N·m

1
2 5

167 ± 9 N·m

AC304153 AB

Removal steps Removal steps (Continued)

1. Front ABS sensor harness bracket 4. Strut nut (self-locking nut)
2. Brake hose bracket 5. Strut assembly
3. Knuckle connection

INSPECTION
M1332001200247
• Check for oil leaks from the strut assembly.
• Check the strut assembly for damage or
deformation.
33-8 FRONT SUSPENSION
STRUT ASSEMBLY

DISASSEMBLY AND REASSEMBLY

M1332001300329

60 ± 10 N·m
1

3
8
4

7
9 5
6

<Sport> <Comfort>

10

AC300065 AC

Disassembly steps Disassembly steps (Continued)

<<A>> >>B<< 1. Strut nut (self-locking nut) 6. Strut cover <Comfort>
2. Strut insulator 7. Strut damper <Comfort>
3. Strut bearing 8. Coil spring
>>A<< 4. Spring upper seat 9. Spring lower pad
5. Strut damper <Sport> <<B>> 10. Strut
 FRONT SUSPENSION 33-9
STRUT ASSEMBLY

DISASSEMBLY SERVICE POINTS 2. Use following special tools to secure the strut, and
<<A>> STRUT NUT (SELF-LOCKING NUT) then remove the strut nut (self-locking nut).
• MB991681: Wrench
REMOVAL • MB991682: Socket
CAUTION
• Install special tool arm set (MB991238) evenly, <<B>> STRUT DISPOSAL
and so that the maximum length will be
attained within the installation range. WARNING
• Do not use an impact wrench to tighten the
Wear goggles when drilling to protect your
bolt of special tool spring compressor body eyes from flying metal debris.
(MB991237), otherwise the special tool will
break.

MB991238 MB991237

AC001087

The gas must be discharged from the strut before

AC001085AB discarding it. Place the strut horizontally with its
piston rod extended. Then drill a hole of
1. Use following special tools to compress the coil approximately 3 mm in diameter at the location
spring. shown in the illustration and discharge the gas.
• MB991237: Spring Compressor Body
• MB991238: Arm Set REASSEMBLY SERVICE POINTS
>>A<< SPRING UPPER SEAT
WARNING
Do not use an impact wrench to remove the INSTALLATION
strut nut (self-locking nut). Vibration of the
impact wrench will cause special tools
(MB991237 and MB991238) to slip and cause Seat

personal injury.

MB991682 Pad

MB991681
AC304396 AB

If the spring upper seat peeled off the pad, adhere

the seat and the pad with a double-sided tape.

AC006091 AB
33-10 FRONT SUSPENSION
STRUT ASSEMBLY

>>B<< STRUT NUT (SELF-LOCKING NUT) 5. Align lower end of the coil spring with the groove
INSTALLATION in the spring lower seat, and then loosen the
special tools.
1. Ensure that the bearing is seated correctly.
CAUTION
CAUTION
Do not use an impact wrench to tighten the bolt
Do not use an impact wrench to tighten the
of special tool spring compressor body
self-locking nut, otherwise the strut nut
(MB991237), otherwise the special tool will break.
(self-locking nut) will be damaged.

MB991238 MB991682
MB991237

MB991681

AC001085AB
AC006091 AB

2. Install following special tools to the strut assembly 6. Using following special tools, tighten the strut nut
same as its removal. (self-locking nut) to 60 ± 10 N⋅m.
• MB991237: Spring Compressor Body • MB991681: Wrench
• MB991238: Arm Set • MB991682: Socket
3. While the coil spring is being compressed by the
special tools, temporarily tighten the strut nut INSPECTION
(self-locking nut). M1332001400188
• Check the strut bearing for wear or rust.
4. Align the hole in the strut spring lower seat with • Check the rubber parts for damage or
the hole in the spring upper seat. deterioration.
NOTE: • Check the coil spring for deformation,
deterioration or damage.
• Check the strut for deformation.
Rod

AC006091 AB

Using a rod as shown facilitates the alignment.

 FRONT SUSPENSION 33-11
LOWER ARM

LOWER ARM
REMOVAL AND INSTALLATION
M1332001600331

CAUTION
*
: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in an unladen condition.
Post-installation Operation
• Check the lower arm ball joint cover for cracks or damage
by pushing it with your finger.
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-5).

N 1
Specified grease :
Multipurpose grease SAE J310,
NLGI No.2 or equivalent

4
6

186 ± 10 N·m*

7
6
3 108 ± 10 N·m
5
167 ± 9 N·m 2
AC006097 AD

Removal steps Removal steps (Continued)

>>A<< 1. Self-locking nut 5. Lower arm bolt
2. Bolt <<A>> 6. Lower arm bolt
3. Stabilizer rubber 7. Lower arm assembly
4. Collar
33-12 FRONT SUSPENSION
LOWER ARM

REMOVAL SERVICE POINT LOWER ARM BALL JOINT ROTATION

<<A>> LOWER ARM BOLT REMOVAL STARTING TORQUE CHECK
Piece of wood
MB991006

Lower arm bolt (front) AC001091 AB

Transmission jack AC006133 AD

Lift the transmission with a transmission jack, and 1. After shaking the ball joint stud several times, use
then withdraw the lower arm bolt (front) on the lower special tool preload socket (MB991006) to
arm assembly (L.H.). measure the rotation starting torque of the ball
joint.
INSTALLATION SERVICE POINT Standard value: 0 − 3.9 N⋅m
>>A<< SELF-LOCKING NUT 2. If the measured value is not within the standard
INSTALLATION value, or if the ball joint is difficult to turn or does
not turn smoothly, replace the lower arm
assembly.
A

LOWER ARM BALL JOINT COVER

CHECK
1. Check the lower arm ball joint cover for cracks or
damage by pushing it with your finger.
2. If the lower arm ball joint cover is cracked or
damaged, replace the lower arm assembly.
AC101741AC
NOTE: Cracks or damage to the dust cover may
Tighten the self-locking nut until the stabilizer link cause damage to the ball joint. When it is
thread part protruding length meets the standard damaged during service work, replace the lower
value. arm ball joint cover.
Standard value (A): 22 ± 1.5 mm
LOWER ARM BALL JOINT COVER
INSPECTION REPLACEMENT
M1332001700286
M1332008200260
• Check the lower arm bushings for wear and If the lower arm ball joint cover is damaged
deterioration. accidentally during service work, replace the lower
• Check the lower arm assembly for bend or arm ball joint cover as follows:
breakage. 1. Remove the lower arm ball joint cover.
• Check all bolts for condition and straightness.
2. Apply specified grease to the lip and the inside of
a new lower arm ball joint cover.
Specified grease: Multipurpose grease SAE
J310, NLGI No.2 or equivalent
Grease amount for the inside the dust cover
(reference): 8 − 10g
 FRONT SUSPENSION 33-13
LOWER ARM

MB990800
MB990883
Lower arm
ball joint
cover
MB990972
Lower arm
assembly
AC006135 AD

3. Using special tool ball joint remover and installer

(MB990800), drive in the lower arm ball joint
cover until it is fully seated.
MB990887

Lower arm
ball joint cover 22 mm
MB990890

AC006137 AC

1. Use following special tools to drive out the lower

arm bushing (rear).
AC107030AC
• MB990883: Rear Suspension Bushing Arbor
• MB990972: Torsion Bar Bushing Remover Base
4. Position the lower arm ball joint cover as shown in • MB990887: Ring
the illustration. Make sure that there is no • MB990890: Rear Suspension Bushing Base
abnormal bulge or pressure applied on the lower
arm ball joint cover. MB990883
5. Check the lower arm ball joint cover for cracks or
damage by pushing it with your finger. MB990972
Lower arm
LOWER ARM BUSHING (REAR) assembly
Outer tube
REPLACEMENT
M1332008100348

MB990887
Lower arm bushing (rear)

MB990890

Lower arm assembly

30˚

AC006136 AD

Replace the lower arm bushing (rear) as follows: Projection

AC006138 AC

2. Position the lower arm bushing (rear) so that its

projection is as shown, and then use the special
tools to press in the bushing.
3. Press the lower arm bushing (rear) until its outer
tube is flush with the lower arm assembly surface.
33-14 FRONT SUSPENSION
STABILIZER BAR

STABILIZER BAR
REMOVAL AND INSTALLATION
M1332004000468

CAUTION
• Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Service
Precautions P.52B-5 and Air Bag Module and Clock Spring P.52B-210. Also, put the front wheels in
straight-ahead position. Failure to do so may damage the SRS clock spring and render the SRS air
bag inoperative, which results serious driver injury.
• *: 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 Operation Post-installation Operation
• Steering Wheel and Air Bag Module Assembly Removal • Front Exhaust Pipe Installation (Refer to GROUP 15,
(Comfort: refer to GROUP 37, Steering Wheel Exhaust Pipe and Main Muffler P.15-11).
P.37-17/Sport: refer to GROUP 37, Steering Wheel • Centermember Installation (Refer to GROUP 32, Engine
P.37-19). Roll Stopper, Centermember P.32-7).
• Clock Spring Removal (Refer to GROUP 52B, Air Bag • Clock Spring Installation (Refer to GROUP 52B, Air Bag
Modules and Clock Spring P.52B-210). Modules and Clock Spring P.52B-210).
• Centermember Removal (Refer to GROUP 32, Engine • Steering Wheel and Air Bag Module Assembly Installation
Roll Stopper, Centermember P.32-7). (Comfort: refer to GROUP 37, Steering Wheel
• Front Exhaust Pipe Removal (Refer to GROUP 15, P.37-17/Sport: refer to GROUP 37, Steering Wheel
Exhaust Pipe and Main Muffler P.15-11). P.37-19).
• Check the dust covers for cracks or damage by pushing it
with your finger.
• Checking Steering Wheel Position with Wheels Straight
Ahead
• Front Wheel Alignment Check and Adjustment (Refer to
P.33-5).
 FRONT SUSPENSION 33-15
STABILIZER BAR

6 18 ± 2 N·m

7
21 ± 4 N·m
11
9

10
1
2
25 ± 5 N·m

3
5 2

8
52 ± 7 N·m*
167 ± 9 N·m

2 4 49 ± 10 N·m 108 ± 10 N·m

167 ± 9 N·m

AC006139 AD

Removal steps Removal steps (Continued)

>>B<< 1. Self-locking nut 7. Steering gear and joint
2. Stabilizer rubber connecting bolt
3. Collar 8. Engine rear roll stopper
4. Lower arm and knuckle bracket connecting bolt
connection <<B>> >>A<< 9. Stabilizer bar bracket
<<A>> 5. Tie rod end and knuckle <<B>> >>A<< 10. Stabilizer bushing
connection <<B>> >>A<< 11. Stabilizer bar
6. Steering shaft cover
33-16 FRONT SUSPENSION
STABILIZER BAR

REMOVAL SERVICE POINTS <<B>> STABILIZER BAR

<<A>> TIE ROD END AND KNUCKLE BRACKET/STABILIZER
DISCONNECTION BUSHING/STABILIZER BAR REMOVAL
Carry out the following operations to ensure working
CAUTION
space in order to remove the stabilizer bar brackets,
• Do not remove the nut from the tie rod end
the stabilizer bushings and the stabilizer bar.
ball joint. Loosen it and use special tool ball
joint remover (MB991897) to avoid possible
damage to the ball joint threads.
• Hang special tool ball joint remover Piece of wood
(MB991897) with rope or wire to prevent them
from falling.

Cord

Transmission
jack AC102600 AD

Nut MB991897
1. Use a transmission jack to hold the crossmember,
and then remove the crossmember mounting nuts
and bolts.
Bolt
Ball joint
CAUTION
AC208247AD
Be careful not to lower the crossmember
1. Install the special tool ball joint remover excessively, otherwise the power steering return
(MB991897) as shown in the figure. hose bracket may deform.
2. Lower the crossmember until the stabilizer bar
brackets, the stabilizer bushings and the stabilizer
Bolt
bar can be removed.
Parallel
INSTALLATION SERVICE POINTS
>>A<< STABILIZER BAR/STABILIZER
Knob Good
BUSHING/STABILIZER BAR BRACKET
INSTALLATION
Bad AC106821AB Outside of Approximately
vehicle 10 mm
2. After turning the bolt and knob to adjust the insert
arms of the special tool in parallel, tighten the bolt Identification
mark
by hand and confirm that the insert arms are
parallel.
NOTE: When adjusting the insert arms in parallel,
turn the knob in the direction shown in the figure. Stabilizer Stabilizer bar
3. Tighten the bolt with a wrench to disconnect the bushing (LH) bracket (LH)
tie rod end. AC006141AI

Align the stabilizer bar identification mark with the

right end of the stabilizer bushing (LH).
 FRONT SUSPENSION 33-17
STABILIZER BAR

>>B<< SELF-LOCKING NUT Tighten the self-locking nut until the stabilizer link
INSTALLATION thread part protruding length meets the standard
value.
Standard value (A): 22 ± 1.5 mm
A

INSPECTION
M1332002000279
• Check the stabilizer rubbers and stabilizer
bushings for wear and deterioration.
• Check the stabilizer bar for deterioration or
damage.
• Check all bolts for condition and straightness.
AC101741AC
NOTES
 34-1

GROUP 34

REAR SUSPENSION
CONTENTS

GENERAL INFORMATION . . . . . . . . 34-2 REMOVAL AND INSTALLATION . . . . . . . . 34-8

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-9
SERVICE SPECIFICATIONS. . . . . . . 34-3 LOWER ARM BUSHING AND LOWER
ARM PILLOW BALL BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-10
LUBRICANT. . . . . . . . . . . . . . . . . . . . 34-3
TRAILING ARM ASSEMBLY . . . . . . . 34-12
SPECIAL TOOLS. . . . . . . . . . . . . . . . 34-4
REMOVAL AND INSTALLATION . . . . . . . . 34-12
ON-VEHICLE SERVICE. . . . . . . . . . . 34-5 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-13

REAR WHEEL ALIGNMENT CHECK TRAILING ARM BUSHING

AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 34-5 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-13

CONTROL LINK PILLOW BALL BUSHING

AXIAL PLAY CHECK <Sport> . . . . . . . . . . 34-6 SHOCK ABSORBER ASSEMBLY . . . 34-15
UPPER ARM PILLOW BALL BUSHING REMOVAL AND INSTALLATION . . . . . . . . 34-15
AXIAL PLAY CHECK <Sport> . . . . . . . . . . 34-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-16
LOWER ARM PILLOW BALL BUSHING DISASSEMBLY AND REASSEMBLY . . . . . 34-17
AXIAL PLAY CHECK . . . . . . . . . . . . . . . . . 34-7
STABILIZER LINK BALL JOINT STABILIZER BAR. . . . . . . . . . . . . . . . 34-20
DUST COVER INSPECTION . . . . . . . . . . . 34-7
REMOVAL AND INSTALLATION . . . . . . . . 34-20
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 34-21
CONTROL LINK, UPPER ARM AND
STABILIZER LINK BALL JOINT
LOWER ARM . . . . . . . . . . . . . . . . . . . 34-8 DUST COVER REPLACEMENT . . . . . . . . . 34-21
34-2 REAR SUSPENSION
GENERAL INFORMATION

GENERAL INFORMATION
M1341000100353
A trailing arm type multi-link suspension has been
adopted as the rear suspension. The shock absorber
is a hydraulic, cylindrical double-acting type.

CONSTRUCTION DIAGRAM
<Comfort>

Shock absorber <Sedan>

Rear shock
absorber damper
Upper arm assembly
Coil spring

Stabilizer bar
<Wagon>
Rear shock
absorber damper
Trailing arm

Rear shock
absorber cover

Control link Lower arm assembly

Trailing arm bushing

AC304024 AB

<Sport>
Shock absorber

Upper arm assembly

Coil spring
Stabilizer bar Rear shock
absorber damper

Trailing arm

Control link Lower arm assembly

Trailing arm bushing AC304025 AB

 REAR SUSPENSION
SERVICE SPECIFICATIONS
34-3
SPECIFICATION
COIL SPRING
Item Sedan Wagon
Comfort Sport Comfort Sport
Wire diameter mm 10 10 10 10
Average diameter mm 78 − 90 78 − 90 78 − 90 78 − 90
Free length mm 359 331 377 368

SERVICE SPECIFICATIONS
M1341000300409

Item Standard value

Camber (Difference between right and left within 30') −0°40' ± 30'
Toe-in At the centre of tyre tread mm 3±2
Toe-angle (per wheel) 0°08' ± 05'
Thrust angle 0°00' ± 0°09'
Control link pillow ball bushing rotation starting torque <Sport> N⋅m 0.5 − 3.0
Upper arm pillow ball bushing rotation starting torque <Sport> N⋅m 0.5 − 3.0
Lower arm pillow ball bushing rotation starting torque N⋅m 0.5 − 3.0
Protruding length of stabilizer link bolt mm 6−8
Stabilizer link ball joint continuous rotating torque N⋅m 0.5 − 1.5

LUBRICANT
M1341000400172

Item Specified lubricant Quantity

Stabilizer link ball joint (inside of dust cover) Multipurpose grease SAE J310, NLGI No.2 As required
or equivalent
34-4 REAR SUSPENSION
SPECIAL TOOLS

SPECIAL TOOLS
M1341000600392

Tool Number Name Use

MB991014 Wheel alignment gauge Wheel alignment
attachment measurement <vehicles
with aluminium wheels>

MB991004

MB990326 Preload socket • Pillow ball bushing

rotation starting
torque check
• Stabilizer link ball
joint turning torque
MB990326
check
MB991447 Bushing remover and Lower arm bushing
installer removal and press-fitting

MB991448 Bushing remover and

installer base

MB991449 Bushing remover and

installer supporter

B MB990957 Lower arm bushing Lower arm pillow ball

A A: MB990969 remover and installer bushing removal and
B: MB990971 A: Guide press-fitting
B: Base
MB990957

MB990996 Lower arm bushing arbor

B990996
 REAR SUSPENSION
ON-VEHICLE SERVICE
34-5
Tool Number Name Use
MB990947 Lower arm bushing arbor Trailing arm bushing
removal and press-fitting

MB990947

MB991816 Bushing remover and

installer base

MB990890 Rear suspension bushing

base

MB990890

A: MB991237 A: Spring compressor Coil spring compressing

B: MB991239 body
B: Arm set
A

B MB991237

ON-VEHICLE SERVICE
REAR WHEEL ALIGNMENT CHECK AND CAUTION
ADJUSTMENT Never subject the wheel bearings to the vehicle
M1341011000372 load when the rear wheel hub nuts (self-locking
Measure wheel alignment with an alignment nuts) or special tool wheel alignment gauge
equipment on level earth. attachment (MB991014) are loosened.
The rear suspension, wheels, and tyres should be
NOTE:
serviced to the normal condition prior to wheel <Vehicles with aluminium wheels>
alignment measurement. MB991014
CAMBER
Standard value: -0° 40' ± 30' (Left/right
deviation within 30')

AC001079 AG

For vehicles with aluminium wheels, attach the

camber/caster/kingpin gauge to the trailing arm
spindle by using special tool wheel alignment gauge
attachment (MB991014). Tighten the special tool to
the same torque 175 ± 25 N⋅m as the rear wheel hub
nut (self-locking nut).
34-6 REAR SUSPENSION
ON-VEHICLE SERVICE

If camber is not within the standard value, adjust by If toe-in is not within the standard value, adjust by
following procedures. following procedures.
1. Disconnect the conjunction of the control link and CAUTION
the trailing arm. To prevent bushings from breakage, the control
link mounting nut should be temporarily
Camber adjusting bolt tightened, and then fully tightened to 120 ± 10
Lower arm
assembly N⋅m with the vehicle on the earth in the unladen
condition.
<Control link front view> <Control link rear view>

AC006159 AC
Toe adjusting bolt Control link
2. Carry out adjustment by turning the camber mounting nut
adjusting bolt (lower arm assembly mounting bolt Control link Control link
which is located on the inner side of the body). AC006145 AD
NOTE: .
Carry out adjustment by turning the toe adjusting bolt
• LH: Clockwise viewed from the front → (+)
(control link mounting bolt which is located on the
camber
inner side of the body).
• RH: Clockwise viewed from the front → (-)
camber NOTE: .
• The scale has gradations of approximately 14'. • LH: Clockwise viewed from the front → Toe-in
• RH: Clockwise viewed from the front → Toe-out
CAUTION
• Turning the toe adjusting bolt by one groove of
the scale, toe can be changed approximately 2.6
mm (single side toe angle equivalent to 16').

CONTROL LINK PILLOW BALL BUSHING

AXIAL PLAY CHECK <Sport>
M1341018500011
1. Raise the vehicle.
Connecting bolt

AC006160 AC

To prevent bushings from breakage, the Front of

connecting bolt should be temporarily tightened, vehicle
and then fully tightened to 90 ± 10 N⋅m with the
vehicle on the earth in the unladen condition.
3. Tighten the control link to the trailing arm.
4. After adjusting the camber, the toe should be
Control link pillow ball bushing
adjusted. AC304398 AB

2. Move the control link up and down with your

TOE-IN hands to check for an excessive play in the axial
Standard value: direction of the pillow ball bushing. If there is an
At the centre of tyre tread: 3 ± 2 mm excessive play, replace the control link (Refer to
Toe angle (per wheel): 0°08' ± 05' P.34-8).
 REAR SUSPENSION
ON-VEHICLE SERVICE
34-7
UPPER ARM PILLOW BALL BUSHING
AXIAL PLAY CHECK <Sport>
M1341018400014
1. Raise the vehicle.
Front of
vehicle
Upper arm pillow
ball bushing

Front of
vehicle
Lower arm pillow ball bushing
AC304398 AD

3. Move the lower arm up and down with your hands

to check for an excessive play in the axial
direction of the pillow ball bushing. If there is an
AC304398 AC
excessive play, replace the lower arm pillow ball
2. Move the upper arm up and down with your hands bushing (Refer to P.34-10).
to check for an excessive play in the axial 4. After inspection, install the stabilizer link and
direction of the pillow ball bushing. If there is an shock absorber to the lower arm assembly (Refer
excessive play, replace the upper arm (Refer to to P.34-8).
P.34-8).
STABILIZER LINK BALL JOINT DUST
LOWER ARM PILLOW BALL BUSHING COVER INSPECTION
AXIAL PLAY CHECK M1341012800274
M1341016900057 1. Check stabilizer link ball joint dust covers for
1. Raise the vehicle. cracks or damage by pushing it with your finger.
2. Remove the stabilizer link and shock absorber 2. If a dust cover is cracked or damaged, replace the
from the lower arm assembly. stabilizer link assembly.
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint.
34-8 REAR SUSPENSION
CONTROL LINK, UPPER ARM AND LOWER ARM

CONTROL LINK, UPPER ARM AND LOWER ARM

REMOVAL AND INSTALLATION
M1341004800172

CAUTION
*
: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in an unladen condition.
Post-installation Operation
• Rear Wheel Alignment Check and Adjustment (Refer to
P.34-5).

<Comfort>
120 ± 10 N·m*

<Sport> 2
3 120 ± 10 N·m*

<Sport> 2 120 ± 10 N·m*

5
120 ± 10 N·m*
90 ± 10 N·m*
1 95 ± 15 N·m*
<Comfort> 6

1 95 ± 15 N·m*
N

4
AC304154 AB

Control link and upper arm Lower arm assembly removal

assembly removal steps steps
<<A>> >>B<< 1. Control link >>A<< 3. Stabilizer link connection
<<B>> >>B<< 2. Upper arm assembly <<B>> 4. Lower arm assembly and trailing arm
connection
5. Shock absorber connection
<<A>> 6. Lower arm assembly
 REAR SUSPENSION
CONTROL LINK, UPPER ARM AND LOWER ARM
34-9
REMOVAL SERVICE POINTS Tighten the self-locking nut until the stabilizer link
thread part protruding length meets the standard
<<A>> CONTROL LINK/LOWER ARM
value.
ASSEMBLY REMOVAL
Standard value (A): 6 − 8 mm

Mating mark >>B<< UPPER ARM

ASSEMBLY/CONTROL LINK
INSTALLATION
<COMFORT>
Upper arm assembly

AC304404 AB Hole
After making a mating mark on the toe adjusting bolt
or camber adjusting bolt, remove the control link or Trailing arm
lower arm assembly.

<<B>> UPPER ARM ASSEMBLY/LOWER AC304674 AB

ARM ASSEMBLY AND TRAILING ARM Install the upper arm assembly as shown so that its
DISCONNECTION hole is body side. <Comfort>

<SPORT>
Identification colour
Upper arm
assembly

Control link

Piece of wood

Trailing arm AC300343AC

AC107126 AB

After supporting the lower arm with a jack, separate Install the upper arm assembly/control link as shown
the upper arm assembly/lower arm assembly and the so that its identification colour faces the trailing arm.
trailing arm. <Sport>

INSTALLATION SERVICE POINTS INSPECTION

M1341004900157
>>A<< STABILIZER LINK CONNECTION • Check the bushings for wear and deterioration.
• Check the control link, upper arm and lower arm
for bending or breakage.
• Check all bolts for condition and straightness.

AC103744 AC
34-10 REAR SUSPENSION
CONTROL LINK, UPPER ARM AND LOWER ARM

CONTROL LINK <Sport>/UPPER ARM LOWER ARM BUSHING AND LOWER

<Sport>/LOWER ARM PILLOW BALL ARM PILLOW BALL BUSHING
BUSHING ROTATION STARTING TORQUE REPLACEMENT
M1341011800204
CHECK
Control link pillow ball bushing <Sport> Lower arm pillow
ball bushing

Lower arm bushing

Upper arm pillow ball bushing <Sport>

AC304399 AB

Replace the lower arm bushing and lower arm pillow

ball bushing as follows.

Lower arm pillow ball bushing

LOWER ARM BUSHING REPLACEMENT
CAUTION
Because the outside diameter of both edges of
the bushing are different, be careful not to
mistake the direction.
AC107127AD Driving Out

Check each pillow ball bushing as follows.

MB991447
1. Insert the mounting bolt to the pillow ball bushing.
In the opposite direction, insert a washer, then Lower arm
install the mounting nut. MB991449

MB990326 MB991448

AC006168 AC

Press-Fitting

1.5 mm
MB991447

AC102498 AC Lower arm

MB991449
2. After rotating the inner sleeve (contained washer)
several times, measure the rotation starting
torque of the pillow ball bushing using special tool MB991448
preload socket (MB990326). AC006169 AC

Standard value: 0.5 − 3.0 N⋅m Use following special tools to drive out and press fit
3. If the measured value exceeds the standard the bushing.
value, replace the control link, the upper arm, or • MB991447: Bushing Remover and Installer
the lower arm pillow ball bushing. • MB991448: Bushing Remover and Installer Base
• MB991449: Bushing Remover and Installer
4. If the measured value is lower than the standard
Supporter
value, check that the pillow ball bushing turns
After press fitting, the space between the edges of
smoothly without excessive play. If there is no
the bushing outer sleeve and of the lower arm should
excessive play and it turns smoothly, the pillow
be 1.5 mm.
ball bushing can be reused.
 REAR SUSPENSION
CONTROL LINK, UPPER ARM AND LOWER ARM
34-11
LOWER ARM PILLOW BALL BUSHING Use following special tools to drive out and press fit
REPLACEMENT the bushing.
• MB990957: Lower Arm Bushing Remover and
MB990996
Installer
• MB990969: Guide
• MB990971: Base
3 mm
• MB990996: Lower Arm Bushing Arbor
After press fitting, the space between the edges of
Lower arm the bushing outer sleeve and of the lower arm should
be 3 mm.
MB990969
MB990971
AC102522AC
34-12 REAR SUSPENSION
TRAILING ARM ASSEMBLY

TRAILING ARM ASSEMBLY

REMOVAL AND INSTALLATION
M1341002200594

CAUTION
*
: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in the unladen condition.
Pre-removal Operation Post-installation Operation
• Brake Fluid Draining • Rear Hub Assembly Installation (Refer to GROUP 27,
• Rear Hub Assembly Removal (Refer to GROUP 27, Rear Rear Axle Hub Assembly P.27-5).
Axle Hub Assembly P.27-5). • Brake Fluid Supplying and Bleeding (Refer to GROUP
35A, On-vehicle Service − Bleeding P.35A-6).
• Rear Wheel Alignment Check and Adjustment (Refer to
P.34-5).
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service − Parking Brake Lever Stroke
Check and Adjustment P.36-3).

AC101449
8 120 ± 10 N·m* AC301223

15 ± 2 N·m
90 ± 10 N·m*
11

7 3

10
4
120 ± 10 N·m*

6
5
9 63 ± 7 N·m
95 ± 15 N·m*

AC304155 AB

Removal steps Removal steps (Continued)

<<A>> • Lifting point >>A<< 5. Lower arm assembly and stabilizer
1. Rear ABS Sensor (Refer to link connection
GROUP 35B, ABS Sensor 6. Lower arm assembly and shock
P.35B-71). absorber connection
2. Parking brake cable 7. Control link and trailing arm
3. Brake hose and trailing arm connection
connection 8. Upper arm assembly and trailing
4. Rear parking brake assembly arm connection
 REAR SUSPENSION
TRAILING ARM ASSEMBLY
34-13
Removal steps (Continued)
<<B>> 9. Lower arm assembly and trailing
arm connection
10. Trailing arm and body connection
11. Trailing arm

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINT

<<A>> LIFTING POINT >>A<< STABILIZER LINK INSTALLATION

Trailing arm A

AC006171 AC AC103744 AC

When removing the trailing arm, move the lifting arm Tighten the self-locking nut until the stabilizer link
slightly towards the front of the vehicle so that it will thread part protruding length meets the standard
not be in the way. value.
Standard value (A): 6 − 8 mm
<<B>> LOWER ARM ASSEMBLY AND
TRAILING ARM DISCONNECTION INSPECTION
M1341002300182
• Check the bushings for wear and deterioration.
• Check the trailing arm for bending or damage.

TRAILING ARM BUSHING

REPLACEMENT
M1341011300221

Driving out
MB990947
Piece of wood
MB990890

AC107126 AB

After supporting the lower arm assembly with a jack, Trailing arm
separate the lower arm assembly and trailing arm
MB991816
connection.
AC006172 AE

1. Use the following special tools to drive out the

trailing arm bushing.
• MB990890: Rear Suspension Bushing Base
• MB990947: Lower Arm Bushing Arbor
• MB991816: Bushing Remover and Installer Base
34-14 REAR SUSPENSION
TRAILING ARM ASSEMBLY

(2) Make sure that the hollow of the trailing arm

bushing is located as shown in the illustration.
Press-fitting
MB990947

MB990890
16.2 ± 0.5 mm

Trailing arm
AC006173AB
MB991816
2. Set the installation direction and installation
location of the trailing arm bushing. AC006172 AF

(1) Place the long projection end of the trailing 3. Using the special tools, press the trailing arm
arm bushing inner pipe towards the inside of bushing into the position shown.
the vehicle.
 REAR SUSPENSION
SHOCK ABSORBER ASSEMBLY
34-15
SHOCK ABSORBER ASSEMBLY
REMOVAL AND INSTALLATION
M1341002500261

CAUTION
*
: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in the unladen condition.
Pre-removal and Post-installation Operation
• Centre Luggage Floor Lid <Wagon> Removal and
Installation
• Centre Luggage Floor Box <Wagon> Removal and
Installation

3
44 ± 5 N·m

95 ± 15 N·m*
95 ± 15 N·m*

2 AC304794 AB

Removal steps Removal steps (Continued)

>>B<< 1. Stabilizer link connection 4. Coil spring bolt
<<A>> 2. Lower arm bolt >>A<< 5. Shock absorber assembly
3. Coil spring nut
34-16 REAR SUSPENSION
SHOCK ABSORBER ASSEMBLY

REMOVAL SERVICE POINT >>B<< STABILIZER LINK INSTALLATION

<<A>> LOWER ARM BOLT REMOVAL

Piece of wood AC103744 AC

Tighten the self-locking nut until the stabilizer link

AC107126 AB thread part protruding length meets the standard
After supporting the lower arm with a jack, remove value.
the lower arm bolt. Standard value (A): 6 − 8 mm

INSTALLATION SERVICE POINTS INSPECTION

M1341002600150
>>A<< SHOCK ABSORBER ASSEMBLY • Check the rubber parts for cracks and wear.
INSTALLATION • Check the shock absorber for malfunctions, oil
leakage, or abnormal noise.

Rear of
the vehicle

Spring seat
stepped section
AC304795 AB

Install the spring seat stepped section so that it

points towards the rear side of the vehicle.
 REAR SUSPENSION
SHOCK ABSORBER ASSEMBLY
34-17
DISASSEMBLY AND REASSEMBLY
M1341005300222

25 ± 5 N·m
Sedan, Wagon
Wagon (comfort) 1
(sport)
2
8
11 4
3

8 5
9
12
6
7
13

10

AC304156 AB

Disassembly steps Disassembly steps (Continued)

<<A>> >>E<< 1. Rear suspension coil spring nut 9. Rear shock absorber cover <Wagon
(self-locking nut) (comfort)>
2. Rear suspension coil spring washer >>C<< 10. Rear suspension spring upper pad
3. Rear suspension coil spring bushing >>B<< 11. Rear suspension coil spring
4. Rear suspension coil spring collar >>A<< 12. Rear suspension spring lower pad
>>D<< 5. Rear shock absorber insulator <<B>> 13. Rear suspension shock absorber
6. Rear suspension coil spring bushing
7. Rear suspension spring damper plate
8. Rear shock absorber damper
34-18 REAR SUSPENSION
SHOCK ABSORBER ASSEMBLY

DISASSEMBLY SERVICE POINTS 2. While holding the piston rod, remove the rear
<<A>> REAR SUSPENSION COIL SPRING suspension coil spring nut (self-locking nut).
NUT (SELF-LOCKING NUT) REMOVAL
<<B>> REAR SUSPENSION SHOCK
CAUTION
ABSORBER DISPOSAL
• To hold the coil spring securely, install
special tool arm set (MB991239) evenly, and WARNING
so that the space between both arms of the Wear goggles when drilling to protect your
special tool will be maximum within the eyes from flying metal debris.
installation range.
• Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237). It will break the special tool.

MB991237

AC102270 AC

The gas must be discharged from the shock

absorber before discarding it. Place the shock
MB991239 absorber horizontally with its piston rod extended.
AC001070 AB Then drill a hole of approximately 3 mm in diameter
at the location shown in the illustration and discharge
1. Use following special tools to compress the coil the gas.
spring.
• MB991237: Spring Compressor Body
REASSEMBLY SERVICE POINTS
• MB991239: Arm Set
>>A<< REAR SUSPENSION SPRING
WARNING LOWER PAD INSTALLATION
Do not use an impact wrench to remove the
rear suspension coil spring nut (self-locking Spring lower pad
nut). Vibration of the impact wrench will
cause special tools (MB991237 and
MB991239) to slip and cause personal injury.
Stepped section
Spring seat

AC304800 AB
Piston rod
Align the stepped section of the spring lower pad
with the stepped section of the spring seat of the
shock absorber, and install the spring lower pad.

AC102268AC
 REAR SUSPENSION
SHOCK ABSORBER ASSEMBLY
34-19
>>B<< REAR SUSPENSION COIL SPRING Align the stepped section of the spring upper pad
INSTALLATION with the upper end of the coil spring, and install the
spring upper pad.
CAUTION
Do not use an impact wrench to tighten the bolt
>>D<< REAR SHOCK ABSORBER
of special tool spring compressor body
(MB991237). It will break the special tool. INSULATOR INSTALLATION

Lower bushing inner pipe

MB991237

Rear shock absorber

insulator mounting bolt

MB991239
AC001070 AB

1. Use following special tools to compress the coil

spring, and install the rear suspension coil spring
to the spring lower pad.
• MB991237: Spring Compressor Body
• MB991239: Arm Set
Lower bushing
inner pipe

AC304802 AB

Install the rear shock absorber insulator so that the

Less than 10 mm axis of the lower bushing inner pipe of the shock
Stepped section absorber and the line between the rear shock
absorber insulator mounting bolts are straight when
looking from above.
AC304800AC
>>E<< REAR SUSPENSION COIL SPRING
2. The rear suspension coil spring lower end must
be positioned as illustrated. NUT (SELF-LOCKING NUT)
INSTALLATION
>>C<< REAR SUSPENSION SPRING 1. Temporarily tighten the rear suspension coil
UPPER PAD INSTALLATION spring nut (self-locking nut).
CAUTION
Do not use an impact wrench to tighten the rear
Spring upper pad suspension coil spring nut (self-locking nut),
stepped section otherwise the piston rod locking nut inside the
shock absorber will be damaged.
2. Remove the special tools (MB991237,
MB991239), and then tighten the rear suspension
coil spring nut (self-locking nut) to 25 ± 5 N⋅m.

AC304801AC
34-20 REAR SUSPENSION
STABILIZER BAR

STABILIZER BAR
REMOVAL AND INSTALLATION
M1341003000258

Post-installation Operation
• Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.

12 ± 2 N·m
7

4
5
6
39 ± 5 N·m
25 ± 4 N·m
3 3
2

AC107102

Specified grease:
Multipurpose grease SAE J310,
NLGI No.2 or equivalent

N 1 AC304232 AB

Removal steps Removal steps (Continued)

>>B<< 1. Self-locking nut >>A<< 5. Bushing
2. Stabilizer rubber >>A<< 6. Stabilizer bar
3. Stabilizer link 7. Stabilizer bracket
>>A<< 4. Fixture
 REAR SUSPENSION
STABILIZER BAR
34-21
INSTALLATION SERVICE POINTS STABILIZER LINK BALL JOINT TURNING
>>A<< STABILIZER TORQUE CHECK
BAR/BUSHING/FIXTURE INSTALLATION
MB990326
Approximately
Outside of vehicle 9.5 mm

Identification colour
Bushing (LH) AC001129 AB
Fixture (LH)
AC102279AC 1. After shaking the ball joint stud several times,
Install the stabilizer bar, the bushings and the fixtures install the nut to the stud and use special tool
as illustrated. preload socket (MB990326) to measure the
turning torque of the ball joint.
>>B<< SELF-LOCKING NUT Standard value: 0.5 − 1.5 N⋅m
INSTALLATION 2. If the measured value exceeds the standard
value, replace the stabilizer link.
3. If the measured value is lower than the standard
value, check that the ball joint turns smoothly
without excessive play. If so, it is possible to
re-use that ball joint.

A
STABILIZER LINK BALL JOINT DUST
COVER CHECK
1. Check the dust cover for cracks or damage by
AC103744 AC pushing it with your finger.
Tighten the self-locking nut until the stabilizer link 2. If the dust cover is cracked or damaged, replace
thread part protruding length meets the standard the stabilizer link.
value. NOTE: Cracks or damage of the dust cover may
Standard value (A): 6 − 8 mm cause damage to the ball joint. When it is
damaged during service work, replace the dust
INSPECTION cover (Refer to P.34-21).
M1341001400294
• Check the bushings for wear and deterioration. STABILIZER LINK BALL JOINT DUST
• Check the stabilizer bar for deterioration or
COVER REPLACEMENT
damage. M1341010900242
• Check all bolts for condition and straightness. Only when the dust cover is damaged accidentally
during service work, replace the dust cover as
follows:
34-22 REAR SUSPENSION
STABILIZER BAR

2. Apply specified grease to the inside of a new dust

cover.
Specified grease: Multipurpose grease SAE
J310, NLGI No.2 or equivalent
3. Wrap plastic tape around the stabilizer link stud,
and then install the dust cover to the stabilizer
link.
4. Secure the dust cover by the clip ring.
Clip ring
AC006188AB
5. Check the dust cover for cracks or damage by
pushing it with finger.
1. Remove the clip ring and the dust cover.
 35-1

GROUP 35

SERVICE BRAKES
CONTENTS

BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A

ANTI-SKID BRAKING SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . 35B

NOTES
 36-1

GROUP 36

PARKING BRAKES
CONTENTS

GENERAL INFORMATION . . . . . . . . 36-2 PARKING BRAKE LEVER . . . . . . . . . 36-5

REMOVAL AND INSTALLATION . . . . . . . . 36-5
SERVICE SPECIFICATIONS. . . . . . . 36-2
PARKING BRAKE CABLE. . . . . . . . . 36-6
LUBRICANTS . . . . . . . . . . . . . . . . . . 36-3 REMOVAL AND INSTALLATION . . . . . . . . 36-6

ON-VEHICLE SERVICE. . . . . . . . . . . 36-3 PARKING BRAKE LINING AND

PARKING BRAKE LEVER STROKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . 36-7
CHECK AND ADJUSTMENT . . . . . . . . . . . 36-3 REMOVAL AND INSTALLATION . . . . . . . . 36-7
LINING RUNNING-IN . . . . . . . . . . . . . . . . . 36-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 36-9
PARKING BRAKE SWITCH CHECK . . . . . 36-4
36-2 PARKING BRAKES
GENERAL INFORMATION

GENERAL INFORMATION
M1361000100496
The parking brake is of a mechanical rear-wheel
acting type, and its operation utilises a parking brake
lever.

SPECIFICATIONS
Item Specification
Type Drum-in disc
Clearance adjustment Manual

CONSTRUCTION DIAGRAM
AC211553
AC104333
Drum-in-disc brake

Parking brake lever assembly

Parking brake cable

AC304152 AB

SERVICE SPECIFICATIONS
M1361000300382

Item Standard value Limit

Parking brake lever stroke 5 − 7 notches −
Rear brake lining thickness mm 2.8 1.0
Rear drum inside diameter mm 168.0 169.0
 PARKING BRAKES
LUBRICANTS
36-3
LUBRICANTS
M1361000400293

Item Specified lubricant

Rear brake shoe and backing plate contact surface Brake grease SAE J310, NLGI No.1
Rear brake shoe assembly
Rear brake shoe slack adjuster

ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE (5) Remove the rear wheel hub plug, and then
CHECK AND ADJUSTMENT use a flat-tipped screwdriver to turn the shoe
M1361000900339 slack adjuster in the direction of the arrow (the
1. Pull the parking brake lever with a force of direction which expands the shoe) so that the
approximately 200 N and count the number of disc will not rotate.
notches. Return the shoe slack adjuster 5 notches in
Standard value: 5 − 7 notches the direction opposite to the direction of the
2. If the parking brake lever stroke is not the arrow.
standard value, adjust as described below. (6) Turn the adjusting nut to adjust the parking
(1) Remove the rear console assembly (Refer to brake lever stroke to the standard value. After
GROUP 52A, Rear Floor Console P.52A-8). adjusting, check that there is no space
between the adjusting nut and the parking
brake lever. Check that the adjusting nut is
Cable rod secured with the nut holder.
Adjusting nut
CAUTION
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
(7) Release the parking brake and turn the rear
wheels to check that the rear brakes are not
AC006190 AD
dragging.

(2) Loosen the adjusting nut to move it to the LINING RUNNING-IN

cable rod end so that the cable will be free. M1361001100240

(3) Remove the wheels. CAUTION

(4) Complete air bleeding of brake circuit. (Refer Carry out running-in in a place with good
to GROUP 35A, On-vehicle Service, Bleeding visibility, and pay careful attention to safety.
P.35A-6.) Carry out running-in by the following procedure when
replacing the parking brake linings or the rear brake
Shoe slack
disc rotors, or when brake performance is
adjuster
insufficient.
1. Adjust the parking brake lever stroke to the
standard value.
Specified value: 5 − 7 notches (Operation
force: Approximately 200 N)

AC304403 AB
36-4 PARKING BRAKES
ON-VEHICLE SERVICE

Pull
PARKING BRAKE SWITCH CHECK
M1361003300381
1. Remove the rear console assembly (Refer to
GROUP 52A, Rear Floor Console P.52A-8).
Spring balance 2. Remove the front seat assembly (RH). (Refer to
GROUP 52A, Front Seat P.52A-24).

Approximately
40 mm
AC212035 AC

2. Hook a spring balance onto the centre of the

parking brake lever grip and pull it with a force of
100 − 150 N in a direction perpendicular to the
handle.
3. Drive the vehicle at a constant speed of 35 − 50 AC304746 AB
km/h for 100 metres.
4. Release the parking brake and let the brakes cool 3. Check for continuity between the parking brake
for 5 − 10 minutes. switch terminal and the switch mounting bolt.
5. Repeat the procedure in steps 2 to 4, four or five When parking brake lever is pulled Less than 2 Ω
times. When parking brake lever is Open circuit
released
 PARKING BRAKES
PARKING BRAKE LEVER
36-5
PARKING BRAKE LEVER
REMOVAL AND INSTALLATION
M1361001300330

Pre-removal Operation Post-installation Operation

Rear Console Assembly and Rear Console Bracket Removal • Parking Brake Lever Stroke Adjustment (Refer to P.36-3.)
(Refer to GROUP 52A, Rear Floor Console P.52A-8.) • Rear Console Bracket and Rear Console Assembly
Installation (Refer to GROUP 52A, Rear Floor Console
P.52A-8.)

4
1

Section A - A Section B - B
A

Ratchet pawl

Ratchet pawl
B

B
AC006199 AB

Removal steps
1. Adjusting nut
2. Parking brake switch connector
3. Parking brake cable connection
4. Parking brake lever assembly
5. Parking brake switch
36-6 PARKING BRAKES
PARKING BRAKE CABLE

PARKING BRAKE CABLE

REMOVAL AND INSTALLATION
M1361001900785

Pre-removal Operation Post-installation Operation

• Rear Console Assembly and Rear Console Bracket • Parking Brake Lever Stroke Adjustment (Refer to P.36-3).
Removal (Refer to GROUP 52A, Rear Floor Console • Rear Seat Cushion Assembly Installation (Refer to
P.52A-8). GROUP 52A, Rear Seat P.52A-28).
• Rear Seat Cushion Assembly Removal (Refer to GROUP • Rear Console Bracket and Rear Console Assembly
52A, Rear Seat P.52A-28). Installation (Refer to GROUP 52A, Rear Floor Console
P.52A-8).

AC301226 AB

Removal steps Removal steps (Continued)

• Rear brake shoe assembly (Refer to 1. Parking brake cable connection
P.36-7). 2. Parking brake cable connection
• Loosen the parking brake lever stroke 3. Parking brake cable
adjusting nut.
 PARKING BRAKES
PARKING BRAKE LINING AND DRUM
36-7
PARKING BRAKE LINING AND DRUM
REMOVAL AND INSTALLATION
M1361002500296

Post-installation Operation
• Parking Brake Lever Stroke Check and Adjustment (Refer
to P.36-3).
• Lining Running-in (Refer to P.36-3).

60 ± 5 N·m

20 1

13

18 10 6
5
4
19 17 9 3
N 16 2

14

63 ± 7 N·m
12
11 7
15 8

AC304238 AB

14 15 8

20

Specified grease: Brake grease SAE J310, NLGI No.1

Removal steps Removal steps (Continued)

<<A>> 1. Rear brake assembly 10. Shoe to strut spring
2. Rear brake disc 11. Shoe spring cup
3. Rear hub assembly (Refer to 12. Shoe hold-down spring
GROUP 27, Rear Hub Assembly 13. Rear brake pin
P.27-5). 14. Rear brake primary shoe assembly
>>D<< 4. Shoe return spring 15. Rear brake secondary shoe
>>D<< 5. Shoe return spring assembly
6. Shoe guide plate <<B>> >>B<< 16. Rear brake chamber retainer
7. Shoe auto adjuster spring >>A<< 17. Rear brake washer
>>C<< 8. Shoe slack adjuster 18. Parking brake operating lever
9. Parking brake operating lever strut 19. Parking brake cable clip
20. Rear brake backing plate
36-8 PARKING BRAKES
PARKING BRAKE LINING AND DRUM

REMOVAL SERVICE POINTS >>B<< REAR BRAKE CHAMBER

<<A>> REAR BRAKE ASSEMBLY RETAINER INSTALLATION
REMOVAL Rear brake secondary
shoe assembly pin
Remove the rear brake assembly and support it with
wire or something similar.

<<B>> REAR BRAKE CHAMBER

RETAINER REMOVAL
Rear brake secondary
shoe assembly pin
Rear brake chamber retainer
AC000926AI

Use pliers or a similar tool to close the rear brake

chamber retainer end onto the pin.

>>C<< SHOE SLACK ADJUSTER

INSTALLATION
Rear brake chamber retainer
AC000924AG
Left rear wheel
Use a flat-tipped screwdriver or a similar tool to open
up the rear brake chamber retainer joint. Then
remove the rear brake chamber retainer. Rear of
the vehicle

INSTALLATION SERVICE POINTS

>>A<< REAR BRAKE WASHER
INSTALLATION
Rear brake
chamber retainer Parking brake
Shoe adjusting bolt
Rear brake operating lever
washer Right rear wheel

Rear of
the vehicle

Rear brake secondary

shoe assembly AC304675 AB

Install the rear brake washer in the direction shown

in the illustration.
Shoe adjusting bolt
AC304676 AB

Install the shoe slack adjuster so that the shoe

adjusting bolt for the left rear wheel is attached
towards the front of the vehicle, and the shoe
adjusting bolt for the right rear wheel is towards the
rear of the vehicle.
 PARKING BRAKES
PARKING BRAKE LINING AND DRUM
36-9
>>D<< SHOE RETURN SPRINGS 1. Measure the thickness of the brake lining at
INSTALLATION several places.
Standard value: 2.8 mm
Limit: 1.0 mm
2. If the thickness of the brake lining is below the
Front of the vehicle
limit, replace the shoe assemblies on both sides
of the vehicle. Never replace only one side.

Blue paint Yellow paint

AC202302AC

The shoe return springs are not interchangeable as

their constants are different. The one with blue paint
mark should be install at the front of the vehicle, and
the other with yellow paint at the rear of the vehicle,
respectively. ACX00709

NOTE: The illustration shows the left rear wheel. The

right rear wheel is symmetrical to that. 3. Measure the inside diameter of the brake disc in
two places or more.
INSPECTION Standard value: 168.0 mm
M1361002600248
Limit: 169.0 mm
PARKING BRAKE LINING AND DRUM
4. If the inside diameter exceeds the limit, or if it is
CHECK excessively worn on one side, replace the rear
brake disc.

ACX00708AB
NOTES
 37-1

GROUP 37

POWER STEERING
CONTENTS

GENERAL INFORMATION . . . . . . . . 37-3 DRIVE BELT TENSION CHECK . . . . . . . . . 37-13

FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37-13
SERVICE SPECIFICATIONS. . . . . . . 37-6 FLUID REPLACEMENT . . . . . . . . . . . . . . . 37-13
POWER STEERING SYSTEM AIR
LUBRICANTS . . . . . . . . . . . . . . . . . . 37-7 BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37-13
OIL PUMP PRESSURE TEST . . . . . . . . . . 37-14
SEALANTS . . . . . . . . . . . . . . . . . . . . 37-7 POWER STEERING PRESSURE
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . 37-15
SPECIAL TOOLS. . . . . . . . . . . . . . . . 37-8 TIE ROD END BALL JOINT DUST COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-15

ON-VEHICLE SERVICE. . . . . . . . . . . 37-11 STEERING COLUMN SHAFT

ASSEMBLY SHOCK ABSORBING
STEERING WHEEL FREE PLAY MECHANISM CHECK . . . . . . . . . . . . . . . . . 37-15
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-11
STEERING ANGLE CHECK . . . . . . . . . . . . 37-11 STEERING WHEEL*. . . . . . . . . . . . . . 37-17
TIE ROD END BALL JOINT TURNING REMOVAL AND INSTALLATION
TORQUE CHECK . . . . . . . . . . . . . . . . . . . . 37-12
<COMFORT> . . . . . . . . . . . . . . . . . . . . . . . 37-17
STATIONARY STEERING EFFORT
REMOVAL AND INSTALLATION
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-12
<SPORT> . . . . . . . . . . . . . . . . . . . . . . . . . . 37-19
STEERING WHEEL RETURN TO
CENTRE CHECK . . . . . . . . . . . . . . . . . . . . 37-13
Continued on next page

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
paassenger (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 (*).
37-2

STEERING SHAFT* . . . . . . . . . . . . . . 37-21 POWER STEERING OIL PUMP

REMOVAL AND INSTALLATION . . . . . . . . 37-21 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 37-37
DISASSEMBLY AND REASSEMBLY. . . . . 37-22 REMOVAL AND INSTALLATION . . . . . . . . 37-37
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37-38
POWER STEERING GEAR BOX AND DISASSEMBLY AND REASSEMBLY . . . . . 37-39
LINKAGE* . . . . . . . . . . . . . . . . . . . . . 37-24 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 37-41
REMOVAL AND INSTALLATION . . . . . . . . 37-24
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 37-26 POWER STEERING HOSES*. . . . . . . 37-42
DISASSEMBLY AND REASSEMBLY. . . . . 37-27 REMOVAL AND INSTALLATION . . . . . . . . 37-42
TIE ROD END BALL JOINT DUST COVER
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 37-36
 POWER STEERING
GENERAL INFORMATION
37-3
GENERAL INFORMATION
M1372000100337
Power steering has been adopted in all vehicles to • Integral-type rack and pinion gear with high
make the steering system easier to handle. rigidity and excellent response is used.
• A vane type pump with a fluid flow rate control
FEATURES system which change steering effort according to
• A 4-spoke steering wheel is used. <Comfort> the engine speed is used.
• MOMO leather-wrapped 3-spoke steering wheel • The separate plastic resin oil reservoir is used to
is used. <Sport> reduce weight and to make the fluid level
• A steering column has a shock absorbing checking easier.
mechanism and a tilt steering mechanism.

SPECIFICATIONS
Item Comfort Sport
Steering Type 4-spoke type MOMO leather-wrapped
wheel 3-spoke type
Outside diameter mm 380 365
Maximum number of turns 3.19 2.86 <L.H. drive vehicles>
3.08 <R.H. drive vehicles>
Steering Column mechanism Shock absorbing mechanism and Tilt steering mechanism
column
Power steering type Integral type
Oil pump Type Vane pump
Basic discharge amount cm3/rev. 7.2 <1300, 1600> 7.2 <1300, 1600>
8.1 <2000> 8.1 <2000>
Relief pressure MPa 8.8 8.8
Reservoir type Separate type (plastic)
Pressure switch Equipped
Steering Type Rack and pinion
gear Stroke ratio (Rack stroke/Steering 45.74 45.74
wheel maximum turning radius)
Rack stroke mm 146 131 <L.H. drive vehicles>
141 <R.H. drive vehicles>
37-4 POWER STEERING
GENERAL INFORMATION

CONSTRUCTION DIAGRAM
1300, 1600 - L.H. drive vehicles
Steering wheel

Oil reservoir
Steering column
shaft assembly
Pressure hose
assembly

Return hose
Suction hose

Oil pump assembly

Steering gear

AC304488AB

1300, 1600 - R.H. drive vehicles

Steering wheel

Steering column
Oil reservoir shaft assembly

Pressure hose
Suction hose assembly
Return hose

Oil pump assembly

Steering gear

AC304489AB
 POWER STEERING
GENERAL INFORMATION
37-5
2000 - L.H. drive vehicles
Steering wheel

Oil reservoir
Steering column
shaft assembly
Pressure hose
Suction hose assembly

Return hose

Oil pump assembly

Steering gear

AC304486AB

2000 - R.H. drive vehicles

Steering wheel

Steering column
Oil reservoir shaft assembly

Suction hose
Pressure hose
assembly

Return hose

Oil pump assembly

Steering gear

AC304487AB
37-6 POWER STEERING
SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
M1372000300386

Item Standard value Limit

Steering wheel free With engine running − 30
play mm
With engine stopped 10 or less −
Steering angle Inner wheel Comfort 39°30' ± 1°30' −
Sport (L.H. drive vehicles) 33°40' +1°00'/-2°00' −
Sport (R.H. drive vehicles) 37°00' +1°00'/-2°00' −
Outer wheel Comfort 32°30' −
(reference) Sport (L.H. drive vehicles) 28°46' −
Sport (R.H. drive vehicles) 30°00' −
Toe-in At the centre of tyre tread mm 1±2 −
Toe-angle (per wheel) 0°03' ± 06' −
Tie rod end ball joint turning torque N⋅m 0.5 − 2.5 −
Tie rod swing resistance N [Tie rod swing torque N⋅m] 8 − 27 [1.5 − 4.9] −
Stationary steering effort N [Fluctuation allowance N] 29 or less [5.9 or less] −
Oil pump pressure Oil pump relief pressure 8.8 − 9.5 −
MPa (750 ± 100 r/min.) Pressure under no-load conditions 0.2 − 0.7 −
Steering gear retention hydraulic pressure 8.8 − 9.5 −
Oil pressure switch operating pressure OFF → ON 1.5 − 2.0 −
MPa
ON → OFF 0.7 − 2.0 −
Steering gear total pinion torque N⋅m 1300, 1600 (Comfort) 0.8 − 2.1 [0.6 or less] −
[Change in torque N⋅m] 1600 (Sport), 2000 0.7 − 2.1 [0.6 or less] −
Opening dimension of special tool boot band crimping tool (MB991561) 2.9 −
mm
Band crimped width mm 2.4 − 2.8 −
 POWER STEERING
LUBRICANTS
37-7
LUBRICANTS
M1372000400350

Item Specified lubricant Quantity

Power steering fluid ATF DEXRON III or DEXRON II Approximately 1.0 L
Steering gear Bearing ATF DEXRON III or DEXRON II As required
O-ring and seal ring
Oil seal
Special tool (MB991212,
MB991213)
Pinion and valve assembly
seal ring part
Bellows Silicon grease As required
Tie rod end ball joint Multipurpose grease SAE J310, As required
NLGI No.2 or equivalent
Oil pump Friction surface of rotor vane, ATF DEXRON III or DEXRON II As required
cam ring and pump cover
O-ring

SEALANTS
M1372000500357

Item Specified sealant

Steering shaft cover assembly bolt hole on the toeboard 3M ATD Part No.8513 or equivalent
Steering gear End plug 3M ATD Part No.8661, 8663 or
Rack support cover equivalent
37-8 POWER STEERING
SPECIAL TOOLS

SPECIAL TOOLS
M1372000600354

Tool Number Name Use

MB991897 Ball joint remover Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113) is also
available to disconnect knuckle and
AC106827
tie rod end ball joint.
MB990326 Preload socket Tie rod end ball joint turning torque
check

MB990326

MB991548 Power steering oil Oil pump pressure test

pressure gauge
adapter (Pump
side)

MB991548

MB991549 Power steering oil

pressure gauge
adapter (Hose
side)

MB991549

MB990662 Power steering oil

pressure gauge

MB990662

MB990784 Ornament remover Cover removal

MB990784

MB990228 or Preload socket Steering gear total pinion torque

MB991006 check and adjustment

MB991006
 POWER STEERING
SPECIAL TOOLS
37-9
Tool Number Name Use
MB990607 Torque wrench • Rack support cover removal
socket <Comfort>
• Rack support adjustment
<Comfort>

MB991621 Piston driver • Rack support cover removal

<Sport>
• Rack support adjustment <Sport>

MB991621

MB990925 Bearing and oil • Lower bearing removal

seal installer set • Oil seal and bearing installation
• MB990927, MB990938, MB990939
(For details, refer to GROUP 26,
Special Tools P.26-4).
MB990925

MB991120 Needle bearing Needle bearing removal

puller

MB991120

MB991202 Oil seal and • Oil seal installation <Comfort>

bearing installer • Needle bearing installation
• Lower bearing installation

MB991202

MB991199 Oil seal and Oil seal installation <Sport>

bearing installer

MB991199
AB

MB991197 Bar (long type) Oil seal installation

MB991197

MB991212 Oil seal protector Rack installation

MB991213

MB991212
37-10 POWER STEERING
SPECIAL TOOLS

Tool Number Name Use

MB991203 Oil seal and Oil seal and bearing installation
bearing installer

MB991203

MB991317 Seal ring installer Seal rings installation

MB991317

MB990941 Torque tube Lower oil seal installation

bearing installer

MB990941

MB991561 Boot band crimping Bellows band installation

tool

MB991561

MB990776 Front axle base Tie rod end ball joint dust cover
installation

MB990776
 POWER STEERING
ON-VEHICLE SERVICE
37-11
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK 1. Place the front wheel on a turning radius gauge
M1372001000311 and measure the steering angle.
1. With the engine running (hydraulic operation), set
Standard value:
the front wheels straight ahead.
Inner Comfort 39°30' ± 1°30'
wheels Sport (L.H. 33°40' +1°00'/-2°00'
drive vehicles)
Sport (R.H. 37°00' +1°00'/-2°00'
drive vehicles)
Outer Comfort 32°30'
wheels Sport (L.H. 28°46'
(reference) drive vehicles)
ACX01122AB Sport (R.H. 30°00'
drive vehicles)
2. Measure the play on the steering wheel
circumference before the wheels start to move 2. If the steering angle is not within the standard
when slightly moving the steering wheel in both value, adjust the toe-in as follows.
directions. Standard value:
Limit: 30 mm at the centre of tyre tread: 1 ± 2 mm
3. When the play exceeds the limit, check for the Toe angle (per wheel): 0°03' ± 06'
play on the steering shaft and steering linkage Lock nut
connection. Correct or replace.
4. If the free play still exceeds the limit value, set the Clip
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
5. If the play exceeds the standard value, remove
AC006074 AD
the steering gear (Refer to P.37-24) and check
the total pinion torque (Refer to P.37-27). 3. Loosen the lock nut, and unclip the bellows.
4. Adjust the toe-in by turning the left and right tie
STEERING ANGLE CHECK rod turnbuckles by the same amount (in opposite
M1372001100374
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: 40 ± 5 N⋅m
AC000756AB
6. Recheck the steering angle.
37-12 POWER STEERING
ON-VEHICLE SERVICE

TIE ROD END BALL JOINT TURNING 4. Move the ball joint stud several times and install
TORQUE CHECK the nut on the stud. Using special tool preload
M1372001500297 socket (MB990326), measure the ball joint turning
CAUTION torque.
• Do not remove the tie rod end nut from the Standard value: 0.5 − 2.5 N⋅m
ball joint. Loosen it and use special tool to
5. If the turning torque exceeds the standard value,
avoid possible damage to the ball joint
replace the tie rod end.
threads.
6. If the turning torque is under the standard value,
• Hang special tool with cord to prevent it from
check the ball joint for axial play or ratcheting. If
falling.
no axial play or ratcheting, the ball joint can be
Cord re-used.
CAUTION
Always use a new ball joint nut as it is a
self-locking nut.
Nut MB991897 7. Install the tie rod end to the knuckle, then tighten a
new self-locking nut to the specified torque.
Tightening torque: 25 ± 5 N⋅m
Bolt
Ball joint AC208247AD STATIONARY STEERING EFFORT CHECK
M1372001700332
1. Install special tool ball joint remover (MB991897) 1. With the vehicle stopped on a flat and paved
as shown in the figure. surface, turn the steering wheel to the straight
ahead position.
2. Start the engine and set the engine idle speed.
Bolt
Standard value: 1000 ± 100 r/min
Parallel

Knob Good

Bad AC106821AB

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. ACX01122AB

NOTE: When adjusting the jaws in parallel, make 3. Attach a spring balance to the outer
sure the knob is in the position shown in the circumference of the steering wheel and measure
figure. the steering force required to turn the steering
3. Tighten the bolt with a wrench to disconnect the wheel from the straight ahead position to the left
tie rod end. and right (within a range of 1.5 turns). Also check
to be sure that there is no significant change in
MB990326 the required steering effort.
Standard value:
Steering effort: 29 N or less
Fluctuation allowance: 5.9 N or less
4. If the measured value exceeds the standard
value, check and adjust the related parts.

ACX01129 AB
 POWER STEERING
ON-VEHICLE SERVICE
37-13
STEERING WHEEL RETURN TO CENTRE 4. Check the fluid in the oil reservoir for foaming or
CHECK milkiness. Check the difference of the fluid level
M1372001800317 when the engine is stopped, and while it is
Conduct a road test: running. If the change of the fluid level is 5 mm or
1. Make both gradual and sudden turns and check more, air bleeding should be done.
the steering wheel return.
FLUID REPLACEMENT
M1372002100333
1. Raise and support the front wheels.

70˚ 70˚ Return hose

Return hose
Vinyl hose

ACX01130AB

2. At a vehicle speed of approximately 35 km/h, turn

the steering wheel 90°, hold a few seconds, then AC100369AB

release. If the steering wheel then returns 70° or

more, the return can be judged satisfactory. 2. Disconnect the return hose connection, and then
connect a vinyl hose to the return hose, and drain
NOTE: There will be a momentary feeling or the fluid into a container.
"heaviness" when the wheel is turned quickly, but
3. Disconnect the ignition coil connectors (Refer to
this is not abnormal (Oil pump discharge amount
GROUP 16, Ignition Coil P.16-38or P.16-39).
is especially apt to be insufficient during idling).
4. While operating the starter motor intermittently,
DRIVE BELT TENSION CHECK turn the steering wheel all the way to the left and
M1372001900392 right several times to drain all of the fluid.
For vehicles with 1300 and 1600 engine, refer to
5. Connect the return hose securely, and then
GROUP 11A, On-vehicle Service − Drive Belt
secure with the clip.
Tension Check P.11A-7.
For vehicles with 2000 engine, refer to GROUP 11C, 6. Fill the oil reservoir with specified fluid up to
On-vehicle Service − Drive Belt Tension Check between "MAX" and "MIN" marks, and then bleed
the air.
P.11C-7.
Specified fluid: ATF DEXRON III or DEXRON
FLUID LEVEL CHECK II
M1372002000284
1. Park the vehicle on a flat, level surface. POWER STEERING SYSTEM AIR
2. Start the engine, and then turn the steering wheel BLEEDING
several times to raise the temperature of the fluid M1372002200330

to approximately 50 − 60°C. Perform air bleeding procedure as necessary after

replacing the steering gear or the steering fluid lines.
3. With the engine running, turn the wheel all the
way to the left and right several times. 1. Raise and support the front wheels.
2. Disconnect the ignition coil connectors (Refer to
Fluid level change: Within 5 mm GROUP 16, Ignition Coil P.16-38 or P.16-39).

While engine running While engine stopped

ACX01131AC
37-14 POWER STEERING
ON-VEHICLE SERVICE

CAUTION OIL PUMP PRESSURE TEST

M1372002300315
Perform air bleeding only while cranking the
engine. If air bleeding is performed while the
engine is running, air could enter the fluid. Pressure
gauge Shut-off valve
During air bleeding, refill the steering fluid Temperature
(MB990662) (fully closed)
gauge
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 Oil reservoir
right five or six times while using the starter motor
Adapter
to crank the engine intermittently several times (MB991548)
(for 15 to 20 seconds).
4. Connect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-38 or P.16-39).
5. Start the engine (idling). Oil
6. Turn the steering wheel to the left and right until pump
there are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the Adapter
level is between "MAX" and "MIN" marks. (MB991549)
8. Confirm that there is very little change in the fluid
level when the steering wheel is turned left and
right.
ACX01133 AB
CAUTION
If the fluid level rises suddenly after the engine is 1. Disconnect the pressure hose from the oil pump,
stopped, the air has not been completely bled. If and then connect the following special tools.
air bleeding is not complete, there will be • MB990662: Power Steering Oil Pressure Gauge
abnormal noises from the pump and the • MB991548: Power Steering Oil Pressure Gauge
flow-control valve, and this condition could Adapter (pump side)
cause reduce the life of the power steering • MB991549: Power Steering Oil Pressure Gauge
components. Adapter (hose side)
Fluid level change: Within 5 mm
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
− 60°C.
3. Start the engine and idle it at 1000 ± 100 r/min.
CAUTION
The pressure gauge shut-off valve must not
remain closed for more than 10 seconds.
While engine running While engine stopped 4. Fully close the shut-off valve of the pressure
ACX01131AC
gauge and measure the oil pump relief pressure
9. Confirm that the change in the fluid level is no to confirm that it is within the standard value
more than 5 mm when the engine is stopped and range. Open it again immediately after checking
when it is running. the pressure.
10.If the change of the fluid level is 5 mm or more, Standard value: 8.8 − 9.5 MPa
the air has not been completely bled from the 5. If it is not within the standard value, replace the oil
system. The air bleeding procedure must be pump.
repeated. 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 − 0.7 MPa
 POWER STEERING
ON-VEHICLE SERVICE
37-15
7. If it is not within the standard value, the probable 2. Bleed air, and then turn the steering wheel several
cause is a malfunction of the oil line or steering times while the vehicle is not moving so that the
gear, so check these parts and repair as temperature of the fluid rises to approximately 50
necessary. − 60°C.
8. Turn the steering wheel all the way to the left or 3. The engine should be idling.
right; then check whether or not the retention 4. Disconnect the connector for the oil pressure
hydraulic pressure is the standard value. switch, and place an ohmmeter at the switch.
Standard value: 8.8 − 9.5 MPa 5. Gradually close the shut-off valve of the pressure
9. If not the standard value, overhaul the steering gauge and increase the hydraulic pressure, then
gear. Remeasure fluid pressure. check whether or not the hydraulic pressure that
10. Remove the special tools, and then tighten the activates the switch is the standard value.
pressure hose to the specified torque. Standard value: 1.5 − 2.0 MPa
Tightening torque: 57 ± 7 N⋅m 6. Gradually open the shut-off valve and reduce the
11. Bleed the system (Refer to P.37-13). hydraulic pressure; then check whether or not the
hydraulic pressure that deactivates the switch is
POWER STEERING PRESSURE SWITCH the standard value.
CHECK Standard value: 0.7 − 2.0 MPa
M1372007200324
7. Remove the special tools, and then tighten the
pressure hose to the specified torque.
Tightening torque: 57 ± 7 N⋅m
Shut-off valve
Adapter 8. Bleed the system (Refer to P.37-13).
(MB991548)
Pressure gauge
Temperature (MB990662) TIE ROD END BALL JOINT DUST COVER
gauge
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,
Oil the ball joint could be damaged.
pump

STEERING COLUMN SHAFT ASSEMBLY

Adapter
Oil reservoir (MB991549) SHOCK ABSORBING MECHANISM
CHECK
M1372013500090
If a collision accident occurs or severe impact is
ACX01134 AB applied on the steering wheel, the collision energy
absorbing mechanism may have operated. Once the
1. Disconnect the pressure hose from the oil pump, mechanism has operated, it will be inoperative even
and then connect the following special tools. it has suffered no apparent damage. Determine if the
• MB990662: Power Steering Oil Pressure Gauge steering column shaft can be reused by the following
• MB991548: Power Steering Oil Pressure Gauge procedure. If the collision energy absorbing
Adapter (pump side) mechanism has already operated, replace the
• MB991549: Power Steering Oil Pressure Gauge steering column shaft assembly.
Adapter (hose side) 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.
37-16 POWER STEERING
ON-VEHICLE SERVICE

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 AC304673
AC304673
1. Remove the lower and upper column covers.
CAUTION
Do not release the tilt lever until the steering
One way capsule
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.
AC304672
AC304923 AB

Steering 4. Hold the one-way capsules as shown, and then

column
assembly 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
Steering shaft assembly, place the tilt lever in the lock
column position, if it is not in place.
mounting
bolt AC304673 AB CAUTION
• Be careful that nothing is pinched between
3. Loosen the two steering column mounting bolts the one-way capsules and the body.
(upper) by two turns.
• 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 N⋅m
 POWER STEERING
STEERING WHEEL
37-17
STEERING WHEEL
REMOVAL AND INSTALLATION
<COMFORT>
M1372011400183

WARNING
• Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210).
• 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

Section A - A

2 Tab

2
1
Section B - B
Tab
1
A 50 ± 5 N·m
B
B 2
1 A
AC107402AB

Removal steps NOTE: For air bag module removal, refer to GROUP
<<A>> 1. Cover 52B, Air Bag Module and Clock Spring P.52B-210.
<<B>> 2. Steering wheel and air bag module
assembly
37-18 POWER STEERING
STEERING WHEEL

REMOVAL SERVICE POINTS 1. By sliding section A of the clock spring connector

<<A>> COVER REMOVAL shown in the illustration in the arrow direction,
disconnect the connector.

Hexagonal bit socket

MB990784

AC006294 AB
AC100442 AC
Insert special tool ornament remover (MB990784) at
the indicated position to remove the cover. 2. Loosen the bolt completely. Then, remove the
NOTE: The special tool can be inserted through the steering wheel and air bag module assembly.
notch behind the area shown. NOTE: Use a hexagonal bit socket or a hexagonal
wrench having an effective length of 75 mm or
<<B>> STEERING WHEEL AND AIR BAG more in the hexagonal section and the diameter of
8 mm or more.
MODULE ASSEMBLY REMOVAL

Steering
wheel

AC304700

Air bag module

connector

AC105823

AC305145AB
 POWER STEERING
STEERING WHEEL
37-19
REMOVAL AND INSTALLATION <SPORT>
M1372011400194

WARNING
• Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210).
• 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 N·m 2
1

AC211760AD

Removal steps NOTE: For air bag module removal, refer to GROUP
<<A>> 1. Cover 52B, Air Bag Module and Clock Spring P.52B-210.
<<B>> 2. Steering wheel and air bag module
assembly

REMOVAL SERVICE POINTS

<<A>> COVER REMOVAL

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.
37-20 POWER STEERING
STEERING WHEEL

<<B>> STEERING WHEEL AND AIRBAG 1. By sliding section A of the clock spring connector
MODULE ASSEMBLY REMOVAL as shown in the illustration in the arrow direction,
disconnect the connector.

Hexagonal bit
Steering socket
wheel

AC211762 AC
AC304700
2. Loosen the bolt completely. Then, remove the
steering wheel and airbag module assembly.
Air bag module NOTE: Use a hexagonal bit socket or a hexagonal
connector
wrench having an effective length of 75 mm or
more in the hexagonal section and the diameter of
8 mm or more.
A

AC105823

AC305145AB
 POWER STEERING
STEERING SHAFT
37-21
STEERING SHAFT
REMOVAL AND INSTALLATION
M1372011500113

WARNING
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210).
Pre-removal Operation Post-installation Operation
• Steering Wheel and Air bag Module Assembly Removal • Under Cover Installation (Refer to GROUP 52A,
(Comfort: refer to P.37-17/Sport: refer to P.37-19). Instrument Panel P.52A-2).
• Under Cover Removal (Refer to GROUP 52A, Instrument • Steering Wheel and Air bag Module Assembly Installation
Panel P.52A-2). (Comfort: refer to P.37-17/Sport: refer to P.37-19).

2.5 ± 0.5 N·m

2 A (mounting screw)
Section A - A 3
2 A
Tab

1
7
Section B - B
B B 1
Toe board
12 ± 2 N·m
B B 6
4
8 5
18 ± 2 N·m
8

Specified sealant:
3M ATD Part No.8513 or equivalent 5.0 ± 1.0 N·m
AC304919 AB

Removal steps Removal steps (Continued)

1. Lower column cover 5. Key interlock cable <A/T> (Refer to
2. Upper column cover GROUP 23A, A/T Key Interlock and
3. Clock spring and column switch Shift Lock Mechanism P.23A-151).
assembly 6. Shaft cover
4. Cover <A/T> <<A>> >>A<< 7. Steering column shaft assembly
8. Cover assembly

REMOVAL SERVICE POINT from the vehicle, the steering column can not be
reinstalled correctly. If the steering column is
<<A>> STEERING COLUMN SHAFT
installed incorrectly, the collision energy
ASSEMBLY REMOVAL absorbing mechanism may be damaged.
CAUTION 1. Ensure that the tilt lever is in the lock position, and
The tilt lever should be held in the lock position remove the steering column mounting bolts.
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
37-22 POWER STEERING
STEERING SHAFT

• When the steering column is replaced, do not

release the tilt lever until it has been installed.
Clip Do not remove the tilt lever fixing band until
the installation has completed.
• When installing the steering column, do not
Steering column leave it fixed temporarily at only one point
shaft 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.
AC210969AD 4

2. Pinch the steering column shaft clip with pliers, 1 2

and pull up the shaft towards the direction shown
to disengage the steering column shaft assembly.
3
Tilt lever
INSTALLATION SERVICE POINT
>>A<< STEERING COLUMN SHAFT
ASSEMBLY INSTALLATION
AC209383AD
CAUTION
• When reusing the steering column, do not Ensure that the tilt lever is in the lock position, and
release the tilt lever until the steering column install the steering column. Tighten the four bolts in
shaft has been installed. the order shown by hand, and then tighten them to
the specified torque in the order shown.
Tightening torque: 12 ± 2 N⋅m

DISASSEMBLY AND REASSEMBLY

M1372011700106

4 3

AC210967AD
Disassembly steps Disassembly steps (Continued)
<<A>> >>A<< 1. Special bolt >>A<< 3. Steering lock cylinder assembly
>>A<< 2. Steering lock bracket 4. Steering column shaft assembly
 POWER STEERING
STEERING SHAFT
37-23
DISASSEMBLY SERVICE POINT REASSEMBLY SERVICE POINT
<<A>> SPECIAL BOLT REMOVAL >>A<< STEERING LOCK CYLINDER
Reverse screw tap
ASSEMBLY/STEERING LOCK
Special bolt BRACKET/SPECIAL BOLT
Steering lock INSTALLATION
bracket
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
Steering lock
cylinder ACX01138AB
assembly and steering lock bracket to the column
tube, temporarily install the steering lock in
1. Drill in the special bolt a hole deep enough for the alignment with the column boss.
tap to stand.
2. Remove the special bolt with a left-hand tap.

ACX01139 AB

2. After checking that the lock works properly,

tighten the special bolts until the head twists off.
37-24 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING GEAR BOX AND LINKAGE

REMOVAL AND INSTALLATION
M1372010900237

WARNING
Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-5) and
Air Bag Module and Clock Spring (P.52B-210). Centre the front wheels. Failure to do so may
damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
Pre-removal Operation Post-installation Operation
• Power Steering Fluid Draining (Refer to P.37-13.) • Check the dust cover for cracks or damage by pushing it
with your finger.
• Power Steering Fluid Supplying (Refer to P.37-13.)
• Power Steering Fluid Line Bleeding (Refer to P.37-13.)
• Checking Steering Wheel Position with Wheels Straight
Ahead.
• Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service − Front Wheel Alignment Check and
Adjustment P.33-5.)

<L.H. drive vehicles>

12 ± 2 N·m
8
70 ± 10 N·m
5
7
6
57 ± 7 N·m

9 15 ± 3 N·m
4
3
2
12 ± 2 N·m
10

AC304920 AB

Removal steps Removal steps (Continued)

1. Crossmember (Refer to GROUP 32, 4. Return tube
Crossmember P.32-8). 5. O-ring
• Engine rear roll stopper bracket (Refer 6. Return tube
to GROUP 32, Engine Roll Stopper 7. Eye bolt
and Centermember P.32-7). 8. Pressure hose assembly
>>A<< 2. Joint cover grommet 9. Clamp
3. Return hose 10. Steering gear and linkage
 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE
37-25

<R.H. drive vehicles>

4 15 ± 3 N·m
3
2
70 ± 10 N·m
5

6
57 ± 7 N·m

AC304921AC

Removal steps Removal steps (Continued)

1. Crossmember (Refer to GROUP 32, 5. Pressure hose connection
Crossmember P.32-8). 6. Clamp
>>A<< 2. Joint cover grommet 7. Steering gear and linkage
3. Return hose connection
4. Return tube
37-26 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE

INSTALLATION SERVICE POINT NOTE: When measuring, remove the bellows from
the rack housing. Measure the pinion torque through
>>A<< JOINT COVER GROMMET
the whole stroke of the rack.
INSTALLATION If the measured value is not within the standard
range, first adjust the rack support cover, and then
Joint cover check the total pinion torque again.
grommet
If the total pinion torque cannot be adjusted to within
A
the standard range by adjusting the rack support
B
cover, check the rack support cover, rack support
spring, rack support and replace any parts if
necessary.

Steering gear TIE ROD SWING RESISTANCE CHECK

AC304922 AB 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
M1372011000237

STEERING GEAR TOTAL PINION

TORQUE CHECK
CAUTION
AC000997
When holding the steering gear in a vice, secure
its mounting positions. If it is secured in any 2. Measure the tie rod swing resistance [tie rod
other place, the gear housing may become swing torque] with a spring balance.
deformed or damaged. Standard value: 8 − 27 N [1.5 − 4.9 N⋅m]
3. If the measured value exceeds the standard
value, replace the tie rod.
MB991006
4. If the measured value is below the standard value,
the tie rod can be re-used if it swings smoothly
without excessive play.

TIE ROD END BALL JOINT DUST COVER

CHECK
AC000996 AC 1. Check the dust cover for cracks or damage by
pushing it with your finger.
Using special tool preload socket (MB991006), rotate
2. If the dust cover is cracked or damaged, replace
the pinion gear at the rate of one rotation in
the tie rod end (Refer to P.37-27).
approximately 4 to 6 seconds to check the total
pinion torque. NOTE: Cracks or damage of the dust cover may
damage the ball joint. If it is damaged during
Standard value: 0.7 − 1.6 N⋅m
service work, replace the dust cover (Refer to
1300, 1600(Comfort): 0.8 − 2.1
1600(Sport), 2000: 0.7 − 2.1 P.37-36).
[Change in torque: 0.6 N⋅m or less]
 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE
37-27
DISASSEMBLY AND REASSEMBLY
M1372011100193
<L.H. drive vehicles>

22 ± 4 N·m
Flare nut

3 13 ± 3 N·m
4 24 3
23
4 22
20 18
21
35 34 19 23
Repair kit grease
13 59 ± 10 N·m 21
19
1 36 12 4
40 ± 5 N·m 11 8
15 14 23 ± 2 N·m
2 33 -30˚ 8
17 11 35
16
6 25 ± 4 N·m 17 31 29 28
5 59 ± 10 N·m 32
7
9 Steering gear seal kit
8 11 26
10 27
88 ± 10 N·m
25 32
28
29

31
30

AC100244 AE

Disassembly steps Disassembly steps (Continued)

>>O<< 1. Gear mounting rubber 18. Valve housing assembly
2. Gear housing mounting bushing <<B>> >>H<< 19. Lower oil seal
3. Feed pipe <<B>> 20. Pinion and valve assembly
4. O-ring <<C>> >>G<< 21. Seal ring
>>N<< 5. Lock nut <<D>> >>F<< 22. Upper bearing
>>N<< 6. Tie rod end <<D>> >>F<< 23. Upper oil seal
7. Clip 24. Valve housing
>>M<< 8. Bellows band <<E>> >>E<< 25. Circlip
9. Bellows <<F>> 26. Rack stopper
>>L<< 10. Tie rod <<F>> >>D<< 27. Rack bushing
>>L<< 11. Tab washer <<F>> >>D<< 28. Oil seal
>>K<< • Total pinion torque adjustment <<F>> 29. O-ring
>>J<< 12. Lock nut <<F>> >>C<< 30. Rack assembly
<<A>> >>J<< 13. Rack support cover <<C>> 31. Seal ring
14. Support spring 32. O-ring
15. Rack support <<G>> >>B<< 33. Lower bearing
>>I<< 16. End plug <<H>> >>B<< 34. Needle bearing
17. Lock nut <<I>> >>A<< 35. Oil seal
36. Gear housing
37-28 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE

<R.H. drive vehicles>

22 ± 4 N·m Flare nut
24
4 13 ± 3 N·m 3
23
18 3
22
21

20 4 23 Repair kit grease

19 34 21
4
1 19
4
11 8
2
36 8 35
33 35 11
25 ± 4 N·m 17 31 29 28
32
17
12 Steering gear seal kit
16 15
14
59 ± 10 N·m 13 59 ± 10 N·m

23 ± 2 N·m -30˚

30

31 88 ± 10 N·m
29
32 27 26
11 40 ± 5 N·m
28 25 10
8
9 7
5
6
AC102865 AE

Disassembly steps Disassembly steps (Continued)

>>O<< 1. Gear mounting rubber 18. Valve housing assembly
2. Gear housing mounting bushing <<B>> >>H<< 19. Lower oil seal
3. Feed pipe <<B>> 20. Pinion and valve assembly
4. O-ring <<C>> >>G<< 21. Seal ring
>>N<< 5. Lock nut <<D>> >>F<< 22. Upper bearing
>>N<< 6. Tie rod end <<D>> >>F<< 23. Upper oil seal
7. Clip 24. Valve housing
>>M<< 8. Bellows band <<E>> >>E<< 25. Circlip
9. Bellows <<F>> 26. Rack stopper
>>L<< 10. Tie rod <<F>> >>D<< 27. Rack bushing
>>L<< 11. Tab washer <<F>> >>D<< 28. Oil seal
>>K<< • Total pinion torque adjustment <<F>> 29. O-ring
>>J<< 12. Lock nut <<F>> >>C<< 30. Rack assembly
<<A>> >>J<< 13. Rack support cover <<C>> 31. Seal ring
14. Support spring 32. O-ring
15. Rack support <<G>> >>B<< 33. Lower bearing
>>I<< 16. End plug <<H>> >>B<< 34. Needle bearing
17. Lock nut <<I>> >>A<< 35. Oil seal
36. Gear housing
 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE
37-29
LUBRICATION AND SEALING POINTS

Fluid:
ATF DXRON III or Fluid: Fluid:
DEXRON II ATF DXRON III or ATF DXRON III or
DEXRON II 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, 8663
or equivalent

AC200119 AC

Grease: Silicone grease

Fluid: Grease: Repair kit grease

ATF DXRON III or Fluid:
DEXRON II ATF DXRON III or DEXRON II
37-30 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE

DISASSEMBLY SERVICE POINTS <<C>> SEAL RING REMOVAL

<<A>> RACK SUPPORT COVER CAUTION
REMOVAL When cutting the seal ring, be careful not to
damage the pinion and valve assembly or the
<Comfort> rack.
MB990607

AC209838 AC

<Sport> ACX01144 AB

Cut the seal ring and remove it from the pinion and
valve assembly or the rack.

<<D>> UPPER BEARING/UPPER OIL

SEAL REMOVAL
MB991621

AC103692 AD

Using the following special tool, remove the rack

support cover from the steering gear.
• MB990607: Torque Wrench Socket <Comfort>
• MB991621: Piston Driver <Sport>

Socket
<<B>> LOWER OIL SEAL/PINION AND
ACX01145AC
VALVE ASSEMBLY REMOVAL
Using a socket, remove the oil seal and the ball
bearing from the valve housing simultaneously.

ACX01143AB

Using a plastic hammer, gently tap the pinion to

remove it.
 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE
37-31
<<E>> CIRCLIP REMOVAL 2. Partially bend the oil seal and remove it from the
rack bushing.
CAUTION
If the rack stopper is first turned anticlockwise,
the circlip will get caught in the slot in the <<G>> LOWER BEARING REMOVAL
housing and the rack stopper will not turn.
MB990939
Rack stopper Valve housing

Lower bearing

Circlip ACX01149 AC

ACX01146 AB Use a brass bar or special tool brass bar

(MB990939) to remove the lower bearing from the
1. Turn the rack stopper clockwise until the end of valve housing.
the circlip comes out of the slot in the rack
housing. <<H>> NEEDLE BEARING REMOVAL
2. Turn the rack stopper anticlockwise to remove the
circlip. CAUTION
Do not open special tool excessively to prevent
damaging housing interior.
<<F>> RACK STOPPER/RACK
BUSHING/OIL SEAL/O-RING/RACK
ASSEMBLY REMOVAL MB991120

Valve housing Needle

bearing

ACX01150 AB

Use special tool needle bearing puller (MB991120) to

remove the needle bearing from the valve housing.
ACX01147 AB

1. Pull out the rack slowly. Take out the rack stopper
<<I>> OIL SEAL REMOVAL
and the rack bushing at the same time. CAUTION
Be careful not to damage the inner surface of the
CAUTION rack cylinder of the gear housing.
Do not damage the oil seal press fitting surface.
Gear housing
Pipe or similar tool

Rack bushing

Oil seal

AC100259 AB

ACX01148 AB Use a piece of pipe or similar tool to remove the oil

seal from the gear housing.
37-32 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE

REASSEMBLY SERVICE POINTS >>C<< RACK ASSEMBLY INSTALLATION

>>A<< OIL SEAL INSTALLATION CAUTION
1. Apply a coating of ATF DEXRON III or DEXRON II Do not close the vent hole in the rack with
to the both sides of the oil seal. grease.

Vent hole
MB991202 <Comfort>
Gear housing MB991199 <Sport>
MB991197

Oil seal
Seal ring and O-ring
AC100260 AD ACX01154 AB

2. Using the following special tools, press the oil seal 1. Apply a coating of repair kit grease to the rack
into the rack housing. teeth face.
• MB991197: Bar (long type)
• MB991199: Oil Seal Installer <Sport>
• MB991202: Oil Seal and Bearing Installer Oil seal
<Comfort>

>>B<< NEEDLE BEARING/LOWER

BEARING INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing
MB991212 <Comfort>
and bearing press fitting surface. MB991213 <Sport>
ACX01155 AG
CAUTION
Press-fit straight. The valve housing is 2. Cover rack serrations with the following special
aluminium, and may become deformed if tool.
press-fit on an angle. • MB991212: Oil Seal Protector <Comfort>
• MB991213: Oil Seal Protector <Sport>
Needle bearing
MB990938
3. Apply ATF DEXRON III or DEXRON II to special
MB990938 tool, and to the outer surface of the seal ring and
MB991202 the O-ring.
MB991202
4. Align the centre of the oil seal with the rack to
Lower prevent the retainer spring from slipping. Slowly
bearing
insert the rack from power cylinder side.

ACX01153 AE

2. Press fit needle bearing/lower bearing with the

following special tools.
• MB990938: Bar (snap-in type)
• MB991202: Oil Seal and Bearing Installer
 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE
37-33
>>D<< OIL SEAL/RACK BUSHING >>F<< UPPER OIL SEAL/UPPER
INSTALLATION BEARING INSTALLATION

MB990938
MB990938

MB990927

Oil seal
O-ring
MB991203
Rack MB991203
Bearing
bushing Oil seal

ACX01156 AE ACX01159AC

1. Apply ATF DEXRON III or DEXRON II to the outer Apply a coating of ATF DEXRON III or DEXRON II to
surface of the oil seal. Using special tool installer the outside of the upper oil seal/upper bearing. Using
adapter (MB990927), press in the oil seal until it is the following special tools, press the upper oil
flush with the bushing end face. seal/upper bearing into the valve housing.
• MB990938: Bar (Snap-in type)
• MB991203: Oil Seal and Bearing Installer
Rack
>>G<< SEAL RINGS INSTALLATION

Plastic tape MB991317

Rack bushing

AC100261AC

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 ACX01160 AB
rack bushing onto the rack. Because the seal rings expand after installation,
tighten after installing by using special tool seal ring
>>E<< CIRCLIP INSTALLATION installer (MB991317) to compress the rings, or press
CAUTION down by hand.
Insert the circlip to the rack stopper hole while
turning the rack stopper clockwise.

Circlip Circlip

Slot
Slot
ACX01158 AB

Insert the circlip to the rack stopper hole through

cylinder hole. Turn the rack stopper clockwise and
insert the circlip firmly.
37-34 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE

>>H<< LOWER OIL SEAL INSTALLATION

CAUTION
Approximately
1 mm
MB990941
Oil
seal

Housing MB990607 <Comfort>

MB991621 <Sport>
AC100273 AD

3. Use the following special tool to tighten the rack

ACX01161 AC support cover to 23 ± 2 N⋅m.
• MB990607: Torque Wrench Socket <Comfort>
To eliminate a seal malfunction at the valve
• MB991621: Piston Driver <Sport>
housing alignment surface, the upper surface of
the oil seal should project outward 4. Turn the rack support cover 30° anticlockwise.
approximately 1 mm from the housing edge 5. Use the special tool to hold the rack support
surface. cover, and then tighten the lock nut to 59 ± 10
Using special tool torque tube bearing installer N⋅m.
(MB990941), press the oil seal into the valve
housing. >>K<< TOTAL PINION TORQUE
ADJUSTMENT
>>I<< END PLUG INSTALLATION
CAUTION
• Be sure there is no ratcheting or catching
when operating the rack towards the shaft.
End plug End plug
• Measure the total pinion torque through the
whole stroke of the rack.

MB991006

ACX01162 AB

1. Apply specified sealant to the threaded part of the

end plug.
Specified sealant: 3M ATD Part No.8661,
AC100274AB
8663 or equivalent
2. Secure the threaded portion of the end plug at two 1. Using special tool preload socket (MB991006),
places by using a punch. rotate the pinion shaft at the rate of one rotation in
4 to 6 seconds to check the total pinion torque and
>>J<< RACK SUPPORT COVER/LOCK the change in torque.
NUT INSTALLATION Standard value:
Total pinion torque: 0.8 − 2.1 N⋅m <1300,
1. Position the rack at its centre.
1600(Comfort)>
2. Apply specified sealant to the threaded part of the [Change in torque: 0.6 N⋅m or less]
rack support cover. Total pinion torque: 0.7 − 2.1 N⋅m <1600(Sport),
Specified sealant: 2000>
3M ATD Part No.8661, 8663 or equivalent [Change in torque: 0.6 N⋅m or less]
 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE
37-35
CAUTION <When more than 2.9 mm>: Screw in the
When adjusting, set at the highest value of the adjusting bolt.
standard value range. <When less than 2.9 mm>: Loosen the
adjusting bolt.
NOTE: If the total pinion toque cannot be adjusted
to the standard value within the specified return CAUTION
angle, check the rack support cover components • Hold the rack housing, and use special tool to
and replace any parts if necessary. crimp the bellows band securely.
2. If the total pinion torque or the change in torque is • Crimp the bellows band until special tool
outside the standard value, move the rack support touches the stopper.
cover 0 − 30°, and adjust the pinion torque again.
MB991561
>>L<< TAB WASHER/TIE ROD
INSTALLATION

ACX01165 AB

2. Use special tool boot band crimping tool

(MB991561) to crimp the bellows band.

ACX01163 AB

After installing the tie rod to the rack, fold tab washer A
end (two locations) to tie rod notch.

>>M<< BELLOWS BAND INSTALLATION

MB991561
Stopper
ACX01166 AB

W 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
Adjusting bolt dimension (W) of step (1) to the value
ACX01164 AB calculated by the following equation, and
repeat step (2).
1. Turn the adjusting bolt of special tool boot band W = 5.5 mm − A [Example: if (A) is 2.9 mm,
crimping tool (MB991561) to adjust the opening (W) is 2.6 mm.]
dimension (W) to the standard value. <When less than 2.4 mm>: Remove the
NOTE: The dimension (W) is adjusted by bellows band, readjust the dimension (W) of
approximately 0.7 mm per one turn. step (1) to the value calculated by the
NOTE: Do not turn the adjusting bolt more than following equation, and use a new bellows
one turn. band to repeat steps (2) to (3).
Standard value (W): 2.9 mm W = 5.5 mm − A [Example: if (A) is 2.3 mm,
(W) is 3.2 mm.]
37-36 POWER STEERING
POWER STEERING GEAR BOX AND LINKAGE

>>N<< TIE ROD END/LOCK NUT TIE ROD END BALL JOINT DUST COVER
INSTALLATION REPLACEMENT
M1372008200327
If the dust cover is damaged accidentally during
Edge of bellows Lock nut service work, replace the dust cover as follows:
assembly groove

180 mm
MB990776

AC001011AM

Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the lock nut. AC001012AB

NOTE: The lock nuts must be tightened securely

1. Apply specified grease to the lip and inside of the
only after the steering gear is installed to the vehicle
dust cover.
and toe-in is adjusted.
Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
>>O<< GEAR MOUNTING RUBBER
equivalent
INSTALLATION
2. Drive in the dust cover with special tool front axle
base (MB990776) until it is fully seated.
220 mm
3. Check the dust cover for cracks or damage by
pushing it with your finger.

AC100275AB

Install the gear mounting rubber to the rack housing

so that the distance is as shown in the illustration.
 POWER STEERING
POWER STEERING OIL PUMP ASSEMBLY
37-37
POWER STEERING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATION
M1372005200298

Pre-removal Operation Post-installation Operation

• Power Steering Fluid Draining (Refer to P.37-13). • Power Steering Fluid Supplying and Bleeding (Refer to
P.37-13).
• Drive Belt Tension Check (1300, 1600: refer to GROUP
11A, On-vehicle Service − Drive Belt Tension Check
P.11A-7/2000: refer to GROUP 11C, On-vehicle Service −
Drive Belt Tension Check P.11C-7).

<1300, 1600>

40 ± 5 N·m

4 7
57 ± 7 N·m

6N
3

2
8 1

22 ± 4 N·m
40 ± 4 N·m 9
AC209708 AC

Removal steps Removal steps (Continued)

1. Pressure switch connector 5. Eye bolt
2. A/C compressor harness connector 6. O-ring
bracket <Vehicles with A/C> 7. Pressure hose
3. Drive belt 8. Oil pump assembly
4. Suction hose 9. Oil pump brace
37-38 POWER STEERING
POWER STEERING OIL PUMP ASSEMBLY

<2000>

57 ± 7 N·m 12 ± 2 N·m

3
4

1
2

49 ± 9 N·m

7
22 ± 4 N·m

22 ± 4 N·m

6
49 ± 9 N·m
AC200116 AB

Removal steps Removal steps (Continued)

1. Pressure switch connector <<A>> 5. Oil pump assembly
2. Drive belt 6. A/C compressor harness
3. Suction hose 7. Power steering pump bracket
4. Pressure hose

REMOVAL SERVICE POINT INSPECTION

M1372005300187
<<A>> OIL PUMP ASSEMBLY REMOVAL • Check the drive belt for cracks.
<2000> • Check the pulley for uneven rotation.
With the engine lifted by the jack, remove the oil
pump assembly mounting bolt (lower side) at the
pulley side.
 POWER STEERING
POWER STEERING OIL PUMP ASSEMBLY
37-39
DISASSEMBLY AND REASSEMBLY
M1372005400300

CAUTION
Never disassemble the terminal assembly. It cannot be reassembled.
<1300, 1600>

11 12 ± 1 N·m
4
17

18 59 ± 9 N·m
14
15
16
10
2
8
9
5
13 6

13 7 3
1

12 28 ± 1 N·m
28 ± 2 N·m

: ATF DEXRON III or DEXRON II

AC209709 AC

18 15 8 4
5
11 10
2

9
6
3 7 3
13 3
10
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit

Disassembly steps Disassembly steps (Continued)

1. Pump cover 8. Pin
2. O-ring 9. Side plate
3. Snap ring >>A<< 10. O-ring
4. Pulley and shaft >>B<< 11. Oil seal
5. Vanes 12. Terminal assembly
>>C<< 6. Cam ring >>A<< 13. O-ring
7. Rotor 14. Plug assembly
37-40 POWER STEERING
POWER STEERING OIL PUMP ASSEMBLY

Disassembly steps (Continued) Disassembly steps (Continued)

>>A<< 15. O-ring 17. Suction connector
16. Flow control spring >>A<< 18. O-ring

<2000>

11
4 28 ± 2 N·m

12
13

10
18 2
9
17 8
6
5
7
16 3
15 1
9.9 ± 2.1 N·m
<Sedan, Wagon (Comfort)>
12 ± 1 N·m
<Wagon (Sport)>
14
28 ± 1 N·m
59 ± 9 N·m

: ATF DEXRON III or DEXRON II

AC100143 AF

13
13 8 4
10 5
2
11 7
3 3
3 9
18 6
15 10
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit

Disassembly steps Disassembly steps (Continued)

1. Pump cover >>A<< 10. O-ring
2. O-ring >>B<< 11. Oil seal
3. Snap ring 12. Terminal assembly
4. Pulley and shaft >>A<< 13. O-ring
5. Vanes 14. Plug assembly
>>C<< 6. Cam ring >>A<< 15. O-ring
7. Rotor 16. Flow control spring
8. Pin 17. Suction connector
9. Side plate >>A<< 18. O-ring
 POWER STEERING
POWER STEERING OIL PUMP ASSEMBLY
37-41
REASSEMBLY SERVICE POINTS >>B<< OIL SEAL INSTALLATION
>>A<< O-RING INSTALLATION MB990938

Suction connector Plug assembly

MB991203

1 2
AC000752AB

Use following special tool to install the oil seal.

Terminal assembly Side plate • MB990938: Bar (Snap-in type)
• MB991203: Oil Seal and Bearing Installer

>>C<< CAM RING INSTALLATION

3 CAUTION
Be sure to install the cam ring in the correct
direction as shown.
4
5
AC100170 AB Side plate side Pump cover side

No. ID × Width mm
1 15.8 × 2.4
2 21.0 × 1.9
3 14.8 × 2.4
4 3.8 × 1.9 AC100171AB

5 14.8 × 1.9 Install the cam ring as shown in the illustration.

INSPECTION
M1372005500200
• Check the flow control valve of the pump body for
clogging.
• Check the pulley and shaft for wear or damage.
• Check the rotor and vane groove for "stepped"
wear.
• Check the contact surface of cam ring and vanes
for "stepped" wear.
• Check the vanes for damage.
37-42 POWER STEERING
POWER STEERING HOSES

POWER STEERING HOSES

REMOVAL AND INSTALLATION
M1372005700679

CAUTION
• Before removing the clock spring, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag
Module and Clock Spring (P.52B-210). Also, put the front wheels in straight-ahead position.
Failure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which
results serious driver injury.
• *: 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.37-13). and Bleeding (Refer to P.37-13).

<LH drive vehicles>

2 12 ± 2 N·m
7
57 ± 7 N·m
9 12 ± 2 N·m

8 1

3
<2000> 12 ± 2 N·m
2
8 12 ± 2 N·m
7 15 ± 3 N·m
57 ± 7 N·m 12 ± 2 N·m 13 12
11
12 ± 2 N·m
7 9
8
10
57 ± 7 N·m
8 7
<1300, 1600> 12 ± 2 N·m
4
18 ± 2 N·m 57 ± 7 N·m

6
167 ± 9 N·m
Crossmember
5

49 ± 10 N·m
57 ± 7 N·m* 167 ± 9 N·m
AC304699AB

Removal steps Removal steps (Continued)

1. Oil reservoir • Clock spring (Refer to GROUP 52B,
>>C<< 2. Suction hose Air Bag Modules and Clock Spring
>>B<< 3. Return hose P.52B-210).
 POWER STEERING
POWER STEERING HOSES
37-43
Removal steps (Continued) Removal steps (Continued)
• Centermember (Refer to GROUP 32, 8. Gasket
Engine Roll Stopper Centermember 9. Pressure hose assembly
P.32-7). 10. Return tube
• Front exhaust pipe (Refer to GROUP >>A<< 11. Return hose
15, Exhaust Pipe and Main Muffler <<A>> 12. Return tube
P.15-11). 13. O-ring
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
6. Rear roll stopper (Refer to GROUP
32, Engine Roll Stopper
Centermember P.32-7).
<<A>> 7. Eye bolt

<RH drive vehicles>

12 ± 2 N·m

<1300, 1600>
2 12 ± 2 N·m
12 ± 2 N·m

8 9
15 ± 3 N·m

57 ± 7 N·m
7 57 ± 7 N·m
10
6 7 4
6 18 ± 2 N·m

<2000>
2 167 ± 9 N·m
57 ± 7 N·m
6 12 ± 2 N·m

8
5 Crossmember
7 167 ± 9 N·m
57 ± 7 N·m*
7 49 ± 10 N·m
57 ± 7 N·m

6 AC304698AB

Removal steps Removal steps (Continued)

1. Oil reservoir • Clock spring (Refer to GROUP 52B,
>>C<< 2. Suction hose Air Bag Modules and Clock Spring
>>B<< 3. Return hose P.52B-210).
37-44 POWER STEERING
POWER STEERING HOSES

Removal steps (Continued) INSTALLATION SERVICE POINTS

• Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember >>A<< RETURN HOSE INSTALLATION
P.32-7). <LH DRIVE VEHICLES>
• Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-11).
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
<<A>> 6. Eye bolt
7. Gasket
8. Pressure hose assembly
<<A>> 9. Return tube
10. O-ring Return hose AC100277AB

REMOVAL SERVICE POINT Install the return hose so that the marking is
positioned as shown in the illustration.
<<A>> EYE BOLT/RETURN TUBE
REMOVAL >>B<< RETURN HOSE INSTALLATION
CAUTION
<L.H. drive vehicles> <R.H. drive vehicles>
If the joint cover grommet has been removed,
install it properly as follows. Return hose Return hose

Joint cover
grommet
A
B

Return tube AC305132 AB

Install the return hose so that the markings are

Steering gear
positioned as shown in the illustration.
AC304922 AB

Align the joint cover grommet notch (arrow A) >>C<< SUCTION HOSE INSTALLATION
with the steering gear lug (arrow B), and then Install the suction hose (oil pump side) so that the
install the steering joint cover to the steering marking is positioned forward.
gear.
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.
 42-1

GROUP 42

BODY
CONTENTS

HOOD. . . . . . . . . . . . . . . . . . . . . 42-3 WINDOW GLASS. . . . . . . . . . . 42-9

ON-VEHICLE SERVICE. . . . . . . . . 42-3 ADHESIVE . . . . . . . . . . . . . . . . . . . 42-9

ADJUSTMENT OF CLEARANCE
AROUND HOOD . . . . . . . . . . . . . . . . . . 42-3 SPECIAL TOOLS . . . . . . . . . . . . . . 42-9
ADJUSTMENT OF ALIGNMENT OF
HOOD STEPPED PORTION AND
HOOD STRIKER . . . . . . . . . . . . . . . . . . 42-3 WINDOW REPAIR . . . . . . . . . . . . . 42-10
ADJUSTMENT OF HOOD HEIGHT . . . 42-3
WINDSHIELD . . . . . . . . . . . . . . . . . 42-12
HOOD. . . . . . . . . . . . . . . . . . . . . . . 42-4 REMOVAL AND INSTALLATION. . . . . . 42-12
REMOVAL AND INSTALLATION . . . . . 42-4
REAR WINDOW GLASS . . . . . . . . 42-16
FENDER. . . . . . . . . . . . . . . . . . . 42-5 REMOVAL AND INSTALLATION. . . . . . 42-16

QUARTER WINDOW GLASS . . . . 42-19

SPECIAL TOOL . . . . . . . . . . . . . . . 42-5
REMOVAL AND INSTALLATION. . . . . . 42-19

FENDER. . . . . . . . . . . . . . . . . . . . . 42-6
TAILGATE WINDOW GLASS . . . . 42-22
REMOVAL AND INSTALLATION . . . . . 42-6 REMOVAL AND INSTALLATION. . . . . . 42-22

FUEL FILLER LID . . . . . . . . . . . 42-8 DOOR . . . . . . . . . . . . . . . . . . . . 42-25

REMOVAL AND INSTALLATION . 42-8

SERVICE SPECIFICATIONS . . . . . 42-25

STRUT TOWER BAR . . . . . . . . 42-9 SEALANT . . . . . . . . . . . . . . . . . . . . 42-25

REMOVAL AND INSTALLATION . 42-9 SPECIAL TOOLS . . . . . . . . . . . . . . 42-25

Continued on next page

42-2

TROUBLESHOOTING . . . . . . . . . . 42-26 TRUNK LID . . . . . . . . . . . . . . . . . . . 42-43

REMOVAL AND INSTALLATION. . . . . . 42-43
ON-VEHICLE SERVICE. . . . . . . . . 42-27 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-45
DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-27
DOOR WINDOW GLASS ADJUSTMENT 42-28 TAILGATE . . . . . . . . . . . . . . . . 42-46
GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . 42-28
POWER WINDOW OPERATING SERVICE SPECIFICATIONS . . . . . 42-46
CURRENT CHECK . . . . . . . . . . . . . . . . 42-28
POWER WINDOW RELAY CHECK . . . 42-29
CIRCUIT BREAKER (INCORPORATED SEALANTS . . . . . . . . . . . . . . . . . . . 42-46
IN THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29 SPECIAL TOOL . . . . . . . . . . . . . . . 42-46
POWER WINDOW CHECK . . . . . . . . . . 42-29
CENTRAL DOOR LOCKING SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29 TROUBLESHOOTING . . . . . . . . . . 42-46
DOOR OUTSIDE HANDLE PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 42-29
DOOR INSIDE HANDLE PLAY ON-VEHICLE SERVICE . . . . . . . . . 42-46
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 42-30 TAILGATE FIT ADJUSTMENT. . . . . . . . 42-46
TAILGATE HANDLE PLAY CHECK. . . . 42-47
DOOR ASSEMBLY . . . . . . . . . . . . 42-31
REMOVAL AND INSTALLATION . . . . . 42-31 TAILGATE . . . . . . . . . . . . . . . . . . . 42-48
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-32 REMOVAL AND INSTALLATION. . . . . . 42-48

DOOR GLASS AND TAILGATE HANDLE AND

REGULATOR. . . . . . . . . . . . . . . . . 42-32 LATCH . . . . . . . . . . . . . . . . . . . . . . 42-50
REMOVAL AND INSTALLATION . . . . . 42-32 REMOVAL AND INSTALLATION. . . . . . 42-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-34 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-51

DOOR HANDLE AND LATCH. . . . 42-36 KEYLESS ENTRY SYSTEM . . 42-51

REMOVAL AND INSTALLATION . . . . . 42-36
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-37
SERVICE SPECIFICATIONS . . . . . 42-51
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING SPECIAL TOOLS . . . . . . . . . . . . . . 42-52
WEATHERSTRIP. . . . . . . . . . . . . . 42-39
REMOVAL AND INSTALLATION . . . . . 42-39 TROUBLESHOOTING . . . . . . . . . . 42-53

TRUNK LID . . . . . . . . . . . . . . . . 42-41 ON-VEHICLE SERVICE . . . . . . . . . 42-53

KEYLESS ENTRY SYSTEM CHECK. . . 42-53
KEYLESS ENTRY SYSTEM TIMER
SPECIAL TOOL . . . . . . . . . . . . . . . 42-41 LOCK FUNCTION INSPECTION . . . . . . 42-53
ENABLING/DISABLING
ON-VEHICLE SERVICE. . . . . . . . . 42-41 THE ANSWERBACK FUNCTION . . . . . 42-53
HOW TO REGISTER SECRET CODE . 42-55
TRUNK LID ADJUSTMENT . . . . . . . . . . 42-41
ADJUSTMENT OF CLEARANCE
AROUND TRUNK LID . . . . . . . . . . . . . . 42-42 TRANSMITTER. . . . . . . . . . . . . . . . 42-58
TRUNK LID STRIKER ADJUSTMENT . 42-42 DISASSEMBLY AND REASSEMBLY . . 42-58
TRUNK LID HEIGHT ADJUSTMENT . . 42-42 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-59
 BODY
HOOD
42-3
HOOD
ON-VEHICLE SERVICE ADJUSTMENT OF HOOD HEIGHT
M1421007400123

ADJUSTMENT OF CLEARANCE AROUND

HOOD A
M1421007200129

Y0215AU

Section A – A
Hood
AC005945

ADJUSTMENT OF ALIGNMENT OF HOOD

STEPPED PORTION AND HOOD 17 mm
STRIKER
M1421007300126

Hood bumper X0424CA

AC005948AB

Rotate the hood bumper by using arrow mark on the

hood bumper as a guide to adjust the hood height. If
the hood bumper is rotated just one turn, the hood
height changes by approximately 3 mm.

AC005947
42-4 BODY
HOOD

HOOD
REMOVAL AND INSTALLATION
M1421001600561

Post-installation Operation
• Adjustment of Clearance Around Hood (Refer to P.42-3).
• Adjustment of Alignment of Hood Stepped Portion and
Hood Striker (Refer to P.42-3).
• Adjustment of Hood Height (Refer to P.42-3).

8 3
21 ± 4 N·m
11 ± 2 N·m

2
4
7
10
9
21 ± 4 N·m

1 6

4
1

9.0 ± 2.0 N·m

2 5
AC304739AD

Removal Hood and hood hinge removal

1. Hood bumper steps
2. Hood latch 6. Hood insulator
3. Hood weatherstrip 7. Hood weatherstrip
Hood lock release cable removal • Washer hose (Refer to GROUP 51,
steps Windshield wiper and washer
4. Hood lock release handle P.51-23.)
5. Hood lock release cable 8. Hood
9. Hood support rod
10. Hood hinge
 BODY
FENDER
42-5

Clip positions
8 Section A – A

8
Clip

A
A
6
6
Note
: Clip positions AC300865 AC

FENDER
SPECIAL TOOL
M1421000600256

Tool Number Name Use

MB990784 Ornament remover Side turn-signal lamp removal

MB990784
42-6 BODY
FENDER

FENDER
REMOVAL AND INSTALLATION
M1421001900302

Pre-removal and Post-installation Operation

• Front Bumper Removal and Installation (Refer to GROUP
51, Front Bumper P.51-2.)
• Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper and Washer P.51-23.)
• Side Air Dam Removal and Installation <Vehicles with
side air dam> (Refer to GROUP 51, Side Air Dam
P.51-15.)

A
3 Section A – A

A
4
3

Clip
AC303863

Note AC300491
: Clip positions AC304753 AB

Removal steps Removal steps (Continued)

1. Splash shield 3. Delta outer garnish
<<A>> >>A<< 2. Side turn-signal lamp 4. Fender
 BODY
FENDER
42-7
REMOVAL SERVICE POINT INSTALLATION SERVICE POINT
<<A>> SIDE TURN-SIGNAL LAMP >>A<< SIDE TURN-SIGNAL LAMP
REMOVAL INSTALLATION
Front of vehicle
Side turn-signal light Hook
Claw
Fender panel

Fender panel
MB990784
AC005980AB : Front of vehicle AC005719 AE

Use special tool ornament remover (MB990784) to Engage the claw with the fender panel, and install
prize out the tab from the fender, and remove the the side turn-signal lamp.
side turn signal light.
42-8 BODY
FUEL FILLER LID

FUEL FILLER LID

REMOVAL AND INSTALLATION
M1421002500277

Pre-removal and Post-installation Operation

• Rear Seat Removal and Installation (Refer to GROUP
52A, Rear Seat P.52A-28.)
• Front Scuff Plate (Driver's Seat Side), Rear Scuff Plate
(Driver's Side), Centre Pillar Lower Trim (Driver's Side),
Quarter Trim (Driver's Side) Removal and Installation
(Refer to GROUP 52A, Trims P.52A-11.)

W0570AQ
18M0109
Fuel filler lid height and clearance
adjustment

4
5

1
3
2 5.0 ± 1.0 N·m
AC005973

AC005996 AC

Removal steps Removal steps (Continued)

1. Fuel filler lid panel assembly 4. Fuel filler lid lock release cable
2. Clip 5. Fuel filler lid lock release handle
3. Fuel filler lid hook assembly
 BODY
STRUT TOWER BAR
42-9
STRUT TOWER BAR
REMOVAL AND INSTALLATION
M1421005600091

44 ± 5 N·m

Strut tower bar

AC304680AB

WINDOW GLASS
ADHESIVE
M1422000500081

Item Specified adhesive

Windshield 3M ATD Part No.8609 Super Fast Urethane Auto Glass
Rear window glass Sealant or equivalent
3M ATD Part No.8608 Super Fast Urethane Primer or
Quarter window glass equivalent
Tailgate window glass

SPECIAL TOOLS
M1422000600293

Tool Number Name Use

MB990480 Glass holder Removal and installation of window glass

MB990480

MB990784 Ornament remover Removal of rear window lower moulding

MB990784
42-10 BODY
WINDOW GLASS

WINDOW REPAIR
M1422005600027
The windshield, rear window glass, quarter window
glass and tailgate window glass are attached by an
urethane-base adhesive to the window frame. This
adhesive provides improved glass holding and
sealing, and also gives body openings a greater
structural strength.
ITEMS
Name Remark
Adhesive 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent
Spacers Available as service part
Dam Available as service part
Anti-rust solvent (or Tectyl For rust prevention
506T.Valvoline Oil Company)
Isopropyl alcohol For grease removal from bonded surface
Steel piano wire Dia. × length... 0.6mm × 1m For cutting adhesive
Glass adhesive knife For cutting adhesive
Adhesive gun For pressing-out adhesive

HANDLING OF AUTO WINDOW SEALER BODY PINCH-WELD FLANGE SERVICING

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

Window glass installation procedure

Body side Window glass side

Reusing the glass Replace the glass

Cleaning of adhesion surface Cleaning of adhesion surface Cleaning of adhesion surface

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

Attaching of dual lock fastener Gluing of window dam, window spacer, dual lock fastener and glass stopper
Attach the dual lock fastener to set Glue the window dam, window spacer, dual lock fastener and glass stopper to the glass,
the positions for the glass to be installed. following the standard position all the way around the inside edge of the glass.

Application of primer Application of primer

Apply the primer to the adhesion surface Apply sufficient primer evenly to the adhesion surface so that there is no patchiness.
of the body, and let dry for 3 minutes or After application, let dry for 3 to 30 minutes.
more.

Application of adhesive
Within 30 minutes after applying the primer , apply the adhesive evenly all the way around
the inside edge of the glass.

Installing the glass

After applying the adhedive, lighty press the glass evenly so that it adheres
completely.

Cleaning
After removing excess adhesive from the body or glass with a spatula, etc.
clean off with isopropyl alcohol.

Checking for water leaks

Carry out a shower test to check that no water will leaks through.

AC300393
42-12 BODY
WINDOW GLASS

WINDSHIELD
REMOVAL AND INSTALLATION
M1422001000313

Pre-removal and Post-installation Operation

• Front Deck Garnish Removal and Installation (Refer to
GROUP 51,Windshield Wiper and Washer P.51-23.)
• Inside Rear View Mirror Removal and Installation (Refer
to GROUP 52A, Inside Rear View Mirror P.52A-23.)
• Front Pillar Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-11.)
• Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)

4 N
N3

2N

N5

3N

N6 5N
Y0495AU

A Units: mm
Section A – A Section B – B
A
Seal line
Seal line centre centre
1
Ceramic line B
B
Seal line
1
C
Primer
16 X0111AU
X0112AU
C Primer
13

Ceramic line Section C – C

1
Apply the primer and Seal line
adhesive along the centre
fictitious lines (seal line)
between each of Primer
the marks.
Mark
16
Seal line Y0496AU

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
AC006003 AC
 BODY
WINDOW GLASS
42-13
Removal steps Removal steps (Continued)
Roof drip moulding (Refer to GROUP
• >>A<< 3. Window dam
51, Moulding P.51-10.) >>A<< 4. Glass stopper
<<A>> >>B<< 1. Windshield >>A<< 5. Spacer
>>A<< 2. Windshield moulding >>A<< 6. Windshield spacer

REMOVAL SERVICE POINT Glass adhesive knife

<<A>> WINDSHIELD REMOVAL
1. To protect the body (paint surface), apply cloth
tape to all body areas around the installed
windshield.
2. Make mating marks on the windshield and body.

AC207478 AD

Inserting the glass adhesive knife too deeply into

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

AC002060

ACX00476 AB
42-14 BODY
WINDOW GLASS

Be careful not to remove more adhesive than is 8. When reusing the windshield, remove the
necessary. adhesive still adhering to the windshield, and
• Be careful also not to damage the paintwork clean with isopropyl alcohol.
on the body surface with the knife. If the 9. Clean the body side in the same way.
paintwork is damaged, repair the damaged
area with repair paint or anti-rust agent.
INSTALLATION SERVICE POINTS
6. Use a knife to cut away the remaining adhesive so
that the thickness is within 2 mm around the entire >>A<< WINDSHIELD
circumference of the body flange. SPACER/SPACER/GLASS
7. Finish the flange surfaces so that they are STOPPER/WINDOW DAM/WINDSHIELD
smooth. MOULDING INSTALLATION
CAUTION CAUTION
Allow the cleaned area to dry for at least three Leave the degreased parts for 3 or more minutes
minutes. Do not touch any surface that has been to dry well, before starting on the next step. Do
cleaned. not touch the degreased parts.
1. Use isopropyl alcohol to degrease the inside and
outside of the windshield and the body flanges.

Glass stopper, spacer, windshield spacer and window dam installation position

Align the window

Glass stopper Glass end line dam and with the
seal line mark.

17.5 mm Align the glass Mark

stopper end with
the ceramic notch.
Seal line 13 mm
Ceramic line
Ceramic line

Windshield
Glass end line

Window dam Y0628AU

Section A – A

Seal line 14 mm
centre

Windshield spacer
Y0497AU
Align the spacer Section B – B
and with glass
end line
B
A

B 14 mm

A 10138AU
Align the windshield Spacer
spacer end with the
ceramic notch. 10139AU
AC006029AB
 BODY
WINDOW GLASS
42-15
2. The inner side of the windshield is curved,
therefore, make a point to assemble the glass
stopper and windshield spacer without any lifting
and assemble in the position shown in the Figure
of the instructions.
3. Install the windshield moulding.
10 mm
>>B<<WINDSHIELD INSTALLATION 15 mm
1. When replacing the windshield, temporarily set
the windshield against the body, and place a ACX00480 AB
mating mark on the windshield and body.
4. Fill a sealant gun with adhesive. Then apply the
CAUTION adhesive evenly around the windshield within 30
• The primer strengthens the adhesive, so be minutes after applying the primer.
sure to apply it evenly around the entire
NOTE: Cut the tip of the sealant gun nozzle into a
circumference. However, a too thick
V shape to simplify adhesive application.
application will weaken the adhesive.
5. Align the mating marks on the windshield and the
• Do not touch the coated surface.
body, and lightly press the windshield evenly so
• Do not apply the primer on the remaining
that it adheres completely.
adhesive because of weakening the adhesive.
6. Use a spatula or similar tool to remove any
2. Soak a sponge in the primer, and apply evenly to excessive adhesive. Clean the surface with
the windshield in the specified places. If the isopropyl alcohol. Avoid moving the vehicle until
adhesive does not remain on the body flange the adhesive sets.
surface because of the panel replacement on the
7. Bond the windshield to the body, and install the
body side, apply evenly to the body side in the
roof drip moulding quickly before the adhesive
specified places.
cures. (Refer to GROUP51, Moulding P.51-10.)
3. Allow the windshield to dry for at least three
minutes after applying primer. CAUTION
• Do not move the vehicle unless absolutely
necessary.
• When testing for water leakage, do not pinch
the end of the hose to spray the water.
8. Wait 30 minutes or more, and then test for water
leakage.
42-16 BODY
WINDOW GLASS

REAR WINDOW GLASS

REMOVAL AND INSTALLATION
M1422001600111

Pre-removal and Post-installation Operation

• High-mounted Stop Lamp Assembly Removal and
Installation <Rear Shelf Mounted Type> (Refer to GROUP
54A, High-Mounted Stop Lamp P.54A-81.)
• Rear Pillar Trim and Rear Shelf Trim Removal and
Installation (Refer to GROUP 52A, Trims P.52A-11.)
• Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)

N 10
7 Section A – A
7
N8 1
1
N2
6
N9 Y0564AU
N3
A 2N

4N
3N
3N 2N
A
2N 5N Y0500AU
N4

B Apply the primer and Section B – B

adhesive along the
fictitious lines (seal line) Seal line
between each of centre
B the marks.

Ceramic line 16 mm

7
Primer Y0502AU
Y0501AU
Mark

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent

AC006056 AB

Removal steps Removal steps (Continued)

Roof drip moulding (Refer to GROUP
• 4. Grommet B
51, Moulding P.51-10.) 5. Grommet C
<<A>> >>B<< 1. Rear window lower moulding 6. Connecting the harness connector
2. Clip <<B>> >>A<< 7. Rear window glass
3. Grommet A >>A<< 8. Rear window upper moulding
 BODY
WINDOW GLASS
42-17
Removal steps (Continued)
>>A<< 9. Window dam
>>A<< 10. Glass stopper

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

<<A>> REAR WINDOW LOWER >>A<< GLASS STOPPER/WINDOW
MOULDING REMOVAL DAM/REAR WINDOW UPPER
CAUTION MOULDING/REAR WINDOW GLASS
If the drip moulding has become warped, it INSTALLATION
should not be reused. 1. When replacing the rear window glass,
temporarily set the rear window glass against the
body, and place a mating mark on the rear
window glass and body.
MB990784 CAUTION
Leave the degreased parts for 3 or more minutes
to dry well, before starting on the next step. Do
not touch the degreased parts.
2. Use isopropyl alcohol to degrease the inside and
outside of the rear window glass and the body
AC006073AB
flanges.
Use special tool ornament remover (MB990784) to
lever out the moulding. CAUTION
• The primer strengthens the adhesive, so be
sure to apply it evenly around the entire
<<B>> REAR WINDOW GLASS REMOVAL circumference. However, a too thick
Removal the rear window glass using the same application will weaken the adhesive.
procedure as for the windshield. (Refer to P.42-12.)
• Do not touch the coated surface.
3. Soak a sponge in the primer, and apply evenly to
the rear window glass and the body in the
specified places.
4. Allow the rear window glass to dry for at least 3
minutes after applying primer.
42-18 BODY
WINDOW GLASS

Glass stopper and window dam installation position

Align the window
Glass end line dam end with
Glass stopper the ceramic notch.

18 mm Align the glass Mark

stopper end with
the ceramic notch.
Seal line 19 mm
Ceramic line
Rear window
glass
Ceramic
line
Y0629AU

Window dam

Section A - A

19 mm Window dam

Y0630AU
A
AC006075 AB

5. Install the glass stopper and window dam to the >>B<< REAR WINDOW LOWER
specified positions so that there are no adrift or MOULDING INSTALLATION
bent surfaces inside the rear window glass. Install the clips to the rear window lower moulding,
6. Install the rear window upper moulding. and then fix the rear window moulding to the vehicle
7. Install the glass in the same manner as the body.
windshield. (Refer to P.42-12.)
 BODY
WINDOW GLASS
42-19
QUARTER WINDOW GLASS
REMOVAL AND INSTALLATION
M1422002500247

Pre-removal and Post-installation Operation

• Quarter Trim Upper Removal and Installation (Refer to
GROUP 52A, Trims P.52A-11).

2N
N 3

N 4

N 3
AC304783AB

Section A – A Section B – B Units: mm

16 1
Mark Primer

B 1
16
B
Y1507AU Seal line
A A Seal line centre centre Y1509AU
Ceramic line D D Primer
Section C – C Primer Section D – D

C 16 Primer
16
C Y1485AU
Seal line
centre
Apply the primer and adhesive
along the fictitious lines (seal line) 1
between each of the marks. Y1508AU
Seal line 1 Y1535AU
centre

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent

AC304784 AB

Removal steps Removal steps (Continued)

<<A>> >>B<< 1. Quarter window glass assembly >>A<< 3. Clip
>>A<< 2. Dual lock fastener >>A<< 4. Gasket
42-20 BODY
WINDOW GLASS

REMOVAL SERVICE POINT

MB990480
<<A>> QUARTER WINDOW GLASS
REMOVAL

AC103605 AD

4. Make mating marks on the quarter window glass

and body.
Cloth tape AC103600AD 5. Use special tool glass holder (MB990480) to
remove the quarter window glass.
1. Apply cloth tape to protect the quarter window
glass. CAUTION

ACX00476 AB
AC002060

• Be careful not to remove more adhesive than

2. Use glass adhesive knife to cut away adhesive. is necessary.
CAUTION • Be careful also not to damage the paintwork
on the body surface with the knife. If the
Glass adhesive knife
paintwork is damaged, repair the damaged
area with repair paint or anti-rust agent.
6. Use a knife to cut away the remaining adhesive so
that the thickness is within 2 mm around the entire
circumference of the body flange.
7. Finish the flange surfaces so that they are
smooth.
AC301614AB CAUTION
Allow the cleaned area to dry for at least three
Inserting the adhesive knife too deeply into minutes. Do not touch any surface that has been
windshield adhesive may damage quarter cleaned.
window glass.
8. When reusing the quarter window glass, remove
3. Keep the glass adhesive knife at right angles with the adhesive still adhering to the quarter window
body flange (from inside the vehicle), and put the glass, and clean with isopropyl alcohol.
blade at body flange. Then cut away adhesive 9. Clean the body side in the same way.
along the body flange.
 BODY
WINDOW GLASS
42-21
INSTALLATION SERVICE POINTS CAUTION
>>A<< GASKET/CLIP/DUAL LOCK Leave the degreased parts for 3 or more minutes
FASTENER INSTALLATION to dry well, before starting on the next step. Do
not touch the degreased parts.
1. Carry out the following procedure to re-install
quarter window glass. 2. Use isopropyl alcohol to degrease the inside and
outside of the quarter window glass and the body
CAUTION flanges.
Do not forget gasket.
(1) Fit clips into body. Dual lock fastener

Cut off these convex parts

Install the dual lock fastener

with aligning it onto the bumps
of the body flange. AC304793 AB

AC103606 AC 3. Assemble the dual lock fastener according to the

(2) Cut away clip fitting convex on quarter window standard location of the body flange.
glass. 4. Assemble the dual lock fastener to the quarter
window glass relative to the body flange dual lock
NOTE: Convex gets broken when quarter
fastener.
window glass is removed.
>>B<< QUARTER WINDOW GLASS
INSTALLATION
Remove the quarter window glass using the same
procedure as for the windshield removal (Refer to
P.42-12).
42-22 BODY
WINDOW GLASS

TAILGATE WINDOW GLASS

REMOVAL AND INSTALLATION
M1422003700170

Pre-removal and Post-installation Operation

• Tailgate Trim Removal and Installation (Refer to GROUP
52A, Tailgate Trim P.52A-19).
• Tailgate Spoiler Assembly Removal and Installation
(Refer to GROUP 51, Tailgate Spoiler P.51-19).
• Rear Wiper Arm Assembly Removal and Installation
(Refer to GROUP 51, Rear Wiper and Washer P.51-29).

5N

N 7 N 3
N 5

N 3

N 4 6N
AC304811 AB

Section A – A Section B – B Units: mm

Apply the primer and adhesive
2
along the fictitious lines (seal line) Primer
between each of the marks. Seal line Primer
centre Seal line
A centre

A 2 13
C 14
C
Y1537AU Y1537AU
Ceramic line
Section C – C Seal line
centre
B 2

B Y1522AU Primer

Mark
14
Y1538AU

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent

AC304812 AB
 BODY
WINDOW GLASS
42-23
Removal steps Removal steps (Continued)
1. Connecting the harness connector >>A<< 5. Dual lock fastener
<<A>> >>B<< 2. Tailgate window glass >>A<< 6. Glass stopper
>>A<< 3. Window lower dam >>A<< 7. Window spacer
>>A<< 4. Window side dam

REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS

<<A>> TAILGATE WINDOW GLASS >>A<< WINDOW SPACER/GLASS
REMOVAL STOPPER/DUAL LOCK
Remove the tailgate window glass using the same FASTENER/WINDOW DAM
procedure as for the windshield (Refer to P.42-12). INSTALLATION
CAUTION
Leave the degreased parts for 3 or more minutes
to dry well, before starting on the next step. Do
not touch the degreased parts.
1. Use isopropyl alcohol to degrease the inside and
outside edges of the tailgate window glass and
the surface of the tailgate flange.
42-24 BODY
WINDOW GLASS

Window spacer, glass stopper and window dam installation position

Seal line
14.5 mm
Glass end line

Align the glass spacer and with

the tailgate window glass mark.
AC107207
Glass spacer Position the window side dam
2 mm inside from the tailgate
window glass end.
Window side dam

Ceramic line
2 mm
Ceramic line

Seal line
Y1484AU

Window lower dam Butt the ends of

the window lower
and side dams.
Tailgate window glass Y1484AU
Glass stopper

22 mm

Seal line
Align the glass stopper and with
the tailgate window glass mark.
Glass end line AC107207
AC304816 AB

2. Assemble the window spacer, glass stopper and 3. Assemble the dual lock fastener according to the
window dam to the tailgate window glass location standard location of the tailgate flange.
shown. 4. Assemble the dual lock fastener to the quarter
Flange convex at the tailgate flange window glass relative to the tailgate flange dual
lock fastener.

>>B<< TAILGATE WINDOW GLASS

INSTALLATION
Dual lock fastener
Install the tailgate window glass in the same way as
for the windshield installation (Refer to P.42-12).

AC304849AB
 BODY
DOOR
42-25
DOOR
SERVICE SPECIFICATIONS
M1423000300091

Item Standard value

Power window operation current (Power supply voltage 14.5 ± 0.5 V, at 25 °C) A 5±1
Door outside handle play mm Front door 2.6 ± 2.5
Rear door 1.3 ± 1.3
Door inside handle play mm Front door 10.4 ± 9.6
Rear door 10 ± 9.6

SEALANT
M1423000500095

Item Specified sealant

Door waterproof film 3M ATD Part No.8633 or equivalent

SPECIAL TOOLS
M1423000600337

Tool Number Name Use

MB990480 Window glass holder Removal of power window regulator
assembly

MB990480

MB990900 or Door hinge adjusting Door alignment

MB991164 wrench

MB990900

MB990925 Bearing and oil seal Door striker adjustment

A
A: MB990939 installer set
A: Brass bar
MB990925AF

MB990211 Sliding hammer

MB990211

MB990241 Axle shaft puller

A: MB990243 A: Body puller

A
MB990241AE
42-26 BODY
DOOR

Tool Number Name Use

A
MB991223 Harness set Terminal voltage measurement
A: MB991219 A: Test harness A: For checking connector pin contact
B: MB991220 B: LED harness pressure
C: MB991221 C: LED harness adapter B: For checking power supply circuit
B D: MB991222 D: Probe C: For checking power supply circuit
D: For connecting a locally sourced
tester
C

D
MB991223 AD

TROUBLESHOOTING
M1423000700312
The door system is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to GROUP
54B, Troubleshooting P.54B-17 or GROUP 54C,
Troubleshooting P.54C-4.
 BODY
DOOR
42-27
ON-VEHICLE SERVICE 3. When the door is stiff to lock and unlock

DOOR FIT ADJUSTMENT

M1423001100175

CAUTION
• Attach protection tape to the fender and door
edges where the hinge is installed.
• Do not rotate special tool door adjusting MB990939
wrench (MB991164) with a torque of over 98
Temporary
N⋅m bolt Striker
AC006109AB

(1) Adjustment by using the striker (toward the

inside of the vehicle and vertical direction)
Install a temporary bolt instead of the striker
MB990900
or
mounting bolts, and use special tool brass bar
MB991164 (MB990939) and a hammer to tap the bolt to
the desired direction.

AC000592 AB

MB990211
1. Use the special tool door adjusting Wrench MB990243
(MB990900 or MB991164) to loosen the hinge
mounting bolts on the body side, and then adjust
the clearance around the door so that it is uniform
on all sides.
2. If a door is not flush with its surrounding panels, Striker
loosen the door-side door hinge mounting bolts AC006110 AB
and obtain the flushness by moving the door. (2) Adjustment by using the striker (toward the
NOTE: outside of the vehicle)
Weld point Washer Use special tools slide hammer (MB990211)
and body puller (MB990243) to pull the striker
toward the outside of the vehicle.

Bolts Shim
Striker

Weld point Washer

Door hinge AC206498 AF

If the door hinge mounting bolt washers are

welded, grind off the welding according to the
procedure below beforehand. AC006111AB
.
(3) Adjustment by using shims (forward and
1. Remove the door hinge (Refer to P.42-31).
rearward)
2. Use a chisel or grinder to release the door
Increase or decrease the number of shims so
hinge mounting bolt washers, which are
that the striker engages with the door latch
welded to the door hinge.
properly.
3. On completion, paint the affected area with a
suitable touch-in brush to prevent corrosion.
4. Install the door hinge (Refer to P.42-31).
42-28 BODY
DOOR

DOOR WINDOW GLASS ADJUSTMENT

M1423001000327 Runchannel Door
Check that the door glass moves while contacting sash
the door glass channel when it is raised and lowered
fully. If not, adjust the door window according to the
following procedures.
1. Remove the door trim assembly (Refer to GROUP
52A, Door trim P.52A-15). Lower
sash
2. Remove the waterproof film (Refer to P.42-39).
3. Loosen the door glass mounting screw via the AC003777AB
adjusting hole with the door window glass fully
closed, then lower the window glass a little. 4. If the door window glass does not move up and
down smoothly, check or repair the following
<Front> <Rear> points.
• Check the installation condition of the
runchannel.
• Repair any twisting in the door sash.
• Check the installation condition of the lower sash
Adjusting
Adjusting or the centre sash.
hole
hole
NOTE: The lower sash cannot normally be
adjusted, but it may be possible to adjust the sash
Y0238AU Y0239AU span slightly within the range allowed by
AC006112 AB
manufacturing tolerances by pushing the lower
4. Fully close the door window glass again and sash outwards while re-installing it.
tighten the door glass mounting screw firmly via 5. If repair or adjustment is not possible, replace the
the adjusting hole. door assembly.

GLASS SLIDING MECHANISM CHECK POWER WINDOW OPERATING CURRENT

AND ADJUSTMENT CHECK
M1429000900091 M1429001100184
If the window glass automatically starts moving
downwards at the wrong time while it is being raised,
carry out the following adjustment or replacement
procedures.
1. Remove the door trim assembly (Refer to GROUP
52A, Door trim P.52A-15).
2. Remove the waterproof film (Refer to P.42-39).
3. Remove the window regulator assembly from the
door window glass, and then raise and lower the
door window glass by hand to check the operation AC006115AB
force.
1. Remove the power window fuse and connect an
NOTE: Insert a cushion or similar object to ammeter as shown in the illustration.
prevent damage to the glass if it should happen to
2. When the power window switch is pressed to the
fall down.
“UP” position, a large amount of current flows at
the time the window starts to close and when it is
fully closed, so measure the operation current in
the interval between these two points.
Standard value (A): 5 ± 1A (Power supply
voltage 14.5 ± 0.5V, 25°C)
 BODY
DOOR
42-29
3. If the operation current is outside the standard 2. Release the power window switch from the UP
value, refer to GROUP 54B, Troubleshooting position and immediately press it to the DOWN
P.54B-17, refer to GROUP 54C, Troubleshooting position. The condition of the circuit breaker is
P.54C-4. good if the door window glass starts to move
downwards within 60 seconds.
POWER WINDOW RELAY CHECK
M1429001800202 POWER WINDOW CHECK
M1429004400203
Check the system as described below. If the system
does not work, carry out troubleshooting. Refer to
GROUP 54B, Troubleshooting P.54B-17 or GROUP
Junction block
54C, Troubleshooting P.54C-4.
(front view) • Operate the power window switch of each seat to
check that the power window works.
• Turn on the power window lock switch of the
power window main switch, and operate the front
passenger's and rear power window sub switches
Power window relay
to check that the power windows do not work.
• Turn on the power window lock switch of the
power window main switch, and operate the
Power window
relay power window main switch to check that each
power window operates.
5 1 2 3
4 4 CENTRAL DOOR LOCKING SYSTEM
INSPECTION
1 3 5 M1427001100133
Check that the central door locking system works by
operating the key cylinders (driver’s and passenger’s
AC305140 AB door) and the inside lock knob (driver's door). Carry
out troubleshooting if the system does not activate.
BATTERY Tester Specified Refer to GROUP 54B, Troubleshooting P.54B-17,
VOLTAGE connection condition refer to GROUP 54C, Troubleshooting P.54C-4.
Not applied 4−5 Open circuit
• Connect Less than 2
DOOR OUTSIDE HANDLE PLAY CHECK
M1423001600277
terminal No. 3 ohms
and the
negative
battery
terminal.
A
• Connect
terminal No. 1
and the
positive battery
terminal.
AC006113AB

CIRCUIT BREAKER (INCORPORATED IN 1. Check that the door outside handle play is within
THE POWER WINDOW MOTOR) the standard value range.
INSPECTION Standard value (A):
M1429001000273 Front door: 2.3 ± 2.1 mm
1. Pull the power window switch to the UP position Rear door: 1.3 ± 1.7 mm
to fully close the door window glass, and keep 2. If the door outside handle play is not within the
pulling the switch for 10 additional seconds. standard value range, check the door outside
handle or the door latch assembly. Replace, if
necessary.
42-30 BODY
DOOR

DOOR INSIDE HANDLE PLAY 2. If the door inside handle play is outside the
ADJUSTMENT standard value range.
M1423001500292 3. Remove the door trim assembly (Refer to GROUP
Section A – A 52A, Door trim P.52A-15).
4. Remove the waterproof film (Refer to P.42-39).
A
A
B Inner cable Clip

Outer cable end

Y0705AU
AC006114 AB

1. Check that the door inside handle play is within Door inside handle
the standard value range. Inside handle rod AC100404 AB

Standard value (B): 5. Adjust the door inside handle play with the outer
Front door: 10.4 ± 9.6 mm cable end connecting the door inside handle and
Rear door: 10 ± 9.6 mm inside lock cable.
 BODY
DOOR
42-31
DOOR ASSEMBLY
REMOVAL AND INSTALLATION
M1423002200283

Post-installation Operation
• Door Fit Adjustment (Refer to P.42-27.)

<FRONT DOOR>

4 1
7 8

27 ± 5 N·m 5
11 ± 2 N·m
1

21 ± 4 N·m
2 3 9 10
1.5 ± 0.5 N·m

27 ± 5 N·m 11 ± 2 N·m Y0652AU

6 <REAR DOOR>
21 ± 4 N·m 11 ± 2 N·m
4
27 ± 5 N·m
5, 6 5
7 8
1
1.5 ± 0.5 N·m

21 ± 4 N·m
2
27 ± 5 N·m
ACX00503 3 9 10
21 ± 4 N·m 11 ± 2 N·m Y0655AU
6 AC006125AB

Removal Striker removal steps

1. Damper mail >>A<< 7. Striker
Door assembly removal steps 8. Striker shim
2. Harness connector Door switch removal steps
3. Door check connecting bolt 9. Door switch cap
4. Door assembly 10. Door switch
5. Door upper hinge
6. Door lower hinge
42-32 BODY
DOOR

INSTALLATION SERVICE POINT INSPECTION

M1423006000322
>>A<< STRIKER INSTALLATION DOOR SWITCH CHECK

Striker centre Latch centre

+1.5 mm 2 3
1

-1.5 mm

Striker
Latch
AC305098AB
AC211414 AC
Align the centre of the striker and latch within ±1.5
mm, and install. Switch Tester Specified
position connection condition
Released (ON) 1 − switch body, Less than 2
2 − switch body, ohms
3 − switch body
Depressed 1 − switch body, Open circuit
(OFF) 2 − switch body,
3 − switch body

DOOR GLASS AND REGULATOR

REMOVAL AND INSTALLATION
M1429001300315

Post-installation Operation
• Door Window Glass Adjustment (Refer to P.42-28).

<FRONT DOOR> <REAR DOOR>

4 5 6

1
1

2
2
AC212124 AB
 BODY
DOOR
42-33

<FRONT DOOR> View A

7
C C C C
B
B

B B
C C C C

A
7 Section B - B Section C - C
7 7

Door trim
Door trim
NOTE Clip Claw
: Clip positions
: Claw positions AC305108 AB

<REAR DOOR>
View D
F F F
F
E E

E E
F
F F F
7
D
7 Section E - E Section F - F
7 7

Door trim Door trim

Clip Claw
NOTE
: Clip positions
: Claw positions AC305109 AB

Door window regulator assembly Stationary window glass removal

removal steps steps
• Door trim assembly (Refer to GROUP • Window glass runchannel (Refer to
52A, Door Trim P.52A-15.) P.42-39.)
• Waterproof film (Refer to P.42-39.) • Door beltline inner weatherstrip
<<A>> >>B<< 1. Window regulator assembly (Refer to P.42-39.)
<<A>> >>B<< 2. Power window motor assembly 3. Door window glass
Door window glass removal steps <<B>> >>A<< 4. Centre sash upper
• Window glass runchannel (Refer to 5. Stationary window glass
P.42-39.) 6. Stationary window weatherstrip
3. Door window glass Power window switch removal steps
7. Power window switch panel assembly
42-34 BODY
DOOR

REMOVAL SERVICE POINTS >>B<< WINDOW REGULATOR

<<A>> WINDOW REGULATOR ASSEMBLY/POWER WINDOW
ASSEMBLY/POWER WINDOW REGULATOR MOTOR ASSEMBLY
REGULATOR MOTOR ASSEMBLY INSTALLATION
REMOVAL <FRONT DOOR>
1. Remove the door window glass installation bolts.
1
CAUTION
If film or others are adhered to the door window 4
7
glass, attach special tool window glass holder
3
(MB990480) to the outside of the glass to prevent
2
the film from peeling off.
6
5
MB990480
<REAR DOOR> Y1536AU

1
4 6

3
AC100009AB
2 5
2. Lift the door window glass, and attach special tool
window glass holder (MB990480) to the glass as Y1476AU
shown to prevent the glass from falling. AC100010AB

3. Remove the window regulator assembly and When installing the window regulator assembly,
power window motor assembly tighten the bolts to the specified torque in the order
shown.
<<B>> CENTRE SASH UPPER REMOVAL
INSPECTION
M1429001400282

How to make the power window switch

learn the fully closed position of the
power window
How to make the power window switch
Door outer learn the fully closed position when the
opening
weatherstrip power window switch is removed, or the
Door centre power window regulator assembly is
sash AC000602AB
removed or replaced
1. Remove the door outer opening weatherstrip from 1. If the anti-trap function (safety mechanism) is
the centre sash upper only. activated consecutively three times or more, the
2. Remove the centre sash upper mounting screws, fully closed position that the power window switch
and then remove the centre sash upper from the has learned will be erased (initialised).
door panel. 2. Operate the power window switch and fully open
the door window glass.
INSTALLATION SERVICE POINTS
>>A<< CENTRE SASH UPPER
INSTALLATION
Securely insert the centre sash upper into the
window rear sash (door).
 BODY
DOOR
42-35
CAUTION How to make the power window switch
The anti-trap function does not work until the learn the fully closed position when the
power window switch completes learning the power window switch is replaced with a
fully closed position (It is because the anti-trap
new one
function is reset).
CAUTION
3. Operate the power window switch and fully close
the door window glass. The power window The anti-trap function does not work until the
power window switch completes learning the
activates for 0.7 seconds and stops automatically
when the power window switch is pressed once. fully closed position (It is because the anti-trap
Repeat this operation until the door window glass function is reset).
Operate the power window main switch to fully close
fully closes and release the switch once. Then,
hold the power window switch to the fully closed the door window glass by one-shot up action so that
side again for one second so that the power the power window switch will complete learning
(Initialisation is not needed).
window switch completes learning the fully closed
position. NOTE: When the power window sub switch of each
NOTE: If the power window switch is operated to seat is replaced, operate the power window main
switch to fully close the applicable power window by
open the door window glass while the switch is
learning, learning will be cancelled. If this one-shot up action (It is because the power window
happens, return to step 2. sub switch does not have one-shot up/down
function).
42-36 BODY
DOOR

DOOR HANDLE AND LATCH

REMOVAL AND INSTALLATION
M1423004600328

Pre-removal Operation Post-installation Operation

• Door Trim Removal (Refer to GROUP 52A, Door trim • Door Inside Handle Play Check (Refer to P.42-30.)
P.52A-15.) • Door Outside Handle Play Check (Refer to P.42-29.)
• Door Trim Installation (Refer to GROUP 52A, Door trim
P.52A-15.)

<FRONT DOOR> <REAR DOOR>

N
2 N
3
7
6
9.0 ± 2.0 N·m
9.0 ± 2.0 N·m
8 5
8 5

1
1

9 4 9 4

5.0 ± 1.0 N·m 5.0 ± 1.0 N·m

AC305110 AB

Door handle and door latch assembly Door handle and door latch assembly
removal steps removal steps (Continued)
>>C<< 1. Door inside handle 6. Inside lock cable (Front door)
• Waterproof film (Refer to P.42-39.) 7. Inside lock rod (Rear door)
2. Door outside handle 8. Inside handle rod
3. Door lock key cylinder Door check removal steps
>>B<< 4. Lower sash • Waterproof film (Refer to P.42-39.)
5. Door latch assembly >>A<< 9. Door check
 BODY
DOOR
42-37
INSTALLATION SERVICE POINTS 2. Install the inside handle rod to the door inside
>>A<< DOOR CHECK INSTALLATION handle.
3. Install the door inside handle to the door.

INSPECTION
Identification mark M1423004700392

FRONT DOOR LOCK ACTUATOR CHECK

Front door <Left side>
Lock Unlock

ACX00541AB
View A
Install the door check so that the identification mark
Lever
faces upwards. 1 2 3
Item Identification 4 5 6
mark A
<Right side>
Front Door Left door 39L Unlock Lock
Right door 39R
Rear Door Left door 40L
Right door 40R
View B
>>B<< LOWER SASH INSTALLATION Lever
Securely insert the rear lower sash into the window 1 2 3
rear sash. 4 5 6

>>C<< DOOR INSIDE HANDLE B AC305111 AB

INSTALLATION Actuator Operation Check

Lever Battery connection Lever
Inner cable Clip position operation

Outer cable end

At the • Connect terminal The lever
"LOCK" No. 4 and the moves from the
position negative battery "LOCK"
terminal. position to the
• Connect terminal "UNLOCK"
No. 6 and the position.
Door inside handle positive battery
Inside handle rod AC100404 AB terminal.
1. Install the inside lock cable to the door inside At the • Connect terminal The lever
handle as follows: "UNLOCK" No. 6 and the moves from the
(1) Install the inner cable end in the inside lock position negative battery "UNLOCK"
cable to the clip in the door inside handle. terminal. position to the
(2) Turn the inside lock knob to the door lock • Connect terminal "LOCK"
position. No. 4 and the position.
positive battery
(3) Install the outer cable end to the door inside
terminal.
handle securely.
(4) Install the clip to the inner cable.
42-38 BODY
DOOR

Actuator Switch Check <Driver’s side> Actuator Operation Check

Lever position Tester Specified Lever Battery connection Lever
connection condition position operation
At the "LOCK" 1−2 Less than 2 At the • Connect terminal The lever
position ohms "LOCK" No. 4 and the moves from the
1−3 Open circuit position negative battery "LOCK"
terminal. position to the
At the "UNLOCK" 1−2 Open circuit • Connect terminal "UNLOCK"
position 1−3 Less than 2 No. 6 and the position.
ohms positive battery
terminal.
REAR DOOR LOCK ACTUATOR CHECK At the • Connect terminal The lever
"UNLOCK" No. 6 and the moves from the
Rear door
<Left side> Unlock position negative battery "UNLOCK"
Lock terminal. position to the
• Connect terminal "LOCK"
No. 4 and the position.
positive battery
terminal.
View A
Lever
1 2 3 DOOR LOCK KEY CYLINDER SWITCH
4 5 6 CHECK <PASSENGER’S SIDE>
A
Lock
<Right side>

Unlock

View B

Lever 1 2 3
1 2 3
4 5 6
AC101318
B
AC305112 AB
Switch Tester Specified
position connection condition
LOCK 2−3 Less than 2
ohms
NEUTRAL 1 − 2, 2 − 3 Open circuit
(OFF)
UNLOCK 1−2 Less than 2
ohms
 BODY
DOOR
42-39
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP
REMOVAL AND INSTALLATION
M1423003100290

<FRONT DOOR>
6 5 3
: Sectional view of
clip position
4

A 2

: Sectional view of
clip position

1 Section A – A

<Front door>

6
1

Door

Sealant: 3M ATD Part No.8633 or equivalent

AC304409AB

Waterproof film removal steps Door window glass runchannel

• Door trim assembly, speaker (Refer to removal
GROUP 52A, Trims P.52A-11). 4. Door window glass runchannel
1. Waterproof film Door beltline inner weatherstrip
Door inner opening weatherstrip removal steps
removal steps • Front door trim(Refer to GROUP 52A,
• Scuff plate, centre pillar lower trim Door trim P.52A-15.)
and cowl side trim (Refer to GROUP 5. Door beltline inner weatherstrip
52A, Trims P.52A-11.) Door beltline moulding removal steps
2. Door inner opening weatherstrip • Door mirror assembly (Refer to
(Body side) GROUP 51, Door mirror P.51-45.)
Door outer opening weatherstrip • Door window glass (Refer to
removal steps P.42-32.)
• Front door check mounting bolt (Door 6. Door beltline moulding
side) (Refer to P.42-31.)
<<A>> >>A<< 3. Door outer opening weatherstrip
42-40 BODY
DOOR

<REAR DOOR>

: Sectional view of
clip position
6
4
A
5
A

: Sectional view of
3 2 clip position

B B Section A – A

1
6
Door
<Rear door>

Section B – B
Door
1

6
3
Sealant: 3M ATD Part No.8633 or equivalent
AC304418AB

Waterproof film removal steps Door window glass runchannel

• Door trim assembly (Refer to GROUP removal
52A, Door trim P.52A-15). 5. Door window glass runchannel
1. Waterproof film Door beltline inner weatherstrip
Door inner opening weatherstrip removal steps
removal steps • Rear door trim (Refer to GROUP 52A,
• Scuff plate, centre pillar lower trim Door trim P.52A-15.)
and cowl side trim (Refer to GROUP • Centre sash upper (Refer to P.42-32.)
52A, Trims P.52A-11.) 6. Door beltline inner weatherstrip
2. Door inner opening weatherstrip Door beltline moulding removal steps
(Body side) • Door window glass (Refer to
Door outer opening weatherstrip P.42-32.)
removal steps • Stationary glass (Refer to P.42-32.)
• Rear door check mounting bolt (Door 7. Door beltline moulding
side) (Refer to P.42-31.)
3. Retainer weatherstrip
<<A>> >>A<< 4. Door outer opening weatherstrip
 BODY
TRUNK LID
42-41
REMOVAL SERVICE POINT Make a fabricated tool as shown in the illustration to
remove the door weatherstrip.
<<A>> DOOR OUTER OPENING
WEATHERSTRIP REMOVAL INSTALLATION SERVICE POINT
Fabricated
>>A<< DOOR OUTER OPENING
15 mm
4 mm
tool WEATHERSTRIP INSTALLATION
The clip colour identifies the left and right
8 mm
weatherstrips so be sure to use the colours so as to
install correctly.
Thickness:
1 mm Applicable side Identification colour
Right door Pink
Left door Natural (White)
ACX00555AB

TRUNK LID
SPECIAL TOOL
M1421000600245

TOOL Number Name Use

MB991244 Torsion bar remover and Removal and installation of
installer trunk lid torsion bar

MB991244

ON-VEHICLE SERVICE Trunk lid panel

assembly
TRUNK LID ADJUSTMENT
M1421001000042
1. If the clearance around the trunk lid panel A A
assembly is not uniform and locking and A A
unlocking of the trunk lid is difficult, make
adjustments to the trunk lid bumpers (refer to
P.42-42) and trunk lid hinges (refer to P.42-42).
2. If the clearance around the trunk lid panel AC202324
assembly is uniform, but locking and unlocking of Side outer panel
the trunk lid is difficult, make adjustments to the
Section A – A
trunk lid bumpers (refer to P.42-42) and trunk lid
striker (refer to P.42-42). Trunk lid panel assembly

Side outer panel

AC202325
AC202913 AB
42-42 BODY
TRUNK LID

3. If there is a difference in height between the side After checking the trunk lid release cable for proper
outer panels and the side edges of the trunk lid routing, loosen the trunk lid striker mounting bolts.
panel assembly, check the trunk lid hinges and, if Change the position of the trunk lid striker relative to
necessary, replace them the trunk lid latch assembly so that trunk lid locking
4. If the clearance around the trunk lid panel and unlocking effort is correct.
assembly is not uniform, and the trunk lid can be
locked and unlocked smoothly, make adjustments TRUNK LID HEIGHT ADJUSTMENT
M1421008300033
to the trunk lid bumpers (refer to P.42-42) and
trunk lid hinges (Refer to P.42-42). Trunk lid panel assembly

5. If the locking and unlocking of the trunk lid still is

difficult after making the above adjustments,
adjust the trunk lid striker (Refer to P.42-42).

ADJUSTMENT OF CLEARANCE AROUND A

TRUNK LID A
M1421008100039

Trunk lid hinge Trunk lid bumper

Section A - A

Trunk lid bumper

14 mm
Trunk lid panel
assembly
AC202897 AB Trunk lid panel assembly

Loosen the trunk lid panel assembly mounting bolts

and move the trunk lid panel assembly to make the AC305144 AB
clearance around the trunk lid uniform.
Turn each trunk lid bumper until the height shown in
the drawing is reached. If the trunk lid panel height
TRUNK LID STRIKER ADJUSTMENT
M1421008200036 on one side is different from that on the other side
(even after the trunk lid bumpers have been adjusted
Trunk lid striker to the height indicated in the drawing), turn the trunk
lid bumper(s) slightly to make fine adjustments to the
trunk lid panel height.
NOTE: When the bumper is new, one full turn of the
trunk lid bumper changes the height approximately 3
mm. Turn it clockwise to reduce height. Turn it
anticlockwise to increase height.

AC202898 AB
 BODY
TRUNK LID
42-43
TRUNK LID
REMOVAL AND INSTALLATION
M1421002200180

Section A - A 5

11 9 9
10
15 mm

Y0637AU

Section B - B
5

12 A 1
9
A 14 mm
2
B
Y0636AU
8 B

5
6
3
7
8.9 ± 1.9 N·m

4
AC301676 AB

Trunk lid weatherstrip removal steps Trunk lid striker removal steps
• Rear end trim (Refer to GROUP 52A, • Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.) Trims P.52A-11.)
>>B<< 1. Trunk lid weatherstrip 4. Trunk lid striker
Trunk lid release cable and trunk lid Trunk lid panel removal steps
release handle removal steps • Licence plate garnish (Refer to
• Rear end trim (Refer to GROUP 52A, GROUP 51, Garnishes P.51-17.)
Trims P.52A-11.) 5. Trunk lid bumper
• Trunk rear side trim (LH) (Refer to • Rear spoiler (Refer to GROUP 51,
GROUP 52A, Trims P.52A-11.) Rear spoiler P.51-18.)
• Front scuff plate (LH) (Refer to 6. Trunk lid lock cylinder
GROUP 52A, Trims P.52A-11.) 7. Trunk lid latch assembly
• Cowl side trim (LH) (Refer to GROUP 8. Trunk lid hinge mounting bolt
52A, Trims P.52A-11.) 9. Trunk lid panel assembly
• Rear scuff plate (LH) (Refer to Trunk lid latch removal
GROUP 52A, Trims P.52A-11.) 7. Trunk lid latch assembly
• Centre pillar lower trim (Refer to Trunk lid hinge removal steps
GROUP 52A, Trims P.52A-11.) • Rear shelf trim (Refer to GROUP
• Rear seat (Refer to GROUP 52A, 52A, Trims P.52A-11.)
Rear seat assembly P.52A-28.) • Rear seat (Refer to GROUP 52A,
• Accelerator pedal stopper (Refer to Rear seat assemblyP.52A-28.)
GROUP 17, Accelerator pedal 9. Trunk lid panel assembly
P.17-3.) <<A>> >>A<< 10. Trunk lid torsion bar (RH)
2. Trunk lid release handle <<A>> >>A<< 11. Trunk lid torsion bar (LH)
3. Trunk lid release cable 12. Trunk lid hinge
42-44 BODY
TRUNK LID

Grease application area

6 7
AC305143 AB

REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS

<<A>> TRUNK LID TORSION BAR >>A<< TRUNK LID TORSION BAR
REMOVAL INSTALLATION
Trunk lid torsion bar <RH> Trunk lid torsion bar <LH>

Colour mark

Trunk lid torsion bar <RH>

A
MB991244 F
Trunk lid torsion bar <LH> Trunk lid hinge <LH>
AC205068 AB

1. Attach the special tool to the illustrated portion of B

the trunk lid torsion bar <RH> on the left hand of
the vehicle, then use the tool to detach the trunk
lid torsion bar <RH> from the trunk lid hinge <LH>
2. Remove the trunk lid torsion bar <LH> in the
same way as the trunk lid torsion bar <RH>.
Trunk lid torsion bar <LH>
Hole

View F
Trunk lid hinge <RH>

E D C
A

Trunk lid torsion bar

<LH> B

MB991244 AC305282 AB

Install the trunk lid torsion bars using the following

procedure.
 BODY
TRUNK LID
42-45
CAUTION >>B<< TRUNK LID WEATHERSTRIP
Install the trunk lid torsion bar <LH> before the INSTALLATION
trunk lid torsion bar <RH>. If the sequence is
reversed, the trunk lid torsion bar <LH> will not
be able to be installed because the special tool
will interfere with the trunk lid torsion bar <RH>
during installation of the trunk lid torsion bar
<LH>.
1. Identify the LH and RH torsion bars by the colour
mark made at the centre of each torsion bar. Marking
section
Trunk lid torsion bar Mark Joint
section
colour AC006104AB

LH Vehicles with rear spoiler Green Install the trunk lid weatherstrip so that the marking
and the joint are aligned with the body centre line,
Vehicles without rear spoiler White
green
INSPECTION
RH Vehicles with rear spoiler Yellow M1421004800133

Vehicles without rear spoiler Red TRUNK LID LATCH SWITCH CONTINUITY
2. Insert the left end of the trunk lid torsion bar <LH>
CHECK
in the hole in the trunk lid hinge <LH>.
3. Press portion A of the trunk lid torsion bar <LH>
right end against point A on the trunk lid hinge
<RH> as shown in View F in the drawing.
4. Twist the portion B of the trunk lid torsion bar
<LH> right end using the special tool until it is
moved from point B and pressed against point C
of the trunk lid hinge <RH> as shown in View F.
Then force the portion into point D. Trunk lid latch assembly
AC305142 AB
5. Twist the portion A of the trunk lid torsion bar
<LH> right end until it reaches point E on the trunk Switch position Tester Specified
lid hinge <RH> as shown in View F. connection condition
6. Attach the trunk lid torsion bar <RH> to the trunk ON (Latch open) 1 − Earth Less than 2
lid hinge <LH> using the same method as the ohms
trunk lid torsion bar <LH>.
OFF (Latch shut) Open circuit
42-46 BODY
TAILGATE

TAILGATE
SERVICE SPECIFICATIONS
M1421000300288

Item Standard value

Tailgate handle play 2.3 to 5.9 mm

SEALANTS
M1424000500098

Item Specified sealant

Tailgate waterproof film 3M ATD Part No.8633 or equivalent
Tailgate hinge 3M ATD Part No.8531 Heavy drip check sealer, 3M
ATD Part No.8646 Automotive joint and seam sealer
or equivalent

SPECIAL TOOL
M1424000600170

Tool Number Name Use

MB991223 Harness set Terminal voltage measurement
A
A: MB991219 A: Test harness A: For checking connector pin
B: MB991220 B: LED harness contact pressure
C: MB991221 C: LED harness B: For checking power supply
D: MB991222 adapter circuit
B D: Probe C: For checking power supply
circuit
D: For connecting a locally
sourced tester
C

D
MB991223 AD

TROUBLESHOOTING
M1424000700207
The tailgate system is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to GROUP
54B, Troubleshooting P.54B-17 or GROUP 54C,
Troubleshooting P.54C-4.

ON-VEHICLE SERVICE
TAILGATE FIT ADJUSTMENT AC203659
M1424000900137
1. If the striker and latch mesh badly, replace the
2. Move the replaced striker forward and backward
striker and striker installation blots with
or to the left and right to adjust, after bolt the
replacement parts (striker: MR523105, striker
striker temporarily.
installation blot: MU000474).
3. After adjusting, tighten the bolts to the specified
torque [24 ± 4 N⋅m].
 BODY
TAILGATE
42-47
NOTE: 4. If uneven clearance is present between tailgate
and body, reposition the hinge to adjust the
Grind here clearance.

TAILGATE HANDLE PLAY CHECK

M1424002400138

Section A – A
Holder

A
AC203660AB

When the bolt head interferes with the rear end

Rod
trim, rasp the interference area with a round file. A B

AC103270 AC

1. Check the tailgate handle play.

Standard value (B): 2.3 − 5.9 mm
2. If it deviates from the standard value, remove the
lower tailgate trim (Refer to GROUP 52A, tailgate
trim P.52A-19) and waterproof film (Refer to
P.42-48).
AC201556
3. Remove the holder from the tailgate handle and
adjust according to the tailgate latch rod and
tailgate handle connection position.
42-48 BODY
TAILGATE

TAILGATE
REMOVAL AND INSTALLATION
M1424001100178

CAUTION
• Do not disassemble or throw the tailgate gas spring into fire.
• Punch a hole in the gas spring before disposal to release the gas inside.
• Ensure the tailgate gas spring piston rod does not come into contact with foreign material.
Pre-removal Operation Post-installation Operation
• Tailgate Spoiler Assembly Removal (Refer to GROUP 51, • Tailgate Fit Adjustment (Refer to P.42-46).
Tailgate Spoiler P.51-19). • Rear Wiper Motor Installation (Refer to GROUP 51, Rear
• Tailgate Trim Assembly Removal (Refer to GROUP 52A, Wiper and Washer P.51-29).
Tailgate Trim P.52A-19). • Tailgate Trim Assembly Installation (Refer to GROUP
• Rear Wiper Motor Removal (Refer to GROUP 51, Rear 52A, Tailgate Trim P.52A-19).
Wiper and Washer P.51-29). • Tailgate Spoiler Assembly Installation (Refer to GROUP
51, Tailgate Spoiler P.51-19).

Sealant: 3M ATD Part No. 8633 or equivalent

9.0 ± 2.0 N·m
2
1

12 ± 2 N·m
7 11 6
5

12 ± 2 N·m

5.0 ± 1.0 N·m

4 22 ± 4 N·m
3
5.0 ± 1.0 N·m
8
13 ± 2 N·m

10 9

AC304836 AB
 BODY
TAILGATE
42-49

Adhesive: 3M ATD Part No.8531 Heavy drip check sealer, 3M ATD Part No.8646 Automotive joint and seam sealer
or equivalent
AC305322 AB

Tailgate assembly removal steps Tailgate assembly removal steps

1. Rear washer hose • Rear end trim (Refer to GROUP 52A,
2. Tailgate wiring harness Trims P.52A-11.)
3. Waterproof film 9. Striker
4. Tailgate gas spring 10. Dynamic damper
5. Antenna feeder cable Tailgate opening weatherstrip removal
6. Tailgate assembly 4. Tailgate gas spring
7. Tailgate hinge >>A<< 11. Tailgate opening weatherstrip
8. Bumper

INSTALLATION SERVICE POINT

>>A<< TAILGATE OPENING Positioning Tailgate opening
weatherstrip
mark
WEATHERSTRIP INSTALLATION

SECTION A – A
Tailgate opening
weatherstrip

Rear bumper end

Hatching

AC305091AB

Assemble so the tailgate opening weatherstrip

marking is at the centre of the body.
42-50 BODY
TAILGATE

TAILGATE HANDLE AND LATCH

REMOVAL AND INSTALLATION
M1424001700170

Pre-removal Operation
• Tailgate Handle Play Check (Refer to P.42-47).

5.0 ± 1.0 N·m 6 5

Y1518AU

22 ± 4 N·m
3

2
1
3
Y1520AU
9.0 ± 2.0 N·m
AC305141 AB

Striker removal steps Tailgate latch removal steps

• Rear end trim (Refer to GROUP 52A, • Lower tailgate trim (Refer to GROUP
Trims P.52A-11.) 52A, Tailgate Trim P.52A-19.)
>>A<< 1. Striker • Waterproof film (Refer to P.42-48.)
Tailgate handle and lock key cylinder 2. Bolt (earth)
removal steps 3. Tailgate latch assembly
• Lower tailgate trim (Refer to GROUP Tailgate lock actuator removal steps
52A, Tailgate Trim P.52A-19.) • Lower tailgate trim (Refer to GROUP
• Waterproof film (Refer to P.42-48.) 52A, Tailgate Trim P.52A-19.)
2. Bolt (earth) • Waterproof film (Refer to P.42-48.)
3. Tailgate latch assembly 6. Tailgate lock actuator
4. Tailgate lock key cylinder
5. Tailgate handle
 BODY
KEYLESS ENTRY SYSTEM
42-51
INSTALLATION SERVICE POINT Lever Battery connection Lever
>>A<< STRIKER INSTALLATION position operation
At the • Connect terminal The lever
"LOCK" No.2 and the moves from the
Striker centre Latch centre
position negative battery "LOCK"
+1.5 mm terminal. position to the
• Connect terminal "UNLOCK"
No.3 and the position.
-1.5 mm positive battery
terminal.
Striker
Latch
At the • Connect terminal The lever
AC305098AB "UNLOCK" No.3 and the moves from the
Assemble so the distance between the centre of the position negative battery "UNLOCK"
striker and centre of the latch is ±1.5 mm or less. terminal. position to the
• Connect terminal "LOCK"
INSPECTION No.2 and the position.
M1424001200142 positive battery
TAILGATE LOCK ACTUATOR CHECK terminal.

TAILGATE LATCH CHECK <Vehicles for

Lever keyless entry system>
Lock
A
Lever

View A Unlock 1

Lock
AC103292 AC Unlock
2

AC103291AD

Lever position Tester Specified

connection condition
At the "LOCK" 1 − 2 (Earth) Open circuit
position
At the Less than 2
"UNLOCK" ohms
position

KEYLESS ENTRY SYSTEM

SERVICE SPECIFICATIONS
M1428000300104

Item Standard value

Voltage of transmitter battery V 2.5 − 3.2
42-52 BODY
KEYLESS ENTRY SYSTEM

SPECIAL TOOLS
M1428000600280

Tool Number Name Use

MB991502 MUT-II sub-assembly Encrypted code registration

B991502

MB991529 Diagnosis code check

harness

MB991529

MB991955 MUT-III sub-assembly Encrypted code registration

A A: MB991824 A: Vehicle CAUTION
B: MB991827 communication MUT-III main harness B
C: MB991910 interface (V.C.I.) (MB991911) should be used.
D: MB991911 B: MUT-III USB cable MUT-III main harness A should
MB991824
E: MB991825 C: MUT-III main not be used for this vehicle.
B F: MB991826 harness A
(Vehicles with CAN
communication
system)
MB991827 D: MUT-III main
harness B
C
(Vehicles without
DO NOT USE CAN
communication
MB991910
system)
E: MUT-III
D measurement
adapter
F: MUT-III trigger
harness
MB991911

MB991825

MB991826

MB991955
 BODY
KEYLESS ENTRY SYSTEM
42-53
TROUBLESHOOTING ENABLING/DISABLING THE
M1428000700287
The keyless entry system is controlled by the Smart ANSWERBACK FUNCTION
M1428003200214
Wiring System (SWS). For troubleshooting, refer to If the keyless entry system locks or unlocks the
GROUP 54B, Troubleshooting P.54B-17 or GROUP doors, the room lamp flashes or illuminates, the
54C, Troubleshooting P.54C-4. hazard warning lamp flashes (hazard answerback
function). The hazard answerback function can be
ON-VEHICLE SERVICE enabled or disabled according to the following
procedure:
KEYLESS ENTRY SYSTEM CHECK
M1428001400096
Check the system as described below. If the system ENABLING/DISABLING THE HAZARD
does not work, carry out troubleshooting. Refer to ANSWERBACK FUNCTION
GROUP 54B, Troubleshooting P.54B-17, refer to The hazard answerback function can be enabled or
GROUP 54C, Troubleshooting P.54C-4. disabled by one of the two following procedures.
• Operate the transmitter to check that the doors <When using the transmitter after
and tailgate can be locked and unlocked.
• Operate the transmitter to check that the
diagnosis connector (1) is earthed>
answerback function works in response to door 1. Enter the hazard answerback customize mode by
and tailgate <Wagon> locking/unlocking. performing one of the following steps. If the
ETACS-ECU enters the customize mode, its
NOTE: The adjustment function allows you to
buzzer will sound once.
change the answerback setting as follows. Prior
to that check, confirm which setting is activated. (1) Turn the ignition switch to “LOCK”(OFF)
position.
.
• The hazard warning lamps flash twice when (2) Turn off the hazard warning lamp switch.
locked and once when unlocked. The room CAUTION
lamp flashes twice when locked and Before connecting or disconnecting the earth,
illuminates for 15 seconds when unlocked. turn the ignition switch to the "LOCK" (OFF)
• The hazard warning lamps do not flash when position.
locked and flash once when unlocked. The Steering shaft Diagnosis
room lamp flashes twice when locked and connector
illuminates for 15 seconds when unlocked.
• The hazard warning lamps flash twice when
locked and do not flash when unlocked. The
room lamp flashes twice when locked and MB991529
illuminates for 15 seconds when unlocked.
• The hazard warning lamps do not flash when
both locked and unlocked. The room lamp
flashes twice when locked and illuminates for AC305133AB
15 seconds when unlocked.
(3) Connect the diagnosis connector to the
KEYLESS ENTRY SYSTEM TIMER LOCK special tool diagnosis code check harness
(MB991529).
FUNCTION INSPECTION
M1428004000138 (4) Close the driver's side door.
Push the transmitter unlock button and check to see (5) Keep the windshield washer switch on for at
that the doors and tailgate <Wagon> lock within 30 least ten seconds. Then the ETACS-ECU
seconds. If it doesn't, then execute troubleshooting buzzer will sound once.
remedies. Refer to GROUP 54B, Troubleshooting
2. If the transmitter “LOCK” button is pushed
P.54B-17, refer to GROUP 54C, Troubleshooting consecutively twice (within two seconds), the
P.54C-4. ETACS-ECU buzzer will sound, indicating that the
hazard answerback function can be enabled or
disabled when the doors are locked.
42-54 BODY
KEYLESS ENTRY SYSTEM

• Enable the hazard answerback function CAUTION

when the doors are locked: The Before connecting or disconnecting the MUT-II,
ETACS-ECU buzzer will sound once. turn the ignition switch to the "LOCK" (OFF)
• Disable the hazard answerback function position.
when the doors are locked: The
ETACS-ECU buzzer will sound twice. Steering shaft
16-Pin
3. If the transmitter “UNLOCK” button is pushed
consecutively twice (within two seconds), the
ETACS-ECU buzzer will sound, indicating that the
hazard answerback function can be enabled or
disabled when the doors are unlocked.
• Enable the hazard answerback function
when the doors are unlocked: The MB991502
ETACS-ECU buzzer will sound once. AC304777AC
• Disable the hazard answerback function
(3) Connect the MUT-II to the diagnosis
when the doors are unlocked: The
connector.
ETACS-ECU buzzer will sound twice.
(4) Close the driver's side door.
4. Exit the hazard answerback customize mode by (5) Keep the windshield washer switch on for at
observing one of the following steps. least ten seconds. Then the ETACS-ECU
(1) Disconnect diagnosis connector terminal (1) buzzer will sound once.
form the earth.
2. If the transmitter “LOCK” button is pushed
(2) Turn the ignition switch to position other then consecutively twice (within two seconds), the
“LOCK”(OFF), or remove the ignition key. ETACS-ECU buzzer will sound, indicating that the
(3) Open the driver's side door. hazard answerback function can be enabled or
(4) Any other warning buzzer output occurs. disabled when the doors are locked.
NOTE: If any operation is not done for at least three • Enable the hazard answerback function
minutes after the ETACS-ECU has entered the when the doors are locked: The
customize mode, the hazard answerback customize ETACS-ECU buzzer will sound once.
mode will be canceled automatically. • Disable the hazard answerback function
when the doors are locked: The
<When the transmitter is used after ETACS-ECU buzzer will sound twice.
connecting MUT-II to the diagnosis 3. If the transmitter “UNLOCK” button is pushed
connector> consecutively twice (within two seconds), the
1. Enter the hazard answerback customize mode by ETACS-ECU buzzer will sound, indicating that the
performing one of the following steps. If the hazard answerback function can be enabled or
ETACS-ECU enters the customize mode, its disabled when the doors are unlocked.
buzzer will sound once. • Enable the hazard answerback function
(1) Turn the ignition switch to “LOCK”(OFF) when the doors are unlocked: The
position. ETACS-ECU buzzer will sound once.
(2) Turn off the hazard warning lamp switch. • Disable the hazard answerback function
when the doors are unlocked: The
ETACS-ECU buzzer will sound twice.
4. Exit the hazard answerback customize mode by
observing one of the following steps.
(1) Disconnect MUT-II from the diagnosis
connector.
(2) Turn the ignition switch to position other then
“LOCK”(OFF), or remove the ignition key.
(3) Open the driver's side door.
(4) Any other warning buzzer output occurs.
 BODY
KEYLESS ENTRY SYSTEM
42-55
NOTE: If any operation is not done for at least three 2. If the transmitter “LOCK” button is pushed
minutes after the ETACS-ECU has entered the consecutively twice (within two seconds), the
customize mode, the hazard answerback customize ETACS-ECU buzzer will sound, indicating that the
mode will be canceled automatically. hazard answerback function can be enabled or
disabled when the doors are locked.
<When the transmitter is used after • Enable the hazard answerback function
connecting special tool V. C. I. when the doors are locked: The
(MB991824) to the diagnosis connector> ETACS-ECU buzzer will sound once.
1. Enter the hazard answerback customize mode by • Disable the hazard answerback function
performing one of the following steps. If the when the doors are locked: The
ETACS-ECU enters the customize mode, its ETACS-ECU buzzer will sound twice.
buzzer will sound once. 3. If the transmitter “UNLOCK” button is pushed
(1) Turn the ignition switch to “LOCK”(OFF) consecutively twice (within two seconds), the
position. ETACS-ECU buzzer will sound, indicating that the
(2) Turn off the hazard warning lamp switch. hazard answerback function can be enabled or
CAUTION disabled when the doors are unlocked.
Before connecting or disconnecting the V. C. I., • Enable the hazard answerback function
turn the ignition switch to the "LOCK" (OFF) when the doors are unlocked: The
position. ETACS-ECU buzzer will sound once.
• Disable the hazard answerback function
when the doors are unlocked: The
ETACS-ECU buzzer will sound twice.
4. Exit the hazard answerback customize mode by
observing one of the following steps.
(1) Disconnect V. C. I. from the diagnosis
connector.
(2) Turn the ignition switch to position other then
“LOCK”(OFF), or remove the ignition key.
(3) Open the driver's side door.
16-Pin
(4) Any other warning buzzer output occurs.
NOTE: If any operation is not done for at least three
minutes after the ETACS-ECU has entered the
MB991911 customize mode, the hazard answerback customize
mode will be canceled automatically.

HOW TO REGISTER SECRET CODE

M1428001000292
Each individual secret code is registered inside the
MB991824
transmitter, and so it is necessary to resister these
AC305153AB
codes with the EEPROM inside the receiver in the
(3) Connect the V. C. I. to the diagnosis following cases.
connector. • When the transmitter or ETACS-ECU is replaced
(4) Turn the V.C.I. power switch to the "ON" • If more transmitters are to be used
position. • If it appears that a problem is occurring because
(5) Close the driver's side door. of faulty registration of a code.
(6) Keep the windshield washer switch on for at A maximum of four different codes can be stored in
least ten seconds. Then the ETACS-ECU the EEPROM memory (four different transmitters can
buzzer will sound once. be used). When the code for the first transmitter is
registered, the previously registered codes for all
transmitters are cleared. Therefore, if you are using
four transmitters or are adding more transmitters, the
codes for all transmitters must be registered at the
same time.
42-56 BODY
KEYLESS ENTRY SYSTEM

WHEN THE SPECIAL TOOL DIAGNOSIS 7. If you are using two or more transmitters or have
CODE CHECK HARNESS (MB991529) IS added a second transmitter, the same registration
procedure should be carried out within one minute
USED
after registering the code for the first transmitter.
1. Check that the doors lock normally when the key
8. Registration mode will be cancelled under the
is used.
following conditions:
2. Insert the ignition key. • When the secret code for four transmitters has
CAUTION been registered;
Before connecting or disconnecting the earth, • When one minute has passed after registration
turn the ignition switch to the "LOCK" (OFF) mode started;
position. • When the diagnosis connector is disconnected
from earth;
Steering shaft Diagnosis
connector • When the key is removed from the key cylinder;
9. After the registration is completed, remove the
ignition key and close all the doors, and then
check that the keyless entry system operates
MB991529 normally.

WHEN THE MUT-II IS USED

1. Check that the doors lock normally when the key
AC305133AB is used.
2. Insert the ignition key.
3. Connect the diagnosis connector to the special
tool diagnosis code check harness (MB991529). CAUTION
NOTE: This will connect terminal (1) of the Before connecting or disconnecting the MUT-II,
diagnosis connector to earth, and the system will turn the ignition switch to the "LOCK" (OFF)
be in secret code registration standby mode. position.
Steering shaft
16-Pin
Ground connected

Within 10 seconds

1 2 3 4 5 6
Hazard ON
warning
switch OFF MB991502
AC304777AC
ACX00571 AG

3. Connect the MUT-II to the diagnosis connector.

4. Press the hazard warning lamp switch six times
within 10 seconds.
NOTE: Once the process is completed six times, MUT-II connected
then it will operate with all doors and tailgate lock
and unlock operations once and then go to the Within 10 seconds
save mode.
NOTE: The hazard warning lamp switch is turned
1 2 3 4 5 6
on and off alternately whenever it is pushed. Hazard ON
5. Press the transmitter switch, and then press it two warning
switch OFF
times within 10 seconds of the first press. This will ACX00571 AB
register the code.
6. Once the program is saved, it will operate once 4. Press the hazard warning switch six times within
with the all doors and tailgate lock and unlock 10 seconds.
operations.
 BODY
KEYLESS ENTRY SYSTEM
42-57
NOTE: Once the process is completed six times, CAUTION
then it will operate with all doors and tailgate lock Before connecting or disconnecting the V. C. I.,
and unlock operations once and then go to the turn the ignition switch to the "LOCK" (OFF)
save mode. position.
NOTE: The hazard warning lamp switch is turned
on and off alternately whenever it is pushed.
5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will
register the code.
6. Once the program is saved, it will operate once
with the all doors and tailgate lock and unlock
operations.
7. If you are using two or more transmitters or have
added a second transmitter, the same registration
procedure should be carried out within one minute 16-Pin
after registering the code for the first transmitter.
8. Registration mode will be cancelled under the
following conditions: MB991911
• When the secret code for four transmitters has
been registered;
• When one minute has passed after registration
mode started;
• When the MUT-II is disconnected from the MB991824
diagnosis connector; AC305153AB
• When the key is removed from the key cylinder;
9. After the registration is completed, remove the 3. Connect the V. C. I. to the diagnosis connector.
ignition key and close all the doors, and then Connect V. C. I. and turn
check that the keyless entry system operates the V. C. I. power supply
normally. switch ON.

WHEN THE SPECIAL TOOL V. C. I. Within 10 seconds

(MB991824) IS USED
1. Check that the doors lock normally when the key Hazard ON
1 2 3 4 5 6
is used. warning
OFF
2. Insert the ignition key. switch
ACX00571 AJ

4. Within 10 seconds after turning the V.C.I. power

switch to the "ON" position, press the hazard
switch six times.
NOTE: Once the process is completed six times,
then it will operate with all doors and tailgate lock
and unlock operations once and then go to the
save mode.
NOTE: The hazard warning lamp switch is turned
on and off alternately whenever it is pushed.
5. Press the transmitter switch, and then press it two
times within 10 seconds of the first press. This will
register the code.
6. Once the program is saved, it will operate once
with the all doors and tailgate lock and unlock
operations.
42-58 BODY
KEYLESS ENTRY SYSTEM

7. If you are using two or more transmitters or have • When one minute has passed after registration
added a second transmitter, the same registration mode started;
procedure should be carried out within one minute • When the V.C.I. is disconnected from the
after registering the code for the first transmitter. diagnosis connector;
8. Registration mode will be cancelled under the • When the key is removed from the key cylinder;
following conditions: 9. After the registration is completed, remove the
• When the secret code for four transmitters has ignition key and close all the doors, and then
been registered; check that the keyless entry system operates
normally.

TRANSMITTER
DISASSEMBLY AND REASSEMBLY
M1428002800172

Post-reassembly operation
• Transmitter operation check

AC303199
2 1 AC304118

AC310838 AF

Disassembly steps Disassembly steps (Continued)

1. Screw 4. Transmitter assembly
2. Upper cover <<A>> >>A<< 5. Battery
3. Transponder 6. Master key
 BODY
KEYLESS ENTRY SYSTEM
42-59
DISASSEMBLY SERVICE POINT Install a new battery to the transmitter assembly with
its (+) side facing towards the upper cover side.
<<A>> BATTERY REMOVAL
Battery required for replacement: Coin type
CAUTION battery CR1616
Do not allow water or dust to enter the inside of
the transmitter assembly when it is open. Also, INSPECTION
do not touch the precision electronic device. M1428003800067
TRANSMITTER BATTERY CHECK
REASSEMBLY SERVICE POINT
>>A<< BATTERY INSTALLATION
CAUTION
Do not allow water or dust to enter the inside of
the transmitter assembly when it is open. Also,
do not touch the precision electronic device.
Transmitter assembly

AC004486

– + Measure the voltage of the battery. If the voltage of

the battery is not within the standard value, replace
the battery.
Upper cover side
Standard value: 2.5 − 3.2 V
Battery
Master key side AC304118 AD
NOTES
 51-1

GROUP 51

EXTERIOR
CONTENTS

FRONT BUMPER ASSEMBLY . . . . . 51-2 TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-22

ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-22
FRONT BUMPER ASSEMBLY . . . . . . . . . . 51-2 WINDSHIELD WIPER AND WASHER . . . . 51-23
REMOVAL AND INSTALLATION . . . . . . . . 51-2 REMOVAL AND INSTALLATION . . . . . . . . 51-23
DISASSEMBLY AND REASSEMBLY. . . . . 51-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-25

REAR BUMPER ASSEMBLY . . . . . . 51-5 REAR WIPER AND WASHER . . . . . . 51-28

REMOVAL AND INSTALLATION . . . . . . . . 51-5 GENERAL INFORMATION . . . . . . . . . . . . . 51-28
DISASSEMBLY AND REASSEMBLY. . . . . 51-7 SERVICE SPECIFICATION . . . . . . . . . . . . 51-28
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-28
MOULDINGS . . . . . . . . . . . . . . . . . . . 51-9 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-28
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 51-9 REAR WIPER AND WASHER . . . . . . . . . . 51-29
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-9 REMOVAL AND INSTALLATION . . . . . . . . 51-29
MOULDINGS . . . . . . . . . . . . . . . . . . . . . . . 51-10 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-30
REMOVAL AND INSTALLATION . . . . . . . . 51-10
HEADLAMP WASHER . . . . . . . . . . . . 51-32
SIDE AIR DAM . . . . . . . . . . . . . . . . . . 51-15 TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-32
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-15 HEADLAMP WASHER . . . . . . . . . . . . . . . . 51-32
SIDE AIR DAM . . . . . . . . . . . . . . . . . . . . . . 51-15 REMOVAL AND INSTALLATION . . . . . . . . 51-32
REMOVAL AND INSTALLATION . . . . . . . . 51-15 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-33

GARNISHES . . . . . . . . . . . . . . . . . . . 51-17 MARK . . . . . . . . . . . . . . . . . . . . . . . . . 51-34

REMOVAL AND INSTALLATION . . . . . . . . 51-17 REMOVAL AND INSTALLATION . . . . . . . . 51-34

REAR SPOILER. . . . . . . . . . . . . . . . . 51-18 DOOR MIRROR . . . . . . . . . . . . . . . . . 51-36

REMOVAL AND INSTALLATION . . . . . . . . 51-18 GENERAL INFORMATION . . . . . . . . . . . . . 51-36
SERVICE SPECIFICATION . . . . . . . . . . . . 51-36
TAILGATE SPOILER . . . . . . . . . . . . . 51-19 SPECIAL TOOL. . . . . . . . . . . . . . . . . . . . . . 51-36
REMOVAL AND INSTALLATION . . . . . . . . 51-19 TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-36
DIAGNOSIS TROUBLESHOOTING
ROOF RAIL . . . . . . . . . . . . . . . . . . . . 51-20 FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-36
REMOVAL AND INSTALLATION . . . . . . . . 51-20 TROUBLE SYMPTOM CHART . . . . . . . . . . 51-36
SYMPTOM PROCEDURES . . . . . . . . . . . . 51-37
WINDSHIELD WIPER AND WASHER 51-21 DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . 51-45
GENERAL INFORMATION. . . . . . . . . . . . . 51-21 REMOVAL AND INSTALLATION . . . . . . . . 51-45
SERVICE SPECIFICATION . . . . . . . . . . . . 51-22 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 51-47
51-2 EXTERIOR
FRONT BUMPER ASSEMBLY

FRONT BUMPER ASSEMBLY

ADHESIVE
M1511000500426

Item Specification
Front three-diamond mark Double-sided tape:
20 mm width and 0.8 mm thickness

FRONT BUMPER ASSEMBLY

REMOVAL AND INSTALLATION
M1511001400444

Section A – A Section B – B Section C – C

3
2
3
3
Claw

Clip 5

4 C
5

C
2
A A

A A A 2
A
A A

AC304651 AB
 EXTERIOR
FRONT BUMPER ASSEMBLY
51-3
Removal steps Removal steps (Continued)
1. Splash shield mounting clip • Fog lamp connector connection
2. Radiator grill assembly 4. Front bumper beam assembly
3. Front bumper assembly 5. Front bumper fixing clip

DISASSEMBLY AND REASSEMBLY

M1511001600460

Double-sided tape: Generic products 6

[ 20 mm width and 0.8 mm thickness ]

N 5

2 6
3

1 3
4
5N
7

8
9

AC304652AC

Removal steps Removal steps (Continued)

1. Front three-diamond mark <<A>> >>A<< 5. Front bumper rivet
2. Under duct 6. Front bumper side plate
3. Air intake bezel <Vehicle without fog 7. Front bumper centre cover
lamp> 8. Licence plate garnish
4. Fog lamp bezel <Vehicle with fog 9. Front bumper face
lamp>
51-4 EXTERIOR
FRONT BUMPER ASSEMBLY

DISASSEMBLY SERVICE POINT REASSEMBLY SERVICE POINT

<<A>> FRONT BUMPER SIDE PLATE >>A<< FRONT BUMPER SIDE PLATE
ASSEMBLY REMOVAL ASSEMBLY

Drill Rivet tool

Front bumper
face
Bumper face Rivet

Front bumper
side plate Front bumper face
AC100411AB

Use a drill (4.0 mm) to make a hole in the rivet to Section A

1
break it, and then remove the rivet. Rivet

3 Rivet tool

Flange

Rivet
AC305178 AB

Use the rivet tool shown in the illustration to attach

the rivet by the following procedure.
1. Insert the rivet into the base material front bumper
side plate assembly.
2. Place the recommended tool over section A of the
rivet.
3. While pushing the flange surface of the rivet with
the recommended tool, press the handle of the
tool.
4. The thin part of section A of the rivet will break
and the rivet will then be attached.
 EXTERIOR
REAR BUMPER ASSEMBLY
51-5
REAR BUMPER ASSEMBLY
REMOVAL AND INSTALLATION
M1511001900397

Pre-removal and Post-installation Operation

• Rear Combination Light Removal and Installation.
<Sedan> (Refer to GROUP 54A, Rear Combination Lamp
P.54A-79.)
• Rear End Trim Removal and Installation. (Refer to
GROUP 52A, Trims P.52A-11.)
• Rear Splash Shield Removal and Installation.
AC300413
<Sedan>

B
A

B
A

Rear bumper assembly

B

Section A – A Section B – B

Clip Rear bumper

assembly
Rear bumper assembly
Clip

AC305045 AB
51-6 EXTERIOR
REAR BUMPER ASSEMBLY

AC300199
<Wagon>

C
B

A
B
Rear bumper assembly
A

Section A – A Section B – B Section C – C

Clip
Clip Rear bumper Rear bumper
assembly Rear bumper assembly
Clip assembly

AC305046
 EXTERIOR
REAR BUMPER ASSEMBLY
51-7
DISASSEMBLY AND REASSEMBLY
M1511002100349

AC300414
<Sedan>
3

4
N 1

6
5
8
AC304191 AB

3 AC300200
<Wagon>

4
N 1

6
5
8
AC304193 AB

Disassembly steps Disassembly steps (Continued)

<<A>> >>A<< 1. Rivets 5. Rear fog lamp assembly
2. Rear bumper side plate assembly 6. Rear fog lamp bezel
3. Rear bumper centre reinforcement 7. Extension
4. Rear fog lamp bracket 8. Rear bumper face
51-8 EXTERIOR
REAR BUMPER ASSEMBLY

DISASSEMBLY SERVICE POINT ASSEMBLY SERVICE POINT

<<A>> RIVET REMOVAL >>A<< RIVET INSTALLATION

Drill Recommended tool

Rear bumper
face
Bumper face Rivet

Y0412AU
Rear bumper
side plate Rear bumper face
AC100411AB
Section A
Use a drill (4.0 mm) to make a hole in the rivet to 1
break it, and then remove the rivet. Rivet
2

3 Recommended
tool
Flange

18E0192
Rivet AC005876AB

Use the rivet tool shown in the illustration to attach

the rivet by the following procedure.
1. Insert the rivet into the rear bumper face and rear
bumper side plate.
2. Insert “A” of the rivet into the rivet tool.
3. Pressing the flange surface of the rivet, move the
handle of the rivet tool.
4. The thinnest point of “A” is cut and the rivet is held
in position.
 EXTERIOR
MOULDINGS
51-9
MOULDINGS
SPECIAL TOOL
M1511000601136

Tool Number Name Application

MB990449 Window moulding remover Removal of drip moulding

MB990449

ADHESIVE
M1511000500749

Application Specified adhesive

Front fender, front and rear door mouldings Double-sided tape [a: 6 mm width 1.2 mm thickness,
b: 20 mm width 1.2 mm thickness ]
51-10 EXTERIOR
MOULDINGS

MOULDINGS
REMOVAL AND INSTALLATION
M1511004700295

Section A – A Section B – B Section C – C Section D – D

1 1 1 1

6, 7 8
9
Y0622AU 2, 3, 4 Y0623AU W0740AU Y0624AU
Section E – E
1
<Sedan>

N5

E 5 Y0729AU
C
1 D
E

N4 C
8N
D
N9
B
N3
B
7N
N 2
A

N6

AC304339 AB
 EXTERIOR
MOULDINGS
51-11
<Vehicle without roof rail>
<Wagon>
C

<Vehicle with roof rail>

C
N4
N9
C
B

N3 7N 1
B

N 2 C
N 4
A
B
A 9N
N3 B
N6 N 2 7N
A

N6

AC304340 AB

Removal Roof drip moulding removal steps

• Front deck garnishes (Refer to >>B<< 4. Front drip moulding clip C
P.51-23.) >>B<< 5. Rear drip moulding clip
Roof drip moulding removal steps >>A<< 6. Drip moulding clip A
<<A>> >>C<< 1. Roof drip moulding >>A<< 7. Drip moulding clip B
>>B<< 2. Front drip moulding clip A >>A<< 8. Drip moulding clip C
>>B<< 3. Front drip moulding clip B 9. Roof drip moulding clip

REMOVAL SERVICE POINT

<<A>> ROOF DRIP MOULDING REMOVAL
CAUTION
If the moulding has become warped, it should not
be reused.

MB990449
AC304375 AB

Use special tool window moulding remover

(MB990449) to lever out the moulding.
51-12 EXTERIOR
MOULDINGS

INSTALLATION SERVICE POINTS >>B<< REAR DRIP MOULDING

>>A<< DRIP MOULDING CLIP C/DRIP CLIP/FRONT DRIP MOULDING CLIP
MOULDING CLIP B/DRIP MOULDING C/FRONT DRIP MOULDING CLIP
CLIP A INSTALLATION B/FRONT DRIP MOULDING CLIP A
1. The drip moulding clips A, B and C differ INSTALLATION
according to where they are used, so check the The front drip moulding clips A, B, C and rear drip
identification colour before installation. moulding clip differ according to where they are
Applicable location Identification colour used, so check the identification colour before
installation.
Drip moulding clip A Yellow
Applicable location Identification colour
Drip moulding clip B Blue
Front drip moulding clip A Orange
Drip moulding clip C Milky white
Front drip moulding clip B Purple
Front drip moulding clip C Blue
Front pillar outer Rear drip moulding clip Grey

>>C<< ROOF DRIP MOULDING

Section B INSTALLATION
Install the clips to the roof drip moulding before
installing the moulding to the vehicle body.
Section A
AC304374 AB

2. After installing the clip to the front pillar outer in

alignment with its section A, cut from section B.
 EXTERIOR
MOULDINGS
51-13

Section A – A Section B – B Section C – C

Clip Clip

AC400128

C 3
C

A
1 AC400117
A
AC401196 AB

Adhesive tape position a a

3
1 2
b b AC400840AD

Double-sided tape: Generic products [ a: 6 mm width and 1.2 mm thickness,

b: 20 mm width and 1.2 mm thickness ]

Door moulding removal steps Door moulding removal steps

<<A>> >>A<< 1. Front fender moulding <<A>> >>A<< 2. Front door moulding
<<A>> >>A<< 3. Rear door moulding
51-14 EXTERIOR
MOULDINGS

REMOVAL SERVICE POINT

<<A>> FRONT FENDER, FRONT AND
REAR DOOR MOULDINGS REMOVAL
Gently lift and remove the door moulding. If there is
any double-sided tape remaining on the door
moulding, remove according to the following
instructions.
<Remove double-sided tape remaining on the body
surface>
AC313343

1. Scrape off the double-sided tape on the door

Protection tape
moulding with a resin spatula as possible.
2. Wipe the door moulding surface and clean it with
a rag moistened with isopropyl alcohol.
3. Remove only a small portion of the residual
adhesive.
4. Adhere the double-sided tape as specified on the
Double-sided tape
door moulding.
AC000420 AB

1. Attach protection tape all the way along the edges INSTALLATION SERVICE POINT
of the double-sided tape which is still adhering to >>A<< FRONT FENDER, FRONT AND
the body. REAR DOOR MOULDINGS
INSTALLATION
Double-sided tape

Adhesive tape

AC000421 AB
Backing paper
2. Use a resin spatula to scrape off the double-sided AC313344 AB
tape.
1. Tear off the double-sided tape backing paper.
3. Peel off the protection tape.
NOTE: If attach the adhesive tape to the edge of
4. Wipe the body surface and clean it with a rag
the backing paper, it will be easy to tear off.
moistened with isopropyl alcohol.
2. Install the clips to the front and rear door
mouldings before installing them to the vehicle
<Remove double-sided tape remaining on door body.
moulding and adhere double-sided tape (when
3. Install the door mouldings.
re-using door moulding)>
NOTE: . If the double-sided tape is difficult to affix
in cold temperature, etc., warm the bonding
surfaces of the body and door mouldings to about
40− 60°C before affixing the tape.
4. Firmly press in the door mouldings onto the
respective body surfaces.
 EXTERIOR
SIDE AIR DAM
51-15
SIDE AIR DAM
ADHESIVE
M1511000500437

Item Specification
Side air dam Double-sided tape
4 mm width and 1.2 mm thickness

SIDE AIR DAM

REMOVAL AND INSTALLATION
M1511005500238

A
Section A – A

Clip
A

Clip

1
1

Adhesive tape position

Double-sided tape:
Generic products [ 4 mm width and 1.2 mm thickness ]

AC303877 AD

Removal step
<<A>> >>A<< 1. Side air dam
51-16 EXTERIOR
SIDE AIR DAM

REMOVAL SERVICE POINTS

<<A>> SIDE AIR DAM REMOVAL
Gently lift and remove the side air dam. If there is
any double-sided tape remaining on the side air dam,
remove according to the following instructions.
<Remove double-sided tape remaining on the body
surface>

AC304145

Double-sided tape 1. Scrape off the double-sided tape on the side air
dam with a resin spatula as possible.
2. Wipe the side sill garnish surface and clean it with
a rag moistened with isopropyl alcohol.
Protection tape 3. Remove only a small portion of the residual
adhesive.
AC304143 AB
4. Adhere the double-sided tape as specified on the
1. Attach protection tape all the way along the edges side air dam.
of the double-sided tape which is still adhering to
the body. INSTALLATION SERVICE POINT
>>A<< SIDE AIR DAM INSTALLATION.
Double-sided tape
Backing paper

AC304144 AB Adhesive tape

2. Scrape off the double-sided tape with a resin AC304146 AB

spatula as possible.
1. Tear off the double-sided tape backing paper.
3. Peel off the protection tape.
NOTE: If you attach the adhesive tape to the edge
4. Wipe the body surface and clean it with a rag
of the backing paper, it will be easy to tear off.
moistened with isopropyl alcohol.
2. Install the side air dam.
<Remove double-sided tape remaining on the side NOTE: If the double-sided tape is difficult to affix
air dam and adhere double-sided tape(when re-using in cold temperature, etc., warm the bonding
side air dam)> surfaces of the body and side air dam to about 40
− 60°C before affixing the tape.
3. Firmly press in the side air dam.
 EXTERIOR
GARNISHES
51-17
GARNISHES
REMOVAL AND INSTALLATION
M1511004100107

Section A – A

Delta outer
garnish

Clip
A

Delta outer garnish

AC303863 AB

<Sedan> Section A – A

Trunk lid panel

Licence plate
garnish

Clip

Licence plate garnish

AC303860 AB
51-18 EXTERIOR
REAR SPOILER

REAR SPOILER
REMOVAL AND INSTALLATION
M1511006100136

3
2

1
4

1
AC303713 AB

Removal steps Removal steps (Continued)

• Trunk lid bumper (Refer to GROUP 2. Gasket
42, Trunk lid P.42-43.) 3. Rear spoiler
1. Cap <<A>> 4. High-mounted stop lamp

REMOVAL SERVICE POINT CAUTION

<<A>> HIGH-MOUNTED STOP LAMP Ensure that the string is tightly tied.
REMOVAL String
Use the following steps to easily route high-mounted
stop lamp harness in the event of installation:
Connector

AC303708 AB

1. Tie string on high-mounted stop lamp harness (at

connector side).
2. Carefully pull out high-mounted stop lamp.
 EXTERIOR
TAILGATE SPOILER
51-19
TAILGATE SPOILER
REMOVAL AND INSTALLATION
M1511019900068

3
1

5.2 ± 1.0 N·m

AC303721 AB

Tailgate spoiler removal steps Tailgate spoiler removal steps

• Tailgate trim upper (Refer to GROUP • Rear washer hose connection
52A, Tailgate trim P.52A-19.) 1. Tailgate spoiler assembly
• High-mounted stoplight connector 2. High-mounted stoplight assembly
connection 3. Tailgate spoiler
51-20 EXTERIOR
ROOF RAIL

ROOF RAIL
REMOVAL AND INSTALLATION
M1511016600187

E F
3
F
E

1 C
4
C
B
A B
D
A
D
2

AC303725 AB

Section A – A Section B – B Section C – C

Claw
1 1
Claw 1
4 Claw

Claw Claw
4
4

Section D – D Section E – E Section F – F

Claw
4 3
Claw
3
Claw
Claw

Claw 4
Claw
2 4
AC303828 AB

Removal steps Removal steps (Continued)

1. Front roof rail cover 3. Rear roof rail cover
2. Centre roof rail cover 4. Roof rail
 EXTERIOR
WINDSHIELD WIPER AND WASHER
51-21
WINDSHIELD WIPER AND WASHER
GENERAL INFORMATION Windshield Mist Wiper Operation
M1511000100514
• If the windshield mist wiper switch is turned to the
WINDSHIELD WIPER AND WASHER ON position with the ignition switch at the "ACC"
OPERATION or "ON" position, the mist wiper high-speed
Windshield Low-speed (and High-speed) operation signal is sent to the front-ECU. This
signal turns on the wiper speed control relay,
Wiper Operation causing the wipers to work at high-speed while
• If the windshield low-speed wiper switch is turned the mist switch is on.
to the ON position with the ignition switch at the • While the windshield mist wiper switch remains
"ACC" or "ON" position, the column switch sends turned on when the intermittent mode is still
a low-speed wiper ON and high-speed wiper OFF working, the wipers work as the mist wiper.
signals to the front-ECU. This turns the wiper However, the wipers return to the intermittent
signal on and the wiper speed control relay off mode again when the switch is changed back to
(low-speed), causing the wipers to operate at "INT" position.
low-speed. • To prevent the windshield mist wiper from
• If the windshield high-speed wiper switch is operating when the windshield wiper switch is
turned to the ON position, the column switch turned OFF, the windshield mist wiper does not
sends a low-speed wiper OFF and high-speed work for 0.5 second after the windshield
wiper ON signals to the front-ECU. This turns intermittent wiper switch, the windshield
both the wiper signal and the wiper speed control low-speed wiper switch and the windshield
relay on (high-speed), causing the wipers to high-speed wiper switch are turned OFF.
operate at high-speed.
NOTE: The windshield wiper speed is switchable Windshield Washer Operation
with the built-in wiper speed control relay. • If the windshield washer switch is turned to ON
High-speed operations take place when the wiper position with the ignition switch at "ACC" or "ON"
speed control relay is set to "ON" and low-speed position, the windshield washer ON signal is sent
operations take place when the wiper speed control to the front-ECU. After 0.3 second, the windshield
relay is set to "OFF". wiper signal turns on. After the windshield washer
switch signal turns off, the windshield wiper signal
Windshield Intermittent Wiper Operation turns off in three seconds.
The ETACS-ECU calculates the wiper operation • If the windshield washer switch is turned on while
interval according to the voltage signal sent from the the windshield wiper is at intermittent mode,
column switch. Then the ETACS-ECU sends a signal when the windshield washer switch is turned OFF
to the front-ECU. The front-ECU determines the within 0.2 second, the wiper works only once to
wiper operation interval and turns on the wiper relay perform mist operation by the windshield washer
signal relay. This causes the wiper auto stop relay to switch. When the ON condition of the windshield
turn on. Then the wiper auto stop relay will turn off washer switch continues more than 0.2 second,
after the wipers reach the park position. This causes the wiper performs the same movement as
the wiper signal relay and then the wipers to turn off. normal condition from the time when 0.2 second
If the wiper signal relay remains off for the wiper has elapsed and then returns to the intermittent
operation interval, the relay turns on again, causing motion.
the wipers to operate in intermittent mode.
51-22 EXTERIOR
WINDSHIELD WIPER AND WASHER

SERVICE SPECIFICATION
M1511000300325

Item Standard value

Windshield wiper blade park position mm 34 ± 5

TROUBLESHOOTING ON-VEHICLE SERVICE

M1511000700323 M1511000800461
The windshield wiper and washer are controlled by WINDSHIELD INTERMITTENT WIPER
the Smart Wiring System (SWS). For INSPECTION
troubleshooting, refer to GROUP 54B,
1. If the windshield intermittent wiper interval
Troubleshooting P.54B-17 or GROUP 54C,
adjusting knob is operated, the wiper interval
Troubleshooting P.54C-4.
should change.
NOTE: Even when the ETACS-ECU has failed, the
2. Holding the windshield intermittent wiper interval
windshield wiper can work at low speed as fail-safe
adjusting knob, input the simulated vehicle speed
mode. (Normally, the windshield wiper operates
with MUT-II MB991502 and check that the wiper
when the ignition switch is at the "ACC" position. But,
interval changes as the vehicle speed changes.
if it enters the fail-safe mode, the wiper can operate
only when the ignition switch is at the "ON" position.) 3. If not, carry out the troubleshooting (Refer to
GROUP 54B, Troubleshooting P.54B-17 or
GROUP 54C, Troubleshooting P.54C-4).
 EXTERIOR
WINDSHIELD WIPER AND WASHER
51-23
WINDSHIELD WIPER AND WASHER
REMOVAL AND INSTALLATION
M1511007600350

View A Section A – A
6 7
B 6, 7

A B

A
Clip A
Y0616AU Y0597AU

Note Section B – B
: Clip A positions 1
: Clip B positions
2 6, 7

5 3
Clip B
Y0599AU

A 1
2

4
6 27 ± 3 N·m
8

8.9 ± 1.9 N·m

7
7.4 ± 1.4 N·m

9
11

10

14
11
13
11 ± 2 N·m

11 ± 2 N·m
12
AC304408 AB
51-24 EXTERIOR
WINDSHIELD WIPER AND WASHER

Wiper blade assembly removal steps Windshield washer nozzle removal

>>B<< 1. Wiper blade assembly steps
>>A<< 2. Wiper blade • Connection of front washer hose
Windshield wiper motor and link 11. Washer nozzle
assembly removal steps Washer tank and washer motor
3. Cover removal steps
4. Wiper arm • Side undercover (RH)
5. Hood weather strip • Front splash shield (Refer to GROUP
6. Front deck garnish (passenger's side) 42, Fender P.42-6)
7. Front deck garnish (driver's side) • Connection of front washer hose and
<<A>> 8. Windshield wiper motor assembly rear washer hose
9. Link assembly 12. Washer tank assembly
Washer hose removal steps 13. Front washer motor
• Front splash shield (Refer to GROUP 14. Rear washer motor <Wagon>
42, Fender P.42-6) NOTE: For removal and installation of the wiper and
10. Rear washer hose <Wagon> washer switch, refer to GROUP 54A, Column switch
11. Front washer hose
P.54A-87.

REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS

<<A>> WINDSHIELD WIPER MOTOR >>A<< WIPER BLADE INSTALLATION
ASSEMBLY REMOVAL Backing Section A – A
Wiper blade
Windshield wiper
motor assembly Wiper
blade Backing

A
Link assembly
connection
Backing AC101090AD
Flat-tipped screwdriver
AC304411 AB
CAUTION
1. Remove the windshield wiper motor assembly The driver's side wiper blade is not warped.
mounting bolt. When installing the passenger's wiper blade, check
CAUTION that the backing inside the wiper blade is warped
Be careful not to damage the windshield glass toward the wiper arm.
when the windshield wiper motor assembly is
>>B<< WIPER BLADE ASSEMBLY
removed.
2. Use the fiat-tipped screwdriver to disengage the INSTALLATION
link between the windshield wiper motor assembly
and the link assembly to remove the windshield
wiper motor assembly.

A A

Front deck garnish terminal

AC000427AD

Install the wiper blade at the specified position

(standard value).
Standard value (A): 34 ± 5 mm
 EXTERIOR
WINDSHIELD WIPER AND WASHER
51-25
INSPECTION Wiper Motor at Stop Position Operation
M1511007700313
1. Connect the battery to the windshield wiper motor
FRONT WIPER MOTOR CHECK to rotate the motor in a low speed as shown in the
illustration (A) and disconnect the battery during
rotation to stop the motor.
2. Connect between the terminals and the battery as
shown in the illustration (B) and confirm whether
the motor stops at the automatic stop position
after rotating in a low speed.
1 2 3
4 5
FRONT WASHER MOTOR CHECK

Check operation
1
2
1 2 3 1 2 3
4 5 4 5

Low speed High speed

Stop position check

1 2 3 1 2 3
AC005891
4 5 4 5
1. Remove the washer tank assembly with the
(A) Low speed (B) Automatical stop AC305201 AB washer hose attached. Then fill the washer tank
Inspect the windshield wiper motor by removing the with water.
harness connector with the motor attached to the 2. Check to see that the water is vigorously spray is
vehicle. when connecting the positive battery terminal to
terminal number 2 and terminal number 1 to the
Wiper Motor at Low-Speed and negative battery terminal.
High-Speed Operation
Connect the battery to the windshield wiper motor to
inspect the operation of motor rotation in low or high
speed.
51-26 EXTERIOR
WINDSHIELD WIPER AND WASHER

WINDSHIELD WASHER FLUID EJECTION

CHECK
Move the nozzle to adjust the position so that the
spray is in area shown in the area shown in the
illustration.
UNITS: mm

120 115 100 140

25 25
25 25
<Right> <Left>
65 70
60 60
55 55
50 50

25 305 25 25 305
25
300 300

Ceramic line terminal

Windshield washer 600 Windshield washer

nozzle perpendicular nozzle perpendicular

Windshield washer nozzle

AC304420 AB

WINDSHIELD WIPER AND WINDSHIELD Switch position Tester Specified

WASHER SWITCH CHECK connection condition
OFF 6 − 11, 6 − 10, Open circuit
1 6 − 9, 6 − 8, 6
2
3 −7
4
5
6
7
8
9
10
11
AC000417

Check continuity between the switch terminals.

 EXTERIOR
WINDSHIELD WIPER AND WASHER
51-27
Switch position Tester Specified WINDSHIELD INTERMITTENT WIPER
connection condition VOLUME CHECK
Windshield mist 6 − 11 Less than 2
wiper switch ohms
Windshield 6 − 10
intermittent wiper
switch
Windshield 6−9
low-speed wiper
switch
Windshield 6−8 1
high-speed wiper 2
3
switch 4
Windshield 6−7 5
washer switch 6
7
8
9
10
11

AC201004

Check that the resistance varies between 0 and 1

kiloohm when the windshield intermittent volume is
turned from FAST to SLOW by after measuring
resistance between connector terminals 3 and 6 at
the column switch.
51-28 EXTERIOR
REAR WIPER AND WASHER

REAR WIPER AND WASHER

GENERAL INFORMATION inhibitor switch "R" turns ON. One second later,
M1511000100525 the ETACS-ECU turns ON the rear wiper drive
REAR WIPER AND WASHER OPERATION signal for three seconds (approximately two
Rear Wiper Operation cycles). Then, 7.4 seconds later, the intermittent
motion of eight seconds' cycle is restored.
• If the rear wiper and washer switch is turned to
"INT" position with the ignition switch at "ACC" or Rear Washer Operation
"ON" position, the ETACS-ECU turns ON the rear
• If the rear wiper and washer switch is turned to
wiper drive signal for three seconds
the ON (washer) position with the ignition switch
(approximately two cycles), then 7.4 seconds
at the "ACC" or "ON" position, the rear washer
later the intermittent motion operates every eight
ON signal is sent to the ETACS-ECU, causing the
seconds. If the selector lever is moved to the "R"
rear wiper signal to turn on after 0.3 second. After
position when the rear wiper and washer switch is
the rear washer switch signal turns off, the rear
turned to the "INT" position and the ignition
wiper signal turns off in three seconds. If the rear
switch is at the "ACC" or "ON" position, the
washer switch is turned to the ON position while
the rear wiper is in intermittent mode, the rear
washer works for that period when the washer
switch remains on. Then the rear wipers return to
the intermittent mode.

SERVICE SPECIFICATION
M1511000300336

Item Standard value

Rear wiper blade park position mm 42 ± 5

TROUBLESHOOTING ON-VEHICLE SERVICE

M1511000700334 M1511000800472
The rear wiper and washer are controlled by the CHECK OF REAR WIPER OPERATION
Smart Wiring System (SWS). For troubleshooting, WHEN SELECTOR LEVER IS AT THE "R"
refer to GROUP 54B, Troubleshooting P.54B-17 or
GROUP 54C, Troubleshooting P.54C-4.
POSITION
1. When the selector lever is moved to the "R"
position with the rear wiper switch at the "INT"
position, the wiper should operate twice or three
times at low speed after approximately one
second.
2. If not, carry out the troubleshooting (Refer to
GROUP 54B, Troubleshooting P.54B-17 or
GROUP 54C, Troubleshooting P.54C-4).
 EXTERIOR
REAR WIPER AND WASHER
51-29
REAR WIPER AND WASHER
REMOVAL AND INSTALLATION
M1511008500345

2.5 ± 0.4 N·m

9.8 ± 2.0 N·m

2 1
7.4 ± 1.4 N·m AC304515 AB

Wiper blade assembly removal steps Washer hose removal steps

>>A<< 1. Wiper arm and blade assembly • Front scuff plate, rear scuff plate, cowl
>>B<< 2. Wiper blade side trim and quarter trim (Refer to
Rear wiper motor removal steps GROUP 52A, Trims P.52A-11.)
• Tailgate trim lower (Refer to GROUP • Tailgate lower trim, tailgate proof film
52A, Tailgate trim P.52A-19.) (Refer to GROUP 52A, Tailgate trim
• Tailgate waterproof film (Refer to P.52A-19.)
GROUP 42, Tailgate P.42-48.) • High-mounted stop lamp assembly
3. Rear wiper motor assembly (Refer to GROUP 54A, High-mounted
Rear washer nozzle removal steps stop lamp P.54A-81.)
• High-mounted stop lamp assembly 5. Rear washer hose
(Refer to GROUP 54A, High-mounted NOTE: For removal and installation of the wiper and
stop lamp P.54A-81.) washer switch, refer to GROUP 54A, Column switch
4. Rear washer nozzle
P.54A-87.
51-30 EXTERIOR
REAR WIPER AND WASHER

INSTALLATION SERVICE POINTS INSPECTION

M1511008600193
>>A<< REAR WIPER ARM AND BLADE REAR WIPER MOTOR CHECK
ASSEMBLY INSTALLATION

End of tailgate glass

1 2 3 4
A
AC304536 AC (A) Operation check
Before installing the rear wiper arm and blade
assembly, operate the rear wiper motor so that the 1 2 3 4
motor stops at the predetermined park position.
Install the rear wipe arm and blade assembly and
adjust the rear wiper blade position so that the blade (B) Stop position check
end stops at the predetermined position (standard
position). 1 2 3 4
Standard value (A): 42 ± 5 mm

AB304538 AB
>>B<< WIPER BLADE INSTALLATION
Inspect the rear wiper motor is conducted by
CAUTION removing the harness connector with the motor
Backing Section A – A attached to the vehicle.
Wiper blade Wiper Motor Operation
Wiper
Backing
Connect the battery to the rear wiper motor as shown
blade
in the illustration (A) and check the motor operation.
A Wiper Motor at Stop Position Operation
A 1. Connect the battery to the rear wiper motor as
shown in the illustration (A).
Backing AC101090AD
2. Disconnect the battery cable from the rear
windshield wiper motor while it is turning and then
Use a curved backing like that shown for the check to see that the motor stops.
backing of a wiper blade to ensure sustained
3. Re-connect the battery as shown in Figure (B).
wiper wiping performance.
4. Check to see that the rear windshield wiper motor
runs and then stops at the automatic stop
position.
 EXTERIOR
REAR WIPER AND WASHER
51-31
REAR WASHER MOTOR CHECK For the vertical aiming of washer nozzle, insert the
flat-tipped screwdriver into the nozzle and move it to
the arrow direction.
1
REAR WIPER AND WASHER SWITCH
2
CHECK

1
2
3
4
AC005900 5
6
1. Remove the rear washer tank assembly with the 7
washer hose attached. Then fill the washer tank 8
with water. 9
10
2. Check to see that the water is vigorously sprayed 11
when connecting the positive battery terminal to AC000417

terminal number 2 and terminal number 1 to the Check continuity between the switch terminals.
negative battery terminal. Switch position Tester Specified
connection condition
REAR WASHER FLUID EJECTION CHECK
OFF 4 − 6, 5 − 6 Open circuit
CAUTION
Rear wiper switch 4 − 6 Less than 2
Take care not to damage the nozzle when
Rear washer 5−6 ohms
inserting the flat-tipped screwdriver into it.
switch
A
High-mounted Rear washer nozzle
stop lamp
Section A – A

Flat-tipped screwdriver
UNITS: mm
Windshield ceramic
line terminal 6

125

57 84
Windshield washer
nozzle perpendicular

AC304544 AB
51-32 EXTERIOR
HEADLAMP WASHER

HEADLAMP WASHER
TROUBLESHOOTING
M1511000700356
The headlamp washer is controlled by the Smart
Wiring System (SWS). For troubleshooting, refer to
GROUP 54B, Troubleshooting P.54B-17 or GROUP
54C, Troubleshooting P.54C-4.

HEADLAMP WASHER
REMOVAL AND INSTALLATION
M1511009700063

2
8
5 6

N 10 7
1

4.9 ± 0.7 N·m

9
11

4.9 ± 0.7 N·m

N 10 9
AC304608 AB

Removal steps Removal steps (Continued)

• Washer fluid draining 4. Headlamp washer motor
1. Headlamp washer hose connection connection
2. Under cover side panel (R.H) 5. Headlamp washer joint
3. Splash shield mounting clip (R.H) 6. Headlamp washer hose
 EXTERIOR
HEADLAMP WASHER
51-33
Removal steps (Continued)
7. Headlamp washer motor
8. Headlamp washer gasket
• Front bumper (Refer to P.51-2).
9. Headlamp washer actuator
assembly
10. O-ring
11. Headlamp washer hose assembly

INSPECTION 1. Remove the headlamp washer motor connector.

M1511009800082
2. Check to see that the water is vigorously sprayed
HEADLAMP WASHER MOTOR CHECK when connecting the positive battery terminal to
terminal number 1 and terminal number 2 to the
negative battery terminal.

1 2

AC304136 AB
51-34 EXTERIOR
MARK

MARK
REMOVAL AND INSTALLATION
M1511011800971

AC304202

<Sedan>

1 2

<Wagon>

1
2

AC400380 AB

Removal Removal (Continued)

>>A<< 1. Front three-diamond mark >>A<< 2. Rear three-diamond mark
>>A<< 3. Lancer mark

INSTALLATION SERVICE POINT

>>A<< MARK APPLICATION
1. Installation position
Attach each mark to the position shown in the
illustration.
 EXTERIOR
MARK
51-35

2. Three-diamond mark
<Sedan> <Wagon>

53 ± 1 mm 112 mm
Press line
Trunk lid
press line

Centre line Centre line

of vehicle of vehicle
AC304163 AC

3. Lancer mark
<Sedan>

Rear combination 19 ± 1 mm
lamp terminal 45 ± 1 mm

13 ± 1 mm

Trunk lid terminal

<Wagon>

33 mm

Tailgate terminal

24 mm

AC304164 AB

2. Installation procedure CAUTION

(1) Use 3M ATD Part number 8906 or equivalent When attaching the marks, the ambient
to clean the mark installation surfaces on the temperature should be 20 − 38°C and the air
body. should be completely free of dust. If the ambient
temperature is lower than 20°C, the marks and
the places on the vehicle body where the marks
are to be attached should be heated to 20 − 38°C.
(2) Peel off the protection sheet on the back of the
marks to paste it on the installation position.
51-36 EXTERIOR
DOOR MIRROR

DOOR MIRROR
GENERAL INFORMATION Heated Door Mirror operation
M1511000100536 • The defogger relay switch is activated (ON) by
DOOR MIRROR OPERATION turning on the A/C-ECU built-in defogger switch
when the ignition switch is in the "ON" position.
Remote Controlled Mirror Operation
When the defogger relay is turned ON, power is
• The mirror on the door mirror moves up/down
supplied to the defogger and door mirror, and the
and left/right by operating the remote controlled
heater of the door mirror (heated door mirror)
door mirror switch when the ignition switch is in
starts operations. The defogger comes with a
the "ON" or "ACC" position.
timer function and will automatically turn OFF the
switch approximately 11 minutes after the
defogger switch is turned ON. The heated door
mirror operations are also terminated along with
the defogger, at this time.

SERVICE SPECIFICATION
M1511000300347

Item Standard value

Heated door mirror operation current Ω 5.9 − 7.8

SPECIAL TOOL
M1511000601103

Tool Number Name Application

MB990784 Ornament remover Removal of remote controlled
mirror switch

MB990784

TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1511014600169
Refer to GROUP 00 − How to Use
Troubleshooting/Inspection Service Points P.00-5.

TROUBLE SYMPTOM CHART

M1511015000160

Symptom Inspection Reference

procedure page
All heated door mirrors do not operate 1 P.51-37
The right or left heated door mirror does not operate 2 P.51-39
 EXTERIOR
DOOR MIRROR
51-37
SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: All Heated Door Mirrors do not Operate

REAR WINDOW
DEFOGGER RELAY

REAR WINDOW
DEFOGGER

REMOTE REMOTE
CONTROLLED CONTROLLED
MIRROR (RH) MIRROR MIRROR MIRROR (LH)
HEATER HEATER

NOTE
LH drive vehicles
RH drive vehicles

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
51-38 EXTERIOR
DOOR MIRROR

COMMENTS ON TROUBLE SYMPTOM STEP 2. Connector check: C-212 junction block

The heated door mirrors should works for connector
approximately 11 minutes when the rear defogger
Connector: C-212
switch is turned on. If the mirror heater does not work Junction block (Front view)
for the specified period, the defogger relay circuit
(heated door mirror power supply circuit) may be
defective.

Possible causes
Harness side
• Damaged harness wires and connectors
14 13 12 11 10 9 8 7 6 5 4 3 2 1

DIAGNOSIS PROCEDURE
28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC304913 AB

STEP 1. Check the rear window defogger. Q: Is the check result normal?
Check that the rear window defogger system should YES : Intermittent malfunction (Refer to GROUP
work normally. 00 − How to Cope with Intermittent
Malfunction P.00-5).
Q: Is the check result normal? NO : Repair the defective connector.
YES : Go to Step 2.
NO : Troubleshoot the rear window defogger
(Refer to GROUP 55,
TroubleshootingP.55-42).
 EXTERIOR
DOOR MIRROR
51-39

INSPECTION PROCEDURE 2: Right or Left Heated Door Mirror does not Operate

REAR WINDOW
DEFOGGER RELAY

REAR WINDOW
DEFOGGER

REMOTE REMOTE
CONTROLLED CONTROLLED
MIRROR (RH) MIRROR MIRROR MIRROR (LH)
HEATER HEATER

NOTE
LH drive vehicles
RH drive vehicles

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
51-40 EXTERIOR
DOOR MIRROR

COMMENTS ON TROUBLE SYMPTOM Step 3. Check the door mirror assembly (RH).
If either of the heated door mirrors does not work, the Check that the heater element of the door mirror
door mirror assembly may be defective. assembly (RH) is in good condition (Refer to
P.51-47).
Possible causes
• Malfunction of the door mirror assembly Q: Is the check result normal?
• Damaged harness wires and connectors YES : Go to Step 4.
NO : Replace the door mirror assembly (RH).
DIAGNOSIS PROCEDURE
Step 4. Resistance measurement at the E-11 door
mirror assembly (RH) connector.
Step 1. Verify the operation of each heated door
mirror. Connector: E-11

Q: Which door mirror does not heat?

Door mirror (RH) : Go to Step 2.
Door mirror (LH) : Go to Step 9.

Step 2. Connector check: E-11 door mirror Harness side

assembly (RH) connector
Connector: E-11
AC304817 AB

(1) Disconnect the connector, and measure at the

wiring harness side.

Harness side
Connector E-11
(harness side)

AC304817 AB

Q: Is the check result normal?

YES : Go to Step 3.
NO : Repair the defective connector.
AC304821 AB

(2) Resistance between E-11 door mirror assembly

connector terminal No.4 and body earth
OK: 2 Ω or less
Q: Is the check result normal?
YES : Go to Step 6.
NO : Go to Step 5.
 EXTERIOR
DOOR MIRROR
51-41

Step 5. Check the wiring harness between E-11 Step 6. Voltage measurement at the E-11 door
door mirror assembly (RH) connector terminal mirror assembly (RH) connector.
No.4 and body earth. (1) Turn the ignition switch to the ON position.
Connector: E-11
(2) Rear window defogger switch: ON
Connector: E-11

Harness side
Harness side

AC304817 AB

• Check the earth wires for open circuit. AC304817 AB

NOTE: (3) Disconnect the connector, and measure at the

Connector: C-112 wiring harness side.

Connector E-11
(harness side)
AC304819 AB

Prior to the wiring harness inspection, check AC304826 AB

intermediate connector C-112 <LHD>, C-30 <RHD> (4) Voltage between E-11 door mirror assembly
and repair if necessary.
connector terminal No.1 and body earth
Q: Is the check result normal? OK: System voltage
YES : Intermittent malfunction (Refer to GROUP
00 − How to Cope with Intermittent Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
Malfunction P.00-5).
NO : Repair the wiring harness.
00 − How to Cope with Intermittent
Malfunction P.00-5).
NO : Go to Step 7.
51-42 EXTERIOR
DOOR MIRROR

NOTE:
Step 7. Connector check: C-212 junction block
Connector: C-112
connector
Connector: C-212
Junction block (Front view)

Harness side
14 13 12 11 10 9 8 7 6 5 4 3 2 1
AC304819 AB
28 27 26 25 24 23 22 21 20 19 18 17 16 15
Prior to the wiring harness inspection, check
AC304913 AB intermediate connector C-112 <LHD>, C-30 <RHD>
and repair if necessary.
Q: Is the check result normal?
YES : Go to Step 8. Q: Is the check result normal?
NO : Repair the defective connector. YES : Intermittent malfunction (Refer to GROUP
00 − How to Cope with Intermittent
Malfunction P.00-5).
Step 8. Check the wiring harness between E-11 NO : Repair the wiring harness.
door mirror assembly (RH) connector terminal
No.1 and C-212 junction block connector
terminal No.3. Step 9. Connector check: E-02 door mirror
assembly (LH) connector
Connector: E-11
Connector: E-02

Harness side
Harness side

AC304817 AB
AC304818 AB
Connector: C-212
Junction block (Front view) Q: Is the check result normal?
YES : Go to Step 10.
NO : Repair the defective connector.

Step 10. Check the door mirror assembly (LH).

Harness side Check that the heater element of the door mirror
14 13 12 11 10 9 8 7 6 5 4 3 2 1 assembly (LH) is in good condition (Refer to
P.51-47).
28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC304913 AB
Q: Is the check result normal?
• Check the power supply line for open circuit. YES : . Go to Step 11.
NO : . Replace the door mirror assembly (LH).
 EXTERIOR
DOOR MIRROR
51-43

Step 11. Resistance measurement at the E-02 Step 12. Check the wiring harness between E-02
door mirror assembly (LH) connector. door mirror assembly (LH) connector terminal
Connector: E-02
No.4 and body earth.
Connector: E-02

Harness side
Harness side

AC304818 AB
AC304818 AB
(1) Disconnect the connector, and measure at the
wiring harness side. • Check the earth wires for open circuit.
NOTE:
Connector: C-29

Connector E-02
(harness side)

AC304827 AB
AC304820 AB
(2) Resistance between E-02 door mirror assembly
connector terminal No.4 and body earth Prior to the wiring harness inspection, check
intermediate connector C-29 <LHD>, C-113 <RHD>
OK: 2 Ω or less
and repair if necessary.
Q: Is the check result normal?
YES : . Go to Step 14. Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
NO : . Go to Step 12.
00 − How to Cope with Intermittent
Malfunction P.00-5).
NO : Repair the wiring harness.

Step 13. Connector check: C-212 junction block

connector
Connector: C-212
Junction block (Front view)

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

28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC304913 AB

Q: Is the check result normal?

YES : Go to Step 14.
NO : Repair the defective connector.
51-44 EXTERIOR
DOOR MIRROR

Step 14. Measure the voltage at the E-02 door Step 15. Check the wiring harness between E-02
mirror assembly (LH) connector. door mirror assembly (LH) connector terminal
(1) Turn the ignition switch to the ON position. No.1 and C-212 junction block connector
(2) Rear window defogger switch: ON terminal No.3.
Connector: E-02 Connector: E-02

Harness side Harness side

AC304818 AB AC304818 AB

(3) Disconnect the connector, and measure at the Connector: C-212

wiring harness side. Junction block (Front view)

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

28 27 26 25 24 23 22 21 20 19 18 17 16 15
Connector E-02
(harness side) AC304913 AB

AC304828 AB
• Check the power supply line for open circuit.
NOTE:
(4) Voltage between E-02 door mirror assembly Connector: C-29
connector terminal No.1 and body earth
OK: System voltage
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Cope with Intermittent
Malfunction P.00-5).
NO : Go to Step 15.

AC304820 AB

Prior to the wiring harness inspection, check

intermediate connector C-29 <LHD>, C-113 <RHD>
and repair if necessary.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Cope with Intermittent
Malfunction P.00-5).
NO : Repair the wiring harness.
 EXTERIOR
DOOR MIRROR
51-45
DOOR MIRROR
REMOVAL AND INSTALLATION
M1511006400308

8
5 4
7
6

Section A – A
Claw 1
3

2
A
Note A
: Claw positions 1
AC304733 AB

Door mirror removal steps Remote controlled mirror switch

1. Cover removal steps
2. Delta inner cover 7. Instrument panel ornament (Refer to
3. Harness connector <Vehicles with GROUP 52A, Instrument panel
remote controlled mirror> P.52A-2.)
4. Door mirror assembly 8. Remote controlled mirror switch
5. Door mirror body assembly
<<A>> >>A<< 6. Mirror
51-46 EXTERIOR
DOOR MIRROR

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> MIRROR REMOVAL >>A<< MIRROR INSTALLATION
Section A – A Section A – A
Flat-tipped Mirror Flat-tipped
screwdriver Mirror
screwdriver

Pivot plate Pivot plate

A A A A
A A A A

Protective
tape

Notch

00007256 00007258
AC000441 AE AC000442 AB

Push the top of the mirror with your hand to tilt it and While supporting the clip position on the underside of
attach the protective tape as shown in the illustration. the pivot plate with a flat-tipped screwdriver, press
Then insert a flat-tipped screwdriver in between the the clip at the front of the mirror to engage the bottom
notch at the rear of the mirror and the pivot plate, and of the mirror.
disengage the bottom of the mirror.
 EXTERIOR
DOOR MIRROR
51-47
INSPECTION ELECTRIC REMOTE CONTROL MIRROR
M1511006500286
OPERATION CHECK <VEHICLES WITH
ELECTRIC REMOTE CONTROL MIRROR
HEATED DOOR MIRROR>
OPERATION CHECK <VEHICLES
WITHOUT HEATED DOOR MIRROR>

1 2 3
4 5 6 7
1 2 3
AC202548

Check that the mirror moves as described in the

AC005969
table when each terminal is connected to the battery.
Check that the mirror moves as described in the
Battery connection Direction
table when each terminal is connected to the battery.
operation
Battery connection Direction
• Connect terminal 5 to the negative Mirror
operation
battery terminal. glass
• Connect terminal 1 to the negative Mirror • Connect terminal 7 to the positive should face
battery terminal. glass battery terminal. upward
• Connect terminal 3 to the positive should face
• Connect terminal 7 to the negative Mirror
battery terminal. upward
battery terminal. glass
• Connect terminal 3 to the negative Mirror • Connect terminal 5 to the positive should face
battery terminal. glass battery terminal. downward
• Connect terminal 1 to the positive should face
• Connect terminal 5 to the negative Mirror
battery terminal. downward
battery terminal. glass
• Connect terminal 1 to the negative Mirror • Connect terminal 6 to the positive should face
battery terminal. glass battery terminal. to the right
• Connect terminal 2 to the positive should face
• Connect terminal 6 to the negative Mirror
battery terminal. to the right
battery terminal. glass
• Connect terminal 2 to the negative Mirror • Connect terminal 5 to the positive should face
battery terminal. glass battery terminal. to the left
• Connect terminal 1 to the positive should face
battery terminal. to the left
51-48 EXTERIOR
DOOR MIRROR

DOOR MIRROR CONTROL SWITCH HEATED DOOR MIRROR CHECK

CONTINUITY CHECK CAUTION
When relocating the car between locations with
extremely different temperatures (warm and
cold), leave the car in the location for a while to
adapt to the temperature prior to checking it.
1 2 3 4
5 6 7 8 9 10 11

AC005970

Switch position Tester Specified 1 2 3

connection condition 4 5 6 7

OFF 9 − 2, 9 − 3, 9 − 6, Open circuit AC202548

9 − 10, 9 − 11, The resistance value between door mirror connector
1 − 2, 1 − 3, 1 − 6, terminals 1 and 4 should meet the standard value
1 − 10, 1 − 11 with the ambient temperature at steady 25°C.
Left side OFF 9 − 6, 9 − 10, 9 − Open circuit Standard value: 5.9 − 7.8 Ω
11, 1 − 6, 1 − 10,
1 − 11
Up 1 − 6, 9 − 11 Less than 2
Down 1 − 11, 6 − 9 ohms
Right 1 − 6, 9 − 10
Left 1 − 10, 6 − 9
Right OFF 9 − 2, 9 − 3, 9 − 6, Open circuit
side 1 − 2, 1 − 3, 1 − 6
Up 1 − 6, 3 − 9 Less than 2
Down 1 − 3, 6 − 9 ohms
Right 1 − 6, 2 − 9
Left 1 − 2, 6 − 9
 52-1

GROUP 52

INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM(SRS)
CONTENTS

INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . 52B

NOTES
 54A-1

GROUP 54A

CHASSIS
ELECTRICAL
CONTENTS

BATTERY. . . . . . . . . . . . . . . . . . 54A-4 IMMOBILIZER SYSTEM

TROUBLESHOOTING . . . . . . . . . . 54A-9
DIAGNOSIS CODE CHART. . . . . . . . . . 54A-9
SERVICE SPECIFICATIONS. . . . . 54A-4

DIAGNOSTIC TROUBLE CODE

ON-VEHICLE SERVICE. . . . . . . . . 54A-4
FLUID LEVEL AND SPECIFIC
PROCEDURES . . . . . . . . . . . . . . . . 54A-10
GRAVITY CHECK . . . . . . . . . . . . . . . . . 54A-4
CHARGING . . . . . . . . . . . . . . . . . . . . . . 54A-4 SYMPTOM CHART. . . . . . . . . . . . . 54A-11
BATTERY TEST . . . . . . . . . . . . . . . . . . 54A-5
SYMPTOM PROCEDURES . . . . . . 54A-12
IGNITION SWITCH* . . . . . . . . . . 54A-6
DATA LIST REFERENCE TABLE . 54A-19
GENERAL INFORMATION . . . . . . 54A-6
CHECK IMMOBILIZER-ECU . . . . . 54A-19
SPECIAL TOOLS. . . . . . . . . . . . . . 54A-8
ON-VEHICLE SERVICE . . . . . . . . . 54A-20
TROUBLESHOOTING . . . . . . . . . . 54A-9 HOW TO REGISTER ENCRYPTED
IGNITION KEY REMINDER BUZZER AND CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 54A-20
DOOR LOCK PREVENTION FUNCTION IGNITION SWITCH . . . . . . . . . . . . . . . . 54A-27
TROUBLESHOOTING. . . . . . . . . . . . . . 54A-9 REMOVAL AND INSTALLATION. . . . . . 54A-27
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-28

Continued on next page

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
paassenger (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 FOG LAMP . . . . . . . . . . . . . . . . 54A-71

ASSEMBLY . . . . . . . . . . . . . . . . 54A-29
SERVICE SPECIFICATION . . . . . . 54A-71
SERVICE SPECIFICATIONS. . . . . 54A-29
SPECIAL TOOL . . . . . . . . . . . . . . . 54A-71
SEALANT. . . . . . . . . . . . . . . . . . . . 54A-29
TROUBLESHOOTING . . . . . . . . . . 54A-71
SPECIAL TOOLS. . . . . . . . . . . . . . 54A-29
ON-VEHICLE SERVICE . . . . . . . . . 54A-71
TROUBLESHOOTING . . . . . . . . . . 54A-31 FRONT FOG LAMP AIMING CHECK . . 54A-71
SYMPTOM CHART . . . . . . . . . . . . . . . . 54A-31
FOG LAMP . . . . . . . . . . . . . . . . . . . 54A-73
SYMPTOM PROCEDURES . . . . . . 54A-32 REMOVAL AND INSTALLATION. . . . . . 54A-73

ON-VEHICLE SERVICE. . . . . . . . . 54A-60

FOG LAMP SWITCH . . . . . . . . . . . 54A-74
SPEEDOMETER CHECK . . . . . . . . . . . 54A-60 REMOVAL AND INSTALLATION. . . . . . 54A-74
TACHOMETER CHECK . . . . . . . . . . . . 54A-60 INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-74
FUEL TANK GAUGE UNIT CHECK . . . 54A-61
ENGINE COOLANT TEMPERATURE GAUGE REAR FOG LAMP . . . . . . . . . . 54A-75
UNIT CHECK . . . . . . . . . . . . . . . . . . . . . 54A-61

TROUBLESHOOTING . . . . . . . . . . 54A-75
COMBINATION METER ASSEMBLY 54A-63
REMOVAL AND INSTALLATION . . . . . 54A-63
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-64 SPECIAL TOOL . . . . . . . . . . . . . . . 54A-75
DISASSEMBLY AND REASSEMBLY . . 54A-65
REAR FOG LAMP . . . . . . . . . . . . . 54A-76
HEADLAMP . . . . . . . . . . . . . . . . 54A-66 REMOVAL AND INSTALLATION. . . . . . 54A-76

REAR FOG LAMP SWITCH . . . . . . 54A-76

SERVICE SPECIFICATIONS. . . . . 54A-66
REMOVAL AND INSTALATION. . . . . . . 54A-76
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-76
TROUBLESHOOTING . . . . . . . . . . 54A-66

SIDE TURN-SIGNAL LAMP. . . 54A-77

ON-VEHICLE SERVICE. . . . . . . . . 54A-66
HEADLAMP AIMING . . . . . . . . . . . . . . . 54A-66
LUMINOUS INTENSITY SPECIAL TOOL . . . . . . . . . . . . . . . 54A-77
MEASUREMENT . . . . . . . . . . . . . . . . . . 54A-67
BULB REPLACEMENT . . . . . . . . . . . . . 54A-68 SIDE TURN-SIGNAL LAMP . . . . . . 54A-77
REMOVAL AND INSTALLATION. . . . . . 54A-77
HEADLAMP . . . . . . . . . . . . . . . . . . 54A-69
REMOVAL AND INSTALLATION . . . . . 54A-69
ROOM LAMP . . . . . . . . . . . . . . 54A-78
TROUBLESHOOTING . . . . . . . . . . . . . . 54A-78
HEADLAMP LEVELING SWITCH . 54A-70
REMOVAL AND INSTALLATION . . . . . 54A-70
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-70 Continued on next page
 54A-3

REAR COMBINATION HORN . . . . . . . . . . . . . . . . . . . . 54A-89

LAMP . . . . . . . . . . . . . . . . . . . . . 54A-79 REMOVAL AND INSTALLATION. . . . . . 54A-89
HORN RELAY CONTINUITY CHECK . . 54A-89

TROUBLESHOOTING . . . . . . . . . . 54A-79
CLOCK . . . . . . . . . . . . . . . . . . . 54A-90
SPECIAL TOOL . . . . . . . . . . . . . . . 54A-79
SPECIAL TOOL . . . . . . . . . . . . . . . 54A-90
REAR COMBINATION LAMP . . . . 54A-79
REMOVAL AND INSTALLATION . . . . . 54A-79 CLOCK . . . . . . . . . . . . . . . . . . . . . . 54A-90
REMOVAL AND INSTALLATION. . . . . . 54A-90
HIGH-MOUNTED
STOP LAMP. . . . . . . . . . . . . . . . 54A-80 CIGARETTE LIGHTER . . . . . . 54A-91
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-91

ON-VEHICLE SERVICE. . . . . . . . . 54A-80

HIGH-MOUNTED STOP LAMP BULB RHEOSTAT . . . . . . . . . . . . . . . 54A-91
REPLACEMENT <WITH REAR SHELF> 54A-80 REMOVAL AND INSTALLATION. . . . . . 54A-91
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-92
HIGH-MOUNTED STOP LAMP . . . 54A-81
REMOVAL AND INSTALLATION . . . . . 54A-81 SPEAKER. . . . . . . . . . . . . . . . . 54A-93
REMOVAL AND INSTALLATION. . . . . . 54A-93
LICENCE PLATE LAMP . . . . . . 54A-84
ANTENNA . . . . . . . . . . . . . . . . 54A-94
REMOVAL AND INSTALLATION . 54A-84 REMOVAL AND INSTALLATION. . . . . . 54A-94

HAZARD WARNING LAMP REAR WINDOW

SWITCH . . . . . . . . . . . . . . . . . . . 54A-85 DEFOGGER . . . . . . . . . . . . . . . 54A-95

TROUBLESHOOTING . . . . . . . . . . 54A-85 GENERAL INFORMATION . . . . . . 54A-95

SPECIAL TOOL . . . . . . . . . . . . . . . 54A-85 TROUBLESHOOTING . . . . . . . . . . 54A-95

HAZARD WARNING LAMP SWITCH 54A-86 ON-VEHICLE SERVICE . . . . . . . . . 54A-96

REMOVAL AND INSTALLATION . . . . . 54A-86 PRINTED HEATER LINES CHECK . . . . 54A-96
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-86
REAR WINDOW DEFOGGER
COLUMN SWITCH. . . . . . . . . . . 54A-87 SWITCH . . . . . . . . . . . . . . . . . . . . . 54A-96
REMOVAL AND INSTALLATION. . . . . . 54A-96
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-96
SPECIAL TOOL . . . . . . . . . . . . . . . 54A-87

COLUMN SWITCH. . . . . . . . . . . . . 54A-87

REMOVAL AND INSTALLATION . . . . . 54A-87
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-88
54A-4 CHASSIS ELECTRICAL
BATTERY

BATTERY
SERVICE SPECIFICATIONS
M1541000300209

Items Specification
Specific gravity of the battery fluid 1.220 − 1.290 (20°C)

ON-VEHICLE SERVICE Dt: Actually measured specific gravity

t: Actually measured temperature
FLUID LEVEL AND SPECIFIC GRAVITY
CHECK CHARGING
M1541001100509
M1541001000438

CAUTION CAUTION
• If the battery fluid is below the LOWER • The battery plus should be removed during
LEVEL, the battery could explode in using. charging.
• If the battery fluid is over the UPPER LEVEL, • The battery electrolyte level may rise and
leakage could result. overflow from the battery during charging.
1. Inspect whether or not the battery fluid is between • Explosions may occur if the battery is
the UPPER LEVEL and LOWER LEVEL marks. brought close to naked flames during
charging.
Thermometer Hydrometer
• 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
Battery fluid rinse away any sulphuric acid, and let the
battery stand to dry.
• Charge the battery in a well-ventilated
AC211242AB
location.
• Do not let the battery electrolyte temperature
2. Use a hydrometer and thermometer to check the rise above approximately 45°C (approximately
specific gravity of the battery fluid. 55°C during rapid charging).
Standard value: 1.220 − 1.290 (20°C) 1. Remove the battery from the vehicle.
3. The specific gravity of the battery fluid varies with 2. The normal charging current is a value in
the temperature, so use the following formula to amperes which is 1/10th of the battery capacity. If
calculate the specific gravity for 20°C. Use the the battery needs to be charged rapidly because
calculated value to determine whether or not the of reasons such as time limitations, the maximum
specific gravity is satisfactory. charging current for rapid charging is the battery
D20 = (t − 20) X 0.0007 + Dt capacity expressed as an ampere value.
D20: Specific gravity of the battery fluid
calculated for 20°C
Battery type Capacity (5-hour rate) Normal charging current Rapid charging current
55D23L 50 A 5.0 A 50 A
75D23L 53 A 5.3 A 53 A
3. Determine when charging is finished. • When the voltage per cell during charging is 2.5 −
• When the specific gravity of the battery 2.8 V constantly for a continuous period of one
electrolyte is constantly within 1.250 − 1.290 for a hour or more.
continuous period of one hour or more.
 CHASSIS ELECTRICAL 54A-5
BATTERY

BATTERY TEST STEP 4. Check the open circuit voltage.

M1541001200506
BATTERY TESTING PROCEDURE (1) Turn headlamps on for 15 seconds.
(2) Turn headlamps off for two minutes to allow
battery positive voltage to stabilize.
STEP 1. Check the battery cables. (3) Disconnect the battery cables.
Remove the negative cable, then the positive cable.
(4) Read open circuit voltage.
Check for dirty or corroded connections.
Q: Is open circuit voltage 12.4 volts or more?
Q: Are the battery cables dirty or have corroded YES : Go to Step 6.
connections? NO : Go to Step 5.
YES : Clean the battery cables. Then go to Step 2.
NO : Go to Step 2.
STEP 5. Charge battery.
STEP 2. Check the battery post. Q: Charging the battery?
Check for loose battery post. YES : Go to Step 6.
NO : Charge the battery at 5 amps for 15 hours.
Q: Are the battery post faulty? Then re-test, go to Step 4.
YES : Replace the battery. Then go to Step 4.
NO : Go to Step 3.
STEP 6. Check the load test.
(1) Connect a load tester to the battery.
STEP 3. Check the battery case and cover. (2) Load the battery at the recommended discharge
(1) Remove the hold-downs and shields. rate (See LOAD TEST RATE CHART) for 15
(2) Check for broken/cracked case or cover. seconds.
Q: Is the battery case or cover faulty? (3) Read voltage after 15 seconds, then remove
YES : Replace the battery. Then go to Step 4. load.
NO : Go to Step 4. (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.

LOAD TEST RATE CHART

Battery type 55D23L 75D23L
Charging time when fully discharged h 11 11
(5-amp. rated current charging)
Load test (Amps) 260 260

LOAD TEST CHART

Temperature °C 21 and 16 10 4 −1 −7 −12 −18
above
Minimum voltage 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
54A-6 CHASSIS ELECTRICAL
IGNITION SWITCH

IGNITION SWITCH
GENERAL INFORMATION the engine are not satisfied, the engine will be
M1543009901274 immobilized. If a registered ignition key is lost, all
IGNITION KEY REMINDER BUZZER your ignition keys need to be registered again using
The ignition key reminder buzzer will sound under MUT-II/III to ensure security (Refer to P.54A-20). An
the following condition, and warn the driver to additional ignition key can be registered as follows
remove the ignition key. (only if no ignition keys are lost):
• The driver's door is opened when the ignition • Using MUT-II/III (Refer to P.54A-20).
switch is at "LOCK" (OFF) or "ACC" position
without removing the ignition key. OPERATION
However, the lamp reminder buzzer will take 1. When the ignition switch is turned to "ON"
precedence over this function. position, the engine-ECU <M/T> or
engine-A/T-ECU <M/T> sends a requirement for
DOOR LOCK PREVENTION FUNCTION the encrypted code to the immobilizer-ECU (at
this time, the engine is remobilized).
If the key is left in the ignition switch while the driver’s
door opened or the assistant door opened, all door 2. When the immobilizer-ECU receives the
are automatically unlock to prevent locking the requirement from the engine-ECU <M/T> or
ignition key in the vehicle after door is locked. engine-A/T-ECU <A/T>, the immobilizer-ECU
supplies power to the transponder inside the
IMMOBILIZER SYSTEM ignition key via the antenna. The energized
transponder sends the encrypted code back to the
The immobilizer system consists of the ignition key
immobilizer-ECU via the antenna.
with a transponder, the immobilizer-ECU, and the
engine-ECU <M/T> or engine-A/T-ECU <A/T>. Only 3. The immobilizer-ECU judges the encrypted code
the registered ignition key permits the engine to start, with its code logic in itself. If they are identical, the
therefore, the engine can never be started by means immobilizer-ECU sends the encrypted code to the
of a forged key or by connecting the ignition wiring engine-ECU <M/T> or engine-A/T-ECU.
directly. The system is significantly safe and reliable 4. If the engine-ECU <M/T> or engine-A/T-ECU can
against theft. In addition, the driver has only to turn not receive the encrypted code, the engine will be
the ignition switch to the "ON" position to activate the immobilized.
immobilizer system. If the requirements for starting

Immobilizer-ECU Engine-ECU <M/T>

with an antenna Engine-A/T-ECU <A/T>
Ignition key Control signal Injector
Power
CPU
(Wireless) CPU
Encrypted Ignition
code
Memory
Transponder
Encrypted code MUT-II/III
Steering lock
(Wireless)

AC304482 AB
 CHASSIS ELECTRICAL 54A-7
IGNITION SWITCH

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-A/T-ECU Immobilizer-ECU Ignition key
When engine-A/T-ECU is − Should not be Should not be replaced
replaced replaced Should be registered
again
When engine-A/T-ECU is − Should not be Should not be replaced
overwritten replaced Should be registered
again
When immobilizer-ECU is Should not be − Should not be replaced
replace replaced All ignition keys should be
registered again
When ignition key is added Should not be Should not be • Additional ignition key
replaced replaced should be registered
• All ignition keys should
be registered again
When ignition key is lost Should not be Should not be All the ignition keys other
replaced replaced than the lost one should
be registered again
54A-8 CHASSIS ELECTRICAL
IGNITION SWITCH

SPECIAL TOOLS
M1543000601641

Tool Number Name Use

MB991502 MUT-II sub • Immobilizer system check
assembly • Encrypted code
registration

B991502

MB991955 MUT-III • Immobilizer system check

A A: MB991824 sub-assembly • Encrypted code
B: MB991827 A: (V. C. I.) Vehicle registration
C: MB991910 communication
D: MB991911 interface
MB991824 E: MB991825 B: MUT-III USB
B F: MB991826 cable
C: MUT-III Main
harness A (Vehicles
with CAN
MB991827 communication
system)
C
D: MUT-III Main
DO NOT USE harness B (Vehicles
without CAN
communication
MB991910
system)
D E: MUT-III
Measurement
adapter
F: MUT-III Trigger
MB991911 harness

MB991825

MB991826

MB991955
 CHASSIS ELECTRICAL 54A-9
IGNITION SWITCH

Tool Number Name Use

MB991223 Harness set Making voltage and
A
A: MB991219 A: Test harness resistance measurements
B: MB991220 B: LED harness during troubleshooting
C: MB991221 C: LED harness A: Connect pin contact
D: MB991222 adapter pressure inspection
B D: Probe B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester
connection

MB991223 AC

TROUBLESHOOTING IMMOBILIZER SYSTEM

TROUBLESHOOTING
IGNITION KEY REMINDER BUZZER AND
DOOR LOCK PREVENTION FUNCTION DIAGNOSIS CODE CHART
M1543007100417
TROUBLESHOOTING
M1543000701002 CAUTION
The ignition key reminder buzzers are controlled by During diagnosis, a diagnosis code associated
the Smart Wiring System (SWS). For with other system may be set when the ignition
troubleshooting, refer to respective Groups below. switch is turned on with connector(s)
• Not using SWS monitor: GROUP 54B, SWS disconnected. On completion, confirm all
Diagnosis P.54B-38. systems for diagnosis code code(s). If diagnosis
• Using SWS monitor: GROUP 54C, SWS code code(s) are set, erase them all.
Diagnosis P.54C-22. Use the following chart to develop proper diagnostic
strategy.
Diagnosis code No. Diagnosis item Reference page
11 Transponder communication system or radio interference P.54A-10.
of encrypted code
12 Encrypted codes are not the same or are not registered P.54A-11.
54A-10 CHASSIS ELECTRICAL
IGNITION SWITCH

DIAGNOSTIC TROUBLE CODE

PROCEDURES

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

IGNITION KEY
RING ANTENNA

NOTE: Diagnosis code No.11 is always set together

DIAGNOSIS CODE SET CONDITION with MPI system diagnosis code No.P0513.
• Diagnosis code No.11 may be set if other ignition
TROUBLESHOOTING HINTS
keys are in the vicinity of the vehicle as it is being
started. • Radio interference of the encrypted code.
• The transponder’s encrypted code is not sent to • Malfunction of the transponder.
the immobilizer-ECU immediately after the • Malfunction of the immobilizer-ECU.
ignition switch is turned to "ON" position.
 CHASSIS ELECTRICAL 54A-11
IGNITION SWITCH

DIAGNOSIS PROCEDURE STEP 4. Connector check: Immobilizer-ECU

connector C-202-1.
STEP 1. Check for presence of other key near the Connector: C-202-1
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. Harness side

STEP 2. Check that the engine start using the

spare ignition key which encrypted code has AC303806 AF
been registered.
Q: Does the engine start using the spare ignition key Q: Are immobilizer-ECU connector C-202-1 in good
for which the encrypted code has been registered? condition?
YES : Replace the ignition key that does not work. YES : Replace immobilizer-ECU and Then
Then register the password (secret code) register the password (secret cod) and
and encrypted code P.54A-20. Retest the encrypted code P.54A-20. Retest the
system. system.
NO : Go to Step 3. NO : Repair or replace the damage
component(s).

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 toP.54A-11.
Code No.11 is set : Go to Step 4.

Code No.12: Encrypted Codes are Not identical or not Registered

DIAGNOSIS CODE SET CONDITION • Malfunction of immobilizer-ECU.

The encrypted code sent by the transponder is not DIAGNOSIS PROCEDURE
the same encrypted code which is registered in the
immobilizer-ECU. Was the encrypted code registered?
YES : Replace the immobilizer-ECU and then
NOTE: Diagnosis code No.12 is always set together re-register the encrypted code (Refer to
with MPI system diagnosis code No.P0513. P.54A-20).
NO : Register the encrypted code (Refer to
TROUBLESHOOTING HINTS
P.54A-20).
• The encrypted code in the ignition key has not
been properly registered.

SYMPTOM CHART
M1543007201075

Symptom Inspection Reference page

procedure No.
Communication with MUT-II/III is impossible. 1 P.54A-12
The ignition key cannot be registered. 2 P.54A-18
Engine does not start (cranking but no initial combustion). 3 P.54A-18
54A-12 CHASSIS ELECTRICAL
IGNITION SWITCH

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Communication with MUT-II/III is Impossible.

Immobilizer-ECU Power Source, Earth and Engine-ECU*3 or Engine-A/T-ECU*4 Communication Line Circuit

ENGINE
CONTROL
RELAY

ENGINE-ECU
ENGINE-
A/T-ECU

IMMOBILIZER-
POWER ECU
SOURCE

NOTE
LH drive vehicles
RH drive vehicles
M/T
A/T

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

TECHNICAL DESCRIPTION (COMMENT) • If the MPI system is normal, the engine control
• This malfunction may be caused by a defective relay can be determined as normal. In addition, if
immobilizer-ECU, engine-ECU <M/T> or the MPI system and MUT-II/III can communicate
engine-A/T-ECU <A/T>, or a defect in the each other, the circuits between the diagnosis
communication line between the connector and the engine-ECU <M/T> or
immobilizer-ECU and engine-ECU <M/T> or engine-A/T-ECU <A/T> can determined as
engine-A/T-ECU <A/T>. If this malfunction normal.
appears when the MPI system and MUT-II/III can NOTE: If this malfunction appears, MPI system
communicate each other, MPI system diagnosis diagnosis code No.P0513 will be set.
code No.P0513 will reset.
 CHASSIS ELECTRICAL 54A-13
IGNITION SWITCH

TROUBLESHOOTING HINTS Q: Is the check result normal?

• Malfunction of the immobilizer-ECU. YES : Go to Step 5.
NO : Go to Step 3.
• Malfunction of the engine-ECU <M/T> or
engine-A/T-ECU <A/T>.
• The wiring harness or connectors may have STEP 3. Connector check: Immobilizer-ECU
loose, corroded, or damaged terminals, or connector C-202-1 and engine control relay
terminals pushed back in the connector. connector B-16X
DIAGNOSIS PROCEDURE Connector: C-202-1

STEP 1. Check if MUT-II/III can communicate with

the MPI system and if an MPI system diagnosis
code other than P0513 is set.
Harness side
Q: Can MUT-II/III communicate with the MPI system?
Is an MPI system diagnosis code other than P0513
set?
YES : Go to Step 2.
AC303806 AF
NO : Refer to GROUP 13A, MPI Diagnosis
P.13A-15, GROUP 13B, MPI Diagnosis Connector: B-16X
P.13B-15.

STEP 2. Voltage measurement at

immobilizer-ECU connector C-202-1.
Harness side
Connector: C-202-1

AC303796 AF

Harness side Q: Are immobilizer-ECU connector C-202-1 and

engine control relay connector B-16X in good
condition?
YES : Go to Step 4.
AC303806 AF
NO : Repair or replace the damaged
component(s). Confirm that MUT-II/III
(1) Disconnect immobilizer-ECU connector C-202-1. communicates normally.
(2) Turn the ignition switch to the "ON" position.

Connector C-202-1
(Harness side)

AC304844 AB

(3) Measure the voltage between terminal 1 and

earth.
OK: System voltage
54A-14 CHASSIS ELECTRICAL
IGNITION SWITCH

STEP 4. Check the harness wires between Connector: C-134, C-137

immobilizer-ECU connector C-202-1 (terminal 1)
and engine control relay connector B-16X
(terminal 4).
Connector: C-202-1

C-137

Harness side C-134

C-134
AC303806 AF

Connector: B-16X
C-137

AC303819 AC
Harness side

Connector: C-202

AC303796 AF

NOTE:
Connector: C-12, C-13
Harness side

AC303806 AG
C-12 Prior to the wiring harness inspection, check
intermediate connector C-13 <LH drive vehicles>,
C-137 <RH drive vehicles>, joint connector C-12
C-13 <LH drive vehicles>, C-134 <RH drive vehicles> and
key reminder switch connector C-202, and repair if
necessary.

C-12 Q: Are the harness wires between immobilizer-ECU

connector C-202-1 (terminal 1) and engine control
relay connector B-16X (terminal 4) in good
condition?
YES : There is no action to be taken.
C-13
NO : Replace damaged component(s). Confirm
that MUT-II/III communicates normally.

AC303801AC
 CHASSIS ELECTRICAL 54A-15
IGNITION SWITCH

STEP 5. Resistance measurement at STEP 7. Check the harness wire between

immobilizer-ECU connector C-202-1. immobilizer-ECU connector C-202-1 (terminal 4)
Connector: C-202-1
and earth.
Connector: C-202-1

Harness side
Harness side

AC303806 AF
AC303806 AF
(1) Disconnect immobilizer-ECU connector C-202-1.
NOTE:
Connector: C-07
Connector 202-1 <R.H. drive vehicles>
(Harness side) C-07(GR)

Harness side

AC304851AB AC303814 AL

(2) Measure the resistance between terminal 4 and Harness connector: C-104
earth. <L.H. drive vehicles>
OK: 2 ohms or less
Q: Is the check result normal? C-104(GR)
YES : Go to Step 8.
NO : Go to Step 6.
Harness side
STEP 6. Connector check: immobilizer-ECU
connector C-202-1 AC303804 AO

Connector: C-202-1
Connector: C-202

Harness side
Harness side

AC303806 AF
AC303806 AG

Q: Is immobilizer-ECU connector C-202-1 in good Prior to the wiring harness inspection, check joint
condition? connector C-104 <LH drive vehicles>, C-07 <RH
YES : Go to Step 7. drive vehicles>, key reminder switch connector
NO : Repair or replace the damaged C-202, and repair if necessary.
component(s). Confirm that MUT-II/III
communicates normally.
54A-16 CHASSIS ELECTRICAL
IGNITION SWITCH

Q: Is the harness wire between immobilizer-ECU Q: Are immobilizer-ECU connector C-202-1 and
connector C-202-1 (terminal 4) and earth in good engine-ECU connector C-127 <M/T> or
condition? engine-A/T-ECU connector C-128 <A/T> in good
YES : There is no action to be taken. condition?
NO : Repair or replace the damaged YES : Go to Step 9.
component(s). Confirm that MUT-II/III NO : Repair or replace the damaged
communicates normally. component(s). Confirm that MUT-II/III
communicates normally.
STEP 8. Connector check: immobilizer-ECU
connector C-202-1 and engine-ECU connector STEP 9. Check the harness wires between
C-127 <M/T> or engine-A/T-ECU connector C-128 immobilizer-ECU connector C-202-1 (terminal 3)
<A/T> and engine-ECU connector C-127 (terminal 51)
<M/T> or engine-A/T-ECU connector C-128
Connector: C-127 <M/T>, C-128 <A/T>
(terminal 111) <A/T>.
Connector: C-127 <M/T>, C-128 <A/T>

C-128 (GR) C-127 (Y)

Harness side C-128 (GR) C-127 (Y)

C-127
Harness side
56 55 54 53 52 51
62 61 60 59 58 57 C-127
C-128 56 55 54 53 52 51
62 61 60 59 58 57
107 106 105 104 103 102 101
120 119 118 117116 115 114 113 112 111 110 109 108
C-128
130 129 128 127 126 125 124 123 122 121

107 106 105 104 103 102 101

AC303805 AJ
120 119 118 117116 115 114 113 112 111 110 109 108
130 129 128 127 126 125 124 123 122 121

Connector: C-202-1 AC303805 AJ

Connector: C-202-1

Harness side

Harness side

AC303806 AF

AC303806 AF
 CHASSIS ELECTRICAL 54A-17
IGNITION SWITCH

NOTE: Q: Are the harness wires between immobilizer-ECU

Connector: C-13 connector C-202-1 (terminal 3) and engine-ECU
<L.H. drive vehicles> connector C-127 (terminal 51) <M/T> or
engine-A/T-ECU connector C-128 (terminal 111)
<A/T> in good condition?
YES : Go to Step 10.
NO : Repair or replace the damaged
Harness side component(s). Confirm that MUT-II/III
communicates normally.

AC303800 AG STEP 10. Replace the immobilizer-ECU or

engine-ECU <M/T> or engine-A/T-ECU <A/T>.
Connector: C-137 Replace the immobilizer-ECU.
<R.H. drive vehicles>
Q: Did the communication with MUT-II/III become
possible after replacing the immobilizer-ECU?
YES : Register the password (secret code) and
encrypted code P.54A-20. Confirm that
MUT-II/III communicates normally
Harness side NO : Go to Step 11.

AC303818 AM STEP 11. Recheck for malfunction.

Connector: C-202
Q: Is a malfunction eliminated?
YES : The procedure is complete. If no
malfunctions are found in all steps, an
intermittent malfunction is suspected (Refer
to GROUP 00, How to Use
Troubleshooting/Inspection Service Points −
Harness side How to Cope with Intermittent Malfunction
P.00-5).
NO : Replace the engine-ECU <M/T> or
AC303806 AG
engine-A/T-ECU <A/T>.

Prior to the wiring harness inspection, check key

reminder switch connector C-202, intermediate
connector C-13 <LH drive vehicles>, C-137 <RH
drive vehicles>, and repair if necessary.
54A-18 CHASSIS ELECTRICAL
IGNITION SWITCH

INSPECTION PROCEDURE 2: The Ignition Key cannot be Registered.

TECHNICAL DESCRIPTION (COMMENT) STEP 2. Retest the system.

The ignition key transponder or the immobilizer-ECU
is suspected to be defective. Q: Does registered ignition key function properly?
YES : The procedure is complete. (If no
TROUBLESHOOTING HINTS malfunctions are found in all steps, an
intermittent malfunction is suspected. Refer
• Malfunction of the ignition key
to GROUP 00, How to Use
• Malfunction of immobilizer-ECU
Troubleshooting/Inspection Service Points −
DIAGNOSIS PROCEDURE How to Cope with Intermittent Malfunction
P.00-5).
STEP 1. MUT-II/III diagnosis code. NO : Replace the immobilizer-ECU.

Q: Does diagnosis code No.11 reset?

YES : Refer to P.54A-9.
NO : Replace the ignition key that cannot be
registered. Then re-register the encrypted
code. (Refer to P.54A-20). Verify that the
ignition key can be registered, then Go to
Step 2.

INSPECTION PROCEDURE 3: Engine does not Start (Cranking but no Initial Combustion).

TECHNICAL DESCRIPTION (COMMENT) STEP 2. Check the immobilizer system diagnosis

If the fuel injectors are not operating, there might be code and MPI system diagnosis code.
a problem with the MPI system in addition to a
malfunction of the immobilizer system. It is normal for Q: Which diagnosis code resets, the immobilizer
system diagnosis code or the MPI system
this to occur if an attempt is made to start the engine
diagnosis code?
using a key that has not been properly registered. Immobilizer system diagnosis code is set : Refer
to P.54A-9.
TROUBLESHOOTING HINTS MPI system diagnosis code is set : Refer to
• Malfunction of MPI system GROUP 13A, Diagnosis P.13A-15, GROUP
• Malfunction of immobilizer-ECU 13B, Diagnosis P.13B-15.
No diagnosis code is set : Go to Step 3.
DIAGNOSIS PROCEDURE
STEP 3. Check the starting system.
STEP 1. Check the system voltage.
Measure the system voltage during cranking. Q: Does the engine start?
YES : Go to Step 4.
Q: Is the voltage 8 volts or more? NO : Refer to GROUP 13A, Diagnosis −
YES : Go to Step 2. Symptom Chart P.13A-215, GROUP 13B,
NO : Check the battery. Refer to P.54A-4. The Diagnosis − Symptom Chart P.13B-189. If
engine should start. the malfunction is not resolved, replace the
immobilizer-ECU. Then register the
password (secret code) and encrypted
code. (Refer to P.54A-20.) The engine
should start.
 CHASSIS ELECTRICAL 54A-19
IGNITION SWITCH

STEP 4. Retest the system

Q: Is the malfunction eliminated?
YES : The procedure is complete. If no
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.

DATA LIST REFERENCE TABLE

M1543007300314

Item No. Inspection item Inspection Normal condition

requirement
01 Key has been registered − Number of registered ignition keys

CHECK IMMOBILIZER-ECU
M1543007600489

TERMINAL VOLTAGE CHECK TABLE

AC304799

Terminal No. Signal Inspection condition Terminal voltage

1 Immobilizer-ECU power supply Ignition switch: "LOCK" 0V
(OFF)
Ignition switch: "ON" System voltage
2 - - -
3 Engine-ECU <M/T> or - -
engine-A/T-ECU
4 Immobilizer-ECU earth Always 0V
54A-20 CHASSIS ELECTRICAL
IGNITION SWITCH

ON-VEHICLE SERVICE Registration with the MUT-II

CAUTION
HOW TO REGISTER ENCRYPTED CODE To prevent damage to MUT-II, always turn the
M1543008100410
ignition switch to "LOCK" (OFF) position before
CAUTION connecting or disconnecting MUT-II.
Because registering the encrypted codes is done
NOTE: .
after all previously-registered codes have been
• Using the key ID register function will cause all
erased, you should keep all of the ignition keys
key IDs that have been previously registered in
that have already been registered accessible.
the immobilizer-ECU to be erased. All keys need
If the ignition key, Immobilizer-ECU,
to be registered. Those which have been
engine-ECU<M/T> or engine-A/T-ECU<A/T> is
registered before should be on hand before using
replaced or an ignition key is added, encrypted
this function.
codes of all the ignition keys must be registered. (A
• If registering more than one key, do not
maximum of eight different ignition key can be
disconnect MUT-II halfway through the
registered.) Moreover, when the immobilizer-ECU
registration process.
has been replaced, you will need to use MUT-II/III to
• After registering key IDs, check that the engine
register the immobilizer-ECU and input the vehicle
can be started using all of the keys that have
secret code and to register the password (secret
been registered. If the engine will not start, refer
code) that the owner specifies into the
to Immobilizer System Diagnosis P.54A-6.
immobilizer-ECU.
If an attempt is made to start the engine with an <Using the MUT-II>
unregistered ignition key, cranking occurs, but fuel Steering shaft
supply is cut off to disable the engine. In
approximately.
NOTE: Engine-ECU<M/T> or engine-A/T-ECU<A/T>
has an encrypted code for immobilizer-ECU, and the
encrypted code is registered in the immobilizer-ECU
and ignition key.
MB991502
AC304777AB
POINTS TO NOTE DURING OPERATION
If none of the functions can be used, check the 1. Connect MUT-II to diagnosis connector (16- pin).
diagnosis codes, and after carrying out any 2. Turn the ignition switch to "ON" position.
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.

KEY ID (ENCRYPTED CODE)

AC000522AD
REGISTRATION <MUT-II>
All ignition keys can be registered with MUT-II. 3. At "System Select," press "YES"
Additional ignition keys can be registered with
MUT-II.
 CHASSIS ELECTRICAL 54A-21
IGNITION SWITCH

ACX01626 AC
AC000523AC

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
AC000530AC
make up the password.
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

9. This will be displayed when the key ID registration

is successful. If an error occurs during key ID
ACX01558 AG
registration, the message "Can't execute" will be
displayed. If the key has already been registered,
6. Select "key ID register", press "YES". "Key ID has been registered" will be displayed.
54A-22 CHASSIS ELECTRICAL
IGNITION SWITCH

<Using the MUT-II>

Steering shaft

MB991502
ACX01563 AC
AC304777AB

10.The number of keys currently registered will be 1. Connect MUT-II (MB991502) to the 16-pin
displayed. To register an additional key, replace diagnosis connector.
the ignition key with the next key to be registered 2. Turn the ignition switch to "ON" position.
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
AC000522AD
for approximately ten seconds.
12.Check that the engine can be started with each of 3. At "System Select," press "YES"
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 MUT-II.

Registration of additional keys with the

MUT-II
Additional key(s) can be registered with the MUT-II
while keeping all existing key data. AC000523AC

CAUTION
4. Select "Immobilizer," press "YES".
To prevent damage to MUT-II, always turn the
ignition switch to "LOCK" (OFF) position before
connecting or disconnecting MUT-II.
NOTE: To register additional keys with the MUT-II,
no registered keys must be lost.

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 54A-23
IGNITION SWITCH

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.
AC000518AC 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 MUT-II.

AC101478 AB KEY ID (ENCRYPTED CODE)

6. Select "Add key ID reg", press "YES". REGISTRATION <MUT-III>
All ignition keys can be registered with MUT-III.
Additional ignition keys can be registered with
MUT-III.
Registration with the MUT-III
CAUTION
To prevent damage to MUT-III, always turn the
ignition switch to "LOCK" (OFF) position before
connecting or disconnecting MUT-III.
NOTE: .
AC101477AB
• Before registration, check that no diagnosis code
is set. If a diagnosis code is set, resolve the
7. Press the "YES" key to start key ID registration.
problem beforehand.
8. This will be displayed when the add key ID • Using the key ID register function will cause all
registration is successful. If an error occurs during key IDs that have been previously registered in
key ID registration, the message "Can't execute" the immobilizer-ECU to be erased. All keys need
will be displayed. If the key has already been to be registered. Those which have been
registered, "Key ID has been registered" will be registered before should be on hand before using
displayed. this function.
• If registering more than one key, do not
disconnect MUT-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.

AC101476 AB
54A-24 CHASSIS ELECTRICAL
IGNITION SWITCH

<Using the MUT-III> IMMOBILIZER

POWERTRAIN
IMMOBILIZER

Check Chart For Simulated Vehicle

Self-diagnosis Speed Out
Problem Sy

Data List Special Resistor

Function
Voltmeter

16-PIN AC305176
MB991911
5. Choose "Special Function" from "IMMOBILIZER"
screen.
MB991824
Special Function
POWERTRAIN IMMOBILIZER
Special Function

Additional Key
Key ID registration Registration

MB991827 AC304950AB

1. Connect the MUT-III to the diagnosis connector

(16-pin). AC305177

2. Turn the ignition switch to "ON" position. 6. Choose "Key registration" from "Special Function"
Function Select Menu screen.
Menu
Special Function
POWERTRAIN IMMOBILIZER
Key registration
System select Special function
7 8 9

4 5 6
CAN bus diagnosis Maintenance 1 2 3

0 Back Clear
Space

AC209666AD

AC207300AD
3. Select "System select" from the start-up screen.
System Select Menu 7. Enter the vehicle’s password (secret code) on the
POWER TRAIN CHASSIS BODY
"Key registration" screen, and then click the check
MPI/GDI/DIESEL IMMOBILIZER mark icon. Follow the prompts on the screen to
ELC-A/T/CVT SS4II insert key(s) into the ignition switch to begin key
TCL/STARLTY CONTROL AUTO CRUISE
registration.
Special Function
POWERTRAIN IMMOBILIZER
Key registration

IMMOBILIZER-ECU registration
Progress In-Complete

AC305175

4. Choose "IMMOBILIZER" from the "POWER

TRAIN" tab.

AC207302
 CHASSIS ELECTRICAL 54A-25
IGNITION SWITCH

8. If the key ID was registered successfully, <Using the MUT-III>

"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. 16-PIN
NOTE: A maximum of eight different keys can be MB991911
registered.
10.This completes the registration operation. Turn MB991824
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 MB991827 AC304950AB

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

AC305177

4. Choose "Transponder ID addition" from "Special

Function" screen.
Special Function
POWERTRAIN IMMOBILIZER
Trasponder ID addition

Password
7 8 9

4 5 6

1 2 3

0 Back Clear
Space

AC207301
54A-26 CHASSIS ELECTRICAL
IGNITION SWITCH

5. Enter the vehicles password (secret code) on the Registration of additional key(s) without
"Transponder ID addition" screen, and then click using the MUT-III
the check mark icon. If the MUT-III is not available, new key(s) can be
POWERTRAIN IMMOBILIZER
Special Function AC207301 registered by operating two keys which have been
Trasponder ID addition
registered to the vehicle (A maximum of eight keys
Key
ey ID register

The number of registered key 3

can be registered to one vehicle). Follow the
Progre
About Additional T
Transponder
ransponder
procedure below to register new key(s) to the
ID SET
If register another key ID, press the
OK button after inserting a new key
vehicle.
within 5 sec and turning on IG-SW.
IG-SW

NOTE: The registered key is the key that allows you

to start the engine.
1. Turn "ON" the ignition switch by using the first
registered key (key A), and wait for five seconds.
AC209775
2. Remove the first registered key (key A).
6. If an additional registration is made successfully, 3. Insert the second registered ignition key (key B),
the screen will ask if another key is registered or and turn it to the ON position.
not. If the third ignition key is registered, remove 4. The immobilizer-ECU identifies the new key to
the key, which has been registered. Then insert accept or reject it, and operates the immobilizer
the third key within five seconds, and then turn it indicator (See the table below).
to the ON position. 5. If a new ignition key is registered further, repeat
7. Register the additional ignition key according to steps 1 to 7 above.
step 6 above. The number of the registered A maximum of eight ignition keys can be registered
ignition keys are shown on "The number of to one vehicle (If you attempt to register the ninth
registered key" screen. key, the immobilizer-ECU rejects the key). If any of
NOTE: A maximum of eight different keys can be the following conditions are satisfied, the additional
registered. key registration mode will terminate:
8. This completes the registration operation. Turn • The ignition switch has been on for more than 30
the ignition switch "LOCK" (OFF) and leave it off seconds.
for approximately ten seconds. • After the ignition key has been turned to the
"LOCK" (OFF), the engine control relay is turned
9. Check that the engine can be started with each of
off.
the ignition keys.
• The MUT-III has started communicating with
10.Check that the immobilizer system diagnosis vehicle systems.
code and MPI system diagnosis code did not set.
6. After the registration mode has terminated, the
11.If not diagnosis code is shown, terminate the additionally registered key(s) should allow you to
MUT-III. start the engine.
12.Turn the ignition switch to "LOCK" (OFF) position.
13.Disconnect MUT-III.
 CHASSIS ELECTRICAL 54A-27
IGNITION SWITCH

IGNITION SWITCH
REMOVAL AND INSTALLATION
M1543002100434

WARNING
• Before removal of the air bag module, refer to GROUP 52B, SRS Service Precautions and
Air Bag Module and Clock Spring P.52B-5.
• When removing and installing the steering wheel, do not let it bump against the air bag
module.

3 2

8
7
6 5

1
AC304659 AB

Removal steps Removal steps (Continued)

1. Column cover lower • Ignition switch connector
2. Column cover upper 6. Ignition switch
3. Steering wheel and air bag module 7. Immobilizer-ECU
assembly (Refer to GROUP 37, • Key reminder switch connector
Steering wheel P.37-17 or P.37-19) 8. Key reminder switch and bulb
4. Clock spring and column switch assembly
assembly (Refer to GROUP 37,
Steering shaft P.37-21)
<<A>> 5. Steering lock cylinder
54A-28 CHASSIS ELECTRICAL
IGNITION SWITCH

REMOVAL SERVICE POINT Switch Tester Specified

<<A>> STEERING LOCK CYLINDER position connection condition
REMOVAL "LOCK" (OFF) 1 − 2, 1 − 3, Open circuit
1 − 4, 1− 5,
Locking pin 1 − 6, 2 − 3,
2 − 4, 2− 5,
2 − 6, 3 − 4,
3 − 5, 3 − 6,
4 − 5, 4 − 6,
5−6
"ACC" 1−6 Less than 2
ohms
AC304831AB "ON" 1 − 2, 1 − 4, Less than 2
1 − 6, 2 − 4, ohms
1. Insert the key in the steering lock cylinder and turn 2 − 6, 4 − 6
it to the "ACC" position.
"START" 1 − 2, 1 − 5, Less than 2
2. Using a small Phillips head screwdriver, pull the
2−5 ohms
steering lock cylinder toward you.

INSPECTION KEY REMINDER SWITCH CONTINUITY

M1544009700203
CHECK
IGNITION SWITCH CONTINUITY CHECK

AC304834AB
AC304833AB
Disconnect key reminder switch connector C-202
Disconnect ignition switch connector C-201 without without removing the ignition switch and key
removing the ignition switch. Then check the reminder switch. Then check the continuity.
continuity.
Status of Tester Specified
ignition key connection condition
Removed 4−6 Less than 2
ohms
Inserted 4−6 Open circuit
 CHASSIS ELECTRICAL 54A-29
COMBINATION METER ASSEMBLY

COMBINATION METER ASSEMBLY

SERVICE SPECIFICATIONS
M1543000300324

Item Standard value

Speedometer indication error km/h (mph) 20 (12) 20 − 24 (12 − 15)
40 (25) 40 − 44 (25 − 28)
80 (50) 80 − 85 (50 − 53)
120 (75) 121 − 127 (75 − 79)
160 (100) 162 − 169 (100 − 105)
200 (125) 203 − 211 (126 − 131)
Tachometer indication error r/min 700 ± 120
2,000 − 175 + 225
3,000 − 175 + 300
4,000 − 225 + 375
5,000 − 225 + 425
6,000 − 225 + 475
7,000 − 200 + 500
8,000 − 100 + 500
Fuel tank gauge unit resistance Ω Float position F (highest) 3±1
Float position E (lowest) 110 ± 1
Fuel gauge unit float height mm Float position F (A) 24.1 ± 2.0
Float position E (B) 151.6 ± 2.0
Engine coolant temperature gauge unit resistance Ω 104 + 13.5 (at 70°C)

SEALANT
M1543024600028

Item Specified sealant

Engine coolant temperature gauge unit 3M 1215 or equivalent

SPECIAL TOOLS
M1543000601652

Tool Number Name Use

MB990784 Ornament remover Removal of meter bezel and
Instrument panel ornament

MB990784

MB991502 MUT-II sub assembly Reading MPI system

diagnosis code

B991502
54A-30 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

Tool Number Name Use

MB991955 MUT-III sub-assembly Reading MPI system
A A: MB991824 A: (V. C. I.) Vehicle diagnosis code
B: MB991827 communication
C: MB991910 interface
D: MB991911 B: MUT-III USB cable
MB991824 E: MB991825 C: MUT-III Main
B F: MB991826 harness A (Vehicles
with CAN
communication system)
D: MUT-III Main
MB991827 harness B (Vehicles
without CAN
C
communication system)
DO NOT USE E: MUT-III
Measurement adapter
F: MUT-III Trigger
MB991910
harness
D

MB991911

MB991825

MB991826

MB991955
 CHASSIS ELECTRICAL 54A-31
COMBINATION METER ASSEMBLY

Tool Number Name Use

MB991223 Harness set Making voltage and
A
A: MB991219 A: Test harness resistance measurements
B: MB991220 B: LED harness during troubleshooting
C: MB991221 C: LED harness A: Connect pin contact
D: MB991222 adapter pressure inspection
B D: Probe B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester
connection

MB991223 AC

TROUBLESHOOTING
SYMPTOM CHART
M1543007201086

Symptom Inspection Reference page

procedure No.
Speedometer does not work (the other meters work). <M/T> 1 P.54A-32
Speedometer does not work (the other meters work). <A/T> 2 P.54A-37
Tachometer does not work (the other meters work). 3 P.54A-44
Fuel gauge does not work (the other meters work). 4 P.54A-48
Engine coolant temperature gauge does not work (the other 5 P.54A-51
meters work).
Combination meters does not work (the instruments do not 6 P.54A-54
work).
54A-32 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Speedometer does not work (the other meters work). <M/T>

Speedometer Circuit

IGNITION
SWITCH (IG1)

COMBINATION
METER

CONTROL CIRCUIT

DIAGNOSIS
CONNECTOR
FRONT SIDE

VEHICLE ENGINE-ECU
SPEED
SENSOR

NOTE
LH drive vehicles
RH drive vehicles
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet
 CHASSIS ELECTRICAL 54A-33
COMBINATION METER ASSEMBLY

TECHNICAL DESCRIPTION (COMMENT) (2) Use the MUT-II/III to enter simulated vehicle
The engine-ECU and its associated components, the speed.
combination meter assembly, the wiring harness, or Q: Does the speedometer show that simulated vehicle
the connector(s) may be defective. speed?
YES : Go to Step 6.
TROUBLESHOOTING HINTS NO : Go to Step 2.
• Malfunction of the vehicle speed sensor
• Malfunction of the engine-ECU
STEP 2. Check the vehicle speed sensor.
• Malfunction of the combination meter assembly
(MUT-II/III diagnosis code)
• The wiring harness or connectors may have
loose, corroded, or damaged terminals, or <Using the MUT-II>
terminals pushed back in the connector. Steering shaft

DIAGNOSIS PROCEDURE

STEP 1. MUT-II/III actuator test.

<Using the MUT-II>
Steering shaft MB991502
AC304777AB

<Using the MUT-III>

MB991502
AC304777AB

<Using the MUT-III>

16-PIN
MB991911

MB991824

16-PIN
MB991911

MB991824 MB991827 AC304950AB

(1) Connect MUT-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 P.13A-186 <4G1> or P.13B-166
<4G6>.
MB991827 AC304950AB
NO : Go to Step 3.
(1) Connect the MUT-II/III to the diagnosis connector.
54A-34 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

STEP 3. Connector check: Combination meter STEP 4. Check the wiring harness between
connector C-04 and diagnosis connector C-11. combination meter connector C-04 (terminal 12)
Connector: C-04
and diagnosis connector C-11 (terminal 14).
<L.H. drive vehicles> NOTE:
Connector: C-03, C-04 C-04
<L.H. drive vehicles>

Harness side
C-03

Harness side C-03 (B)

AC303798 AT
C-04

Connector: C-11 AC303798 AU

<L.H. drive vehicles>
Connector: C-11
<L.H. drive vehicles>
C-11 (B)
Front side
C-11 (B)
Front side

AC303800 AK

Connector: C-04 AC303800 AK

<R.H. drive vehicles>
Connector: C-04
<R.H. drive vehicles>

Harness side

Harness side
AC303814 AT

Connector: C-11 AC303814 AT

<R.H. drive vehicles>
Connector: C-11
<R.H. drive vehicles>

Front side C-11 (B)

Front side C-11 (B)

AC303812 AD

Q: Is combination meter connector C-04 and AC303812 AD

diagnosis connector C-11 in good condition? Prior to the wiring harness inspection, joint connector
YES : Go to Step 4.
C-03 <LH drive vehicles>, and repair if necessary.
NO : Repair or replace the damage
component(s). Q: Is the wiring harness between combination meter
connector C-04 (terminal 12) and diagnosis
connector C-11 (terminal 14) in good condition?
YES : Go to Step 5.
NO : Repair or replace the wiring harness.
 CHASSIS ELECTRICAL 54A-35
COMBINATION METER ASSEMBLY

STEP 5. Retest the system Connector: C-127

Q: Is the speedometer normal?

YES : . The procedure is complete. (If no
malfunctions are found in all steps, an
intermittent malfunction is suspected. Refer C-127 (Y)
to GROUP 00, How to Use Harness side
Troubleshooting/Inspection Service
Points-How to Cope with Intermittent
Malfunction P.00-5).
AC303816BA
NO : . Replace the combination meter assembly.

Q: Is combination meter connector C-04 and

STEP 6. Check whether the diagnosis code is engine-ECU connector C-127 in good condition?
reset. YES : . Go to Step 8.
NO : . Repair or replace the damage
Q: Is the MPI-related diagnosis code set? component(s).
YES : Refer to GROUP 13A − Troubleshooting
P.13A-15, GROUP 13B − Troubleshooting
P.13B-15. STEP 8. Check the wiring harness between
NO : . Go to Step 7. combination meter connector C-04 (terminal 11)
and engine-ECU connector C-125 <LH drive
vehicles>, C-127 <RH drive vehicles> (terminal
STEP 7. Connector check: Combination meter 58).
connector C-04 and engine-ECU connector C-127
<RH drive vehicles> Connector: C-04
<L.H. drive vehicles>
Connector: C-04
<L.H. drive vehicles>

Harness side

Harness side
AC303798 AT

AC303798 AT Connector: C-125

<L.H. drive vehicles>
Connector: C-04
<R.H. drive vehicles>
C-125 (Y)

Harness side
58 57 56 55 54 53 52 51
Harness side 66 65 64 63 62 61 60 59
AC303804 AT

AC303814 AT
54A-36 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

Q: Is the wiring harness between combination meter

Connector: C-04
<R.H. drive vehicles> connector C-04 (terminal 11) and engine-ECU
connector C-127 <RH drive vehicles> (terminal 58)
in good condition?
YES : Go to Step 9.
NO : Repair the wiring harness.

Harness side STEP 9. Retest the system.

Q: Is the speedometer normal?
AC303814 AT YES : The procedure is complete. If no
malfunctions are found in all steps, an
Connector: C-127 intermittent malfunction is suspected (Refer
<R.H. drive vehicles>
to GROUP 00, How to Use
Troubleshooting/Inspection Service
Points-How to Cope with Intermittent
C-127 (Y) Malfunction P.00-5).
NO : Go to Step 10.
Harness side

56 55 54 53 52 51
62 61 60 59 58 57 STEP 10. Pulse check
AC303816AW
Use the MUT-II/III or a voltmeter to check that the
vehicle speed signal is received.
NOTE: System switch Check conditions
Connector: C-12, C-14
<L.H. drive vehicles> Vehicle speed signal When the vehicle speed
has reached 10 km/h or
more
OK: The MUT-II/III sounds or the voltmeter
needle fluctuates.
Q: Is the check result normal?
C-14 (GR) YES : Replace the combination meter assembly.
C-12
NO : Replace the engine-ECU.

Harness side
C-12

C-14

AC303801AD

Prior to the wiring harness inspection, check

intermediate connectors C-14 (LH drive vehicles),
C-136 (RH drive vehicles), joint connectors C-12 (LH
drive vehicles), C-134 (RH drive vehicles) and repair
if necessary.
 CHASSIS ELECTRICAL 54A-37
COMBINATION METER ASSEMBLY

INSPECTION PROCEDURE 2: Speedometer does not work (the other meters work). <A/T>

Speedometer Circuit
IGNITION
SWITCH (IG1)

A/T
CONTROL COMBINATION METER
RELAY

OUTPUT
SHAFT
SPEED CONTROL CIRCUIT
SENSOR

ENGINE-
A/T-ECU

DIAGNOSIS
CONNECOTR
FRONT SIDE

NOTE
LH drive vehicles
RH drive vehicles

ENGINE-
A/T-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
54A-38 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

TECHNICAL DESCRIPTION (COMMENT) (2) Use the MUT-II/III to enter simulated vehicle
The engine-ECU and its associated components, the speed.
combination meter assembly, the wiring harness, or Q: Does the speedometer show that simulated vehicle
the connector(s) may be defective. speed?
YES : Go to Step 6.
TROUBLESHOOTING HINTS NO : Go to Step 2.
• Malfunction of the vehicle speed sensor
• Malfunction of the engine-ECU
STEP 2. Check the output shaft speed sensor.
• Malfunction of the combination meter assembly
(MUT-II/III diagnosis code)
• The wiring harness or connectors may have
loose, corroded, or damaged terminals, or <Using the MUT-II>
terminals pushed back in the connector. Steering shaft

DIAGNOSIS PROCEDURE

STEP 1. MUT-II/III actuator test

<Using the MUT-II>
Steering shaft MB991502
AC304777AB

<Using the MUT-III>

MB991502
AC304777AB

<Using the MUT-III>

16-PIN
MB991911

MB991824

16-PIN
MB991911

MB991824 MB991827 AC304950AB

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

(2) Turn the ignition switch to the "ON" position.
(3) Read the automatic transmission system
diagnosis code.
Q: Is automatic transmission system diagnosis code
23 set?
MB991827 AC304950AB
YES : Refer to P.23A-38.
(1) Connect the MUT-II/III to the diagnosis connector. NO : Go to Step 3.
 CHASSIS ELECTRICAL 54A-39
COMBINATION METER ASSEMBLY

STEP 3. Connector check: Combination meter STEP 4. Check the wiring harness between
connector C-04 and diagnosis connector C-11 combination meter connector C-04 (terminal 12)
Connector: C-04
and diagnosis connector C-11 (terminal 14).
<L.H. drive vehicles> NOTE:
Connector: C-03, C-04 C-04
<L.H. drive vehicles>

Harness side
C-03

Harness side C-03 (B)

AC303798 AT
C-04

Connector: C-11 AC303798 AU

<L.H. drive vehicles>
Connector: C-11
<L.H. drive vehicles>
C-11 (B)
Front side
C-11 (B)
Front side

AC303800 AH

Connector: C-04 AC303800 AH

<R.H. drive vehicles>
Connector: C-04
<R.H. drive vehicles>

Harness side

Harness side
AC303814 AT

Connector: C-11 AC303814 AT

<R.H. drive vehicles>
Connector: C-11
<R.H. drive vehicles>

Front side C-11 (B)

Front side C-11 (B)

AC303812 AD

Q: Is combination meter connector C-04 and AC303812 AD

diagnosis connector C-11 in good condition? Prior to the wiring harness inspection, joint connector
YES : Go to Step 4.
C-03 <LH drive vehicles>, and repair if necessary.
NO : Repair or replace the damage
component(s). Q: Is the wiring harness between combination meter
connector C-04 (terminal 12) and diagnosis
connector C-11 (terminal 14) in good condition?
YES : Go to Step 5.
NO : Repair or replace the wiring harness.
54A-40 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

STEP 5. Retest the system. Connector: C-04

<L.H. drive vehicles>
Q: Is the speedometer normal?
YES : The procedure is complete. (If no
malfunctions are found in all steps, an
intermittent malfunction is suspected. Refer
to GROUP 00, How to Use
Troubleshooting/Inspection Service
Points-How to Cope with Intermittent Harness side
Malfunction P.00-5).
NO : Replace the combination meter assembly.
AC303798 AT

STEP 6. Check whether the diagnosis code is Connector: C-124, C-126

reset. <L.H. drive vehicles>

Q: Is the MPI-related diagnosis code set?

YES : . Refer to GROUP 13A − Troubleshooting
P.13A-15, GROUP 13B − Troubleshooting
P.13B-15.
NO : . Go to Step 7.
C-126 (GR) C-124 (GR)

STEP 7. Connector check: Combination meter

connector C-04 and engine-A/T-ECU connector
C-124, C-126
Harness side
C-124
46 45 44 43 42 41
57 56 55 54 53 52 51 50 49 48 47
66 65 64 63 62 61 60 59 58

C-126
77 76 75 74 73 72 71
89 88 87 86 85 84 83 82 81 80 79 78
98 97 96 95 94 93 92 91 90

AC303805 AK
 CHASSIS ELECTRICAL 54A-41
COMBINATION METER ASSEMBLY

YES : Go to Step 8.
Connector: C-04
NO : Repair or replace the damage
<R.H. drive vehicles>
component(s).

Harness side

AC303814 AT

Connector: C-124, C-126

<R.H. drive vehicles>

C-126 (GR)
C-124 (GR)

Harness side
C-124
46 45 44 43 42 41
57 56 55 54 53 52 51 50 49 48 47
66 65 64 63 62 61 60 59 58

C-126
77 76 75 74 73 72 71
89 88 87 86 85 84 83 82 81 80 79 78
98 97 96 95 94 93 92 91 90

AC303817 AM

Q: Is combination meter connector C-04 and

engine-A/T-ECU connector C-124, C-126 in good
condition?
54A-42 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

STEP 8. Check the wiring harness between Connector: C-124, C-126

combination meter connector C-04 (terminal 11, <R.H. drive vehicles>
12) and engine-A/T-ECU connector C-124 <LH
drive vehicles>, C-126 <RH drive vehicles>
(terminal 43, 80).
Connector: C-03, C-04 C-04 C-126 (GR)
<L.H. drive vehicles>
C-124 (GR)
Harness side
C-03
C-03 (B)

C-04 Harness side

C-124
AC303798 AU 46 45 44 43 42 41
57 56 55 54 53 52 51 50 49 48 47
66 65 64 63 62 61 60 59 58
Connector: C-124, C-126
<L.H. drive vehicles> C-126
77 76 75 74 73 72 71
89 88 87 86 85 84 83 82 81 80 79 78
98 97 96 95 94 93 92 91 90

AC303817 AM

C-126 (GR) C-124 (GR)

Harness side
C-124
46 45 44 43 42 41
57 56 55 54 53 52 51 50 49 48 47
66 65 64 63 62 61 60 59 58

C-126
77 76 75 74 73 72 71
89 88 87 86 85 84 83 82 81 80 79 78
98 97 96 95 94 93 92 91 90

AC303805 AK

Connector: C-04
<R.H. drive vehicles>

Harness side

AC303814 AT
 CHASSIS ELECTRICAL 54A-43
COMBINATION METER ASSEMBLY

NOTE: Q: Is the wiring harness between combination meter

Connector: C-12 connector C-04 (terminal 11, 12) and
<L.H. drive vehicles> engine-A/T-ECU connector C-124 (terminal 43, 80)
in good condition?
YES : Go to Step 9.
Harness side NO : Repair the wiring harness.

STEP 9. Retest the system.

Q: Is the speedometer normal?
YES : The procedure is complete. (If no
AC303800 AI
malfunctions are found in all steps, an
Connectors: C-134, C-136, C-137 intermittent malfunction is suspected. Refer
<R.H. drive vehicles> to GROUP 00, How to Use
Troubleshooting/Inspection Service
Points-How to Cope with Intermittent
Malfunction P.00-5).
NO : Go to Step 10.

C-134
C-137 STEP 10. Pulse check
C-136 (GR)
Use the MUT-II/III or a voltmeter to check that the
vehicle speed signal is received.
System switch Check conditions
Vehicle speed signal When the vehicle speed
C-134 C-137 has reached 10 km/h or
more
OK: The MUT-II/III sounds or the voltmeter
needle fluctuates.
C-136
Q: Is the check result normal?
YES : Replace the combination meter assembly.
NO : Replace the engine-ECU.
AC303819AE

Prior to the wiring harness inspection, check

intermediate connectors C-14 (LH drive vehicles),
C-13 (LH drive vehicles), C-136 (RH drive vehicles),
C-137 (RH drive vehicles), joint connectors C-12 (LH
drive vehicles), C-134 (RH drive vehicles), C-03 (LH
drive vehicles) and repair if necessary.
54A-44 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

INSPECTION PROCEDURE 3: Tachometer does not work (the other meters work).

Tachometer Circuit

COMBINATION
METER

CONTROL
CIRCUIT

NOTE
LH drive vehicles
RH drive vehicles
M/T
A/T

ENGINE-ECU

ENGINE-A/T-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

TECHNICAL DESCRIPTION (COMMENT) TROUBLESHOOTING HINTS

Ignition signal may not be received from the • Malfunction of the combination meter assembly
engine-ECU, or the combination meter assembly, the • The wiring harness or connectors may have
wiring harness, or the connector(s) may be defective. loose, corroded, or damaged terminals, or
terminals pushed back in the connector.
 CHASSIS ELECTRICAL 54A-45
COMBINATION METER ASSEMBLY

DIAGNOSIS PROCEDURE Connector: C-04

<R.H. drive vehicles>
STEP 1. Check whether the diagnosis code is
reset.
Q: Is the MPI-related diagnosis code set?
Code No.P0500 <M/T> or 23 <A/T> is set : Refer to
GROUP 13A − Troubleshooting P.13A-15, Harness side
GROUP 13B − Troubleshooting P.13B-15.
NO : Go to Step 2
AC303814 AT

STEP 2. Connector check: Combination meter Connector: C-124 <A/T>, C-127 <M/T>
connector C-04 and engine-ECU connector C-127 <R.H. drive vehicles>
<M/T> or engine-A/T-ECU connector C-124 <A/T>
Connector: C-04
<L.H. drive vehicles>

C-127 (Y)
C-124 (GR)

Harness side

AC303798 AT Harness side

C-124
Connector: C-124 <A/T>, C-127 <M/T>
<L.H. drive vehicles>

Harness side
C-127

AC303817AO
C-127 (Y)
C-124 (GR) Q: Is combination meter connector C-04 and
engine-ECU connector C-127 <M/T> or
engine-A/T-ECU connector C-124 <A/T> in good
condition?
Harness side YES : Go to Step 3
NO : Repair or replace the damage
C-124
component(s).

STEP 3. Retest the system.

Harness side
C-127 Q: Is the tachometer normal?
YES : Intermittent Malfunction. Refer to GROUP
00, How to Use Troubleshooting/Inspection
AC303805AM Service Points-How to Cope with
Intermittent Malfunction P.00-5).
NO : Go to Step 4
54A-46 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

STEP 4. Check the wiring harness between Connector: C-124 <A/T>, C-127 <M/T>
combination meter connector C-04 (terminal 11) <R.H. drive vehicles>
and engine-ECU connector C-127 (terminal 58)
<M/T> or engine-A/T-ECU connector C-124
(terminal 43) <A/T>.
Connector: C-04
C-127 (Y)
<L.H. drive vehicles> C-124 (GR)

Harness side
Harness side
C-124
AC303798 AT

Connector: C-124 <A/T>, C-127 <M/T>

<L.H. drive vehicles>
Harness side
C-127

AC303817AO

C-127 (Y)
C-124 (GR)

Harness side
C-124

Harness side
C-127

AC303805AM

Connector: C-04
<R.H. drive vehicles>

Harness side

AC303814 AT
 CHASSIS ELECTRICAL 54A-47
COMBINATION METER ASSEMBLY

NOTE: Q: Is the wiring harness between combination meter

Connector: C-12, C-14 connector C-04 (terminal 11) and engine-ECU
<L.H. drive vehicles> connector C-127 (terminal 58) <M/T> or
engine-A/T-ECU connector C-124 (terminal 43)
<A/T> in good condition?
YES : Replace the combination meter assembly.
NO : Repair or replace the damage
component(s).

C-14 (GR)
C-12

Harness side
C-12

C-14

AC303801AD

Connector: C-134, C-136

<R.H. drive vehicles>

C-134

C-136 (GR)

Harness side
C-134

C-136

AC303819 AD

Prior to the wiring harness inspection, check

intermediate connector C-14 <LH drive vehicles>,
C-136 <RH drive vehicles>, joint connector C-12
<LH drive vehicles>, C134 <RH drive vehicles> and
repair if necessary.
54A-48 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

INSPECTION PROCEDURE 4: Fuel gauge does not work (the other meters work).

Fuel Gauge Circuit

COMBINATION
METER

CONTROL
CIRCUIT

,
,

FUEL
GAUGE
UNIT
NOTE
LH drive vehicles
RH drive vehicles
LH drive vehicles SEDAN
LH drive vehicles WAGON

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

TECHNICAL DESCRIPTION (COMMENT) TROUBLESHOOTING HINTS

If only the fuel gauge does not operate, fuel gauge • Malfunction of the fuel gauge unit.
unit the combination meter, wiring harness or • The wiring harness or connectors may have
connector(s) may be defective. loose, corroded, or damaged terminals, or
terminals pushed back in the connector.
• Malfunction of the combination meter.
 CHASSIS ELECTRICAL 54A-49
COMBINATION METER ASSEMBLY

DIAGNOSIS PROCEDURE Connector: D-13

<Wagon>

STEP 1. Check the fuel gauge circuit.

(1) Disconnect D-13 fuel gauge unit connector.
Harness side D-13 (B)

MB991219
Test lamp
(12 V - 3.4 W) AC303917 AH

Fuel gauge Earth

Q: Is combination meter connector C-04, fuel gauge
Harness side unit connector D-13 in good condition?
YES : Go to Step 3.
AC305320AB NO : Repair or replace the damaged
component(s).
(2) Connect a test lamp (12 V − 3.4 W) via test
harness (MB991219) between the wiring harness
connector terminals 1 and 2. STEP 3. Check the wiring harness between
(3) Turn the ignition switch to the "ON" position. combination meter connector C-06 (terminal 51)
and fuel gauge unit connector D-13 (terminal 1).
Q: Does the test lamp illuminate?
YES : Go to Step 4. Connector: C-06
NO : . Go to Step 2. <L.H. drive vehicles>

STEP 2. Connector check: Combination meter

connector C-06, fuel gauge unit connector D-13 C-06 (L)

Connector: C-04
<L.H. drive vehicles> Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

AC303798 AV

Connector: C-06
<R.H. drive vehicles>
Harness side

C-06 (L)
AC303798 AT

Connector: D-13
<Sedan> Harness side

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

D-13 (B) AC303814 AU

Harness side

AC303871AI
54A-50 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

Connector: D-13 Connector: D-18

<Sedan> <Sedan>

D-13 (B)

Harness side
Harness side

AC303871AI AC303871AJ

Connector: D-13 Connector: D-18

<Wagon> <Wagon>

D-13 (B) Harness side

Harness side

AC303917 AH AC303917 AG

NOTE: Prior to the wiring harness inspection, check

Connector C-22 intermediate connector C-22 <LH drive vehicles>,
<L.H. drive vehicles> C-120 <RH drive vehicles>, D-18, and repair if
necessary.
Q: Is the wiring harness between combination meter
connector C-06 (terminal 51) and fuel gauge unit
connector D-13 (terminal 1) in good condition?
Harness side
YES : Go to Step 4.
NO : Repair or replace the damaged
component(s). Then go to Step 4.
AC303798 AW

Connector: C-120
STEP 4. Retest the system.
<R.H. drive vehicles> Q: Is the fuel gauge normal?
YES : The procedure is complete. If no
malfunctions are found in all steps, an
intermittent malfunction is suspected (Refer
Harness side to GROUP 00, How to Use
Troubleshooting/Inspection Service
Points-How to Cope with Intermittent
Malfunction P.00-5).
AC303816 AY NO : Replace combination meter.
 CHASSIS ELECTRICAL 54A-51
COMBINATION METER ASSEMBLY

INSPECTION PROCEDURE 5: Engine Coolant Temperature Gauge does not Work (the other meters
work).

Engine Coolant Temperature Gauge Circuit

COMBINATION
METER

CONTROL
CIRCUIT

NOTE
LH drive vehicles
RH drive vehicles

ENGINE COOLANT
TEMPERATURE
GAUGE UNIT

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

TECHNICAL DESCRIPTION (COMMENT) DIAGNOSIS PROCEDURE

If only the engine coolant temperature gauge does
not operate, the combination meter, the wiring STEP 1. Check the engine coolant temperature
harness or its connector may be defective. gauge unit.
Check to see that the engine coolant temperature
TROUBLESHOOTING HINTS gauge unit operate normally. Refer to P.54A-61.
• Malfunction of the engine coolant temperature
gauge unit Q: Is the engine coolant temperature gauge unit
normal?
• The wiring harness or connectors may have
YES : Go to Step 2.
loose, corroded, or damaged terminals, or
NO : Replace the fuel gauge unit. Then go to step
terminals pushed back in the connector.
4.
• Malfunction of the combination meter.
54A-52 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

STEP 2. Connector check: Combination meter STEP 3. Check the wiring harness between
connector C-06 and engine coolant temperature combination meter connector C-06 (terminal 50)
gauge unit connector B-112 and engine coolant temperature gauge unit
connector B-112 (terminal 1).
Connector: B-112
<4G1-MPI> Connector: B-112
<4G1-MPI>

B-112 (B)
Harness side B-112 (B)
Harness side

AC303784 AF
AC303784 AF
Connector: B-112
<4G6-MPI> Connector: B-112
<4G6-MPI>

Harness side
B-112 (B)
Harness side
B-112 (B)

AC303792 AE
AC303792 AE
Connector: C-06
<L.H. drive vehicles> Connector: C-06
<L.H. drive vehicles>

C-06 (L)
C-06 (L)

Harness side
51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
Harness side
AC303798 AV 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

AC303798 AV
Connector: C-06
<R.H. drive vehicles> Connector: C-06
<R.H. drive vehicles>

C-06 (L)
C-06 (L)

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

AC303814 AU 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

AC303814 AU
Q: Is combination meter connector C-06 and engine
coolant temperature gauge unit connector B-112 in
good condition?
YES : Go to Step 3.
NO : Repair or replace the damage
component(s).
 CHASSIS ELECTRICAL 54A-53
COMBINATION METER ASSEMBLY

NOTE: Q: Is the wiring harness between combination meter

Connector: C-13 connector C-06 (terminal 50) and engine coolant
<L.H. drive vehicles> temperature gauge unit connector B-112 (terminal
1) in good condition?
YES : Go to Step 4.
NO : Repair or replace the damage
component(s).
Harness side

STEP 4. Retest the system

Q: Is the engine coolant temperature gauge normal?
AC303800 AG
YES : The procedure is complete. If no
Connector: C-137 malfunctions are found in all steps, an
<R.H. drive vehicles> 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 combination meter.
Harness side

AC303818 AM

Prior to the wiring harness inspection, check

intermediate connectors C-13 <LH drive vehicles>,
C-137 <RH drive vehicles>, and repair if necessary.
54A-54 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

INSPECTION PROCEDURE 6: Combination meter does not work. (the instruments do not work)

Combination Meter Power Source Circuit

IGNITION
BATTERY SWITCH (IG1)

RELAY
BOX

COMBINATION NOTE
METER LH drive vehicles
RH drive vehicles
CONTROL 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

TECHNICAL DESCRIPTION (COMMENT) TROUBLESHOOTING HINTS

The cause is thought to be malfunction of the power, • Malfunction of the combination meter
earth circuitry or combination meter. • Damaged wiring harness or connectors
 CHASSIS ELECTRICAL 54A-55
COMBINATION METER ASSEMBLY

DIAGNOSIS PROCEDURE Q: IS the check result normal?

YES : Go to Step 4.
NO : Go to Step 2.
STEP 1. Voltage measurement at combination
meter connector C-04 in order to check the
battery circuit of power supply system to the STEP 2. Connector check: Combination meter
combination meter. connector C-04.
Connector: C-04
Connector: C-04
<L.H. drive vehicles>
<L.H. drive vehicles>

Harness side
Harness side

AC303798 AT
AC303798 AT

Connector: C-04
Connector: C-04
<R.H. drive vehicles>
<R.H. drive vehicles>

Harness side
Harness side

AC303814 AT
AC303814 AT

(1) Disconnect the combination meter connector Q: Is combination meter connector C-04 in good
C-04 and measure the voltage at combination condition?
meter connector C-04 harness side. YES : Go to Step 3.
NO : Repair or replace the connector. Check to
see that all meters operate.

Connector C-04
(Harness side)

AC301541EZ

(2) Measure the voltage between terminal 7 and

earth.
OK: System voltage
54A-56 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

STEP 3. Check the wiring harness between Connector: C-103

combination meter connector C-04 (terminal 7) <R.H. drive vehicles>
and battery.
Connector: C-04
<L.H. drive vehicles> C-103 (GR)

Harness side

AC303818 AO
Harness side
Connector: C-115
<R.H. drive vehicles>
AC303798 AT

Harness side
Connector: C-04
<R.H. drive vehicles>

AC303816 AZ
Harness side
Prior to the wiring harness inspection, check
intermediate connectors C-27 <LH drive vehicles>,
AC303814 AT C-115 <RH drive vehicles>, joint connector C-103,
and repair if necessary.
NOTE: .
Q: Are the wiring harness between combination meter
Connector: C-27 connector C-04 (terminal 7) and battery in good
<L.H. drive vehicles>
condition?
YES : There is no action to be taken.
NO : Repair or replace the wiring harness. Check
Harness side to see that all meters operate.

AC303798 AX

Connector: C-103
<L.H. drive vehicles>

Harness side C-103 (GR)

AC303802 AG
 CHASSIS ELECTRICAL 54A-57
COMBINATION METER ASSEMBLY

Q: Is the check result normal?

STEP 4. Voltage measurement at combination YES : Go to Step 7.
meter connector C-04 to check the battery circuit NO : Go to Step 5.
of power supply system to the combination
meter.
STEP 5. Connector check: combination meter
Connector: C-04
<L.H. drive vehicles>
connector C-04
Connector: C-04
<L.H. drive vehicles>

Harness side

Harness side
AC303798 AT

Connector: C-04 AC303798 AT

<R.H. drive vehicles>
Connector: C-04
<R.H. drive vehicles>

Harness side

Harness side
AC303814 AT

(1) Measure at combination meter connector C-04 AC303814 AT

without disconnecting the connector.
(2) Turn the ignition switch to “ON” position. Q: Is combination meter connector C-04 in good
condition?
YES : Go to Step 6.
NO : Repair or replace the connector. Check to
see that all meters operate.

Connector: C-04
(Harness side)

AC301541FA

(3) Measure the voltage between terminal 9 and

earth.
OK: System voltage
54A-58 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

STEP 6. Check the wiring harness between Connector: C-210, C-212

combination meter connector C-04 (terminal 9) <R.H. drive vehicles>
and ignition switch (IG1).
Connector: C-03, C-04 Front view
C-04 C-210
<L.H. drive vehicles>

Harness side
C-03
C-03 (B)
C-212
C-04 Harness side
C-210
AC303798 AU

Connector: C-04
C-212
<R.H. drive vehicles>

AC303823 AU
Harness side
Prior to the wiring harness inspection, check
Junction block connectors C-210 and C-212, joint
AC303814 AT
connector C-03 <LH drive vehicles>, and repair if
NOTE: necessary.
Connector: C-210, C-212 Q: Are the wiring harness between combination meter
<L.H. drive vehicles>
connector C-04 (terminal 42) and ignition switch
(IG1) in good condition?
Front view YES : There is no action to be taken.
C-210 NO : Repair or replace the wiring harness. Check
to see that all meters operate.

C-212
Harness side
C-210

C-212

AC303809 AX
 CHASSIS ELECTRICAL 54A-59
COMBINATION METER ASSEMBLY

Q: Is the check result normal?

STEP 7. Resistance measurement at combination YES : Repair or replace the connector.
meter connector C-04 to check the earth circuit NO : Go to Step 8.
to the combination meter.
Connector: C-04
<L.H. drive vehicles>
STEP 8. Connector check: Combination meter
connector C-04.
Connector: C-04
<L.H. drive vehicles>

Harness side

AC303798 AT
Harness side
Connector: C-04
<R.H. drive vehicles> AC303798 AT

Connector: C-04
<R.H. drive vehicles>

Harness side

AC303814 AT
Harness side
(1) Disconnect the combination meter connector
C-04 and measure the resistance at combination AC303814 AT
meter connector C-04.
Q: Is combination meter connector C-04 in good
condition?
YES : Go to Step 9.
NO : Repair or replace the wiring harness. Check
to see that all meters operate.
Connector: C-04
(Harness side)

AC301541FB

(2) Measure the resistance between terminal 1 and

earth.
OK: 2 ohms or less
(3) Measure the resistance between terminal 2 and
earth.
OK: 2 ohms or less
54A-60 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

STEP 9. Check the wiring harness between 2. To prevent the front wheel from moving from side
combination meter connector C-04 (terminal 1 to side, attach tension bars to the tie-down hook,
and 2) and earth. and secure both ends to anchor plates.

Connector: C-04 Tension bar

<L.H. drive vehicles>

Front

Harness side

Anchor plate
AC001288 AB
AC303798 AT

Connector: C-04 3. To prevent the vehicle from moving, attach a chain

<R.H. drive vehicles> or wire to the rear retraction hook, and make sure
the end of the chain or wire is secured.
4. Check if the speedometer indicator range is within
the standard values.
Standard value:
Harness side Standard indicator Allowance range km/h
km/h (mph) (mph)
AC303814 AT 20 (12) 20 − 24 (12 − 15)
40 (25) 40 − 44 (25 − 28)
Q: Are the wiring harness between combination meter
connector C-04 (terminal 1 and 2) and earth in 80 (50) 80 − 85 (50 − 53)
good condition? 120 (75) 121 − 127 (75 − 79)
YES : This procedure is complete.
NO : Repair or replace the wiring harness. Check 160 (100) 162 − 169 (100 − 105)
to see that all meters operate. 200 (125) 203 − 211 (126 − 131)

ON-VEHICLE SERVICE 5. If not to the standard value, inspect for proper tyre
size. If not correct, replace the tyres with original
SPEEDOMETER CHECK size tyres and retest. If correct, replace the
M1543000900423 speedometer. If still not to standard value, replace
Adjust the pressure of tyres to the specified level. the vehicle speed sensor.
(Refer to GROUP 31, On-vehicle Service P.31-7.)
CAUTION TACHOMETER CHECK
M1543001000434
Do not operate the clutch suddenly. Do not
Engine speed
increase/decrease speed rapidly while testing. indicator

Paper clip

Probe for detection

Wheel stopper of engine speed AC305138AB

AC305135AB 1. Attach an external high quality tachometer to the

engine speed detection connector on the harness
1. Set the vehicle onto a speedometer tester and side (such as with a paper clip).
use wheel chocks to hold the rear wheels.
 CHASSIS ELECTRICAL 54A-61
COMBINATION METER ASSEMBLY

NOTE: For tachometer check, use an external 1. Check that resistance value between the fuel
high quality inductive tachometer. gauge terminal and earth terminal is at the
2. Compare the readings of the vehicle tachometer standard value when the fuel tank gauge unit float
and the external tachometer at every engine is between position "F" (highest) and position "E"
speed, and check if the variations are within the (lowest).
standard values. Standard values:
Standard values:
Float Position Resistance of Gauge
Engine speed (r/min) Indication allowance of Position F 3±1Ω
tachometer r/min
Position E 110 ± 1 Ω
700 ± 120
2. Check that resistance value changes smoothly
2, 000 − 175 + 225 when the float moves slowly between position "F"
3, 000 − 175 + 300 (highest) and position "E" (lowest).
3. If all checks are correct, go to fuel tank gauge unit
4, 000 − 225 + 375
float height check. If any check is not correct,
5, 000 − 225 + 425 replace the fuel tank gauge unit.
6, 000 − 225 + 475
FUEL TANK GAUGE UNIT FLOAT HEIGHT
7, 000 − 200 + 500
8, 000 − 100 + 500
A
Position F
FUEL TANK GAUGE UNIT CHECK
M1543001200461
Remove the fuel tank gauge unit. (Refer to GROUP B
Stopper
13C, Fuel Tank P.13C-4.)
FUEL TANK GAUGE UNIT RESISTANCE Position E

AC005209AD

Earth 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:
1 2 3

Float Position Float Centre Hight

Position F (A) 24.1 ± 2.0 mm
Fuel tank gauge unit Position E (B) 151.6 ± 2.0 mm

Position F
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.

ENGINE COOLANT TEMPERATURE

Position E
GAUGE UNIT CHECK
M1543001500398
1. Drain the engine coolant. (Refer to GROUP 14,
AC005208AE
On-vehicle Service P.14-22.)
2. Remove the engine coolant temperature gauge
unit.
54A-62 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

Circuit tester

Thermometer

11 ± 1 N·m
ACX00779 AI ACX00780AH

3. Put engine coolant temperature gauge unit into 4. After inspection, apply specified sealant at
the hot water in specified temperature, and threads of engine coolant temperature gauge unit,
ensure that basic resistance is within standard and tighten to the specified torque.
value. Semi-drying sealant: 3M 1215 or equivalent
Standard value: 104 ± 13.5 Ω (at 70C°) 5. Add engine coolant. (Refer to GROUP 14,
Reference value On-vehicle Service P.14-22.)
Temperature (°C) Resistance Ω
50 230
60 155
80 73
 CHASSIS ELECTRICAL 54A-63
COMBINATION METER ASSEMBLY

COMBINATION METER ASSEMBLY

REMOVAL AND INSTALLATION
M1543021300028

3
AC304803 AB

1. Vehicle speed sensor Removal steps

2. Meter bezel
3. Instrument panel ornament
4. Combination meter assembly
54A-64 CHASSIS ELECTRICAL
COMBINATION METER ASSEMBLY

INSPECTION OUTPUT SHAFT SPEED SENSOR CHECK

M1543019502407
<A/T>
VEHICLE SPEED SENSOR CHECK <M/T>
Refer to P.23A-38.

COMBINATION METER INTERNAL

RESISTANCE CHECK
Turn
Shaft

Resistor
3 – 10 k ¶

AC305188AB

1. Remove the vehicle speed sensor and connect a

3 − 10 kiloohms resistor as shown in the
illustration. AC005210AC

2. Turn the shaft of the vehicle speed sensor and Use circuit tester to measure combination meter
check that there is voltage between terminals 2 − internal resistance.
3. (1 turn = 4 pulses)
Standard Value:
3. If within the standard value, the vehicle speed
sensor is OK. measurin Terminal name Standard
g terminal value (Ω)
If not within the standard value, replace the
vehicle speed sensor. No.
Standard value: 0 or Battery Voltage (1turn = 1-21 Engine coolant temperature 233 ± 3
4pulses) gauge to earth
31-51 Fuel gauge to earth 181 ± 2
 CHASSIS ELECTRICAL 54A-65
COMBINATION METER ASSEMBLY

DISASSEMBLY AND REASSEMBLY

M1543003100341

<1600 (SPORT), 2000>

3

2
4
1

AC305237AB

Disassembly steps Disassembly steps (Continued)

1. Meter glass 4. Bulb
2. Meter panel 5. Combination meter assembly
3. Circuit board cover

<1300, 1600 (COMFORT)>

3

4 1

AC304664AB

Disassembly steps Disassembly steps (Continued)

1. Meter glass 4. Bulb
2. Meter panel 5. Combination meter assembly
3. Circuit board cover
54A-66 CHASSIS ELECTRICAL
HEADLAMP

HEADLAMP
SERVICE SPECIFICATIONS
M1542000300332

Item Standard value Limit

Headlamp aiming Low beam Vertical 0.69° below horizontal (H) ± 0.29° from the
direction standard value
Horizontal Position at which the stat up point ± 0.5° from the
direction of 15° is crossed with vertical line standard value
(V)
Measurement of headlamp illiminous intensity cd − 30,000 cd or more
per one headlamp

TROUBLESHOOTING 7. Place the vehicle on a level floor, perpendicular to

M1542000701281 a flat screen 10 m away from the bulb
Features the headlamp automatic shutdown function centre-marks on the headlamp lens.
to avoid battery drain when the headlamps are left
8. Rock vehicle sideways to allow vehicle to assume
on. The main features are as follows:
its normal position.
• Extinguishes automatically in three minutes if the
ignition switch is turned off with the lighting switch 9. Bounce the front suspension through three (3)
on. oscillations by applying the body weight to hood
• Extinguishes in one second if the driver's door is or bumper.
opened within that 3-minute period.
• If the headlamps are turned on with the ignition (1)
Screen
Screen Headlamp centre line
switch off, the headlamps and tail lamps will
extinguish in three minutes after the driver's door (2) (3)
is opened or closed. Vehicle crntre
centreline
line
The headlamps are controlled by the Smart Wiring (3)
System (SWS). For troubleshooting, refer to
respective Groups below.
10 m
• Not using SWS monitor: GROUP 54B, SWS
Troubleshooting P.54B-38.
• Using SWS monitor: GROUP 54C, SWS
Troubleshooting P.54C-22.
In the centre
ON-VEHICLE SERVICE of headlamps

HEADLAMP AIMING
M1542000900538

PRE-AIMING INSTRUCTIONS
1. Inspect for badly rusted or faulty headlamp
assemblies.
2. These conditions must be corrected before a AC304804 AB

satisfactory adjustment can be made.

10.Four lines of adhesive tape (or equivalent
3. Inspect tyre inflation, and adjust if it is necessary. markings) are required on screen or wall:
4. If the fuel tank is not full, place a weight in luggage (1) Position a vertical tape or mark so that it is
room of the vehicle to simulate weight of a full aligned with the vehicle centre line.
tank (0.8 kg per litre). (2) Measure the distance from the centre-marks
5. There should be no other load in the vehicle other on the headlamp lens to the floor. Transfer the
than driver or substituted weight of approximately measurement to the screen. Horizontal tape or
75 kg placed in driver's position. mark on the screen is for reference of vertical
6. Thoroughly clean the headlamp lenses. adjustment.
 CHASSIS ELECTRICAL 54A-67
HEADLAMP

NOTE: Height from the floor to the centre of

(V)
the headlamps (Reference value): 840 mm
Distance of Headlamp
(3) Measure the distance from the centre line of vertical direction centre
the vehicle to the centre of each headlamp. [0.69˚]
Transfer the measurement to the screen. 15˚
(H)
Vertical tape or mark on the screen with
reference to the centre line of each headlamp
bulb. High intensity
zone

HEADLAMP ADJUSTMENT AC305155AB

CAUTION Standard value:

• Do not cover a headlamp for more than three (Vertical direction) 0.69° below horizontal (H)
minutes to prevent the plastic headlamp lens (Horizontal direction) Position at which the
deformation. stat up point of 15° is crossed with vertical
• When adjusting one headlamp beam, make line (V)
sure that another headlamp is off by
Limit:
disconnecting the connector from it. When
Vertical direction; ± 0.29° from the standard
reconnecting the connector, make sure that
value
the headlamp beam is not disturbed
Horizontal direction; ± 0.5° from the standard
accidentally.
value
1. The low-beam headlamp should project on the
screen upper edge of the beam (cut-off). LUMINOUS INTENSITY MEASUREMENT
M1542001000464
1. Set the headlamps to high-beam.
2. Using a photometer, and following its
Vertical
manufacturer's instruction manual, measure the
direction
headlamp centre intensity and check to be sure
that the limit value is satisfied.
Limit: 30,000 cd or more {When a screen is
Horizontal set 25m ahead of the vehicle}
direction
NOTE: When measuring the intensity, maintain an
AC300567AB engine speed of 2,000 r/min., with the battery fully
charged.
Horizontal
There may be special local regulations pertaining to
direction 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:
Vertical • I = intensity (cd)
direction AC300658AB • E = illumination (lux)
• r = distance (m) from headlamps to illuminometer
2. If not the case, turn the adjusting screws to
achieve the specified low-beam cut-off location on
the aiming screen.
54A-68 CHASSIS ELECTRICAL
HEADLAMP

BULB REPLACEMENT Position Lamp Bulb

M1542001300658
Headlamp Bulb CAUTION
Do not touch the bulb surface bare-handed or
CAUTION with dirty gloves. If dirt is attached on surface of
Do not touch the surface of the bulb with hands the bulb, immediately use alcohol or thinner to
or dirty gloves as the bulb may pop after a short remove dirt, and install the bulb after well dried.
time. If the surface does become dirty, clean it 1.

with alcohol or thinner, and let it dry thoroughly

Position lamp
before installing.
1. Disconnect the battery.
2. Disconnect the connector.

Spring

AC300668AB

Disconnect the connector.

Headlamp bulb 2. Screw out position lamp socket to pull out
position lamp bulb.

AC300667AB Front Turn-Signal Lamp Bulb

3. Remove the socket cover. CAUTION
4. Remove bulb mounting spring to pull out bulb. Do not touch the bulb surface bare-handed or
5. After bulb is replaced, properly reconnect with dirty gloves. If dirt is attached on surface of
connector. the bulb, immediately use alcohol or thinner to
remove dirt, and install the bulb after well dried.
1.

Front turn signal lamp

AC300669AB

Disconnect the connector.

2. Screw out front turn-signal lamp socket to pull out
front turn-signal lamp bulb.
 CHASSIS ELECTRICAL 54A-69
HEADLAMP

HEADLAMP
REMOVAL AND INSTALLATION
M1542001800244

Post-installation Operation
Headlamp Aiming Adjustment (Refer to P.54A-66.)

1
AC304719AB

Removal steps
<<A>> 1. Headlamp assembly

REMOVAL SERVICE POINT 1. Remove the splash shield, the radiator grill, the
<<A>> HEADLAMP ASSEMBLY front bumper assembly installation clips, the
screws and the bolts as shown.
REMOVAL

AC300678
AC300690
2. Slide the front bumper assembly and remove the
headlamp assembly.
54A-70 CHASSIS ELECTRICAL
HEADLAMP

HEADLAMP LEVELING SWITCH

REMOVAL AND INSTALLATION
M1542013700040

2
1

AC304661AB

Removal steps
1. Switch panel
2. Headlamp leveling switch

INSPECTION Terminal No. Switch Resistance

M1542011200908
position
HEAD LAMP LEVELING SWITCH
4-6 0 750 ohms
RESISTANCE CHECK
1 1050 ohms
2 1410 ohms
3 1710 ohms
4 2010 ohms
5-6 0, 1, 2, 3, 4 2830 ohms

AC305186AB
 CHASSIS ELECTRICAL 54A-71
FOG LAMP

FOG LAMP
SERVICE SPECIFICATION
M1542000300343

Item Standard value

Front fog lamp light axis check Illuminates to within 40 metres

SPECIAL TOOL
M1542000600894

Tool Number Name Use

MB990784 Ornament remover Removal of instrument panel
ornament

MB990784

TROUBLESHOOTING • Run the engine at a speed of 2000 r/min to fully

M1542000701292 charge the battery.
When the front fog lamp switch is turned to ON with Turn on the front fog lamps and check that the
the tail lamp or the headlamp on (the tail lamp switch illumination is within the standard value range.
or the headlamp switch is ON), the fog lamp relay Standard value: Illuminates to within 40
turns on, and the fog lamps will illuminate. metres
If the tail lamps or the headlamps are turned off with
the lighting switch OFF while the fog lamps are on, CAUTION
the front fog lamps turn off at the same time to For the fog lamp which is not being measured,
prevent unattended operation. disconnect that fog lamp’s connector if possible
If the tail lamps are turned off by the headlamp so that it does not illuminate while carrying out
automatic shutdown function, the fog lamps turn off the adjustment. Furthermore, make sure that the
at the same time. However, if the tail lamps illuminate light axis does not get shifted when
again, the fog lamps do not. re-connecting the connector.
The front fog lamps 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-38.
• Using SWS monitor: GROUP 54C, SWS
Troubleshooting P.54C-22.

ON-VEHICLE SERVICE Cross-tipped

screwdriver
AC301337AB
FRONT FOG LAMP AIMING CHECK
M1542001100438 If the value is out of the standard value, insert the
After setting the vehicles to the following condition, screwdriver (+) through the aiming hole on the side
adjust the front fog lamp aiming. under cover to adjust by turning the adjusting gear
• Check that the tyre inflation pressure is at the for fog lamp aiming.
value indicated on the tyre pressure labels. NOTE: Horizontal adjustment is not possible.
• Set the vehicle to the unladen condition and park In addition, the method of checking the light axis on a
it on a level surface. screen (simple check) is given below.
• Have a single person (approximately 75 kg) sit in
the driver’s seat.
54A-72 CHASSIS ELECTRICAL
FOG LAMP

CAUTION
In the centre
For the front fog lamp which is not being
of front fog lamps measured, disconnect that fog lamp’s connector
if possible so that it does not illuminate while
carrying out the adjustment. Furthermore, make
sure that the light axis does not get shifted when
re-connecting the connector.

Screen

Screwdriver (+)

3m
Centre of lamp V

H
AC305200AB Cut-off line Vertical direction
1.15˚ (6cm)
1. Place the screen so that it is directly opposite the
centre of the fog lamp at a distance of 3 metres,
High-luminance
and turn on the fog lamps. zone

AC305154 AB

2. Insert the screwdriver (+) through the aiming hole

on the side under cover. By turning the adjusting
gear for fog lamp aiming, align the cutoff line
(border line of the shadow temperature) with the
specified position in the figure.
NOTE: Horizontal adjustment is not possible.
 CHASSIS ELECTRICAL 54A-73
FOG LAMP

FOG LAMP
REMOVAL AND INSTALLATION
M1542001500469

2
4.9 ± 0.7 N·m

AC304660AB

Removal steps Removal steps (Continued)

• Side under cover <<A>> 1. Front fog lamp bulb
2. Front fog lamp assembly

REMOVAL SERVICE POINT 1. Remove the bulb cover.

<<A>> FRONT FOG LAMP BULB 2. Remove the bulb installation spring and extract
REMOVAL the bulb.

CAUTION
Do not touch the surface of the bulb with bare
hands or dirty gloves. If the surface (glass
section) should become dirty, clean it
immediately with alcohol or thinner, and let it dry
thoroughly before installing it.

Spring

AC301335AB
54A-74 CHASSIS ELECTRICAL
FOG LAMP

FOG LAMP SWITCH

REMOVAL AND INSTALLATION
M1542013900033

AC304663AB

Removal steps
1. Instrument panel ornament (Refer to
GROUP 52A, Instrument panel P.52A-2.)
2. Fog lamp switch (front and rear fog lamp
switch)

INSPECTION Switch position Tester Specified

M1542011200919
connection condition
FRONT FOG LAMP SWITCH CONTINUITY
Pressed 1−2 Less than 2
CHECK
ohms
Released 1−2 Open circuit

AC305187AB
 CHASSIS ELECTRICAL 54A-75
REAR FOG LAMP

FRONT FOG LAMP RELAY CHECK Battery voltage Tester Specified

connection condition
Not supplied 1−4 Open circuit
• Connect 1−4 Less than 2
terminal 2 to ohms
the positive
battery terminal
• Connect
Front fog lamp relay
terminal 3 to
the negative
battery terminal

4
1
2 3

AC305276AB

REAR FOG LAMP

TROUBLESHOOTING The fog lamps are controlled by the Smart Wiring
M1542000701300 System (SWS). For Troubleshooting, refer to
If the rear fog lamp switch is turned ON when the respective Groups below.
headlamp or the front fog lamp is turned ON, the rear • Not using SWS monitor: GROUP 54B, SWS
fog lamp is switched ON and OFF alternatively. Troubleshooting P.54B-38.
If the headlamp and the front fog lamp, the rear fog • Using SWS monitor: GROUP 54C, SWS
lamp is turned OFF at the same time. Troubleshooting P.54C-22.

SPECIAL TOOL
M1542000600902

Tool Number Name Use

MB990784 Ornament remover Removal of instrument panel
ornament

MB990784
54A-76 CHASSIS ELECTRICAL
REAR FOG LAMP

REAR FOG LAMP

REMOVAL AND INSTALLATION
M1542009800077

4
5 2
1

3
AC305278AB

Removal steps Removal steps (Continued)

1. Bracket 4. Socket
2. Rear fog lamp assembly 5. Bulb
3. Bezel

REAR FOG LAMP SWITCH Switch position Tester Specified

connection condition
REMOVAL AND INSTALATION
M1542014200015 Pressed 5−6 Less than 2
Refer to P.54A-74. ohms
Released 5−6 Open circuit
INSPECTION
M1542011200942

REAR FOG LAMP SWITCH CONTINUITY

CHECK

AC305187AB
 CHASSIS ELECTRICAL 54A-77
SIDE TURN-SIGNAL LAMP

FRONT FOG LAMP RELAY CHECK Battery voltage Tester Specified

connection condition
Not supplied 1−4 Open circuit
• Connect 1−4 Less than 2
terminal 3 to ohms
the positive
battery terminal
• Connect
terminal 2 to
the negative
Rear fog lamp relay battery terminal

4
1
3 2

AC305279AB

SIDE TURN-SIGNAL LAMP

SPECIAL TOOL
M1542000600913

Tool Number Name Use

MB990784 Ornament remover Removal of side turn-signal lamp

MB990784

SIDE TURN-SIGNAL LAMP

REMOVAL AND INSTALLATION Side turn signal lamps
M1542003300159

REMOVAL SERVICE POINT

MB990784

: Front of vehicle AC005718 AC

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-78 CHASSIS ELECTRICAL
ROOM LAMP

INSTALLATION SERVICE POINT Clamp the thumb on the fender panel the assemble
the side turn signal lamp.

Hook
Claw
Fender panel

Fender panel

: Front of vehicle AC005719 AE

ROOM LAMP
TROUBLESHOOTING
M1542000701311

Dimmer interior lamp control function • Not using SWS monitor: GROUP 54B, SWS
The room lamp off is delayed by ETACS-ECU. The Troubleshooting P.54B-38.
lamps off delay time vary according to the conditions. • Using SWS monitor: GROUP 54C, SWS
The control details are as follows. The lamp delay off Troubleshooting P.54C-22.
Yes/NO and delay time can be set with the settings
(adjustment function). for adjustment methods and Interior lamp automatic shutdown
adjustment details (post-adjustment operations). function <vehicles with keyless entry
• ADJUSTMENT PROCEDURE system>
• Not using SWS monitor: GROUP 54B, The interior lamp automatic shutdown function, dims
P.54B-423. out the room lamp and other interior lamps by
• The room lamp lights up if the ignition switch is at activating the keep relay built-in the ETACS-ECU
the "LOCK" (OFF) position and either of the when the ignition switch is OFF and the
doors are opened (either of the door switches: multi-purpose fuse loaded signals built-in the
ON). At this time, if all doors are closed (all door ETACS-ECU is ON and 30 minutes passes. The
switches: OFF) then the lamp will gradually dim lamps lights back up if the ignition switch is turned to
down to lamps off in about 15 seconds. the ON position or either of the doors is opened
NOTE: When the lamps are dimmed and the ignition (either of the door switches: ON). The function
switch is turned ON or if the door is locked, then Yes/No feature can be changed with the settings
the dimming operations stop and the lamps are (adjustment function). for adjustment methods and
turned OFF. adjustment details (post-adjustment operations).
• When the ignition switch is at the ON position and • ADJUSTMENT PROCEDURE
one of the doors are opened (one of the door • Not using SWS monitor: GROUP 54B,
switches: ON) then the room lamp will light up. At P.54B-423.
this time, if all doors are closed (all door switches: The head lamp are controlled by the Smart Wiring
OFF) then the lamps will dim out. System (SWS). For troubleshooting, refer to
• When the ignition key is pulled out the room lamp respective Groups below.
lights up and then will dim out in 15 seconds. The • Not using SWS monitor: GROUP 54B, SWS
lamp will dim out if the ignition key is inserted Troubleshooting P.54B-38.
again and the door is locked while the timer is • Using SWS monitor: GROUP 54C, SWS
activated. Troubleshooting P.54C-22.
The room lamp is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to
respective Groups below.
 CHASSIS ELECTRICAL 54A-79
REAR COMBINATION LAMP

REAR COMBINATION LAMP

TROUBLESHOOTING • Not using SWS monitor: GROUP 54B, SWS
M1542000701322 Troubleshooting P.54B-38.
The lamps setup on the rear combination lamp is • Using SWS monitor: GROUP 54C, SWS
controlled in the same manner as the lamps of the Troubleshooting P.54C-22.
headlamp assembly. For details go to the reference.
For troubleshooting, refer to respective Groups
below.

SPECIAL TOOL
M1542000600924

Tool Number Name Use

MB990784 Ornament remover Removal of rear combination
lamp assembly

MB990784

REAR COMBINATION LAMP

REMOVAL AND INSTALLATION
M1542003900441

<Sedan>

4.9 ± 0.7 N·m

3
4

1 2
AC304667 AB

Removal steps Removal steps (Continued)

1. Rear combination lamp assembly 3. Socket assembly
2. Rear combination lamp body 4. Bulb
54A-80 CHASSIS ELECTRICAL
HIGH-MOUNTED STOP LAMP

<Wagon>
1

3 4 2

AC304715AB

Removal steps Removal steps (Continued)

1. Rear combination lamp assembly 3. Socket assembly
2. Rear combination lamp body 4. Bulb

HIGH-MOUNTED STOP LAMP

ON-VEHICLE SERVICE Remove socket from trunk compartment, and
replace bulb.
HIGH-MOUNTED STOP LAMP BULB
REPLACEMENT <WITH REAR SHELF>
M1542014600013

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-81
HIGH-MOUNTED STOP LAMP

HIGH-MOUNTED STOP LAMP

REMOVAL AND INSTALLATION
M1542005100452

<Sedan>

<With rear shelf>

6

4
8
5
4.9 ± 0.7 N·m

3 1
2

AC305293AB

Removal steps Removal steps (Continued)

1. Socket assembly 6. High-mounted stop lamp cover
2. Socket (front)
3. Bulb 7. High-mounted stop lamp cover
4. High-mount stop lamp assembly (rear)
5. Socket holder 8. High-mounted stop lamp body
54A-82 CHASSIS ELECTRICAL
HIGH-MOUNTED STOP LAMP

<With rear spoiler>

2 1

AC304750AB

Removal steps
1. Rear spoiler (Refer to GROUP 51,
Rear spoiler P.51-18.)
<<A>> 2. High-mounted stop lamp
 CHASSIS ELECTRICAL 54A-83
HIGH-MOUNTED STOP LAMP

<Wagon>

AC304722AB

Removal steps Removal steps (Continued)

• Tailgate trim upper (Refer to 1. Tailgate spoiler (Refer to GROUP
GROUP 52A, Tailgate trim 51, Tailgate spoiler P.51-19.)
P.52A-19.) • Rear washer nozzle (Refer to
• High-mounted stop lamp connector GROUP 51, Rear wiper and
connection washer P.51-29.)
• Rear washer hose connection 2. High-mounted stop lamp
(Refer to GROUP 51, Rear wiper
and washer P.51-29.)

REMOVAL SERVICE POINT Use the following steps to easily route high-mounted
stop light harness in the event of installation:
<<A>> HIGH-MOUNTED STOP LIGHT
REMOVAL <WITH REAR SPOILER> CAUTION
Ensure that the string is tightly tied.
String 1. Tie a string on the high-mounted stop light
harness (at the connector side).
Connector 2. Carefully pull out the high-mounted stop light.

AC005190 AC
54A-84 CHASSIS ELECTRICAL
LICENCE PLATE LAMP

LICENCE PLATE LAMP

REMOVAL AND INSTALLATION
M1542004200199

<Sedan>

3 2
4
1

AC304716AB

Removal steps Removal steps (Continued)

1. Licence plate lamp lens 3. Socket
2. Packing 4. Licence plate lamp bulb
 CHASSIS ELECTRICAL 54A-85
HAZARD WARNING LAMP SWITCH

<Wagon>

4
5
3
2
1

AC304717AB

Removal steps Removal steps (Continued)

1. Licence plate lamp lens 4. Socket
2. Packing 5. Licence plate lamp bulb
3. Licence plate lamp body 6. Harness

HAZARD WARNING LAMP SWITCH

TROUBLESHOOTING • Not using SWS monitor: GROUP 54B, SWS
M1542000701333 Troubleshooting P.54B-38.
FLASHER TIMER FUNCTION • Using SWS monitor: GROUP 54C, SWS
The hazard warning lamps (flasher timer function) Troubleshooting P.54C-22.
are controlled by the Smart Wiring System (SWS).
For troubleshooting, refer to respective Groups SPECIAL TOOL
M1542000600935
below.
Tool Number Name Use
MB990784 Ornament remover Removal of centre panel and
centre air outlet panel

MB990784
54A-86 CHASSIS ELECTRICAL
HAZARD WARNING LAMP SWITCH

HAZARD WARNING LAMP SWITCH

REMOVAL AND INSTALLATION
M1542006600449

5
3
4
2

AC304721AB

Removal steps Removal steps (Continued)

1. Knob 4. Centre air outlet panel
2. Centre panel 5. Hazard warning lamp switch
3. Meter bezel

INSPECTION Switch position Tester Specified

M1542011200920
connection condition
HAZARD WARNING LAMP SWITCH
Released 1−2 Open circuit
CONTINUITY CHECK
Pressed 1−2 Less than 2
ohms

AC305304
 CHASSIS ELECTRICAL 54A-87
COLUMN SWITCH

COLUMN SWITCH
SPECIAL TOOL
M1542000600946

Tool Number Name Use

MB990784 Ornament remover Removal of column cover

MB990784

COLUMN SWITCH
REMOVAL AND INSTALLATION
M1543009100446

2
A Claw
A
1
A A
A A
A A
1

AC305305AB

Removal steps Removal steps (Continued)

1. Lower column cover 3. Turn-signal and lighting switch
2. Upper column cover 4. Windshield wiper and washer switch
54A-88 CHASSIS ELECTRICAL
COLUMN SWITCH

INSPECTION
M1542011200931

TURN-SIGNAL AND LIGHTING SWITCH Switch position Tester condition Specified

CHECK condition
OFF 3 − 4, 3 − 6, 3 − 7, Open
3 − 8, 3 − 9, 3 − 10, circuit
3 − 11
Headlamp 3−4 Less than
washer switch 2 ohms
At lighting At wiper/washer
switch side switch side Headlamp 3−6 Less than
1 1 switch 2 ohms
2 2
3 3 Tail lamp switch 3−7 Less than
4 4 2 ohms
5 5
6 6 Passing switch 3−8 Less than
7 7 2 ohms
8 8
9 9 Dimmer switch 3−9 Less than
10 10
11 11 2 ohms
AC005499 AD Turn-signal lamp 3 − 10 Less than
switch (RH) 2 ohms
Turn-signal lamp 3 − 11 Less than
switch (LH) 2 ohms
NOTE: Integrated column ECU does not allow
windshield wiper switch continuity test. For
inspection and diagnosis, refer to the respective
Group below.
.
• Not using SWS monitor: GROUP 54B, SWS
Troubleshooting P.54B-38.
• Using SWS monitor: GROUP 54C, SWS
Troubleshooting P.54C-22.
 CHASSIS ELECTRICAL 54A-89
HORN

HORN
REMOVAL AND INSTALLATION
M1543007900413

1
AC304666AB

Removal Steps
1. Horn <LO>
2. Horn <HI>

HORN RELAY CONTINUITY CHECK Battery voltage Tester Specified

M1543019502418
connection condition
Not applied 1−4 Open circuit
• Connect terminal 1 − 4 Less than 2
2 to the positive ohms
battery terminal
• Connect terminal
3 to the negative
battery terminal

Horn relay

4
1
2 3

AC305306AB
54A-90 CHASSIS ELECTRICAL
CLOCK

CLOCK
SPECIAL TOOL
M1543000601663

Tool Number Name Use

MB990784 Ornament remover Removal of centre panel and
centre air outlet panel

MB990784

CLOCK
REMOVAL AND INSTALLATION
M1543005900224

5
3

4
2

AC304720AB

Removal steps Removal steps (Continued)

1. Knob 4. Centre air outlet panel
2. Centre panel 5. Clock
3. Meter bezel
 CHASSIS ELECTRICAL 54A-91
CIGARETTE LIGHTER

CIGARETTE LIGHTER
INSPECTION • Take out the plug, and check for a worn edge on
M1543005700242 the element spot connection, and for shreds of
CIGARETTE LIGHTER CHECK tobacco or other material on the element.
• Using an ohmmeter, check that the element
resistance value is 1.7 ohms.
Element
Spot

ACX01832AE

RHEOSTAT
REMOVAL AND INSTALLATION
M1542006000306

AC304905AB

Removal steps
1. Switch panel
2. Rheostat switch
54A-92 CHASSIS ELECTRICAL
RHEOSTAT

INSPECTION 1. Connect the battery and the test bulb (40 W) as

M1542006100228 shown in the illumination.
RHEOSTAT RESISTANCE CHECK 2. Operate the rheostat, and if brightness changes
smoothly without switching off, rheostat function is
normal.

40 W

AC305310AB
 CHASSIS ELECTRICAL 54A-93
SPEAKER

SPEAKER
REMOVAL AND INSTALLATION
M1544002600454

<Front speaker - Sedan/Wagon>

1 2

<Rear speaker - Wagon>

<Rear speaker - Sedan>

3 5

AC305311AB

Front speaker removal steps Rear speaker <Wagon> removal

1. Front door trim (Refer to GROUP steps
52A, Door trim P.52A-15.) 5. Quarter trim upper (Refer to
2. Front speaker GROUP 52A, Trims P.52A-11.)
Rear speaker <Sedan> removal 6. Rear speaker
steps
3. Rear speaker garnish
4. Rear speaker
54A-94 CHASSIS ELECTRICAL
ANTENNA

ANTENNA
REMOVAL AND INSTALLATION
M1544002900529

<Sedan>
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-11.)
• Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)

1 2 3

AC305315AB

1. Roof antenna pole Removal steps

2. Roof antenna base
• Instrument panel assembly (Refer to
GROUP 52A, Instrument panel assembly
P.52A-2.)
3. Antenna feeder cable
 CHASSIS ELECTRICAL 54A-95
REAR WINDOW DEFOGGER

<Wagon>
Pre-removal and Post-installation Operation
• Front pillar trim, Centre pillar trim lower, Centre pillar trim
upper, Quarter trim lower, Quarter trim upper (Refer to
GROUP 52A − Trims P.52A-11.)
• Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)

1 3
2

AC305316AB

1. Roof antenna pole 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 TROUBLESHOOTING
M1543000100319 M1543000701013

Rear Defogger operation The rear window defogger is controlled by the

The defogger relay turns ON if the defogger switch A/C-ECU. For troubleshooting, refer to GROUP 55-
built-in the A/C-ECU is turned ON when the ignition Troubleshooting P.55-5.
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-96 CHASSIS ELECTRICAL
REAR WINDOW DEFOGGER

ON-VEHICLE SERVICE REAR WINDOW DEFOGGER SWITCH

PRINTED HEATER LINES CHECK REMOVAL AND INSTALLATION
M1543001800311 M1543006200314
Refer to GROUP 55, Heater Control Assembly and
Normal characteristic curve A/C Switch P.55-77.
Voltage
INSPECTION
M1543019502388

A (Centre point)
DEFOGGER RELAY CHECK
Approximately 6 V

Positive Print heater line Negative

terminal terminal

Abnormal characteristic curve

Voltage
Rear windowdefogger relay
Open circuit point

Positive Print heater line Negative

terminal terminal
ACX00813 AC 5
4
1. Run engine at 2,000 r/min. Check heater element 3 1
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
AC305319AB
indicates about six volts.
3. If 12 volts is indicated at A, there is a break in the Battery voltage Tester Specified
negative terminals from A. Move test bar slowly to connection condition
negative terminal to detect where voltage Not supplied 4−5 Open circuit
changes suddenly (0 volts).
• Connect terminal 4−5 Less than 2
4. If 0 volts is indicated at A, there is a break in the 3 to the positive ohms
positive terminals from A. Defect where the battery terminal
voltage changes suddenly (12 volts) in the same • Connect terminal
method described above. 1 to the negative
battery terminal
 55-1

GROUP 55

HEATER, AIR
CONDITIONER AND
VENTILATION
CONTENTS

SERVICE SPECIFICATIONS. . . . . . . 55-3 DIAGNOSIS TROUBLESHOOTING

FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-5
LUBRICANTS . . . . . . . . . . . . . . . . . . 55-3 SYMPTOM CHART . . . . . . . . . . . . . . . . . . . 55-5
SYMPTOM PROCEDURES . . . . . . . . . . . . 55-5
SPECIAL TOOLS. . . . . . . . . . . . . . . . 55-4 CHECK AT ECU TERMINAL <L.H.D.> . . . . 55-67
CHECK AT ECU TERMINAL <R.H.D.>. . . . 55-68
TROUBLESHOOTING . . . . . . . . . . . . 55-5
Continued on next page

W ARNING S REGA RDING SERVICIN G O F SUPPLEMEN TAL R ESTRAINT SYST EM (SRS) EQUIPPED VEHICL ES

Imp roper service o r m aintenance of any comp onent of the SRS, or an y SRS-related com ponent, can lead to
person al in jury o r d eath to service p er so nnel (fro m inadver tent fi rin g of th e air b ag ) or to the dr iver (from
rend er ing the SRS inop er ative).
Service or m ainten ance of an y SRS com pon ent or SRS-related com ponent m ust be perfor med only at an
author ized MITSUBISHI dealer.
M ITSUBISHI dealer p er so nnel m ust thor oughly review th is m an ual, and esp ecially its GROU P 52B - Su pplem en tal
Restraint System (SR S) b efor e beginn ing an y ser vice o r m aintenance of any comp onent of th e SRS or any SRS-
related com ponent.
NOTE
The SRS includes the following components: front impact sens ors , SRS-ECU, SRS warning lamp, air bag module, c lock spring
and interconnecting wiring. Other SRS-related components (that may have to be remov ed/installed in connec tion with SRS
service or maintenance) are indicated in the table of c ontents by an asterisk (*).
55-2

ON-VEHICLE SERVICE. . . . . . . . . . . 55-69 BLOWERMOTOR, RESISTOR AND

SIGHT GLASS REFRIGERANT OUTSIDE/INSIDE AIR SELECTION
LEVEL TEST. . . . . . . . . . . . . . . . . . . . . . . . 55-69 DAMPER CONTROL MOTOR . . . . . . 55-85
MAGNETIC CLUTCH TEST . . . . . . . . . . . . 55-69 REMOVAL AND INSTALLATION . . . . . . . . 55-85
COMPRESSOR DRIVE BELT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-86
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 55-69
DUAL PRESSURE SWITCH CHECK . . . . . 55-69 EVAPORATOR ASSEMBLY . . . . . . . 55-88
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . 55-70 REMOVAL AND INSTALLATION
CORRECTING LOW REFRIGERANT LEVEL <L.H.D.> . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-88
IN CASE THE SERVICE CAN IN USED. . . 55-72 REMOVAL AND INSTALLATION
DISCHARGING SYSTEM . . . . . . . . . . . . . . 55-72 <R.H.D.> . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-89
REFILLING OF OIL IN THE A/C INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-90
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-72
PERFORMANCE TEST . . . . . . . . . . . . . . . 55-73 COMPRESSOR ASSEMBLY AND
REFRIGERANT LEAK REPAIR TENSION PULLEY . . . . . . . . . . . . . . . 55-91
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-74 REMOVAL AND INSTALLATION . . . . . . . . 55-91
COMPRESSOR NOISE CHECK . . . . . . . . 55-74 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-93
POWER RELAY CHECK . . . . . . . . . . . . . . 55-75 DISASSEMBLY AND REASSEMBLY . . . . . 55-94
IDLE-UP OPERATION CHECK . . . . . . . . . 55-76 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-95
CLEAN AIR FILTER REPLACEMENT
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-76
CONDENSER AND CONDENSER
FAN MOTOR. . . . . . . . . . . . . . . . . . . . 55-96
HEATER CONTROL ASSEMBLY AND A/C
REMOVAL AND INSTALLATION . . . . . . . . 55-96
SWITCH . . . . . . . . . . . . . . . . . . . . . . . 55-77
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-97
REMOVAL AND INSTALLATION . . . . . . . . 55-77
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-79
REFRIGERANT LINE . . . . . . . . . . . . . 55-98
DISASSEMBLY AND REASSEMBLY. . . . . 55-79
REMOVAL AND INSTALLATION
<L.H.D.> . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-98
HEATER UNIT, HEATER CORE,
REMOVAL AND INSTALLATION
BLOWER ASSEMBLY AND <R.H.D.> . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-99
EVAPORATOR UNIT* . . . . . . . . . . . . 55-81
REMOVAL AND INSTALLATION . . . . . . . . 55-81 DUCTS . . . . . . . . . . . . . . . . . . . . . . . . 55-101
HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . 55-82
REMOVAL AND INSTALLATION . . . . . . . . 55-101
DISASSEMBLY AND REASSEMBLY
<L.H.D.> . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-82
DISASSEMBLY AND ASSEMBLY VENTILATORS . . . . . . . . . . . . . . . . . . 55-102
<R.H.D.> . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-83 REMOVAL AND INSTALLATION . . . . . . . . 55-102
BLOWER ASSEMBLY . . . . . . . . . . . . . . . . 55-84
DISASSEMBLY AND REASSEMBLY. . . . . 55-84
 HEATER, AIR CONDITIONER AND VENTILATION
SERVICE SPECIFICATIONS
55-3
SERVICE SPECIFICATIONS
M1552000300292

Item Standard value

Idle speed r/min 750 ± 100
Idle-up speed r/min 850 ± 100
Resistor (for blower motor) Ω LO 2.54
ML 1.24
MH 0.6
Air gap (magnetic clutch) mm 0.3 − 0.5

LUBRICANTS
M1552000400299

Item Specified lubricant Quantity

Compressor refrigerant unit lubricant SUN PAG 56 1300, 1600 140 mL
2000 120 mL
Each connection of refrigerant line SUN PAG 56 As required
Refrigerant R134a (HFC-134a) 480 − 520 g
55-4 HEATER, AIR CONDITIONER AND VENTILATION
SPECIAL TOOLS

SPECIAL TOOLS
M1552000600312

Tool Tool number Name Application

MB991367 Special spanner Armature mounting nut of
compressor removal and
installation

B991367

MB991386 Pin

MB991223 Harness set Continuity check and voltage

A A:MB991219 A: Test harness measurement at harness wire or
B:MB991220 B: LED harness connector
C:MB991221 C: LED harness adapter A: For checking connector pin
D:MB991222 D: Probe contact pressure
B
B: For checking power supply
circuit
C: For checking power supply
circuit
C
D: For connecting a locally
sourced tester

MB991223 AC
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-5
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW SYMPTOM CHART
M1552009600364 M1552009900611
Refer to GROUP 00, How to Use NOTE: Refer to GROUP 14, Troubleshooting P.14-5
Troubleshooting/Inspection Service Points P.00-5. for the condenser fan.
Symptom Inspection Reference
Procedure Page
When the ignition switch is "ON" the A/C does not operate. 1 P.55-5
Inside/outside air selection is not possible. 2 P.55-6
When the A/C is operating, temperature inside the passenger 3 P.55-11
compartment does not decrease (cool air is not emitted). <L.H.D.>
When the A/C is operating, temperature inside the passenger 4 P.55-20
compartment does not decrease (cool air is not emitted). <R.H.D.>
Blower fan and motor do not turn. 5 P.55-29
Blower air amount cannot be changed. 6 P.55-39
Rear window defogger function does not operate. 7 P.55-42
Rear window defogger Timer function does not operate. 8 P.55-52
Malfunction of the A/C-ECU power supply system. <L.H.D.> 9 P.55-53
Malfunction of the A/C-ECU power supply system. <R.H.D.> 10 P.55-56
A/C compressor power supply system. 11 P.55-59
Condenser Fan does not operate. 12 Refer to
GROUP 14
P.14-5

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: When the Ignition Switch is "ON" the A/C does not Operate.

COMMENTS ON TROUBLE SYMPTOM Q: Does the blower motor operate when the blower
The blower system or the compressor system may switch is moved to the "HI" position?
YES <L.H.D.> : Refer to Inspection procedure 3
be defective if there is no cool air coming from the
"When the A/C is operating, temperature
spit hole.
inside the passenger compartment does not
TROUBLESHOOTING HINTS decrease (cool air is not emitted). <L.H.D.>
• Malfunction of blower motor P.55-11."
• Malfunction of A/C compressor YES <R.H.D.> : Refer to Inspection procedure 4
"When the A/C is operating, temperature
DIAGNOSIS inside the passenger compartment does not
decrease (cool air is not emitted). <R.H.D.>
P.55-20."
Check that the blower motor operation when the NO : Refer to Inspection procedure 5 "Blower fan
blower switch is moved to the "HI" position. and motor do not turn P.55-29."
(1) Turn the ignition switch to the "ON" position.
(2) Turn the blower switch to the "HI" position.
55-6 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

INSPECTION PROCEDURE 2: Inside/Outside Air Selection is not possible.

Outside/Inside Air Selection Damper Control Motor Circuit

IGNITION
SWITCH (IG2)

OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL MOTOR

A/C-ECU
HEATER CONTROL PANEL <LHD> <RHD>

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM TROUBLESHOOTING HINTS

If the inside/outside air selection damper motor does • Malfunction of the inside/outside air selection
not operate normally, the inside/outside air selection damper motor
damper motor system may be defective. • Damaged the wiring harness or connectors
• Malfunction of the manual air conditioner control
panel (A/C-ECU)
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-7
DIAGNOSIS STEP 3. Voltage measurement at the C-107
outside/inside air selection damper control motor
STEP 1. Check the defogger and A/C operations. connector.
Q: Do the defogger and A/C work normally? Connector: C-107
YES : Go to Step 2. <L.H.D.>
NO <L.H.D.> : Refer to Inspection procedure 9
"Malfunction of the A/C-ECU power supply
system <L.H.D.>P.55-53 ."
NO <R.H.D.> : Refer to Inspection procedure 10
"Malfunction of the A/C-ECU power supply
system <R.H.D.>P.55-56 ." Harness side

AC303804 AD
STEP 2. Connector check: C-107 outside/inside
air selection damper control motor connector Connector: C-107
Connector: C-107 <R.H.D.>
<L.H.D.>

Harness side

Harness side
AC303816 AI

AC303804 AD (1) Disconnect the connector, and measure at the

wiring harness side.
Connector: C-107
(2) Turn the ignition switch to the "ON" position.
<R.H.D.>

Connector C-107
(Harness side)

3 2 1
Harness side 7 6 5 4

AC303816 AI

Q: Is the check result normal? AC301541 EF

YES : Go to Step 3.
NO : Repair the connector. (3) Measure the voltage between terminal 7 and
body earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 5.
NO : Go to Step 4.
55-8 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 4. Check the wiring harness between C-107 Connector: C-106

outside/inside air selection damper control motor <L.H.D.> C-106
connector terminal No.7 and the ignition switch
(IG2).
Connector: C-107
<L.H.D.>

AC303804 AC

Connector: C-106
Harness side
<R.H.D.>

AC303804 AD

Connector: C-107
<R.H.D.>

AC303816 AH
Harness side
Connectors: C-209, C-210
<L.H.D.>
Junction block (front view)
AC303816 AI

NOTE: C-210
Connector: C-35
<L.H.D.>

C-209

C-35 (L)

1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
C-209 C-210
AC303798 AJ Harness side Harness side
6 5 4 3 2 1 2 1
14 13 12 11 10 9 8 7 6 5 4 3
Connector: C-35
<R.H.D.>

AC303809 AF
C-35(L)

AC303814AI
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-9

Connectors: C-209, C-210 STEP 5. Connector check: C-139 A/C-ECU

<R.H.D.> connector
Junction block (front view)
Connector: C-139
<L.H.D.>
C-210
C-209
Harness side
C-139 (B)

C-209
Harness side AC303802 AE
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Connector: C-139
<R.H.D.>
C-210
Harness side
2 1
6 5 4 3
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303823 AE

Prior to the wiring harness inspection, check

AC303818 AJ
intermediate connector C-106, joint connector C-35,
junction block connectors C-209 and C-210, and Q: Is the check result normal?
repair if necessary. YES <L.H.D.> : Go to Step 6.
• Check the outside/inside air selection damper YES <R.H.D.> : Go to Step 7.
control motor power supply line for open circuit. NO : Repair the connector.
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 : Repair the wiring harness.
55-10 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 6. Check the wiring harness between C-107 STEP 7. Check the wiring harness between C-107
outside/inside air selection damper control motor outside/inside air selection damper control motor
connector (terminals 6 and 4) and C-139 A/C-ECU connector (terminals 6 and 4) and C-139 A/C-ECU
connector (terminals 2 and 3). connector (terminals 10 and 11).
Connectors: C-106, C-107 Connectors: C-106, C-107
<L.H.D.> <R.H.D.>
C-107 C-107
C-106 C-106

C-106 C-106

Harness side Harness side

C-107 C-107

AC303804 AK AC303816 AO

Connector: C-139 Connector: C-139

<L.H.D.> <R.H.D.>

Harness side
Harness side
C-139 (B)
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7

AC303802 AE AC303818 AJ

NOTE: Prior to the wiring harness inspection, check NOTE: Prior to the wiring harness inspection, check
intermediate connector C-106, and repair if intermediate connector C-106, and repair if
necessary. necessary.
• Check the outside/inside air selection damper • Check the outside/inside air selection damper
control motor earth line for open or short circuit. control motor earth line for open or short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 8. YES : Go to Step 8.
NO : Repair the wiring harness. NO : Repair the wiring harness.

STEP 8. Check the outside/inside air selection

damper control motor
Refer to P.55-86.
Q: Does outside/inside air selection damper control
motor work normally?
YES : Replace the manual air conditioner control
panel (A/C-ECU).
NO : Replace the outside/inside air selection
damper control motor.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-11

INSPECTION PROCEDURE 3: When the A/C is Operating, Temperature Inside the Passenger
Compartment does not Decrease (Cool Air is not Emitted). <L.H.D.>

A/C-ECU System Circuit

ENGINE-ECU
ENGINE-A/T-ECU

DUAL
PRESSURE
SWITCH

A/C-ECU

HEATER CONTROL PANEL

RESISTOR

AIR THERMO
SENSOR

Wire colour code NOTE

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue M/T
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet A/T
55-12 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

COMMENTS ON TROUBLE SYMPTOM STEP 4. Connector check: B-114 A/C compressor

If cool air is not distributed when the A/C switch is on, connector and C-123 engine-ECU connector
the air thermo sensor or the A/C compressor relay <M/T> or C-122 engine-A/T-ECU connector <A/T>
system may be defective.
Connector: B-114
<4G1-L.H.D.>
TROUBLESHOOTING HINTS
• Improper amount of refrigerant
• Malfunction of the air thermo sensor Harness side
• Malfunction of the dual pressure switch
• Malfunction of the A/C compressor relay
• Malfunction of the A/C refrigerant temperature
switch
B-114 (B)
• Malfunction of the magnetic clutch
AC303782 AC
• Malfunction of the manual air conditioner control
panel (A/C-ECU) Connector: B-114
• Damaged the wiring harness or connectors <4G6-L.H.D.>
• Malfunction of the engine-ECU <M/T> or the
engine-A/T-ECU <A/T>
Harness side
DIAGNOSIS

STEP 1. Check the defogger and outside/inside

air selection damper control motor operation. B-114 (B)
AC303790 AC
Q: Do the defogger and outside/inside air selection
damper control motor work normally? Connectors: C-122 <A/T>, C-123 <M/T>
YES : Go to Step 2. <L.H.D.>
NO : Refer to Inspection procedure 9
"Malfunction of the A/C-ECU power supply
system <L.H.D.>P.55-53 ."

STEP 2. Check the blower motor operation.

Q: Does the blower motor work normally?
YES : Go to Step 3.
NO : Refer to Inspection procedure 5 "Blower fan
and motor do not turn P.55-29." C-122 (GR)
C-123 (Y)

STEP 3. Check the A/C compressor. Harness side

Check the A/C compressor for compressor oil leaks. C-122

Q: Is the check result satisfactory?

YES : Go to Step 4.
NO : Replace the A/C compressor or the C-123
expansion valve.

AC303805 AE

Q: Is the check result normal?

YES : Go to Step 5.
NO : Repair the connector.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-13
STEP 5. Voltage measurement at the B-114 A/C
Connector C-123
compressor connector. (Harness side)
Connector: B-114
<4G1-L.H.D.>

Harness side

AC305159 AB

B-114 (B) (3) Disconnect engine-ECU connector C-123, and

AC303782 AC earth terminal 8. <M/T>

Connector: B-114 Connector C-122

<4G6-L.H.D.> (Harness side)

Harness side

B-114 (B) AC305161AB

AC303790 AC

(1) Disconnect the connector, and measure at the (4) Disconnect engine-A/T-ECU connector C-122,
wiring harness side. and earth terminal 20. <A/T>
(2) Turn the ignition switch to the "ON" position.
Connectors: C-122 <A/T>, C-123 <M/T>
Connector B-114
<L.H.D.>
(Harness side)

AC301541EW

(5) Measure the voltage between terminal 1 and

body earth.
C-122 (GR)
C-123 (Y) OK: System voltage
Harness side Q: Is the check result normal?
C-122 YES : Go to Step 6.
NO : Refer to Inspection procedure 11 "A/C
compressor power supply system P.55-59."
C-123

AC303805 AE
55-14 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 6. Connector check: C-139 A/C-ECU STEP 8. Connector check: C-109 resistor
connector connector
Connector: C-139 Connector: C-109
<L.H.D.> <L.H.D.>

Harness side
C-139 (B)

Harness side

AC303802 AE AC303804 AE

Q: Is the check result normal? Q: Is the check result normal?

YES : Go to Step 7. YES : Go to Step 9.
NO : Repair the connector. NO : Repair the connector.

STEP 7. Voltage measurement at C-139 A/C-ECU STEP 9. Check the wiring harness between C-109
connector. resistor connector terminal No.4 and C-139
A/C-ECU connector terminal No.8.
Connector: C-139
<L.H.D.> Connector: C-109
<L.H.D.>

Harness side
C-139 (B)

Harness side
AC303802 AE

(1) Disconnect the connector, and measure at the AC303804 AE

wiring harness side.

Connector: C-139
(2) Turn the ignition switch to the "ON" position.
<L.H.D.>
(3) Turn the blower switch to the "ON" position.

Connector C-139
Harness side
(Harness side)
C-139 (B)

8 7 6 5 4 3 2 1
AC303802 AE
16 15 14 13 121110 9

Q: Is the check result normal?

YES : The trouble can be an intermittent
AC301541EX
malfunction (Refer to GROUP 00, How to
(4) Measure the voltage between terminal 8 and Cope with Intermittent Malfunction P.00-5).
body earth. NO : Repair the wiring harness.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 10.
NO : Go to Step 8.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-15
STEP 10. Connector check: A-31 dual pressure STEP 13. Check the wiring harness between
switch connector C-106 air thermo sensor connector (terminals 4
and 5) and C-139 A/C-ECU connector (terminals
Connector: A-31
<L.H.D.>
16 and 13).
A-31 (BR)
Connector: C-106
<L.H.D.> C-106
Harness side

AC303839 AH

Q: Is the check result normal? AC303804 AC

YES : Go to Step 11.
NO : Repair the connector. Connector: C-139
<L.H.D.>
STEP 11. Check the dual pressure switch
operation.
Harness side
Refer to P.55-69.
C-139 (B)
Q: Is the dual pressure switch operating properly?
YES : Go to Step 12.
NO : Replace the dual pressure switch.
AC303802 AE
STEP 12. Connector check: C-106 air thermo • Check the air thermo sensor output and earth line
sensor connector for open or short circuit.
Connector: C-106 Q: Is the check result normal?
<L.H.D.> C-106 YES : Go to Step 14.
NO : Repair the wiring harness.

AC303804 AC

Q: Is the check result normal?

YES : Go to Step 13.
NO : Repair the connector.
55-16 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 14. Check the wiring harness between A-31 STEP 15. Connector check: C-125 engine-ECU
dual pressure switch connector terminal No.1 connector <M/T> or C-126 engine-A/T-ECU
and C-139 A/C-ECU connector terminal No.4. connector <A/T>
Connector: A-31 Connectors: C-125 <M/T>, C-126 <A/T>
<L.H.D.> <L.H.D.>
A-31 (BR)

Harness side

C-125 (Y)

AC303839 AH

C-126 (GR)
Connector: C-139
<L.H.D.>

Harness side
Harness side
C-139 (B) C-125 C-126
77 76 75 7473 7271
38 37363534 33 3231
89 88 87 86 85 84 83 82 81 80 79 78
4645 44 4342 41 4039 98 97 96 95 9493 92 91 90

AC303802 AE
AC303805 AG

NOTE:
Connector: C-114 Q: Is the check result normal?
<LHD> YES : Go to Step 16.
NO : Repair the connector.

1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25
AC303804 AN

Prior to the wiring harness inspection, check

intermediate connector C-114, and repair if
necessary.
• Check the dual pressure switch output line for
open or short circuit.
Q: Is the check result normal?
YES : Go to Step 15.
NO : Repair the wiring harness.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-17
STEP 16. Check the wiring harness between NOTE:
Connector: C-15
C-125 engine-ECU connector <M/T> terminal
<L.H.D.>
No.45 or C-126 engine-A/T-ECU connector <A/T>
terminal No.83 and A-31 dual pressure switch
connector terminal No.2.
Connector: A-31
<L.H.D.>
A-31 (BR)
C-15 (L)
AC303800 AE
Harness side

Connector: C-104
<L.H.D.> C-104 (GR)

AC303839 AH

Connectors: C-125 <M/T>, C-126 <A/T>

<L.H.D.>

AC303804 AB

Prior to the wiring harness inspection, check

intermediate connector C-114 and C-15, and repair if
C-125 (Y)
necessary.
• Check the communication line for open or short
circuit.
C-126 (GR)
Q: Is the check result normal?
YES : Go to Step 17.
NO : Repair the wiring harness.
Harness side
C-125 C-126
77 76 75 7473 7271
38 37363534 33 3231
89 88 87 86 85 84 83 82 81 80 79 78
4645 44 4342 41 4039 98 97 96 95 9493 92 91 90

AC303805 AG
55-18 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 17. Connector check: C-123 engine-ECU STEP 18. Check the wiring harness between
connector <M/T> or C-124 engine-A/T-ECU C-123 engine-ECU connectors terminal No.24
connector <A/T> <M/T> or C-124 engine-A/T-ECU connectors
terminal No.61 <A/T> and C-139 A/C-ECU
Connectors: C-123 <M/T>, C-124 <A/T>
connector terminal No.5.
<L.H.D.>
Connectors: C-123 <M/T>, C-124 <A/T>
<L.H.D.>

C-123 (Y)

C-124 (GR) C-123 (Y)

C-124 (GR)

Harness side

C-123 C-124
Harness side
4645 44 43 42 41
57565554 5352 5150 49 48 47
666564 63 62 6160 59 58 C-123 C-124
4645 44 43 42 41
57565554 5352 5150 49 48 47
AC303805 AF 666564 63 62 6160 59 58

Q: Is the check result normal? AC303805 AF

YES : Go to Step 18.
NO : Repair the connector. Connector: C-139
<L.H.D.>

Harness side
C-139 (B)

AC303802 AE
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-19
NOTE: STEP 20. Check the refrigerant temperature
Connector: C-15
switch.
<L.H.D.>
Refer to P.55-95.
Q: Is the refrigerant temperature switch operating
properly?
YES : Go to Step 21.
NO : Replace the refrigerant temperature switch.

C-15 (L)
STEP 21. Check the air thermo sensor.
AC303800 AE Refer to P.55-90.
Prior to the wiring harness inspection, check Q: Is the air thermo sensor in good condition?
intermediate connector C-15, and repair if necessary. YES : Go to Step 22.
• Check the communication line for open or short NO : Replace the air thermo sensor.
circuit.
Q: Is the check result normal? STEP 22. Check the refrigerant level.
YES : Go to Step 19. Refer to P.55-69.
NO : Repair the wiring harness.
Q: Is the refrigerant level correct?
YES : Go to Step 23.
STEP 19. Check the magnetic clutch operation. NO : Correct the refrigerant level (Refer to
Refer to P.55-93. P.55-70).
Q: Can the sound of the magnetic clutch (click) be
heard? STEP 23. Replace the A/C-ECU.
YES : Go to Step 20. Check that the air conditioner works normally.
NO : Replace the compressor magnet clutch.
Q: Is the check result normal?
YES : This diagnosis is complete.
NO : Replace the engine-ECU <M/T> or the
engine-A/T-ECU <A/T>.
55-20 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

INSPECTION PROCEDURE 4: When the A/C is Operating, Temperature Inside the Passenger
Compartment does not Decrease (Cool Air is not Emitted). <R.H.D.>

A/C-ECU System Circuit

ENGINE-ECU
ENGINE-A/T-ECU

DUAL
PRESSURE
SWITCH

A/C-ECU

HEATER CONTROL PANEL

RESISTOR

AIR THERMO
SENSOR

NOTE
Wire colour code M/T
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue A/T
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-21
COMMENTS ON TROUBLE SYMPTOM STEP 4. Connector check: B-114 A/C compressor
If cool air is not distributed when the A/C switch is on, connector and C-123 engine-ECU connector
the air thermo sensor or the A/C compressor relay <M/T> or C-122 engine-A/T-ECU connector <A/T>
system may be defective.
Connector: B-114
TROUBLESHOOTING HINTS <4G1-R.H.D.>

• Improper amount of refrigerant

• Malfunction of the air thermo sensor Harness side
• Malfunction of the dual pressure switch
• Malfunction of the A/C compressor relay
• Malfunction of the A/C refrigerant temperature
switch
• Malfunction of the magnetic clutch B-114 (B)
AC303786 AB
• Malfunction of the manual air conditioner control
panel (A/C-ECU)
Connector: B-114
• Damaged the wiring harness or connectors <4G6-R.H.D.>
• Malfunction of the engine-ECU <M/T> or the
engine-A/T-ECU <A/T>
Harness side
DIAGNOSIS

STEP 1. Check the defogger and outside/inside

air selection damper control motor operation. B-114 (B)
AC303794 AB
Q: Do the defogger and outside/inside air selection
damper control motor work normally? Connectors: C-122 <A/T>, C-123 <M/T>
YES : Go to Step 2. <R.H.D.>
NO : Refer to Inspection procedure 10
"Malfunction of the A/C-ECU power supply
system <R.H.D.>P.55-56 ."

STEP 2. Check the blower motor operation.

Q: Does the blower motor work normally?
YES : Go to Step 3.
NO : Refer to Inspection procedure 5 "Blower fan C-122 (GR)
and motor do not turn P.55-29." C-123 (Y)

STEP 3. Check the A/C compressor. Harness side

Check the A/C compressor for compressor oil leaks. C-122

Q: Is the check result satisfactory?

YES : Go to Step 4.
NO : Replace the A/C compressor or the C-123
expansion valve.

AC303817AF

Q: Is the check result normal?

YES : Go to Step 5.
NO : Repair the connector.
55-22 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 5. Voltage measurement at the B-114 A/C

Connector C-123
compressor connector. (Harness side)
Connector: B-114
<4G1-R.H.D.>

Harness side

AC305159 AB

B-114 (B) (3) Disconnect engine-ECU connector C-123, and

AC303786 AB earth terminal 8. <M/T>
Connector C-122
Connector: B-114
(Harness side)
<4G6-R.H.D.>

Harness side

B-114 (B)
AC305161AB
AC303794 AB

(1) Disconnect the connector, and measure at the (4) Disconnect engine-A/T-ECU connector C-122,
wiring harness side. and earth terminal 20. <A/T>
(2) Turn the ignition switch to the "ON" position.
Connectors: C-122 <A/T>, C-123 <M/T>
<R.H.D.> Connector B-114
(Harness side)

AC301541EW

(5) Measure the voltage between terminal 1 and

C-122 (GR)
body earth.
C-123 (Y)
OK: System voltage
Harness side Q: Is the check result normal?
C-122 YES : Go to Step 6.
NO : Refer to Inspection procedure 11 "A/C
compressor power supply system P.55-59."
C-123

AC303817AF
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-23
STEP 6. Connector check: C-139 A/C-ECU STEP 8. Connector check: C-109 resistor
connector connector
Connector: C-139 Connector: C-109
<R.H.D.> <R.H.D.>

Harness side
C-139 (B) Harness side
6 5 4 3 2 1
12 11 10 9 8 7

AC303818 AJ AC303816 AJ

Q: Is the check result normal? Q: Is the check result normal?

YES : Go to Step 7. YES : Go to Step 9.
NO : Repair the connector. NO : Repair the connector.

STEP 7. Voltage measurement at C-139 A/C-ECU STEP 9. Check the wiring harness between C-109
connector. resistor connector terminal No.4 and C-139
A/C-ECU connector terminal No.8.
Connector: C-139
<R.H.D.> Connector: C-109
<R.H.D.>

Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
Harness side

AC303818 AJ

(1) Disconnect the connector, and measure at the AC303816 AJ

wiring harness side.

Connector: C-139
(2) Turn the ignition switch to the "ON" position.
<R.H.D.>
(3) Turn the blower switch to the "ON" position.

Connector C-139
(Harness side) Harness side
C-139 (B)
6 5 4 3 2 1 6 5 4 3 2 1
12 11 10 9 8 7 12 11 10 9 8 7

AC303818 AJ

Q: Is the check result normal?

YES : The trouble can be an intermittent
AC301541EY
malfunction (Refer to GROUP 00, How to
(4) Measure the voltage between terminal 8 and Cope with Intermittent Malfunction P.00-5).
body earth. NO : Repair the wiring harness.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 10.
NO : Go to Step 8.
55-24 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 10. Connector check: A-31 dual pressure STEP 13. Check the wiring harness between
switch connector C-106 air thermo sensor connector (terminals 4
Connector: A-31
and 5) and C-139 A/C-ECU connector (terminals 4
<R.H.D.> and 6).
A-31 (BR)
Connector: C-106
<R.H.D.>
Harness side

AC303825 AH

Q: Is the check result normal? AC303816 AH

YES : Go to Step 11.
NO : Repair the connector. Connector: C-139
<R.H.D.>
STEP 11. Check the dual pressure switch
operation.
Refer to P.55-69. Harness side
Q: Is the dual pressure switch operating properly? C-139 (B)
6 5 4 3 2 1
YES : Go to Step 12. 12 11 10 9 8 7

NO : Replace the dual pressure switch.

AC303818 AJ
STEP 12. Connector check: C-106 air thermo • Check the air thermo sensor output and earth line
sensor connector for open or short circuit.
Connector: C-106 Q: Is the check result normal?
<R.H.D.> YES : Go to Step 14.
NO : Repair the wiring harness.

AC303816 AH

Q: Is the check result normal?

YES : Go to Step 13.
NO : Repair the connector.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-25
STEP 14. Check the wiring harness between A-31 STEP 15. Connector check: C-125 engine-ECU
dual pressure switch connector terminal No.1 connector <M/T> or C-126 engine-A/T-ECU
and C-139 A/C-ECU connector terminal No.1. connector <A/T>
Connector: A-31 Connectors: C-125 <M/T>, C-126 <A/T>
<R.H.D.> <R.H.D.>
A-31 (BR)

Harness side

C-125 (Y)

AC303825 AH
C-126 (GR)
Connector: C-139
<R.H.D.>

Harness side
Harness side C-125 C-126
C-139 (B)
6 5 4 3 2 1 77 76 75 7473 7271
38 37363534 33 3231
12 11 10 9 8 7 89 88 87 86 85 84 83 82 81 80 79 78
4645 44 4342 41 4039 98 97 96 95 9493 92 91 90

AC303818 AJ
AC303817AH

NOTE:
Q: Is the check result normal?
Connector: C-28
<RHD> YES : Go to Step 16.
NO : Repair the connector.

AC303814 AJ

Prior to the wiring harness inspection, check

intermediate connector C-28, and repair if necessary.
• Check the dual pressure switch output line for
open or short circuit.
Q: Is the check result normal?
YES : Go to Step 15.
NO : Repair the wiring harness.
55-26 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 16. Check the wiring harness between NOTE:

Connector: C-28
C-125 engine-ECU connector <M/T> terminal
<RHD>
No.45 or C-126 engine-A/T-ECU connector <A/T>
terminal No.83 and A-31 dual pressure switch
connector terminal No.2.
Connector: A-31
<R.H.D.>
A-31 (BR)

AC303814 AJ
Harness side

Connector: C-135
<RHD>

AC303825 AH

Connectors: C-125 <M/T>, C-126 <A/T>

<R.H.D.>
C-135 (L)

AC303818 AH

Prior to the wiring harness inspection, check

C-125 (Y) intermediate connector C-28 and C-135, and repair if
necessary.
• Check the communication line for open or short
C-126 (GR) circuit.
Q: Is the check result normal?
YES : Go to Step 17.
NO : Repair the wiring harness.
Harness side
C-125 C-126
77 76 75 7473 7271
38 37363534 33 3231
89 88 87 86 85 84 83 82 81 80 79 78
4645 44 4342 41 4039 98 97 96 95 9493 92 91 90

AC303817AH
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-27
STEP 17. Connector check: C-123 engine-ECU STEP 18. Check the wiring harness between
connector <M/T> or C-124 engine-A/T-ECU C-123 engine-ECU connectors terminal No.24
connector <A/T> <M/T> or C-124 engine-A/T-ECU connectors
terminal No.61 <A/T> and C-139 A/C-ECU
Connectors: C-123 <M/T>, C-124 <A/T>
<R.H.D.> connector terminal No.2.
Connectors: C-123 <M/T>, C-124 <A/T>
<R.H.D.>

C-124 (GR)

C-124 (GR)
C-123 (Y)

C-123 (Y)

Harness side
C-123 C-124
Harness side
4645 44 43 42 41
57565554 5352 5150 49 48 47 C-123 C-124
666564 63 62 6160 59 58
4645 44 43 42 41
57565554 5352 5150 49 48 47
666564 63 62 6160 59 58
AC303817AG

Q: Is the check result normal? AC303817AG

YES : Go to Step 18.
NO : Repair the connector. Connector: C-139
<R.H.D.>

Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7

AC303818 AJ

• Check the communication line for open or short

circuit.
Q: Is the check result normal?
YES : Go to Step 19.
NO : Repair the wiring harness.
55-28 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 19. Check the magnetic clutch operation. STEP 21. Check the air thermo sensor.
Refer to P.55-93. Refer to P.55-90.
Q: Can the sound of the magnetic clutch (click) be Q: Is the air thermo sensor in good condition?
heard? YES : Go to Step 22.
YES : Go to Step 20. NO : Replace the air thermo sensor.
NO : Replace the compressor magnet clutch.
STEP 22. Check the refrigerant level.
STEP 20. Check the refrigerant temperature Refer to P.55-69.
switch.
Q: Is the refrigerant level correct?
Refer to P.55-95. YES : Go to Step 23.
Q: Is the refrigerant temperature switch operating NO : Correct the refrigerant level (Refer to
properly? On-vehicle Service P.55-70).
YES : Go to Step 21.
NO : Replace the refrigerant temperature switch.
STEP 23. Replace the A/C-ECU.
Check that the air conditioner works normally.
Q: Is the check result normal?
YES : This diagnosis is complete.
NO : Replace the engine-ECU <M/T> or the
engine-A/T-ECU <A/T>.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-29

INSPECTION PROCEDURE 5: Blower Fan and Motor do not Turn.

Blower Motor Circuit

IGNITION
FUSIBLE LINK 1 SWITCH (IG2)

<RHD> <LHD>

BLOWER
RELAY

BLOWER
SWITCH

<LHD> <RHD>

<LHD>
<RHD>

BLOWER
MOTOR

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
55-30 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

COMMENTS ON TROUBLE SYMPTOM STEP 3. Resistance measurement at the C-110

If the blower fan and motor does not turn when the blower motor connector.
blower switch is operated, the blower switch may be
defective. Connector: C-110
<L.H.D.>
TROUBLESHOOTING HINTS
• Malfunction of the blower relay
• Malfunction of the blower switch
• Damaged the wiring harness or connectors
• Malfunction of the blower motor Harness side

DIAGNOSIS
AC303804 AF

STEP 1. Check that the blower motor operates Connector: C-110

when the blower switch is moved to the "4 (HI) " <R.H.D.>
position.
(1) Turn the ignition switch to the "ON" position.
(2) Turn the blower switch to the "4 (HI) " position.
Harness side
Q: Does the blower motor operate when the blower
switch is moved to the "4 (HI) " position?
YES : Refer to Inspection procedure 6 "Blower air
amount cannot be changed P.55-39."
AC303816 AK
NO : Go to Step 2.
(1) Disconnect the connector, and measure at the
wiring harness side.
STEP 2. Connector check: C-110 blower motor
connector Connector C-110
(Harness side)
Connector: C-110
<L.H.D.> 1
2

Harness side
AC301541EG

AC303804 AF (2) Measure the resistance between terminal 2 and

body earth.
Connector: C-110
OK: 2 ohms or less
<R.H.D.>
Q: Is the check result normal?
YES : Go to Step 5.
NO : Go to Step 4.
Harness side

AC303816 AK

Q: Is the check result normal?

YES : Go to Step 3.
NO : Repair the connector.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-31
STEP 4. Check the wiring harness between C-110 STEP 5. Voltage measurement at C-110 blower
blower motor connector terminal No.2 and body motor connector.
earth.
Connector: C-110
Connector: C-110 <L.H.D.>
<L.H.D.>

Harness side
Harness side

AC303804 AF
AC303804 AF
Connector: C-110
Connector: C-110 <R.H.D.>
<R.H.D.>

Harness side
Harness side

AC303816 AK
AC303816 AK
(1) Disconnect the connector, and measure at the
• Check the blower motor earth line for open wiring harness side.
circuit. (2) Turn the ignition switch to the "ON" position.
Q: Is the check result normal?
(3) Turn the blower switch to the "4 (HI) " position.
YES : The trouble can be an intermittent
malfunction (Refer to GROUP 00, How to
Connector C-110
Cope with Intermittent Malfunction P.00-5). (Harness side)
NO : Repair the wiring harness.

1
2
AC301541 CA

(4) Measure the voltage between terminal 1 and

body earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 20.
NO : Go to Step 6.
55-32 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 6. Connector check: C-214 blower relay STEP 8. Voltage measurement at C-214 blower
connector relay connector.
Connector: C-214 Connector: C-214
<L.H.D.> <L.H.D.>
Junction block (front view) Junction block (front view)

Junction block side Junction block side

AC303808AL AC303808AL

Connector: C-214 Connector: C-214

<R.H.D.> <R.H.D.>
Junction block (front view) Junction block (front view)

Junction block side Junction block side

AC303822AM AC303822AM

Q: Is the check result normal?

(1) Remove the relay, and measure at the junction
YES : Go to Step 7. block side.
NO : Repair the connector. (2) Turn the ignition switch to the "ON" position.

STEP 7. Check the blower relay continuity. Connector C-214

Refer to P.55-75. (Junction block side)

Q: Is the blower relay continuity in good condition?

YES : Go to Step 8.
NO : Replace the blower relay.
3 2 1
4
5
AC301541EI

(3) Measure the voltage between terminal 3 and

earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 10.
NO : Go to Step 9.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-33
Q: Is the check result normal?
STEP 9. Check the wiring harness between C-214
YES : The trouble can be an intermittent
blower relay connector terminal No.3 and the
malfunction (Refer to GROUP 00, How to
ignition switch (IG2).
Cope with Intermittent Malfunction P.00-5).
Connectors: C-210, C-214 NO : Repair the wiring harness.
<L.H.D.>
Junction block (front view)
STEP 10. Resistance measurement at C-214
C-210 blower relay connector.
Connector: C-214
<L.H.D.>
Junction block (front view)

C-214

Junction block side

Harness side Junction block side

AC303808AL
C-210 C-214

Connector: C-214
<R.H.D.>
Junction block (front view)

AC303809 AL
Junction block side
Connectors: C-210, C-214
<R.H.D.>
Junction block (front view)
AC303822AM

C-210 (1) Remove the relay, and measure at the junction

block side.

Connector C-214
(Junction block side)
C-214

3 2 1
Harness side Junction block side 4
C-210 C-214 5
AC301541EJ

(2) Measure the resistance Continuity between

terminal 1 and body earth.
OK: 2 ohms or less
AC303823 AK
Q: Is the check result normal?
NOTE: Prior to the wiring harness inspection, check YES : Go to Step 13.
NO <L.H.D.> : Go to Step 11.
junction block connector C-210, and repair if
NO <R.H.D.> : Go to Step 12.
necessary.
• Check the blower relay power supply line for
open circuit.
55-34 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 11. Check the wiring harness between STEP 12. Check the wiring harness between
C-214 blower relay connector terminal No.1 and C-214 blower relay connector terminal No.1 and
earth. earth.
Connectors: C-212, C-214 Connectors: C-212, C-214
<L.H.D.> <R.H.D.>
Junction block (front view) Junction block (front view)

C-212 C-214 Junction block side C-212 C-214

Junction block side
C-214
C-214

Harness side
Harness side
C-212
C-212

AC303809 AP AC303823 AO

NOTE: Prior to the wiring harness inspection, check NOTE:

junction block connectors C-212, and repair if Connector: C-07
necessary. <R.H.D.>
• Check the blower relay earth wires for open
circuit.
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 : Repair the wiring harness.
AC303814 AR

Prior to the wiring harness inspection, check junction

block connectors C-212 and joint connectors C-07,
and repair if necessary.
• Check the blower relay earth wires for open
circuit.
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 : Repair the wiring harness.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-35
STEP 13. Voltage measurement at C-214 blower STEP 14. Check the wiring harness between
relay connector. C-214 blower relay connector terminal No.5 and
fusible link (1).
Connector: C-214
<L.H.D.> Connectors: C-211, C-214
Junction block (front view) <L.H.D.>
Junction block (front view)

Junction block side C-211

AC303808AL

C-214
Connector: C-214
<R.H.D.>
Junction block (front view)

Harness side Junction block side

C-211 C-214
Junction block side

AC303822AM

(1) Remove the relay, and measure at the junction AC303809 AN

block side.
NOTE:
Connector C-214 Connector: C-21
(Junction block side) <L.H.D.>
3 2 1
4
5

AC301541EK AC303798 AK

(2) Measure the voltage between terminal 5 and Prior to the wiring harness inspection, check
body earth. intermediate connectors C-21 and junction block
OK: System voltage connector C-211, and repair if necessary.
• Check the blower relay power supply line for
Q: Is the check result normal? open circuit.
YES : Go to Step 16.
NO <L.H.D.> : Go to Step 14. Q: Is the check result normal?
NO <R.H.D.> : Go to Step 15. YES : The trouble can be an intermittent
malfunction (Refer to GROUP 00, How to
Cope with Intermittent Malfunction P.00-5).
NO : Repair the wiring harness.
55-36 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

Q: Is the check result normal?

STEP 15. Check the wiring harness between
YES : The trouble can be an intermittent
C-214 blower relay connector terminal No.5 and
malfunction (Refer to GROUP 00, How to
fusible link (1).
Cope with Intermittent Malfunction P.00-5).
Connectors: C-211, C-214 NO : Repair the wiring harness.
<R.H.D.>
Junction block (front view)
STEP 16. Connector check: C-140 blower switch
connector

C-211 Connector: C-140

<L.H.D.>

Harness side
C-214

Harness side Junction block side

AC303802 AF
C-211 C-214

Connector: C-140
<R.H.D.>

AC303823 AL Harness side

NOTE:
Connector: C-121
<RHD>
AC303818 AK

Q: Is the check result normal?

YES : Go to Step 17.
NO : Repair the connector.

STEP 17. Check the blower switch continuity.

AC303816 AB Refer to P.55-79.
Q: Is the blower switch continuity in good condition?
Connector: C-138 YES : Go to Step 18.
<R.H.D.>
NO : Replace the blower switch.

AC303818 AI

Prior to the wiring harness inspection, check

intermediate connectors C-121, C-138 and junction
block connector C-211, and repair if necessary.
• Check the blower relay power supply line for
open circuit.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-37
STEP 18. Check the wiring harness between Connectors: C-210, C-214
C-140 blower switch connector terminal No.2 and <R.H.D.>
C-214 blower relay connector terminal No.4. Junction block (front view)

Connector: C-140 C-210

<L.H.D.>

Harness side

C-214

AC303802 AF

Harness side Junction block side

Connector: C-140 C-210 C-214
<R.H.D.>

Harness side

AC303823 AK

NOTE: Prior to the wiring harness inspection, check

AC303818 AK
junction block connectors C-210, and repair if
necessary.
Connectors: C-210, C-214 • Check the blower relay output line for open
<L.H.D.> circuit.
Junction block (front view)
Q: Is the check result normal?
YES : Go to Step 19.
C-210
NO : Repair the wiring harness.

C-214

Harness side Junction block side

C-210 C-214

AC303809 AL
55-38 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

Q: Is the check result normal?

STEP 19. Check the wiring harness between
YES : The trouble can be an intermittent
C-110 blower motor connector terminal No.1 and
malfunction (Refer to GROUP 00, How to
C-140 blower switch connector terminal No.6.
Cope with Intermittent Malfunction P.00-5).
Connector: C-110 NO : Repair the wiring harness.
<L.H.D.>

STEP 20. Check the blower fan and motor

operation.
Refer to P.55-86.
Q: Is the check result normal?
Harness side
YES : The trouble can be an intermittent
malfunction (Refer to GROUP 00, How to
AC303804 AF Cope with Intermittent Malfunction P.00-5).
NO : Replace the blower motor.
Connector: C-110
<R.H.D.>

Harness side

AC303816 AK

Connector: C-140
<L.H.D.>

Harness side

AC303802 AF

Connector: C-140
<R.H.D.>

Harness side

AC303818 AK

• Check the blower motor power supply line for

open circuit.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-39

INSPECTION PROCEDURE 6: Blower Air Amount cannot be Changed.

Blower Switch and Resistor Circuit

BLOWER RELAY

BLOWER
SWITCH

RESISTOR

<LHD>
<RHD>

BLOWER
MOTOR

Wire colour code

B : Black LG : Light green G : Green L : Blue
W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM DIAGNOSIS

If the blower air amount can not be changed when
the blower switch is operated, the blower switch may STEP 1. Check that the blower motor operates
be defective. when the blower switch is moved to the "4 (HI)"
position.
TROUBLESHOOTING HINTS
(1) Turn the ignition switch to the "ON" position.
• Malfunction of the resistor (2) Turn the blower switch to the "4 (HI) " position.
• Damaged the wiring harness or connectors
• Malfunction of the blower switch Q: Does the blower motor operate when the blower
switch is moved to the "4 (HI)" position?
YES : Go to STEP 2.
NO : Refer to Inspection procedure 5 "Blower fan
and motor do not turn P.55-29."
55-40 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 2. Connector check: C-140 blower switch STEP 3. Check the blower switch continuity.
connector and C-109 resistor connector Refer to P.55-79.
Connector: C-109 Q: Is the blower switch continuity in good condition?
<L.H.D.> YES : Go to Step 4.
NO : Replace the blower switch.

STEP 4. Check the resistor resistance value.

Refer to P.55-86.
Harness side Q: Is the measured value at the standard value?
YES : Go to Step 5.
NO : Replace the resistor.
AC303804 AE

Connector: C-109 STEP 5. Check the wiring harness between C-140

<R.H.D.> blower switch connector (terminals 1, 4 and 5)
and C-109 resistor connector (terminals 4, 1 and
3).
Connector: C-109
Harness side
<L.H.D.>

AC303816 AJ

Connector: C-140
Harness side
<L.H.D.>

AC303804 AE
Harness side
Connector: C-109
<R.H.D.>

AC303802 AF
Harness side
Connector: C-140
<R.H.D.>

AC303816 AJ

Harness side

AC303818 AK

Q: Is the check result normal?

YES : Go to Step 3.
NO : Repair the connector.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-41
Q: Is the check result normal?
Connector: C-140 YES : Go to Step 7.
<L.H.D.>
NO : Repair the connector.

Harness side STEP 7. Check the wiring harness between C-110

blower motor connector (terminal 1) and C-109
resistor connector (terminal 2).

Connectors: C-109, C-110

<L.H.D.>
AC303802 AF

Connector: C-140
<R.H.D.>
C-109
Harness side
C-109 C-110
Harness side C-110

AC303804 AL

Connectors: C-109, C-110

<R.H.D.>
AC303818 AK

• Check the blower switch output line for open

circuit. Harness side C-109
Q: Is the check result normal? C-109 C-110
YES : Go to Step 6.
NO : Repair the wiring harness. C-110

AC303816 AP
STEP 6. Connector check: C-110 blower motor
• Check the blower motor power supply line for
connector
open circuit.
Connector: C-110
Q: Is the check result normal?
<L.H.D.>
YES : No action to be taken.
NO : Repair the wiring harness.

Harness side

AC303804 AF

Connector: C-110
<R.H.D.>

Harness side

AC303816 AK
55-42 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

INSPECTION PROCEDURE 7: Rear Window Defogger Function does not Operate.

Rear Window Defogger Circuit

IGNITION
SWITCH (IG2) FUSIBLE LINK 1

<RHD> <LHD>

REAR WINDOW
DEFOGGER
RELAY

<LHD>
<RHD>

<RHD>
REAR WINDOW REAR WINDOW
<LHD> DEFOGGER
DEFOGGER
A/C-ECU OR
HEATER
CONTROL UNIT

<LHD> <RHD> NOTE

: SEDAN <LHD>
: WAGON <LHD>
: SEDAN <RHD>
: WAGON <RHD>

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
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-43
COMMENTS ON TROUBLE SYMPTOM STEP 2. Connector check: F-22 rear window
If the rear window defogger does not operate when defogger connector
the rear window defogger switch is turned on, the
Connector: F-22
rear window defogger relay system may be <WAGON - L.H.D.>
defective.
Harness side
TROUBLESHOOTING HINTS
• Malfunction of the rear window defogger relay
• Malfunction of the rear window defogger
• Damaged the wiring harness or connectors
• Malfunction of the manual air conditioner control
panel (A/C-ECU) or the heater control unit
AC303954 AI

DIAGNOSIS Connector: F-22

<SEDAN - L.H.D.>

STEP 1. Check the A/C and outside/inside air

selection damper control motor operation. Harness side

Q: Do the A/C and outside/inside air selection damper

control motor work normally?
YES : Go to Step 2.
NO <L.H.D.> : Refer to Inspection procedure 9
"Malfunction of the A/C-ECU Power Supply
AC303943 AD
system <L.H.D.>P.55-53 ."
NO <R.H.D.> : Refer to Inspection procedure 10 Connector: F-22
"Malfunction of the A/C-ECU Power Supply <WAGON - R.H.D.>
system <R.H.D.>P.55-56 ." Harness side

AC303956 AH

Connector: F-22
<SEDAN - R.H.D.>

Harness side

AC303945 AE

Q: Is the check result normal?

YES : Go to Step 3.
NO : Repair the connector.
55-44 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 3. Voltage measurement at F-22 rear (2) Turn the ignition switch to the "ON" position.
window defogger connector. (3) Turn the rear window defogger switch to the "ON
" position.
Connector: F-22
<WAGON - L.H.D.> SEDAN <L.H.D.> and WAGON <R.H.D.>
Connector F-22
Harness side
(Harness side)

1
AC303954 AI

Connector: F-22 AC400965AJ

<SEDAN - L.H.D.>
SEDAN <R.H.D.> and WAGON <L.H.D.>

Harness side Connector F-22

(Harness side)

AC303943 AD

Connector: F-22
<WAGON - R.H.D.> AC400965AI

Harness side (4) Measure the voltage between terminal 1 and

body earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 14.
NO : Go to Step 4.

AC303956 AH

Connector: F-22
<SEDAN - R.H.D.>

Harness side

AC303945 AE

(1) Disconnect the connector, and measure at the

wiring harness side.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-45
STEP 4. Connector check: C-213 rear window STEP 6. Voltage measurement at C-213 rear
defogger relay connector window defogger relay connector.
Connector: C-213 Connector: C-213
<L.H.D.> <L.H.D.>
Junction block (front view) Junction block (front view)

Junction block side Junction block side

AC303808AK AC303808AK

Connector: C-213 Connector: C-213

<R.H.D.> <R.H.D.>
Junction block (front view) Junction block (front view)

Junction block side Junction block side

AC303822AL AC303822AL

Q: Is the check result normal?

(1) Remove the relay, and measure at the junction
YES : Go to Step 5. block side.
NO : Repair the connector.
Connector C-213
(Junction block side)
STEP 5. Check the rear window defogger relay 3 2 1
continuity. 4
Refer to P.54A-96. 5

Q: Is the rear window defogger relay continuity in

good condition?
YES : Go to Step 6.
NO : Replace the rear window defogger relay.
AC301541EN

(2) Measure the voltage between terminal 5 and

body earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 9.
NO <L.H.D.> : Go to Step 7.
NO <R.H.D.> : Go to Step 8.
55-46 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 7. Check the wiring harness between C-213 STEP 8. Check the wiring harness between C-213
rear window defogger relay connector terminal rear window defogger relay connector terminal
No.5 and the fusible link (1). No.5 and the fusible link (1).
Connectors: C-211, C-213 Connectors: C-211, C-213
<L.H.D.> <RHD>
Junction block (front view) Junction block (front view)

C-211 C-211

C-213
C-213

Harness side Junction block side Harness side Junction block side
C-211 C-213 C-211 C-213

AC303809 AM AC303823 AM

NOTE: NOTE:
Connector: C-21 Connector: C-121
<L.H.D.> <R.H.D.>

AC303798 AK AC303816 AB

Prior to the wiring harness inspection, check

Connector: C-138
intermediate connector C-21 and junction block
<R.H.D.>
connector C-211, and repair if necessary.
• Check the rear window defogger relay power
supply line for open circuit.
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 : Repair the wiring harness. AC303818 AI
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-47
Prior to the wiring harness inspection, check STEP 10. Check the wiring harness between
intermediate connector C-121 and C-138 and
junction block connector C-211, and repair if C-213 rear window defogger relay connector
necessary. terminal No.3 and ignition switch (IG2).
• Check the rear window defogger relay power
Connectors: C-210, C-213
supply line for open circuit.
<L.H.D.>
Q: Is the check result normal? Junction block (front view)
YES : The trouble can be an intermittent
malfunction (Refer to GROUP 00, How to C-210
Cope with Intermittent Malfunction P.00-5).
NO : Repair the wiring harness.

STEP 9. Voltage measurement at C-213 rear

window defogger relay connector. C-213

Connector: C-213
<L.H.D.>
Junction block (front view)

Harness side Junction block side

C-210 C-213
Junction block side

AC303808AK

AC303809 AK
Connector: C-213
<R.H.D.>
Junction block (front view) Connectors: C-210, C-213
<R.H.D.>
Junction block (front view)

Junction block side C-210

AC303822AL

(1) Remove the relay, and measure at the junction C-213

block side.
(2) Turn the ignition switch to the "ON" position.

Connector C-213
(Junction block side) Harness side Junction block side
C-210 C-213

3 2 1
4
5 AC303823 AI
AC301541EO

(3) Measure the voltage between terminal 3 and

earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 11.
NO : . Go to Step 10.
55-48 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

NOTE: Prior to the wiring harness inspection, check Connectors: C-213, C-216
junction block connector C-210, and repair if <R.H.D.>
necessary. Junction block (front view)
• Check the rear window defogger relay power
supply line for open circuit.
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 : Repair the wiring harness. C-213

C-216
STEP 11. Check the wiring harness between
C-213 rear window defogger relay connector
terminal No.4 and F-22 rear window defogger Harness side Junction block side
connector terminal No.1. C-213
C-216
Connectors: C-213, C-215
7 6 5 4 3 2 1
<L.H.D.> 15 14 13 12 11 10 9 8
Junction block (front view)

AC303823 AS

Connectors: F-02, F-22

<WAGON - L.H.D.>

C-213 Harness side

F-02
F-22
C-215 F-22

Harness side Junction block side F-02

C-213
C-215
AC303954 AJ
7 6 5 4 3 2 1
15 14 13 12 11 10 9 8
Connector: F-22
<SEDAN - L.H.D.>

AC303809 AR Harness side

AC303943 AD
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-49
Connector: F-22 STEP 12. Connector check: C-139 A/C-ECU
<WAGON - R.H.D.> connector or heater control unit connector
Harness side
Connector: C-139
<L.H.D.>

Harness side
C-139 (B)

AC303956 AH

Connector: F-22
<SEDAN - R.H.D.> AC303802 AE

Connector: C-139
Harness side <R.H.D.>

Harness side
C-139 (B)
6 5 4 3 2 1
AC303945 AE 12 11 10 9 8 7

NOTE: Prior to the wiring harness inspection, check

intermediate connector F-02 <WAGON-L.H.D> and AC303818 AJ

junction block connector C-215 <L.H.D.> or C-216

Q: Is the check result normal?
<R.H.D.>, and repair if necessary.
YES : Go to Step 13.
• Check the rear window defogger relay output line
NO : Repair the connector.
for open circuit.
Q: Is the check result normal?
YES : Go to Step 12.
NO : Repair the wiring harness.
55-50 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 13. Check the wiring harness between Connectors: C-212, C-213
C-213 rear window defogger relay connector <R.H.D.>
terminal No.1 and C-139 A/C-ECU connector or Junction block (front view)
heater control unit connector terminal No.1
<L.H.D.> or C-139 A/C-ECU connector or heater
control unit connector terminal No.9 <R.H.D.>.
Connector: C-139
<L.H.D.>

C-213
C-212
Junction block side
Harness side
C-139 (B) C-213

Harness side
AC303802 AE C-212

Connector: C-139
<R.H.D.>

AC303823 AN

Harness side NOTE: Prior to the wiring harness inspection, check

6 5 4 3 2 1
C-139 (B) junction block connector C-212, and repair if
12 11 10 9 8 7 necessary.
• Check the rear window defogger relay earth line
AC303818 AJ
for open or short circuit.
Q: Is the check result normal?
Connectors: C-212, C-213 YES : Replace the manual air conditioner control
<L.H.D.> panel (A/C-ECU) or the heater control unit.
Junction block (front view) NO : Repair the wiring harness.

C-213
C-212 Junction block side
C-213

Harness side
C-212

AC303809 AO
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-51
Q: Is the check result normal?
STEP 14. Connector check: F-06 rear window
YES : Go to Step 15.
defogger connector NO : Repair the connector.
Connector: F-06
<WAGON - L.H.D.>
STEP 15. Resistance measurement at F-06 rear
Harness side window defogger connector.
Connector: F-06
<SEDAN - L.H.D.>
Harness side

AC303954 AH

Connector: F-06
<SEDAN - L.H.D.>
Harness side AC303943 AE

Connector: F-06
<SEDAN - R.H.D.>
Harness side

AC303943 AE

Connector: F-06
<WAGON - R.H.D.>
Harness side AC303945 AF

(1) Disconnect the connector, and measure at the

wiring harness side.

Connector F-06
(Harness side)
AC303956 AG

Connector: F-06
<SEDAN - R.H.D.>
Harness side 1

AC301541EP

(2) Measure the resistance value between terminal 1

and earth.
OK: 2 ohms or less
AC303945 AF
Q: Is the check result normal?
YES : Go to Step 17.
NO : Go to Step 16.
55-52 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

Q: Is the check result normal?

STEP 16. Check the wiring harness between F-06
YES : The trouble can be an intermittent
rear window defogger connector terminal No.1
malfunction (Refer to GROUP 00, How to
and earth.
Cope with Intermittent Malfunction P.00-5).
Connector: F-06 NO : Repair the wiring harness.
<SEDAN - L.H.D.>
Harness side
STEP 17. Check the rear window defogger.
Refer to GROUP 54A, Rear window defogger
P.54A-96.
Q: Does the rear window defogger work normally?
YES : Replace the manual air conditioner control
panel (A/C-ECU) or the heater control unit.
AC303943 AE NO : Repair the rear window defogger.

Connector: F-06
<SEDAN - R.H.D.>
Harness side

AC303945 AF

• Check the rear window defogger earth line for

open circuit.

INSPECTION PROCEDURE 8: Rear Window Defogger Timer Function does not Operate.

COMMENTS ON TROUBLE SYMPTOM DIAGNOSIS

Turn ON the rear window defogger switch. If the rear
window defogger does not shut off after roughly 11 Check the performance of the rear window
minutes then the rear window defogger timer is defogger timer operations.
malfunctioning. (1) Turn the ignition switch to the "ON" position.
(2) Turn the rear window defogger switch to the "ON"
TROUBLESHOOTING HINTS
position (operate for approx. 11 minutes)
• Malfunction of the manual air conditioner control
panel (A/C-ECU) or the heater control unit Q: Does the rear window defogger timer function
work normally?
YES : Intermittent malfunction
NO : Replace the manual air conditioner control
panel (A/C-ECU) or the heater control unit.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-53

INSPECTION PROCEDURE 9: Malfunction of the A/C-ECU Power Supply System. <L.H.D.>

A/C-ECU Power Supply Circuit

IGNITION
SWITCH (IG2)

A/C-ECU
HEATER CONTROL PANEL

Wire colour code

B : Black LG : Light green G : Green L : Blue
W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM TROUBLESHOOTING HINTS

The A/C-ECU power system may be defective if the • Damaged the wiring harness or connectors
air conditioner, defogger, and outside/inside air • Malfunction of the manual air conditioner control
selection damper motor all do not operate normally. panel (A/C-ECU)
55-54 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

DIAGNOSIS STEP 3. Check the wiring harness between C-139

A/C-ECU connector terminal No.10 and the
STEP 1. Connector check: C-139 A/C-ECU ignition switch (IG2).
connector Connector: C-139
<L.H.D.>
Connector: C-139
<L.H.D.>

Harness side
C-139 (B)
Harness side
C-139 (B)

AC303802 AE

AC303802 AE
NOTE:
Connectors: C-210, C-212
Q: Is the check result normal?
<L.H.D.>
YES : Go to Step 2.
Junction block (front view)
NO : Repair the connector.
C-210
STEP 2. Voltage measurement the voltage at
C-139 A/C-ECU connector.
Connector: C-139
<L.H.D.>
C-210
C-212
Harness side
Harness side
C-139 (B)

C-212
Harness side

AC303802 AE

(1) Disconnect the connector, and measure at the

wiring harness side.
(2) Turn the ignition switch to the "ON" position.
AC303809 AJ

Connector C-139 Prior to the wiring harness inspection, check junction

(Harness side) block connectors C-210 and C-212, and repair if
necessary.
8 7 6 5 4 3 2 1 • Check the A/C-ECU power supply line for open
16 15 14 13 121110 9 circuit.
Q: Is the check result normal?
YES : The trouble can be an intermittent
malfunction (Refer to GROUP 00, How to
AC301541EQ
Cope with Intermittent Malfunction P.00-5).
NO : Repair the wiring harness.
(3) Measure the voltage between terminal 10 and
body earth.
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 4.
NO : Go to Step 3.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-55
STEP 4. Resistance measurement resistance at STEP 5. Check the wiring harness between C-139
C-139 A/C-ECU connector. A/C-ECU connector terminal No.12 and the earth.
Connector: C-139 Connector: C-139
<L.H.D.> <L.H.D.>

Harness side Harness side

C-139 (B) C-139 (B)

AC303802 AE AC303802 AE

(1) Disconnect the connector, and measure at the NOTE:

wiring harness side. Connector: C-104
<L.H.D.> C-104 (GR)
Connector C-139
(Harness side)

8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC303804 AJ

AC301541ER Prior to the wiring harness inspection, check joint

connector C-104, and repair if necessary.
(2) Measure the resistance between terminal 12 and
• Check the A/C-ECU earth line for open circuit.
body earth.
OK: 2 ohms or less Q: Is the check result normal?
YES : Replace the manual air conditioner control
Q: Is the check result normal? panel (A/C-ECU).
YES : Replace the manual air conditioner control NO : Repair the wiring harness.
panel (A/C-ECU).
NO : Go to Step 5.
55-56 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

INSPECTION PROCEDURE 10: Malfunction of the A/C-ECU Power Supply System. <R.H.D.>

A/C-ECU Power Supply Circuit

IGNITION
SWITCH (IG2)

A/C-ECU
HEATER CONTROL PANEL

Wire colour code

B : Black LG : Light green G : Green L : Blue
W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Gray R : Red P : Pink V : Violet

COMMENTS ON TROUBLE SYMPTOM TROUBLESHOOTING HINTS

The A/C-ECU power system may be defective if the • Damaged the wiring harness or connectors
air conditioner, defogger, and outside/inside air • Malfunction of the manual air conditioner control
selection damper motor all do not operate normally. panel (A/C-ECU)
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-57
DIAGNOSIS STEP 3. Check the wiring harness between C-139
A/C-ECU connector terminal No.7 and the
STEP 1. Connector check: C-139 A/C-ECU ignition switch (IG2).
connector Connector: C-139
<R.H.D.>
Connector: C-139
<R.H.D.>

Harness side
Harness side C-139 (B)
6 5 4 3 2 1
C-139 (B) 12 11 10 9 8 7
6 5 4 3 2 1
12 11 10 9 8 7

AC303818 AJ

AC303818 AJ
NOTE:
Connector: C-35
Q: Is the check result normal?
<R.H.D.>
YES : Go to Step 2.
NO : Repair the connector.

STEP 2. Voltage measurement at C-139 A/C-ECU C-35(L)

connector.
Connector: C-139
<R.H.D.>
AC303814 AS

Connectors: C-210, C-212

Harness side <R.H.D.>
C-139 (B) Junction block (front view)
6 5 4 3 2 1
12 11 10 9 8 7
C-210

AC303818 AJ

(1) Disconnect the connector, and measure at the

wiring harness side.
(2) Turn the ignition switch to the "ON" position. Harness side
C-212 C-210
Connector C-139
(Harness side)

6 5 4 3 2 1 Harness side
12 11 10 9 8 7 C-212

AC301541ES
AC303823 AJ
(3) Measure the voltage between terminal 7 and
body earth. Prior to the wiring harness inspection, check junction
block connectors C-210, C-212 and joint connector
OK: System voltage
C-35, and repair if necessary.
Q: Is the check result normal? • Check the A/C-ECU power supply line for open
YES : Go to Step 4. circuit.
NO : Go to Step 3.
55-58 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

Q: Is the check result normal?

STEP 5. Check the wiring harness between C-139
YES : The trouble can be an intermittent
A/C-ECU connector terminal No.3 and the earth.
malfunction (Refer to GROUP 00, How to
Cope with Intermittent Malfunction P.00-5). Connector: C-139
NO : Repair the wiring harness. <R.H.D.>

STEP 4. Resistance measurement at the C-139

A/C-ECU connector. Harness side
C-139 (B)
Connector: C-139 6 5 4 3 2 1
12 11 10 9 8 7
<R.H.D.>

AC303818 AJ

Harness side • Check the A/C-ECU earth line for open circuit.
C-139 (B)
6 5 4 3 2 1 Q: Is the check result normal?
12 11 10 9 8 7
YES : Replace the manual air conditioner control
panel (A/C-ECU).
AC303818 AJ NO : Repair the wiring harness.
(1) Disconnect the connector, and measure at the
wiring harness side.

Connector C-139
(Harness side)

6 5 4 3 2 1
12 11 10 9 8 7

AC301541ET

(2) Measure the resistance between terminal 3 and

body earth.
OK: 2 ohms or less
Q: Is the check result normal?
YES : Replace the manual air conditioner control
panel (A/C-ECU).
NO : Go to Step 5.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-59

INSPECTION PROCEDURE 11: A/C Compressor power supply system.

A/C Compressor Circuit

IGNITION
BATTERY SWITCH (IG2)

RELAY
BOX

A/C
COMPRESSOR
RELAY

A/C
REFRIGERANT
TEMPERATURE
SWITCH
ENGINE-ECU
ENGINE-A/T-ECU

MAGNETIC
CLUTCH NOTE
: M/T
: A/T

Wire colour code

B : Black LG : Light green G : Green L : Blue
A/C W : White Y : Yellow SB : Sky blue BR : Brown
COMPRESSOR O : Orange GR : Gray R : Red P : Pink V : Violet
55-60 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

COMMENTS ON TROUBLE SYMPTOM STEP 3. Voltage measurement at B-17X A/C

If the power is not supplied to the A/C compressor, compressor relay connector.
the A/C compressor circuit system may be
defective.. Connector: B-17X

TROUBLESHOOTING HINTS
• Malfunction of the A/C compressor relay Relay box side
• Damaged the wiring harness or connectors 2 1
4 3
DIAGNOSIS
Front of
vehicle
STEP 1. Connector check: B-17X A/C AC304988AB
compressor relay connector
(1) Remove the relay, and measure at the relay box
Connector: B-17X side.
(2) Turn the ignition switch to the "ON" position.

Relay box side

Connector B-17X
2 1
(Relay box side)
4 3

Front of
vehicle
AC304988AB
2 1
Front of
Q: Is the check result normal? vehicle 4 3
YES : Go to Step 2. AC301541EU
NO : Repair the connector.
(3) Measure the voltage between terminal 2 and
body earth.
STEP 2. Check the A/C compressor relay OK: System voltage
continuity.
Refer to P.55-75. Q: Is the check result normal?
YES : Go to Step 6.
Q: Is the A/C compressor relay in good condition? NO <L.H.D.> : Go to Step 4.
YES : Go to Step 3. NO <R.H.D.> : Go to Step 5.
NO : Replace the A/C compressor relay.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-61
STEP 4. Check the wiring harness between B-17X Connectors: C-209, C-210
A/C compressor relay connector terminal No.2 <L.H.D.>
and the ignition switch (IG2). Junction block (front view)

Connector: B-17X
C-210

Relay box side

C-209
2 1
4 3

Front of
vehicle
AC304988AB
C-209 C-210
NOTE: Harness side Harness side
Connector: C-15 6 5 4 3 2 1 2 1
<L.H.D.> 14 13 12 11 10 9 8 7 6 5 4 3

AC303809 AF

Prior to the wiring harness inspection, check

C-15 (L) intermediate connector C-15, joint connector C-35,
AC303800 AE junction block connectors C-209 and C-210, and
repair if necessary.
Connector: C-35 • Check the A/C compressor relay power supply
<L.H.D.> line for open circuit.
Q: Is the check result normal?
YES : The trouble can be an intermittent
C-35 (L)
malfunction (Refer to GROUP 00, How to
Cope with Intermittent Malfunction P.00-5).
NO : Repair the wiring harness.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22

AC303798 AJ
55-62 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 5. Check the wiring harness between B-17X Connectors: C-209, C-210
A/C compressor relay connector terminal No.2 <R.H.D.>
and the ignition switch (IG2). Junction block (front view)

Connector: B-17X
C-210
C-209
Relay box side

2 1
4 3

Front of C-209
vehicle Harness side
AC304988AB 6 5 4 3 2 1
14 13 12 11 10 9 8 7

NOTE:
Connector: C-35 C-210
<R.H.D.>
Harness side
2 1
6 5 4 3

C-35(L)
AC303823 AE

Prior to the wiring harness inspection, check

intermediate connector C-135, joint connector C-35,
AC303814AI junction block connectors C-209 and C-210, and
repair if necessary.
Connector: C-135 • Check the A/C compressor relay power supply
<RHD> line for open circuit.
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).
C-135 (L)
NO : Repair the wiring harness.

AC303818 AH
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-63
STEP 6. Voltage measurement at B-17X A/C STEP 7. Check the wiring harness between B-17X
compressor relay connector. A/C compressor relay connector terminal No.1
and the battery.
Connector: B-17X
Connector: B-17X

Relay box side

Relay box side
2 1
4 3 2 1
4 3
Front of
vehicle Front of
AC304988AB vehicle
(1) Remove the relay, and measure at the junction AC304988AB

block side. NOTE:

Connector: A-13
<LHD>
Connector B-17X
(Relay box side) A-13 (B)

2 1
Front of
4 3
vehicle
AC303857AB
AC301541EV

(2) Measure the voltage between terminal 1 and Connector: C-111

body earth. <RHD>
OK: System voltage
Q: Is the check result normal?
YES : Go to Step 8.
NO : Go to Step 7. 1 2 3 4 5
6 7 8 9 10 11 12

AC303816 AF

Prior to the wiring harness inspection, check

intermediate connector A-13 <L.H.D.> or C-111
<R.H.D.>, and repair if necessary.
• Check the A/C compressor relay power supply
line for open circuit.
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 : Repair the wiring harness.
55-64 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 8. Connector check: B-114 A/C compressor STEP 9. Check the wiring harness between B-17X
connector A/C compressor relay connector terminal No.4
and B-114 A/C compressor connector terminal
Connector: B-114
<4G1-L.H.D.> No.1.
Connector: B-17X

Harness side

Relay box side

2 1
4 3
B-114 (B)
AC303782 AC
Front of
vehicle
Connector: B-114 AC304988AB
<4G6-L.H.D.>
Connector: B-114
<4G1-L.H.D.>
Harness side

Harness side

B-114 (B)
AC303790 AC

B-114 (B)
Connector: B-114 AC303782 AC
<4G1-R.H.D.>
Connector: B-114
<4G6-L.H.D.>
Harness side

Harness side

B-114 (B)
AC303786 AB

B-114 (B)
Connector: B-114 AC303790 AC
<4G6-R.H.D.>

Harness side

B-114 (B)
AC303794 AB

Q: Is the check result normal?

YES : Go to Step 9.
NO : Repair the connector.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-65

Connector: B-114 STEP 10. Connector check: C-123 engine-ECU

<4G1-R.H.D.> connector <M/T> or C-122 engine-A/T-ECU
connector <A/T>

Harness side Connectors: C-122 <A/T>, C-123 <M/T>

<L.H.D.>

B-114 (B)
AC303786 AB

Connector: B-114
<4G6-R.H.D.>

C-122 (GR)
Harness side C-123 (Y)
Harness side
C-122

B-114 (B)
AC303794 AB
C-123
• Check the A/C compressor power supply line for
open circuit.
Q: Is the check result normal? AC303805 AE
YES : Go to Step 10.
NO : Repair the wiring harness. Connectors: C-122 <A/T>, C-123 <M/T>
<R.H.D.>

C-122 (GR)
C-123 (Y)

Harness side
C-122

C-123

AC303817AF

Q: Is the check result normal?

YES <M/T> : Go to Step 11.
YES <A/T> : Go to Step 12.
NO : Repair the connector.
55-66 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

STEP 11. Check the wiring harness between STEP 12. Check the wiring harness between
C-123 engine-ECU connector terminal No.8 and C-122 engine A/T-ECU connector terminal No.20
B-17X A/C compressor relay connector terminal and B-17X A/C compressor relay connector
No.3. terminal No.3.
Connector: B-17X Connector: B-17X

Relay box side Relay box side

2 1 2 1
4 3 4 3

Front of Front of
vehicle vehicle
AC304988AB AC304988AB

Connector: C-123 Connector: C-122

<LHD - M/T> <LHD - A/T>

C-123 (Y) C-122 (GR)

Harness side Harness side

AC303804 AH AC303804 AG

Connector: C-123 Connector: C-122

<RHD - M/T> <RHD - A/T>
Harness side Harness side

C-123 (Y) C-122 (GR)

AC303816 AM AC303816 AL

• Check the A/C compressor relay earth line for • Check the A/C compressor relay earth line for
open circuit. open or short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : The trouble can be an intermittent YES : The trouble can be an intermittent
malfunction (Refer to GROUP 00, How to malfunction (Refer to GROUP 00, How to
Cope with Intermittent Malfunction P.00-5). Cope with Intermittent Malfunction P.00-5).
NO : Repair the wiring harness. NO : Repair the wiring harness.
 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING
55-67
CHECK AT ECU TERMINAL <L.H.D.>
M1552010300527

<C-139>

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

AC300861AC

Terminal No. Check item Checking requirement Normal condition

1 Rear defogger switch Defogger switch: ON 0V
Defogger switch: OFF System voltage
2 Inside/outside air selection When the damper is moved to 0V
damper motor (outside air) the inside air recirculation
position
When the damper is moved to System voltage
the outside air inside air intake
position
3 Inside/outside air selection When the damper is moved to System voltage
damper motor (inside air) the inside air recirculation
position
When the damper is moved to 0V
the outside air inside air intake
position
4 Output to the engine-A/T-ECU A/C stopped 0V
(A/C1) • A/C switch: ON System voltage
• Blower switch: ON
5 Output to the engine-A/T-ECU When the A/C is under low load System voltage
(A/C2) When the A/C is under high 0V
load
6 Power supply to the A/C Lighting switch: ON System voltage
illumination
7 - - -
8 Blower switch (lo) blower switch: lo System voltage
9 - - -
10 Power supply to the ignition Ignition switch: ON System voltage
switch (IG2)
11 Earth to the A/C illumination Always 0V
12 Earth Always 0V
13 Air thermo sensor (outlet side) Sensor probe temperature 25°C 2.2 V
(1.5k ohm)
14, 15 - - -
16 Earth to the air thermo sensor Always 0V
55-68 HEATER, AIR CONDITIONER AND VENTILATION
TROUBLESHOOTING

CHECK AT ECU TERMINAL <R.H.D.>

M1552010300538

<C-139>

1 2 3 4 5 6
7 8 9 10 11 12
AC304990AB

Terminal No. Check item Checking requirement Normal condition

1 Output to the engine-A/T-ECU A/C stopped 0V
(A/C1) • A/C switch: ON System voltage
• Blower switch: ON
2 Output to the engine-A/T-ECU When the A/C is under low load System voltage
(A/C2) When the A/C is under high 0V
load
3 Earth Always 0V
4 Earth to the air thermo sensor Always 0V
5 Power supply to the A/C Lighting switch: ON System voltage
illumination
6 Air thermo sensor (outlet side) Sensor probe temperature 25°C 2.2 V
(1.5k ohm)
7 Power supply to the ignition Ignition switch: ON System voltage
switch (IG2)
8 Blower switch (lo) blower switch: lo System voltage
9 Rear defogger switch Defogger switch: ON 0V
Defogger switch: OFF System voltage
10 Inside/outside air selection When the damper is moved to 0V
damper motor (outside air) the inside air recirculation
position
When the damper is moved to System voltage
the outside air inside air intake
position
11 Inside/outside air selection When the damper is moved to System voltage
damper motor (inside air) the inside air recirculation
position
When the damper is moved to 0V
the outside air inside air intake
position
12 Earth to the A/C illumination Always 0V
 HEATER, AIR CONDITIONER AND VENTILATION
ON-VEHICLE SERVICE
55-69
ON-VEHICLE SERVICE
SIGHT GLASS REFRIGERANT LEVEL 3. If the magnetic clutch is normal, there will be a
TEST "click." If the pulley and armature do not make
M1552008400378 contact ("click"), there is a malfunction.
1. Start the engine.
2. Operate the air-conditioner, and then set the COMPRESSOR DRIVE BELT
temperature to maximum cooling. ADJUSTMENT
M1552001000335
3. Hold the engine speed at 1500 r/min.
<1300, 1600>
Insufficient Sufficient or excess Refer to GROUP 11A, On-vehicle Service − Drive
refrigerant refrigerant Belt Tension Check P.11A-7.
Bubbles
<2000>
Refer to GROUP 11C, On-vehicle Service − Drive
Belt Tension Check P.11C-7.

DUAL PRESSURE SWITCH CHECK

M1552010400320
AC005963 AC

High/Low
4. Check the refrigerant level (bubble state) through Pressure Side

the sight glass.

CAUTION
Use the low-pressure service valve.
Items State
Insufficient Many bubbles are seen.
If refrigerant is extremely
low, it appears white.
Sufficient or excess No bubbles are seen.
refrigerant Low-pressure side High-pressure side
NOTE: Use the refrigerant recovery station to 210 ± 25 2060 ± 200
230 ± 20 2650 ± 200
charge the specified refrigerant because you can
not calculate the amount of the refrigerant ON ON
properly with the sight glass.
OFF OFF
MAGNETIC CLUTCH TEST (kPa)
M1552008500405
AC001368 AD
1. Disconnect the magnetic clutch connector to the
magnetic clutch. 1. Remove the dual pressure switch connector and
Magnetic clutch connector connect the high/low pressure side terminals
located on the harness side as shown in the
illustration..
2. Install a gauge manifold to the high-pressure side
service valve of the refrigerant line. (Refer to
P.55-98, P.55-99.)
3. When the high/low pressure sides of the dual
pressure switch are at operation pressure (ON)
the resistance should less than two ohms
between the terminals. If open circuit, replace the
AC005671AC
switch.
2. Connect positive battery voltage directly to the
connector for the magnetic clutch.
55-70 HEATER, AIR CONDITIONER AND VENTILATION
ON-VEHICLE SERVICE

CHARGING 5. Close the high and low-pressure valves of the

M1552001200362 gauge manifold.
CAUTION
Be sure to connect the power plug of the vacuum
Low-pressure High-pressure pump to the vacuum pump adapter, and then
valve valve connect the power plug of the adapter to a 100-V
outlet.
6. Install the vacuum pump adaptor to the vacuum
pump.
7. Connect the charging hose (yellow) to the R-134a
Gauge manifold
connection port of the vacuum pump adaptor.
Adapter Charging hose
8. Tighten the adaptor valve handle (valve open).
valve (yellow)
Charging hose 9. Open the low-pressure valve of the gauge
(blue) manifold.
Switch
R-12 R-134a 10.Turn the power switch of the vacuum pump to the
connection
connection ON position.
port port
NOTE: Even if the vacuum pump power switch is
Vacuum
Quick pump
turned ON, the vacuum pump will not operate
joint adaptor Vacuum because of the power supply connection in step
(for low (6).
pump
pressure) Power supply
plug
Switch CAUTION
Do not operate the compressor for evacuation.
Low-pressure
service valve
A

Sleeve

AC212526AB

1. With the handles turned back all the way (valve Vacuum pump
closed), install the adaptor valve to the adaptor switch
low-pressure side of the gauge manifold.
2. Connect the charging hose (blue) to the adaptor
valve.
3. Connect the quick joint (for low-pressure) to the
charging hose (blue).
Low-pressure Vacuum
CAUTION service valve pump
• Use tools that are suited to R134a.
• To install the quick joint, press section when
connecting, run your hand along the hose AC212535 AB
while pressing to ensure that there are no
bends in the hose. 11.Turn the vacuum pump adaptor switch to the
R134a side to start the vacuum pump.
4. Connect the quick joint (for low-pressure) to the
low- pressure service valve. 12.Evacuate to a vacuum reading of 100 kPa or
higher (takes approx. 10 minutes).
NOTE: The low-pressure service valve should be
connected to the flexible suction hose.
 HEATER, AIR CONDITIONER AND VENTILATION
ON-VEHICLE SERVICE
55-71
CAUTION CAUTION
Do not operate the compressor in the vacuum If the service can is inverted, liquid refrigerant
condition; damage may occur. may be drawn into the compressor damaging it
13.Loosen the valve of the adapter valve fully (valve by liquid compression. Keep the service can
closed), and turn off the vacuum pump adapter upright to ensure that refrigerant is charged in
switch. Then leave it for five minutes. gas state.
14.Check the system for proper sealing (negative
pressure should not decrease). Charging valve

Valve open

Valve close

Charging valve

Adaptor valve
Service can
Service can (Refrigerant container)

AC212536 AB

15.Connect the service can valve to the service can

with the handle loosened fully (valve closed).
Low-pressure
16.Turn the handle of the adaptor valve back all the service valve
way (valve closed), remove it from the gauge
manifold and install the service can.
17.Tighten the handle of the charging valve (valve
closed) to puncture the service can.
AC212537AB

18.Turn the handle of the charging valve back (valve

open) and tighten the handle of the adaptor valve
(valve open) to charge the system with refrigerant.
19.If the refrigerant is not drawn in, turn the handle of
the adaptor valve back all the way (valve closed).
20.Check for gas leaks using a leak detector. If a gas
leak is detected, re-tighten the connections, and
then repeat the charging procedure from
evacuation in step (11).
CAUTION
The leak detector for R-134a should be used.
21.Start the engine.
22.Operate the A/C and set to the lowest
temperature (MAX. COOL).
23.Fix the engine speed at 1,500 r/min.
CAUTION
If the service can is inverted, liquid refrigerant
may be drawn into the compressor damaging it
by liquid compression. Keep the service can
upright to ensure that refrigerant is charged in
gas state.
24.Tighten the handle of the adaptor valve (valve
open) to charge the required volume of
refrigerant.
55-72 HEATER, AIR CONDITIONER AND VENTILATION
ON-VEHICLE SERVICE

25.After charging with refrigerant, turn the handle of 7. Install the quick joint (for low-pressure) to the
the adaptor valve back all the way (valve closed). low-pressure service valve.
26.Tighten the charging valve handle (valve closed). NOTE: The low-pressure service valve should be
Remove the quick joint (for low-pressure) from the connected to the suction hose.
low-pressure service valve. 8. Start the engine.
27.Remove the service can. 9. Operate the air conditioner and set at the lowest
NOTE: If the service can is not emptied temperature (MAX. COOL).
completely, keep the handles of the charging 10.Fix the engine speed at 1,500 r/min.
valve and adaptor valve closed for the next 11.Tighten the handle of the adaptor valve (valve
charging. open), and replenish refrigerant while checking
the quantity through the sight glass.
CORRECTING LOW REFRIGERANT
12.After replenishing is completed, turn the handle of
LEVEL IN CASE THE SERVICE CAN IN the adaptor valve all the way back (valve close),
USED and remove the quick joint.
M1552014600100
NOTE: When there is remainder of refrigerant in
Valve open
Charge valve the service can, keep it for next use with the
Valve close charge value and the valve of the adaptor valve
Adaptor valve being closed.

DISCHARGING SYSTEM
Charging hose (blue) M1552013000105
Use the refrigerant recovery unit to discharge
Service can
(Refrigerant
refrigerant gas from the system.
container) Quick joint (for low-pressure) NOTE: Refer to the Refrigerant Recovery and
AC300372AB Recycling Unit instruction Manual for operation of the
unit.
1. Install the charge valve with the handle turned all
the way back (valve open) to the service can. REFILLING OF OIL IN THE A/C SYSTEM
2. Install the adaptor valve with the handle turned all M1552020000033
the way back (valve close) to the charging valve. Too little oil will provide inadequate compressor
3. Connect the charging hose (blue) to the adaptor lubrication and cause a compressor failure. Too
much oil will increase discharge air temperature.
valve.
When a compressor is installed at the factory, it
4. Connect the charging hose (blue) to the quick contains 140mL <1300, 1600> or 120 mL <2000> of
joint (for low-pressure). compressor oil. While the A/C system is in operation,
5. Tighten the handle of the charge valve (valve the oil is carried through the entire system by the
close), and pierce the service can. refrigerant. Some of this oil will be trapped and
6. Turn the handle of the adaptor valve to bleed the retained in various parts of the system.
air. When the following system components are
changed, it is necessary to add oil to the system to
replace the oil being removed with the component.
Compressor oil: SUN PAG 56
Quick joint
(for low-pressure)
Quantity
Evaporator: 60 mL
Condenser: 15 mL
Flexible suction hose: 10 mL
Low-pressure
Receiver: 10 mL
service valve

AC300373 AB
 HEATER, AIR CONDITIONER AND VENTILATION
ON-VEHICLE SERVICE
55-73
PERFORMANCE TEST NOTE: The high-pressure service valve is on the
M1552001400355 A/C pipe and the low-pressure service valve is on
1. The vehicles to be tested should be in a place that the suction hose.
is not in direct sunlight. 5. Connect the quick joint (for low-pressure) to the
low-pressure service valve and connect the quick
Low-pressure
joint (for high-pressure) to the high-pressure
High-pressure
valve valve
service valve.
6. Start the engine.
7. Set the A/C controls as follows:
• A/C switch: A/C − ON position
• Mode selection: FACE position
• Temperature control: MAXIMUM COOLING
Gauge manifold
position
Charging
hose (red) • Air selection: RECIRCULATION position
Charging • Blower switch: "4" (Fast) position
hose (blue) 8. Keep engine speed to idling speed with A/C clutch
A
engaged.
Adaptor valve
(for low- Sleeve
9. Engine should be warmed up with doors and all
pressure) windows opened.
Adaptor valve
(for high- Thermometer
Low- High- pressure)
pressure pressure
service service
valve valve

AC001388 AB

2. Close the high and low-pressure valve of the

gauge manifold.
3. Connect the charging hose (blue) to the
low-pressure valve and connect the charging AC304576 AB

hose (red) to the high-pressure valve of the gauge 10.Insert a thermometer in the centre air outlet and
manifold. operate the engine for 20 minutes.
CAUTION NOTE: If the clutch cycles, take the reading before
• To connect the quick joint, press section A the clutch disengages.
firmly against the service valve until a click is 11.Note the discharge air temperature.
heard.
• When connecting, run your hand along the
hose while pressing to ensure that there are
no bends in the hose.
4. Install the quick joint (for low-pressure) to the
charging hose (blue), and connect the quick joint
(for high-pressure) to the charging hose (red).
Performance Temperature Chart
Garage ambient temperature °C 20 25 30 35
Discharge air temperature °C 8.0 − 11.0 12.0 − 16.0 17.0 − 21.0 22.5 − 27.5
Compressor high pressure kPa 740 − 840 950 − 1,050 1,160 − 1,300 1,360 − 1,550
Compressor low pressure kPa 150 − 190 190 − 240 240 − 300 300 − 375
55-74 HEATER, AIR CONDITIONER AND VENTILATION
ON-VEHICLE SERVICE

REFRIGERANT LEAK REPAIR Sharper bends will reduce the flow of refrigerant. The
PROCEDURE flexible hose lines should be routed so that they are
M1552001500277 at least 80 mm from the exhaust manifold. It is good
LOST CHARGE practice to inspect all flexible hose lines at least once
If the system has lost all charge due to a leak: a year to make sure they are in good condition and
properly routed.
1. Evacuate the system (Refer to P.55-72).
On standard plumbing fittings with O-rings, these
2. Charge the system with approximately 480 − 520 O-rings are not reusable.
g of refrigerant.
3. Check for leaks. COMPRESSOR NOISE CHECK
M1552008700272
4. Discharge the system.
You must first know the conditions when the noise
5. Repair leaks. occurs. These conditions are: weather, vehicle
CAUTION speed, in gear or neutral, engine temperature or any
Replacement filter-drier units must be sealed other special conditions.
while in storage. The drier used in these units will Noises that develop during A/C operation can often
saturate water quickly upon exposure to the be misleading. For example: what sounds like a
atmosphere. When installing a drier, have all failed front bearing or connecting rod, may be
tools and supplies ready for quick assembly to caused by loose bolts, nuts, mounting brackets, or a
avoid keeping the system open any longer than loose clutch assembly. Verify accessory drive belt
necessary. tension (power steering or alternator).
6. Replace receiver drier. Improper accessory drive belt tension can cause a
7. Evacuate and charge system. misleading noise when the compressor is engaged
and little or no noise when the compressor is
LOW CHARGE disengaged.
Drive belts are speed-sensitive. That is, at different
If the system has not lost all of its refrigerant charge;
engine speeds, and depending upon belt tension,
locate and repair all leaks. If it is necessary to
belts can develop unusual noises that are often
increase the system pressure to find the leak
mistaken for mechanical problems within the
(because of an especially low charge) add
compressor.
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the ADJUSTMENT
procedure for correcting low refrigerant level. 1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch the
HANDLING TUBING AND FITTINGS compressor on and off several times to clearly
Kinks in the refrigerant tubing or sharp bends in the identify compressor noise. To duplicate high
refrigerant hose lines will greatly reduce the capacity ambient conditions (high head pressure), restrict
of the entire system. High pressures are produced in air flow through the condenser. Install a manifold
the system when it is operating. Extreme care must gauge set to make sure discharge pressure
be exercised to make sure that all connections are doesn't exceed 2,070 kPa.
pressure tight. Dirt and moisture can enter the 2. Tighten all compressor mounting bolts, clutch
system when it is opened for repair or replacement of mounting bolt, and compressor drive belt. Check
lines or components. The following precautions must to assure clutch coil is tight (no rotation or
be observed. The system must be completely wobble).
discharged before opening any fitting of connection 3. Check refrigerant hoses for rubbing or
in the refrigeration system. Open fittings with caution interference that can cause unusual noises.
even after the system has been discharged. If any
4. Check refrigerant charge (Refer to P.55-69).
pressure is noticed as a fitting is loosened, allow
trapped pressure to bleed off very slowly. 5. Recheck compressor noise as in Step 1.
Never attempt to rebend formed lines to fit. Use the 6. If noise still exists, loosen compressor mounting
correct line for the installation you are servicing. A bolts and retighten. Repeat Step 1.
good rule for the flexible hose lines is keep the radius 7. If noise continues, replace compressor and repeat
of all bends at least 10 times the diameter of the Step 1.
hose.
 HEATER, AIR CONDITIONER AND VENTILATION
ON-VEHICLE SERVICE
55-75
POWER RELAY CHECK A/C COMPRESSOR RELAY CONTINUITY
M1552008800309
CHECK
BLOWER RELAY CONTINUITY CHECK
A/C compressor relay

Blower relay

1
1 2 4
1 2 3 5
4 3 4 2 3
4
5 1 3 Front of
vehicle

AC305307AB
AC305308 AB

Battery voltage Tester Specified

Battery voltage Tester Specified connection condition
connection condition
Not applied 1−4 Open circuit
Not applied 4−5 Open circuit
• Connect 1−4 Less than 2
• Connect 4−5 Less than 2 terminal 2 to ohms
terminal 3 to ohms the positive
the positive battery
battery terminal
terminal • Connect
• Connect terminal 3 to
terminal 1 to the negative
the negative battery
battery terminal
terminal
55-76 HEATER, AIR CONDITIONER AND VENTILATION
ON-VEHICLE SERVICE

FAN CONTROL RELAY CONTINUITY • Lamps, electric cooling fan and accessories: Set
CHECK to OFF
• Transmission: Neutral ("N" or "P" for vehicles with
A/T)
• Steering wheel: Straightforward
2. Check whether or not the idle speed is the
standard value. <1300, 1600> Refer to GROUP
13A, On-vehicle Service − Basic Idle Speed
Adjustment P.13A-387.
<2000> Refer to GROUP 13B, On-vehicle Service
− Basic Idle Speed Adjustment P.13B-324.
Standard value: 750 ± 50 r/min
Fan control relay 3. When the A/C is running after turning the A/C
switch to ON, and the blower switch to the 3(MH)
or 4(HI) position, check to be sure that the idle
speed is at the standard value.
2 4
2 Standard value: 850 ± 50 r/min
1 3
4 3 1 NOTE: It is not necessary to make an adjustment,
because the idling speed is automatically
adjusted by the ISC system. If, however, a
deviation from the standard value occurs for some
AC305307 AC reason, check the ISC system.

Battery voltage Tester Specified CLEAN AIR FILTER REPLACEMENT

connection condition PROCEDURE
M1552020100030
Not applied 2−4 Open circuit 1. Remove the glove box (Refer to GROUP 52A,
• Connect 2−4 Less than 2 Instrument Panel P.52A-2).
terminal 1 to ohms
the positive
battery Air filter
terminal
• Connect
terminal 3 to
the negative
battery
terminal
Instrument panel
AC305114 AB
IDLE-UP OPERATION CHECK
M1552001600371
2. Remove the two screws as shown, and replace
1. Before inspection and adjustment, set vehicle in
the clean air filter.
the following condition:
• Engine coolant temperature: 80 − 90 °C 3. Install the glove box.
 HEATER, AIR CONDITIONER AND VENTILATION
HEATER CONTROL ASSEMBLY AND A/C SWITCH
55-77
HEATER CONTROL ASSEMBLY AND A/C SWITCH
REMOVAL AND INSTALLATION
M1552002400347

2 1

3
4 5

AC304650AB

Removal steps Removal steps (Continued)

>>B<< 1. Air mixing door control cable 4. Centre panel
connection 5. Manual air conditioner control panel
>>A<< 2. Mode selection damper cable assembly
connection
3. Knob
55-78 HEATER, AIR CONDITIONER AND VENTILATION
HEATER CONTROL ASSEMBLY AND A/C SWITCH

INSTALLATION SERVICE POINT

>>A<< BLOWER VENT CHANGEOVER >>B<< AIR MIX DOOR CABLE
DAMPER CABLE CONNECTION
<R.H.D.> <R.H.D.> MAX. COOL position
Mode locator
MAX HOT
position

FACE Mode selection

position damper link

Mode locator
Air mix damper lever
DEF position AC304856 AB AC304857AB

<L.H.D.> <L.H.D.>
Air mix damper lever Mode locator
Mode
selection
damper link
Mode locator

MAX. COOL
FACE position position
MAX HOT position
DEF position AC304854 AB AC304855AB

1. Turn the heater control assembly’s temperature

1. Set the heater control assembly’s blower vent
adjustment knob all the way to the HOT side.
changeover knob to the DEF position.
2. Set the heater unit’s air mix door lever to the MAX
2. Set the heater unit’s blower vent changeover
HOT position (turn the damper lever as the left
damper relay to the DEF position (turn the
illustration) and attach the cable.
damper relay to the left until it stops) and install
the cable. 3. Set the mode locator to the heater unit case and
secure with a clip.
3. Set the mode locator to the heater unit case and
secure with a clip.
 HEATER, AIR CONDITIONER AND VENTILATION
HEATER CONTROL ASSEMBLY AND A/C SWITCH
55-79
INSPECTION Switch Tester connection Specified
M1552014300927
position condition
BLOWER SWITCH CONTINUITY CHECK
0 (OFF) 1 − 2, 2 − 4, 2 − 5, 2 − 6 Open circuit
1 (LO) 1−2 Less than 2
ohms
2 (ML) 2−4 Less than 2
ohms
1 2 3 3 (MH) 2−5 Less than 2
4 5 6 ohms
4 (HI) 2−6 Less than 2
ohms
AC100615AB

DISASSEMBLY AND REASSEMBLY

M1552014200180

2 3
4

1
7

AC100614 AB
5
Disassembly steps Disassembly steps (Continued)
1. Switch panel 7. Blower switch assembly
2. Rear window defogger switch 8. Manual air conditioner control panel
3. Air conditioner switch (A/C-ECU)
4. Inside/outside air selection switch
<<A>> 5. Mode selection damper control
cable
<<A>> 6. Air mixing damper control cable
55-80 HEATER, AIR CONDITIONER AND VENTILATION
HEATER CONTROL ASSEMBLY AND A/C SWITCH

DISASSEMBLY SERVICE POINT Insert a flat-tipped screwdriver into the clip through
the inside of the control base and prize out the clip
<<A>> BLOW VENT CHANGEOVER
claw to disconnect the cables.
DAMPER CABLE AND AIR MIX DAMPER
CABLE REMOVAL

(-) flat-tipped
screwdriver

Clip
claw AC100619AB
 HEATER, AIR CONDITIONER AND VENTILATION
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
55-81
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY
AND EVAPORATOR UNIT
REMOVAL AND INSTALLATION
M1552011600457

Pre-removal and Post-installation Operation

• Refrigerant draining and Refilling (Refer to Charging
P.55-70 and Discharging P.55-72).
• Engine coolant Draining and Refilling (Refer to GROUP
14, On vehicles service P.14-22).
• Instrument Panel Removal and Installation (Refer to
GROUP 52A, Instrument Panel P.52A-2).
• Air cleaner cover and air flow sensor assembly Removal
and Installation (Refer to GROUP 15, Air cleaner P.15-3).
• Rear console assembly Removal and Installation (Refer
to GROUP 52A, Rear console assembly P.52A-8).
• Front floor console assembly Removal and Installation
(Refer to GROUP 52A, Front floor console assembly
P.52A-6).
• Front seat assembly Removal and Installation (Refer to
GROUP 52A, Front seat assembly P.52A-24).

-Pipe coupling
2 12 ± 2 N·m
5

7
9
6, 7 O ring
A/C compressor oil: 3
SUN PAG 56
6
1 8N

44 ± 10 N·m

44 ± 10 N·m
AC304861AB

Removal steps Removal steps (Continued)

1. Front deck crossmember 4. Blower assembly
2. Centre duct 5. Heater hose connection
3. Intake duct <<A>> 6. Flexible suction hose connection
• Foot duct (RH), Rear heater duct A <<A>> 7. Liquid pipe B connection
(RH) upper side (Refer to 8. O ring
P.55-101.) 9. Heater unit
55-82 HEATER, AIR CONDITIONER AND VENTILATION
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT

REMOVAL SERVICE POINT

<<A>> FLEXIBLE SUCTION HOSE AND
LIQUID PIPE B DISCONNECTION
CAUTION
As the compressor oil and receiver are highly
moisture absorbent, use a non-porous material
to plug the hose and nipples.
To prevent the entry of dust or other foreign bodies,
plug the dismantled hose and the nipples of the
expansion valves.

HEATER UNIT
DISASSEMBLY AND REASSEMBLY
<L.H.D.>
M1551005400224

2
3
8
4
-Pipe coupling 6
10
5N

4, 7 O ring
A/C compressor oil:
SUN PAG 56
AC304862AB

Disassembly steps Disassembly steps (Continued)

1. Foot duct (LH) 6. Evaporator cover
2. Heater core 7. Evaporator
3. Expansion valve 8. Air thermo sensor clip
4. Joint 9. Air thermo sensor
5. O ring 10. Heater case
 HEATER, AIR CONDITIONER AND VENTILATION
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
55-83
DISASSEMBLY AND ASSEMBLY <R.H.D.>
M1551005400235

9
-Pipe coupling

3
7
4N
8
6 O ring
5
A/C compressor oil:
SUN PAG 56
6 AC304863AB

Disassembly steps Disassembly steps (Continued)

1. Foot duct (RH) 6. Evaporator
2. Heater core 7. Air thermo sensor clip
3. Expansion valve 8. Air thermo sensor
4. O ring 9. Heater case
5. Evaporator cover
55-84 HEATER, AIR CONDITIONER AND VENTILATION
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT

BLOWER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
M1551005500179

2 3

5
AC3054131AB

Disassembly steps Disassembly steps (Continued)

1. Joint duct 5. Blower motor
2. Resister 6. Air filter
3. Outside/inside air selection damper 7. Blower case
control motor
4. Hose
 HEATER, AIR CONDITIONER AND VENTILATION
BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR
55-85
BLOWERMOTOR, RESISTOR AND OUTSIDE/
INSIDE AIR SELECTION DAMPER CONTROL MOTOR
REMOVAL AND INSTALLATION
M1551002800320

1
2 3

AC304885AB

Blower motor removal step Outside/inside air selection

• Front passenger's side under cover damper control motor removal
<<A>> 1. Blower motor step
Resistor removal step • Glove box (Refer to GROUP 52A,
• Glove box (Refer to GROUP 52A, Instrument Panel P.52A-2).
Instrument Panel P.52A-2). • Engine-ECU <M/T> or
• Engine-ECU <M/T> or Engine-A/T-ECU <A/T> (Refer to
Engine-A/T-ECU <A/T> (Refer to GROUP 13A, Engine-ECU and
GROUP 13A, Engine-ECU and Engine-A/T-ECU P.13A-401).
Engine-A/T-ECU P.13A-401). 3. Outside/inside air selection damper
2. Resistor control motor
55-86 HEATER, AIR CONDITIONER AND VENTILATION
BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR

REMOVAL SERVICE POINT Use an ohmmeter to measure the resistance

between the terminals. Check that the measured
<<A>> BLOWER MOTOR REMOVAL
value is at the standard value.
NOTE: Standard value:
Measurement terminal Standard value (Ω)
Between terminals 2 and 4 2.54
(LO)
Between terminals 1 and 2 1.24
(ML)
Between terminals 2 and 3 0.6
(MH)
AC304916

Use of commercially available offset screw driver is BLOWER FAN AND MOTOR CHECK
recommended.

INSPECTION
M1551006300275

RESISTER CHECK

1 2
3 4
AC100626 AB

When battery voltage is applied between the

terminals, check that the motor operates. Also, check
that there is no abnormal noise.
AC304843
 HEATER, AIR CONDITIONER AND VENTILATION
BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR
55-87
OUTSIDE/INSIDE AIR SELECTION
DAMPER CONTROL MOTOR CHECK
CAUTION

Inside air

Outside air AC100625AE

Cut off the battery voltage when the damper is in

the inside/outside air position.
Lever position Battery Lever
connection operation
At the inside • Connect The lever
position terminal 7 to moves from the
the positive inside position
battery to the outside
terminal position
• Connect
terminal 4 to
the negative
battery
terminal
At the outside • Connect The lever
position terminal 7 to moves from the
the positive outside position
battery to the inside
terminal position
• Connect
terminal 6 to
the negative
battery
terminal
55-88 HEATER, AIR CONDITIONER AND VENTILATION
EVAPORATOR ASSEMBLY

EVAPORATOR ASSEMBLY
REMOVAL AND INSTALLATION <L.H.D.>
M1552003600355

Pre-removal and Post-installation Operation

• Refrigerant draining and Refilling (Refer to Charging
P.55-70 and Discharging P.55-72).
• Air cleaner assembly <1300,1600> or Air cleaner and air
cleaner air flow sensor assembly <2000> Removal and
Installation (Refer to GROUP 15, Air cleaner P.15-3).

-Pipe coupling

1, 2, 4, 7 O ring
2
A/C compressor oil:
12 ± 2 N·m SUN PAG 56

1
10 4
3 8
9 8

5
Y2346AU

Removal steps Removal steps (Continued)

<<A>> 1. Flexible suction hose connection 9. Air thermo sensor clip
<<A>> 2. Liquid pipe B connection 10. Air thermo sensor
3. Expansion valve
4. Joint REMOVAL SERVICE POINT
• Glove box (Refer to GROUP 52A,
<<A>> FLEXIBLE SUCTION HOSE AND
Instrument Panel P.52A-2).
• Engine-ECU <M/T> or LIQUID PIPE B DISCONNECTION
Engine-A/T-ECU <A/T> (Refer to CAUTION
GROUP 13A, Engine-ECU and As the compressor oil and receiver are highly
Engine-A/T-ECU P.13A-401).
moisture absorbent, use a non-porous material
5. Joint duct
Foot duct (LH), Rear heater duct
to plug the hose and nipples.
•
(LH), Rear heater duct (LH) (Refer To prevent the entry of dust or other foreign bodies,
to P.55-101). plug the dismantled hose and the nipples of the
6. Evaporator cover expansion valves.
7. Evaporator
8. O ring
 HEATER, AIR CONDITIONER AND VENTILATION
EVAPORATOR ASSEMBLY
55-89
REMOVAL AND INSTALLATION <R.H.D.>
M1552003600366

Pre-removal and Post-installation Operation

• Refrigerant draining and Refilling (Refer to Charging
P.55-70 and Discharging P.55-72).
• Air cleaner assembly <1300,1600> or Air cleaner and air
cleaner air flow sensor assembly <2000> Removal and
Installation (Refer to GROUP 15, Air cleaner P.15-3).

-Pipe coupling

1, 2, 6 O ring
A/C compressor oil:
SUN PAG 56
2
12 ± 2 N·m

3
7
1
7 9

6
5

4 AC304886AB

Removal steps Removal steps (Continued)

<<A>> 1. Flexible suction hose connection • Foot duct (LH), Rear heater duct
<<A>> 2. Liquid pipe B connection (LH) (Refer to P.55-101).
3. Expansion valve 5. Evaporator cover
• Glove box (Refer to GROUP 52A, <<B>> 6. Evaporator
Instrument Panel P.52A-2). 7. O ring
• Engine-ECU <M/T> or 8. Air thermo sensor clip
Engine-A/T-ECU <A/T> (Refer to 9. Air thermo sensor
GROUP 13A, Engine-ECU and
Engine-A/T-ECU P.13A-401).
4. Joint duct
55-90 HEATER, AIR CONDITIONER AND VENTILATION
EVAPORATOR ASSEMBLY

REMOVAL SERVICE POINT INSPECTION

M1552014300938
<<A>> FLEXIBLE SUCTION HOSE AND AIR THERMO SENSOR INSPECTION
LIQUID PIPE B DISCONNECTION
CAUTION
As the compressor oil and receiver are highly
moisture absorbent, use a non-porous material
to plug the hose and nipples.
To prevent the entry of dust or other foreign bodies,
plug the dismantled hose and the nipples of the
expansion valves.

<<B>> EVAPORATOR REMOVAL

Resistance
(kΩ) 25
Dashboard pad 20

15

10

5
0
-10 0 10 20 30 40
Blower unit Temperature (˚C)
AC305312 AB
AC103376 AB

CAUTION Measure the resistance between connector terminals

Do not cut the upper side of the pad. 4 and 5 under at least two different temperatures.
1. When removing the evaporator, cut and fold back The resistance values should generally match those
the dashboard pad as in the diagram. (The in the graph.
thickness of the pad interferes with the removal of NOTE: The temperature at the check should not
the evaporator.) exceed the range in the graph.
2. Remove the evaporator.
 HEATER, AIR CONDITIONER AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY
55-91
COMPRESSOR ASSEMBLY AND TENSION PULLEY
REMOVAL AND INSTALLATION
M1552004100472

Pre-removal Operation Post-installation Operation

• Refrigerant Discharging (Refer to P.55-72). • Drive Belt Tension Adjustment (1300, 1600: Refer to
GROUP 11A, On-vehicles Service − Drive Belt Tension
Check P.11A-7, 2000: Refer to GROUP 11C, On-vehicles
Service − Drive Belt Tension Check P.11C-7).
• Refrigerant Charging (Refer to P.55-70).

<2000> 7
-Pipe coupling

7 <1300, 1600>

1, 2 O ring 5
A/C compressor oil:
SUN PAG 56

3 N
<1300, 1600> <2000>

1 12 ± 2 N·m

4
5 AC304850AB

Removal steps Removal steps (Continued)

<<A>> 1. Flexible suction hose connection <<C>> 5. Drive belt <2000>
<<A>> 2. Flexible discharge hose connection <<D>> >>A<< 6. A/C compressor
3. O ring 7. A/C compressor bracket
<<B>> 4. Drive belt <1300, 1600>
55-92 HEATER, AIR CONDITIONER AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY

REMOVAL SERVICE POINTS <<C>> DRIVE BELT REMOVAL <2000>

<<A>> FLEXIBLE SUCTION HOSE AND The following operations will be needed due to the
serpentine drive system with the alternator drive belt
FLEXIBLE DISCHARGE HOSE
auto tensioner.
DISCONNECTION
Alternator drive belt
CAUTION auto tensioner
As the compressor oil and receiver are highly
moisture absorbent, use a non-porous material
to plug the hose and nipples.
To prevent the entry of dust or other foreign bodies,
plug the dismantled hoses and compressor nipples. Hole B

<<B>> DRIVE BELT REMOVAL <1300,

1600> Hole A AC107640AD

CAUTION
Alternator drive belt
auto tensioner

A
B

L-shaped
C hexagon
wrench AC107641AC

1. Securely insert the spindle handle or ratchet

handle with a 12.7 mm insertion angle into the jig
hole of the alternator drive belt auto tensioner,
and turn the alternator drive belt auto tensioner
anti-clockwise until it hits the stopper.
CAUTION
D
To reuse the alternator drive belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the alternator drive belt using chalk.
2. Align hole A with hole B, insert an L-shaped
AC203472 AC hexagon wrench, etc. to fix and then remove the
To reuse the drive belt, draw an arrow indicating alternator drive belt.
the rotating direction (clockwise) on the back of
the belt using chalk. <<D>> COMPRESSOR REMOVAL
Take care not to spill any compressor oil when
1. Loosen the power steering oil pump fixing bolts A,
removing the compressor.
B and C.
2. Turn the adjusting bolt D in the anti-clockwise
direction (to the left) to remove the drive belt.
 HEATER, AIR CONDITIONER AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY
55-93
INSTALLATION SERVICE POINT INSPECTION
M1552014300949
>>A<< A/C COMPRESSOR COMPRESSOR MAGNETIC CLUTCH
INSTALLATION OPERATION CHECK
If a new compressor is installed, first adjust the
amount of oil according to the procedures described Magnetic clutch connector
below, and then install the compressor.
1. Measure the amount (X mL) of oil within the
removed compressor.
2. Drain (from the new compressor) the amount of
oil calculated according to the following formula,
and then install the new compressor.
New compressor oil amount = 140mL <1300,
1600>, 120 mL <2000>
140 mL−X mL = Y mL <1300, 1600> AC005671AC

120 mL−X mL = Y mL <2000> Connect the compressor connector terminal to the

NOTE: Y mL indicates the amount of oil in the battery positive (+) terminal and earth the battery’s
refrigerant line, the condenser, the evaporator, etc. negative (−) terminal to the compressor unit. At that
time, the magnetic clutch should make a definite
NOTE: When replacing the following parts at the
operating sound.
same times as the compressor, subtract the rated oil
amount of the each part from Y mL and discharge
from the new compressor.
Quantity:
• Evaporator: 60 mL
• Condenser: 15 mL
• Suction hose: 10 mL
• Receiver: 10 mL
55-94 HEATER, AIR CONDITIONER AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY

DISASSEMBLY AND REASSEMBLY

M1552004600660

9 3N
2

8
7
6
11 1
5
10

N 4

16 ± 1 N·m
AC100630 AB

Cooling temperature switch Magnetic clutch disassembly

disassembly steps 5. Armature
1. Snap ring >>B<< 6. Snap ring
2. Refrigerant temperature switch 7. Rotor
3. O ring 8. Snap ring
Magnetic clutch disassembly >>A<< 9. Field core
>>D<< • Air gap adjustment 10. Shim
<<A>> >>C<< 4. Self-locking nut 11. A/C compressor

DISASSEMBLY SERVICE POINT REASSEMBLY SERVICE POINTS

<<A>> SELF-LOCKING NUT REMOVAL >>A<< FIELD CORE ATTACHMENT

MB991386 Field core projection

MB991367

Compressor
unit pin hole
AC100633AB AC100634 AB

Use the special tools to remove the self-locking nut. Line up the pin hole on the compressor unit with the
• Special spanner (MB991367) field core projection and attach.
• Pin (MB991386)
 HEATER, AIR CONDITIONER AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY
55-95
>>B<< SNAP RING INSTALLATION INSPECTION
M1552014300950
Snap ring Rotor Clutch coil REFRIGERANT TEMPERATURE SWITCH
CAUTION
Do not heat more than necessary.

Tapered part

AC001412 AB
Thermometer
Using snap ring pliers, fit the snap ring so that the
snap ring’s tapered part is on the outside.
Engine oil

>>C<< SELF-LOCKING NUT

INSTALLATION AC100787 AB

1. Dip the metal part of the cooling temperature

switch into engine oil and increase the oil
MB991386
temperature using a gas burner or similar.

MB991367
120˚C 150˚C

Continuity
No continuity

AC100633AB
Oil temperature
Use the special tools to install the self-locking nut.
• Special spanner (MB991367)
• Pin (MB991386) AC100810 AD

>>D<< AIR GAP ADJUSTMENT 2. When the oil temperature reaches the standard
value, check that voltage is supplied between the
Thickness
terminals.
gauge Standard value:
Item Temperature
Less than 2 Slightly below 150°C
ohms
No continuity 150°C or more
NOTE: When the oil temperature is 150°C or
more and there is no continuity, the resistance will
AC100637AB
not be 2Ω or lower until the oil temperature
Check that the clutch air gap is inside the standard reduces to 120°C or less.
value. If outside the standard value, use a shim to
adjust the gap.
Standard value: 0.3 − 0.5 mm
55-96 HEATER, AIR CONDITIONER AND VENTILATION
CONDENSER AND CONDENSER FAN MOTOR

CONDENSER AND CONDENSER FAN MOTOR

REMOVAL AND INSTALLATION
M1552006700384

Pre-removal and Post-installation Operation

• Refrigerant draining and Refilling (Refer to Charging
P.55-70 and Discharging P.55-72).
• Air cleaner cover and air flow sensor assembly Removal
and Installation (Refer to GROUP 15, Air cleaner P.15-3).

2 3 4

4.9 ± 0.9 N·m

10 N
N 10

-Pipe coupling

7 5, 6 O ring

A/C compressor oil:

SUN PAG 56
9

8
N 10 AC304889AB

Fan shroud assembly removal Condenser removal steps

steps <<A>> 5. Liquid pipe A connection
1. Fan shroud assembly <<A>> 6. Flexible discharge hose connection
2. Fan >>A<< 7. Condenser assembly
3. Fan motor 8. Clamp
4. Fan shroud 9. Receiver
10. O ring
 HEATER, AIR CONDITIONER AND VENTILATION
CONDENSER AND CONDENSER FAN MOTOR
55-97
REMOVAL SERVICE POINT INSPECTION
M1552014300961
<<A>> FLEXIBLE SUCTION HOSE AND CONDENSER FAN MOTOR CHECK
LIQUID PIPE A DISCONNECTION
CAUTION
As the compressor oil and receiver are highly
moisture absorbent, use a non-porous material
to plug the hose and nipples.
To prevent the entry of dust or other foreign bodies,
plug the dismantled hose and condenser assembly
nipples.
1 2

INSTALLATION SERVICE POINT A304852

>>A<< CONDENSER INSTALLATION Check to be sure that the condenser fan motor
When replacing the condenser, refill it with a operates when battery voltage is applied to terminal
specified amount of compressor oil and install it. (to 2 and terminal 1 earthed.
the vehicle).
Compressor oil: SUN PAG 56
Quantity: 15 mL
55-98 HEATER, AIR CONDITIONER AND VENTILATION
REFRIGERANT LINE

REFRIGERANT LINE
REMOVAL AND INSTALLATION <L.H.D.>
M1552006400402

Pre-removal and Post-installation Operation

• Refrigerant Draining and Refilling (Refer to P.55-70.)
• Air Cleaner Removal and Installation (Refer to GROUP
15, Air cleaner P.15-3.)
• Radiator Grille Removal and Installation (Refer to
GROUP 51, Front bumper P.51-2.)

13 ± 1 N·m
6
High-pressure
side service valve 8N

1 8 N

2 Low-pressure side 7
4.9 ± 0.9 N·m service valve
8 N

5 4.9 ± 0.9 N·m

4

8N

12 ± 2 N·m
8N
3 -Pipe coupling

O-ring
1, 2, 3,
5, 6 O-ring 6
A/C compressor oil: SUN PAG 56

AC304553 AB

Removal steps Removal steps (Continued)

<<A>> 1. Dual pressure switch <<A>> >>A<< 5. Flexible suction hose
<<A>> 2. Liquid pipe A <<A>> >>A<< 6. Liquid pipe B
<<A>> 3. Flexible discharge hose 7. Expansion valve cover
4. Expansion valve cover 8. O ring
 HEATER, AIR CONDITIONER AND VENTILATION
REFRIGERANT LINE
55-99
REMOVAL SERVICE POINT INSTALLATION SERVICE POINT
<<A>> HOSE/PIPE DISCONNECTION >>A<< SUCTION HOSE INSTALLATION
CAUTION When replacing the suction hose, refill them with a
As the compressor oil and receiver are highly specified amount of compressor oil, and then install
moisture absorbent, use a non-porous material them.
to plug the hose and nipples. Compressor oil: SUN PAG 56
To prevent the entry of other foreign bodies, plug the Quantity: Suction hose: 10 cm3
condenser, compressor, and expansion valve
nipples.

REMOVAL AND INSTALLATION <R.H.D.>

M1552006400413

Pre-removal and Post-installation Operation

• Refrigerant Draining and Refilling (Refer to P.55-70.)
• Air Cleaner Removal and Installation (Refer to GROUP
15, Air cleaner P.15-3.)
• Radiator Grille Removal and Installation (Refer to
GROUP 51, Front bumper P.51-2.)

8N 13 ± 1 N·m 6
Low-pressure side
High-pressure
service valve
Side Service Valve
1

4.9±0.9 N·m 8N
2
5 7

8N
8N 4 4.9 ± 0.9 N·m

12 ± 2 N·m
3 8N
-Pipe coupling

O-ring
1, 2, 3,
5, 6 O-ring 6
A/C compressor oil: SUN PAG 56

AC304554 AB

Removal steps Removal steps (Continued)

<<A>> 1. Dual pressure switch <<A>> >>A<< 5. Flexible suction hose
<<A>> 2. Liquid pipe A <<A>> >>A<< 6. Liquid pipe B
<<A>> 3. Flexible discharge hose 7. Expansion valve cover
4. Expansion valve cover 8. O ring
55-100 HEATER, AIR CONDITIONER AND VENTILATION
REFRIGERANT LINE

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> HOSE/PIPE DISCONNECTION >>A<< SUCTION HOSE INSTALLATION
CAUTION When replacing the suction hose, refill them with a
As the compressor oil and receiver are highly specified amount of compressor oil, and then install
moisture absorbent, use a non-porous material them.
to plug the hose and nipples. Compressor oil: SUN PAG 56
To prevent the entry of other foreign bodies, plug the Quantity: Suction hose: 10 cm3
condenser, compressor, and expansion valve
nipples.
 HEATER, AIR CONDITIONER AND VENTILATION
DUCTS
55-101
DUCTS
REMOVAL AND INSTALLATION
M1553001000101

Cross-section A-A 4
Clip 5

Instrument panel 4
1 3
2
6

A 1

3
9

10

11 8

13

12

AC304890 AB

Air Outlet Removal steps Foot duct Removal steps

1. Centre Air Outlet Panel 8. Rear heater duct A (RH) upper side
2. Centre Air Outlet • Under cover (Refer to GROUP
3. Side Air Outlet 52A, Instrument panel P.52A-2.)
Defroster nozzle and Distribution 9. Foot duct (LH)
duct Removal steps Rear heater duct Removal steps
• Instrument Panel (Refer to 52A, • Front floor console (Refer to
Instrument Panel P.52A-2.) GROUP 52A, Front floor console
4. Side defroster duct assembly P.52A-6.)
5. Defroster nozzle • Front seat (Refer to GROUP 52A -
6. Distribution duct Front seat assembly P.52A-24.)
Foot duct Removal steps • Floor carpet and Floor pads
• Console cover and Glove box 10. Rear heater duct A (LH)
(Refer to GROUP 52A, Instrument 11. Left -hand rear heater duct B
panel P.52A-2.) 12. Right-hand rear heater duct B
7. Foot duct (RH) 13. Rear heater duct A (RH) lower side
55-102 HEATER, AIR CONDITIONER AND VENTILATION
VENTILATORS

VENTILATORS
REMOVAL AND INSTALLATION
M1553001600318

Cross-Section A-A Cross-Section B-B

1
Claw

Claw

A A
A A

B
1 B
AC304949AB

A A
A A

1 B
AC304951

Rear ventilation duct removal

steps
• Rear bumper assembly (Refer to
GROUP 51, Rear bumper P.51-5.)
1. Rear ventilation duct
 70-1

GROUP 70

COMPONENT
LOCATIONS
CONTENTS

ECU . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2 SOLENOID VALVE. . . . . . . . . . . . . . . 70-11

RELAY . . . . . . . . . . . . . . . . . . . . . . . . 70-5 DIODE . . . . . . . . . . . . . . . . . . . . . . . . . 70-13

SENSOR. . . . . . . . . . . . . . . . . . . . . . . 70-6 EARTH . . . . . . . . . . . . . . . . . . . . . . . . 70-14

FUSIBLE LINK AND FUSE . . . . . . . . 70-10 INSPECTION CONNECTOR AND

SPARE CONNECTOR . . . . . . . . . . . . 70-18
EARTH CABLE . . . . . . . . . . . . . . . . . 70-11
70-2 COMPONENT LOCATIONS
ECU

ECU
M1701000500140

Name Symbol Name Symbol

A/C-ECU E Cooling fan motor drive control unit C
ABS-ECU A Front-ECU B
Column switch (incorporating D Immobilizer-ECU G
Column-ECU)
Engine-A/T-ECU <A/T> I Power window main switch K
(incorporating ECU)
Engine-ECU <M/T> I Power window sub switch J
(incorporating ECU)
ETACS-ECU F SRS-ECU H
<LHD> <RHD>
A B A B

C C

D E E D

F G H I I H F G

AC301182 AB
 COMPONENT LOCATIONS
ECU
70-3

J * K

AC304537AE

NOTE: *: also equipped on the rear doors.

A <LHD> C
Cooling fan motor
drive control unit
ABS-ECU

Hydraulic unit Radiator fan

AC100209 AC AC300571 AC

A <RHD> D Column switch

(incorporating
ABS-ECU column-ECU)

Hydraulic unit

AC206790 AD AC301746 AB

B Front-ECU
E

Battery A/C-ECU

AC301728 AB AC301732 AB
70-4 COMPONENT LOCATIONS
ECU

F I
Junction Engine-ECU <M/T> or
block engine-A/T-ECU <A/T>

ETACS-ECU AC100229 AI
AC301739 AC

G J

Immobilizer-ECU

Power window
sub switch
(incorporating
ECU)
AC301733 AB AC301749AB

H K
Power window
main switch
(incorporating
SRS-ECU ECU)

AC301747 AB AC301748 AB
 COMPONENT LOCATIONS
RELAY
70-5
RELAY
M1701000400369

Name Symbol Name Symbol

A/C compressor relay A Heated seat relay B
A/T control relay A Horn relay A
Accessory socket relay B Ignition coil relay A
Blower relay B Power window relay B
Engine control relay A Radiator fan relay A
Front fog lamp relay A Rear fog lamp relay B
Fuel pump relay (1) B Rear window defogger relay B
Fuel pump relay (2) B

B
AC301758 AB

A Engine control relay

A/C compressor relay

Horn relay

A/T control relay

Front fog lamp relay

Ignition coil relay

Radiator fan relay
AC303951 AB

B Fuel pump relay (1)

Power window relay

Heated seat relay

Fuel pump relay(2) Rear window defogger relay

Accessory socket relay

Blower relay
Rear fog lamp relay
AC301760 AB
70-6 COMPONENT LOCATIONS
SENSOR

SENSOR
M1701000600567

Name Symbol Name Symbol

Air cleaner air flow sensor <4G6> F Output shaft speed sensor <A/T> I
Air thermo sensor J Side impact sensor (Front) K
Camshaft position sensor D Side impact sensor (Rear) L
Engine control detonation sensor B Throttle body throttle sensor C
Engine control oxygen sensor (Front) G Vehicle speed sensor <M/T> E
Engine control oxygen sensor (Rear) N Water temperature sensor unit H
Engine crank angle sensor A Wheel speed sensor (Front) M
Inlet manifold absolute pressure sensor C Wheel speed sensor (Rear) O
(incorporating intake air temperature
sensor) <4G1>
Input shaft speed sensor <A/T> I

A B C D E F J

G H I

M * N O *

K * L *
AC302006 AB

NOTE: *: also equipped at the right side.

 COMPONENT LOCATIONS
SENSOR
70-7

A <4G1>

Engine crank angle

sensor connector
Engine crank
angle sensor

Timing belt front Timing belt front

upper cover lower cover
AC208762 AD

A <4G6>

Crankshaft Engine crank

Engine crank angle sprocket angle sensor
sensor connector

Heat protector
AC302008 AB

B <4G1>
Engine control detonation
sensor connector Engine control
Ignition coil 2
detonation sensor

AC301752 AB

B <4G6>

Engine control detonation

Engine control
sensor connector
detonation sensor

Hydraulic unit
Alternator
AC302009 AB

C <4G1> Throttle body C <4G6>

throttle sensor Throttle body
throttle sensor

Throttle body

Inlet manifold absolute pressure sensor

(incorporating intake air temperature sensor) Throttle body
AC208541 AE AC302479 AB
70-8 COMPONENT LOCATIONS
SENSOR

D <4G1> G <4G1> Engine control

oxygen sensor
Heat protector
(Front) connector

Camshaft position
sensor

Engine control
Rocker cover oxygen sensor (Front)
AC206644 AD AC301754 AC

D <4G6> G <4G6>
Heat protector
Engine control
Rocker cover oxygen sensor
(Front) connector

Camshaft position
sensor Engine control
oxygen sensor (Front)
AC302480AB AC302482 AB

E <M/T> H <4G1>

Idle speed Water temperature

control servo sensor unit

Vehicle speed
sensor

AC208654 AD
Rocker cover
AC206780 AD

F <4G6> Air cleaner H <4G6>

Air cleaner assembly
air flow sensor

Rocker cover
Water temperature
sensor unit

AC302481 AB AC302483 AB
 COMPONENT LOCATIONS
SENSOR
70-9

I <A/T> Air cleaner K

bracket
Output shaft Centre
speed sensor pillar
Side impact
sensor (Front)

Input shaft
speed sensor
AC206775 AD AC300517 AD

J Blower assembly L

Side impact
sensor (Rear)

Air thermo Rear

sensor seat belt
AC301755 AB AC300534 AC

M
Wheel speed
Wheel speed sensor sensor (Front)
(Front) connector

Coil spring
AC209080 AG

Engine control
oxygen sensor
(Rear) connector
Engine control
oxygen sensor
(Rear)
SRS-ECU
AC301753 AB

O Coil spring

Wheel speed sensor Wheel speed

(Rear) connector sensor (Rear)

Parking brake cable

AC209459 AE
70-10 COMPONENT LOCATIONS
FUSIBLE LINK AND FUSE

FUSIBLE LINK AND FUSE

M1701000100476

Name Symbol Name Symbol

Fuses No.1 to 20 C Fusible links No.1 to 5 B
(Passenger compartment) (Engine compartment)
Fuses No.6 to 25 B Fusible link No.26 A
(Engine compartment) (Battery positive terminal)

A B

C
AC301758AD

A Battery B

Fusible link No.26

Fuses
No.6 to 25

Relay box

AC208658 AE AC301730 AB

B Fusible links C
No.4,5

Fuses No.1 to 20

Relay box Fusible links

No.2,3 Junction
block
Fusible link No.1
AC301729 AD AC301761 AB
 COMPONENT LOCATIONS
EARTH CABLE
70-11
EARTH CABLE
M1701001000308

<4G1>

Timing belt front

upper cover
AC206557

<4G6>

Throttle body
AC302485

AC303148 AB

SOLENOID VALVE
M1701000800516

Name Symbol Name Symbol

A/T control solenoid valve assembly D Emission solenoid valve (Purge control B
system) <4G6>
Emission solenoid valve (EGR system) B Hydraulic unit (incorporating solenoid A
Emission solenoid valve (Purge control C valve)
system) <4G1>
70-12 COMPONENT LOCATIONS
SOLENOID VALVE

<LHD> <RHD>

A B C B C A

D D
AC302007 AB

A <LHD> B <4G6>
Hydraulic unit Emission solenoid valve
(incorporating (Purge control system)
solenoid valve)

Emission solenoid
valve (EGR system)
Intake manifold
AC100230 AH AC302484 AB

A <RHD> C <4G1> Idle speed

control servo

Hydraulic unit
(incorporating
solenoid valve)

Air cleaner
Emission solenoid valve
cover
(Purge control system)
AC208527 AD AC208529 AD

B <4G1>
Emission solenoid
valve (EGR system)

Ignition coil 1
AC206782 AC
 COMPONENT LOCATIONS
DIODE
70-13

D Transmission
A/T control solenoid assembly
valve assembly connector

A/T control solenoid

Inhibitor switch valve assembly
AC208684 AD

DIODE
M1701000900223

<WAGON>

Diode

AC300441

AC301240 AD
70-14 COMPONENT LOCATIONS
EARTH

EARTH
M1701000300362

<SEDAN-L.H. drive vehicles>

3 4 5 6 7

AC301175

9 10 11 12 13 14 15 16 17

<SEDAN-R.H. drive vehicles>

6 4 5 3 7

AC301176

9 10 11 12 13 14 15 16 17

AC301751 AB

NOTE: Same earth numbers are used in the circuit diagram.

 COMPONENT LOCATIONS
EARTH
70-15

<WAGON-L.H. drive vehicles>

3 4 5 6 7 8

AC301177

9 10 11 12 13 14 15 16 17

<WAGON-R.H. drive vehicles>

6 4 5 3 7 8

AC301178

9 10 11 12 13 14 15 16 17

AC301756 AB

NOTE: Same earth numbers are used in the circuit diagram.

70-16 COMPONENT LOCATIONS
EARTH

1 4

Glove box

AC300427 AD AC301742 AB

2 , 3 <LHD> 5
3

Diagnosis
connector
AC301737 AB AC301741AB

2 <RHD> 6 <LHD>

Windshield
wiper arm
Junction
block AC300429 AB AC100195 AC

3 ,16 <RHD> 6 <RHD> Steering column

shaft assembly
3

16

AC206768 AD AC212109 AC
 COMPONENT LOCATIONS
EARTH
70-17

7 <SEDAN> 10

Rear seatback
hook (RH)
Rocker cover
AC301208 AC AC301743 AB

7 <WAGON> 11 ,12
Rear Relay box
speaker
(RH)

11 12

AC212111 AC AC300437 AD

8 Rear wiper motor 13

Air cleaner
assembly AC301745 AB
AC212112 AC

9 14

SRS-ECU

Heat protector
AC301744 AB AC301750 AB
70-18 COMPONENT LOCATIONS
INSPECTION CONNECTOR AND SPARE CONNECTOR

15 17 <SEDAN>
Rear seatback
SRS-ECU hook (LH)

AC300436 AC AC301210 AC

16 <LHD> Junction block 17 <WAGON>

Rear
speaker
(LH)

AC208871AC AC300440 AC

INSPECTION CONNECTOR AND SPARE CONNECTOR

M1701000200343

Name Symbol Name Symbol

Diagnosis connector E Spare connector (for front fog lamp A
relay)
Engine speed detection connector A Spare connector (for front fog lamp C
switch)
Spare connector (for front fog lamp) B Spare connector (for audio) D

A C D

B E
AC301758AC
 COMPONENT LOCATIONS
INSPECTION CONNECTOR AND SPARE CONNECTOR
70-19

A Front-ECU D

Spare connector
Spare connector
(for front fog lamp
(for audio)
relay)

Engine speed
detection connector
AC212306 AC AC301735 AB

B E

Spare connector
(for front fog lamp)

Diagnosis connector

Heat protector AC301740 AB AC100188 AH

C Spare connector
(for front fog
lamp switch)

AC301736 AB
NOTES
 80-1

GROUP 80

CONFIGURATION
DIAGRAMS
CONTENTS

OVERALL CONFIGURATION DASH PANEL . . . . . . . . . . . . . . . . . . . 80-16

DIAGRAM. . . . . . . . . . . . . . . . . . . . . . 80-2 DASH PANEL <LHD> . . . . . . . . . . . . . . . . . 80-16
OVERALL WIRING DIAGRAM DASH PANEL <RHD> . . . . . . . . . . . . . . . . . 80-19
<SEDAN (LHD) > . . . . . . . . . . . . . . . . . . . . 80-2
OVERALL WIRING DIAGRAM FLOOR AND ROOF . . . . . . . . . . . . . . 80-22
<SEDAN (RHD) > . . . . . . . . . . . . . . . . . . . . 80-3
FLOOR AND ROOF <SEDAN (LHD) > . . . . 80-22
OVERALL WIRING DIAGRAM FLOOR AND ROOF <SEDAN (RHD) >. . . . 80-23
<WAGON (LHD) > . . . . . . . . . . . . . . . . . . . 80-4
FLOOR AND ROOF <WAGON (LHD) > . . . 80-24
OVERALL WIRING DIAGRAM
<WAGON (RHD) > . . . . . . . . . . . . . . . . . . . 80-5 FLOOR AND ROOF <WAGON (RHD) > . . . 80-25

ENGINE COMPARTMENT. . . . . . . . . 80-6 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 80-26

ENGINE COMPARTMENT <LHD>. . . . . . . 80-6 DOOR <LHD> . . . . . . . . . . . . . . . . . . . . . . . 80-26
ENGINE COMPARTMENT <RHD> . . . . . . 80-7 DOOR <RHD> . . . . . . . . . . . . . . . . . . . . . . . 80-27

ENGINE AND TRANSMISSION. . . . . 80-8 TRUNK

ENGINE AND TRANSMISSION
(LUGGAGE COMPARTMENT). . . . . . 80-28
<4G1-MPI (LHD) > . . . . . . . . . . . . . . . . . . . 80-8 TRUNK (LUGGAGE COMPARTMENT)
<SEDAN (LHD) > . . . . . . . . . . . . . . . . . . . . 80-28
ENGINE AND TRANSMISSION
<4G1-MPI (RHD) > . . . . . . . . . . . . . . . . . . . 80-10 TRUNK (LUGGAGE COMPARTMENT)
<SEDAN (RHD) > . . . . . . . . . . . . . . . . . . . . 80-29
ENGINE AND TRANSMISSION
<4G6-MPI (LHD) > . . . . . . . . . . . . . . . . . . . 80-12
ENGINE AND TRANSMISSION TAILGATE. . . . . . . . . . . . . . . . . . . . . . 80-30
<4G6-MPI (RHD) > . . . . . . . . . . . . . . . . . . . 80-14 TAILGATE <WAGON (LHD) > . . . . . . . . . . 80-30
TAILGATE <WAGON (RHD) > . . . . . . . . . . 80-31
80-2 CONFIGURATION DIAGRAMS
OVERALL CONFIGURATION DIAGRAM

OVERALL CONFIGURATION DIAGRAM

OVERALL WIRING DIAGRAM <SEDAN (LHD) >
M1801000100569

Front wiring Control wiring Instrument panel Roof wiring Floor wiring
harness (RH) harness wiring harness harness harness (RH)

Rear bumper
wiring harness

Rear door
wiring harness *
Front bumper
wiring harness

Battery wiring Front wiring Floor wiring Front door Fuel wiring
harness harness (LH) harness (LH) wiring harness * harness

AC301175 AB

NOTE: .
1. This illustration shows only major wiring harnesses.
2. *: also equipped at the right side.
 CONFIGURATION DIAGRAMS
OVERALL CONFIGURATION DIAGRAM
80-3
OVERALL WIRING DIAGRAM <SEDAN (RHD) >
M1801000100581

Front wiring Control wiring Instrument panel Roof wiring Floor wiring
harness (RH) harness wiring harness harness harness (RH)

Rear bumper
wiring harness

Rear door
wiring harness *
Front bumper
wiring harness

Battery wiring Front wiring Floor wiring Front door Fuel wiring
harness harness (LH) harness (LH) wiring harness * harness

AC301176 AB

NOTE: .
1. This illustration shows only major wiring harnesses.
2. *: also equipped at the right side.
80-4 CONFIGURATION DIAGRAMS
OVERALL CONFIGURATION DIAGRAM

OVERALL WIRING DIAGRAM <WAGON (LHD) >

M1801000100592

Front wiring Control wiring Instrument panel Roof wiring Floor wiring Tailgate wiring
harness (RH) harness wiring harness harness harness (RH) harness

Rear bumper
wiring harness

Rear door
wiring harness *
Front bumper
wiring harness

Battery wiring Front wiring Floor wiring Front door Fuel wiring
harness harness (LH) harness (LH) wiring harness * harness

AC301177AB

NOTE: .
1. This illustration shows only major wiring harnesses.
2. *: also equipped at the right side.
 CONFIGURATION DIAGRAMS
OVERALL CONFIGURATION DIAGRAM
80-5
OVERALL WIRING DIAGRAM <WAGON (RHD) >
M1801000100600

Front wiring Control wiring Instrument panel Roof wiring Floor wiring Tailgate wiring
harness (RH) harness wiring harness harness harness (RH) harness

Rear bumper
wiring harness

Rear door
wiring harness *
Front bumper
wiring harness

Battery wiring Front wiring Floor wiring Front door Fuel wiring
harness harness (LH) harness (LH) wiring harness * harness

AC301178 AB

NOTE: .
1. This illustration shows only major wiring harnesses.
2. *: also equipped at the right side.
80-6 CONFIGURATION DIAGRAMS
ENGINE COMPARTMENT

ENGINE COMPARTMENT
ENGINE COMPARTMENT <LHD>
M1801000301298

Connector
symbol A-01 A-02
A-32

A A-03

A-31 A-04X
A-05X
A-09X
A-10X
A-11X

A-12
1

A-29 Front wiring A-13

harness (RH)
12

A-28
A-14

A-27

A-15
Connector colour
code
B : Black
A-26
BR : Brown
G : Green
GR : Gray A-16
L : Blue
None : Milk white Front wiring
O : Orange harness (LH)
R : Red A-25
V : Violet Front bumper A-17
Y : Yellow wiring harness
A-24 A-23 A-22 A-21 A-20 A-19 A-18
AC301122AB

A-01 (2-GR) Side turn signal lamp (RH) A-17 (2-B) Front fog lamp (LH)
A-02 (2-GR) Side turn signal lamp (LH) A-18 (3-GR) Cooling fan motor drive control unit
A-03 (2-B) Wheel speed sensor (Front: LH) A-19 (1-B) Horn (HI)
A-04X (4) Front fog lamp relay or spare connector A-20 (2-B) Front wiring harness (LH) and front
(for front fog lamp) bumper wiring harness combination
A-05X (4) Horn relay A-21 (1-B) Horn (LO)
A-09X (4) Fan control relay A-22 (2-B) Front fog lamp (RH)
A-10X (11) Front-ECU A-23 (2) Front turn signal lamp (RH)
A-11X (11) Front-ECU A-24 (1) Spare connector (for front fog lamp)
A-12 (2-B) Front wiring harness (LH) and control A-25 (6-B) Front combination lamp (RH)
wiring harness combination A-26 (2) Windshield washer motor
A-13 (12-B) Front wiring harness (LH) and control A-27 (2-G) Rear washer motor
wiring harness combination A-28 (2-B) Headlamp washer motor
A-14 (3-B) Headlamp (LH) A-29 (3-B) Headlamp (RH)
A-15 (6-B) Front combination lamp (LH) A-31 (2-BR) Dual pressure switch
A-16 (2) Front turn signal lamp (LH) A-32 (2-B) Wheel speed sensor (Front: RH)
 CONFIGURATION DIAGRAMS
ENGINE COMPARTMENT
80-7
ENGINE COMPARTMENT <RHD>
M1801000301306

Connector A-01 A-02

symbol
A-32

A A-03

A-31 A-04X
A-05X
A-09X
A-10X
A-11X
A-30 Front wiring
harness (RH)
A-12

A-29
12

A-27 A-14

A-15
Connector colour A-26
code
B : Black
BR : Brown
G : Green A-16
GR : Gray
L : Blue A-25
None : Milk white
Front wiring
O : Orange harness (LH)
R : Red
V : Violet Front bumper A-17
Y : Yellow A-24 A-23 A-22 wiring harness
A-21 A-20 A-19 A-18
AC301125 AB

A-01 (2-GR) Side turn signal lamp (RH) A-18 (3-GR) Cooling fan motor drive control unit
A-02 (2-GR) Side turn signal lamp (LH) A-19 (1-B) Horn (HI)
A-03 (2-B) Wheel speed sensor (Front: LH) A-20 (2-B) Front wiring harness (LH) and front
A-04X (4) Front fog lamp relay or spare connector bumper wiring harness combination
(for front fog lamp) A-21 (1-B) Horn (LO)
A-05X (4) Horn relay A-22 (2-B) Front fog lamp (RH)
A-09X (4) Fan control relay A-23 (2) Front turn signal lamp (RH)
A-10X (11) Front-ECU A-24 (1) Spare connector (for front fog lamp)
A-11X (11) Front-ECU A-25 (6-B) Front combination lamp (RH)
A-12 (2-B) Front wiring harness (LH) and control A-26 (2) Windshield washer motor
wiring harness combination A-27 (2-G) Rear washer motor
A-14 (3-B) Headlamp (LH) A-29 (3-B) Headlamp (RH)
A-15 (6-B) Front combination lamp (LH) A-30 (2-GR) No connection
A-16 (2) Front turn signal lamp (LH) A-31 (2-BR) Dual pressure switch
A-17 (2-B) Front fog lamp (LH) A-32 (2-B) Wheel speed sensor (Front: RH)
80-8 CONFIGURATION DIAGRAMS
ENGINE AND TRANSMISSION

ENGINE AND TRANSMISSION

ENGINE AND TRANSMISSION <4G1-MPI (LHD) >
M1801000400689

Connector B-01 B-02 B-03 B-04 B-05 B-06 B-07 B-09

symbol

B -01
thru
-26
Control wiring
harness
B-10X
B-15X
B-16X
B-17X
13

B-26

B-18

Earth cable 10
Battery wiring
harness
11
* *
Connector colour
code B-25
B : Black
BR : Brown
G : Green
GR : Gray 9
L : Blue
None : Milk white
O : Orange B-19
R : Red
V : Violet B-24 B-23 B-22 B-21 B-20
Y : Yellow
AC301128AB

B-01 (5-GR) Windshield wiper motor B-20 (10-B) Inhibitor switch <A/T>
B-02 (2-GR) Fuel injector 1 B-21 (4-B) Engine control oxygen sensor (Front)
B-03 (2-GR) Fuel injector 2 B-22 (1) Starter
B-04 (2-GR) Fuel injector 3 B-23 (1-B) Starter
B-05 (2-GR) Fuel injector 4 B-24 (1-B) Engine oil pressure switch
B-06 (3-GR) Throttle body throttle sensor B-25 (1) Alternator
B-07 (3-B) Vehicle speed sensor <M/T> B-26 (4-GR) Alternator
B-09 (2-GR) Brake fluid level indicator switch NOTE: On A/T only, the standard routing positions
B-10X (1) Engine speed detection connector for the corrugated tube and wiring harness are
B-15X (4) A/T control relay marked by*.
B-16X (4) Engine control relay
B-17X (4) A/C compressor relay
B-18 (6-B) Control wiring harness and battery wiring
harness combination
B-19 (10-GR) A/T control solenoid valve assembly
 CONFIGURATION DIAGRAMS
ENGINE AND TRANSMISSION
80-9
ENGINE AND TRANSMISSION <4G1-MPI (LHD) > (CONTINUED)

Connector B-101 B-102 B-103 B-104 B-105

symbol

B -101 B-118
thru
-118 B-107

13

B-117
B-108
Control wiring
harness

10
Earth cable Battery wiring
harness
* * 11
Connector colour
code
B : Black
BR : Brown B-116
G : Green
9
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet B-115 B-114 B-113 B-112 B-111 B-110 B-109
Y : Yellow
AC301128AC

B-101 (2-BR)
Emission solenoid valve (EGR system) B-113 (3-GR) Ignition coil 2
B-102 (4-GR)
Inlet manifold absolute pressure sensor B-114 (1-B) A/C compressor
B-103 (6-B)
Throttle body idle speed control servo B-115 (1) Power steering fluid pressure switch
B-104 (3-GR)
Ignition coil 1 B-116 (3-B) Engine crank angle sensor
B-105 (2-B)
Emission solenoid valve (Purge control B-117 (2-GR) Engine control detonation sensor
system) B-118 (28-GR) ABS-ECU
B-107 (3-B) Camshaft position sensor NOTE: On A/T only, the standard routing positions
B-108 (3-GR) Output shaft speed sensor <A/T> for the corrugated tube and wiring harness are
B-109 (3-B) Input shaft speed sensor <A/T> marked by*.
B-110 (2-B) Back-up lamp switch <M/T>
B-111 (2-B) Water temperature sensor unit
B-112 (1-B) Water temperature gauge unit
80-10 CONFIGURATION DIAGRAMS
ENGINE AND TRANSMISSION

ENGINE AND TRANSMISSION

<4G1-MPI (RHD) >
M1801000400690

Connector B-09 B-02 B-03 B-04 B-05 B-06 B-07 B-01

symbol

B -01
thru
-26

B-10X
Control wiring B-14X
harness B-15X
B-16X
13 B-17X

B-26

B-18

Earth cable 10
Battery wiring
harness
* 11
Connector colour *
code B-25
B : Black
BR : Brown
G : Green
GR : Gray 9
L : Blue
None : Milk white
O : Orange
R : Red B-19
V : Violet B-24 B-23 B-22 B-21 B-20
Y : Yellow
AC301131AB

B-01 (5-GR) Windshield wiper motor B-20 (10-B) Inhibitor switch <A/T>
B-02 (2-GR) Fuel injector 1 B-21 (4-B) Engine control oxygen sensor (Front)
B-03 (2-GR) Fuel injector 2 B-22 (1) Starter
B-04 (2-GR) Fuel injector 3 B-23 (1-B) Starter
B-05 (2-GR) Fuel injector 4 B-24 (1-B) Engine oil pressure switch
B-06 (3-GR) Throttle body throttle sensor B-25 (1) Alternator
B-07 (3-B) Vehicle speed sensor <M/T> B-26 (4-GR) Alternator
B-09 (2-GR) Brake fluid level indicator switch NOTE: On A/T only, the standard routing positions
B-10X (1) Engine speed detection connector for the corrugated tube and wiring harness are
B-14X (4) Ignition coil relay marked by*.
B-15X (4) A/T control relay
B-16X (4) Engine control relay
B-17X (4) A/C compressor relay
B-18 (6-B) Control wiring harness and battery wiring
harness combination
B-19 (10-GR) A/T control solenoid valve assembly
 CONFIGURATION DIAGRAMS
ENGINE AND TRANSMISSION
80-11
ENGINE AND TRANSMISSION <4G1-MPI (RHD) > (CONTINUED)

Connector B-101 B-102 B-103 B-104 B-105 B-118

symbol

B -101
thru
-118

B-117 B-107

13

Control wiring
harness B-108

10
Earth cable Battery wiring
harness
*
Connector colour * 11
code
B : Black
BR : Brown B-116
G : Green
GR : Gray 9
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet B-115 B-114 B-113 B-112 B-111 B-110 B-109
Y : Yellow
AC301131AC

B-101 (2-BR)
Emission solenoid valve (EGR system) B-113 (3-GR) Ignition coil 2
B-102 (4-GR)
Inlet manifold absolute pressure sensor B-114 (1-B) A/C compressor
B-103 (6-B)
Throttle body idle speed control servo B-115 (1) Power steering fluid pressure switch
B-104 (3-GR)
Ignition coil 1 B-116 (3-B) Engine crank angle sensor
B-105 (2-B)
Emission solenoid valve (Purge control B-117 (2-GR) Engine control detonation sensor
system) B-118 (28-GR) ABS-ECU
B-107 (3-B) Camshaft position sensor NOTE: On A/T only, the standard routing positions
B-108 (3-GR) Output shaft speed sensor <A/T> for the corrugated tube and wiring harness are
B-109 (3-B) Input shaft speed sensor <A/T> marked by*.
B-110 (2-B) Back-up lamp switch <M/T>
B-111 (2-B) Water temperature sensor unit
B-112 (1-B) Water temperature gauge unit
80-12 CONFIGURATION DIAGRAMS
ENGINE AND TRANSMISSION

ENGINE AND TRANSMISSION

<4G6-MPI (LHD) >
M1801000400708

Connector B-01 B-02 B-03 B-04 B-05 B-06 B-07 B-08

symbol
Earth

B -01
thru
-26
Control wiring
cable B-09

harness
B-10X
B-16X
B-17X
13

B-26

B-18

10
9 Battery wiring
harness
11
Connector colour
code B-25
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet B-24 B-23 B-22 B-21
Y : Yellow AC301134 AB

B-01 (5-GR) Windshield wiper motor B-16X (4) Engine control relay
B-02 (2-GR) Fuel injector 1 B-17X (4) A/C compressor relay
B-03 (2-GR) Fuel injector 2 B-18 (6-B) Control wiring harness and battery wiring
B-04 (2-GR) Fuel injector 3 harness combination
B-05 (2-GR) Fuel injector 4 B-21 (4-B) Engine control oxygen sensor (Front)
B-06 (4-B) Throttle body throttle sensor B-22 (1) Starter
B-07 (3-B) Vehicle speed sensor B-23 (1-B) Starter
B-08 (7-B) Air cleaner air flow sensor B-24 (1-B) Engine oil pressure switch
B-09 (2-GR) Brake fluid level indicator switch B-25 (1) Alternator
B-10X (1) Engine speed detection connector B-26 (4-GR) Alternator
 CONFIGURATION DIAGRAMS
ENGINE AND TRANSMISSION
80-13
ENGINE AND TRANSMISSION <4G6-MPI (LHD) > (CONTINUED)

Connector B-105 B-101 B-103 B-104 B-106

symbol

B -101
thru
-118
B-118 Earth cable

B-112
13
B-117

B-116 Battery wiring

10 harness
11
Connector colour
code
B : Black
Control wiring
BR : Brown harness
G : Green 9
B-110
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet B-115 B-114 B-113 B-107 B-111
Y : Yellow
AC301134 AC

B-101 (2-BR) Emission solenoid valve (EGR system) B-111 (2-B) Water temperature sensor unit
B-103 (6-B) Throttle body idle speed control servo B-112 (1-B) Water temperature gauge unit
B-104 (3-GR) Ignition coil 1 B-113 (3-GR) Ignition coil 2
B-105 (2-B) Emission solenoid valve (Purge control B-114 (1-B) A/C compressor
system) B-115 (1-B) Power steering fluid pressure switch
B-106 (1-B) Capacitor B-116 (3-B) Engine crank angle sensor
B-107 (3-B) Camshaft position sensor B-117 (2-GR) Engine control detonation sensor
B-110 (2-B) Back-up lamp switch B-118 (28-GR) ABS-ECU
80-14 CONFIGURATION DIAGRAMS
ENGINE AND TRANSMISSION

ENGINE AND TRANSMISSION

<4G6-MPI (RHD) >
M1801000400719

Connector B-02 B-03 B-04 B-05 B-06 B-07 B-01

symbol

B -01 Earth B-08

thru B-09 cable
-26

B-10X
B-14X
13 B-16X
Control wiring B-17X
harness

B-18
10
9
B-26
Connector colour Battery wiring
code 11
harness
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet B-25 B-24 B-23 B-22 B-21
Y : Yellow AC301137AB

B-01 (5-GR) Windshield wiper motor B-16X (4) Engine control relay
B-02 (2-GR) Fuel injector 1 B-17X (4) A/C compressor relay
B-03 (2-GR) Fuel injector 2 B-18 (6-B) Control wiring harness and battery wiring
B-04 (2-GR) Fuel injector 3 harness combination
B-05 (2-GR) Fuel injector 4 B-21 (4-B) Engine control oxygen sensor (Front)
B-06 (4-B) Throttle body throttle sensor B-22 (1) Starter
B-07 (3-B) Vehicle speed sensor B-23 (1-B) Starter
B-08 (7-B) Air cleaner air flow sensor B-24 (1-B) Engine oil pressure switch
B-09 (2-GR) Brake fluid level indicator switch B-25 (1) Alternator
B-10X (1) Engine speed detection connector B-26 (4-GR) Alternator
B-14X (4) Ignition coil relay
 CONFIGURATION DIAGRAMS
ENGINE AND TRANSMISSION
80-15
ENGINE AND TRANSMISSION <4G6-MPI (RHD) > (CONTINUED)

Connector B-105 B-101 B-103 B-104 B-106

symbol

B -101
thru
-118
Earth cable

B-117 B-118

13
B-112

B-116

Battery wiring
10 harness

Connector colour Control wiring 11

code harness
B : Black
BR : Brown
G : Green 9
GR : Gray
L : Blue
None : Milk white B-110
O : Orange
R : Red
V : Violet B-115 B-114 B-113 B-107 B-111
Y : Yellow
AC301137AC

B-101 (2-BR) Emission solenoid valve (EGR system) B-111 (2-B) Water temperature sensor unit
B-103 (6-B) Throttle body idle speed control servo B-112 (1-B) Water temperature gauge unit
B-104 (3-GR) Ignition coil 1 B-113 (3-GR) Ignition coil 2
B-105 (2-B) Emission solenoid valve (Purge control B-114 (1-B) A/C compressor
system) B-115 (1-B) Power steering fluid pressure switch
B-106 (1-B) Capacitor B-116 (3-B) Engine crank angle sensor
B-107 (3-B) Camshaft position sensor B-117 (2-GR) Engine control detonation sensor
B-110 (2-B) Back-up lamp switch B-118 (28-GR) ABS-ECU
80-16 CONFIGURATION DIAGRAMS
DASH PANEL

DASH PANEL
DASH PANEL <LHD>
M1801000601040

Connector C-01 C-02 C-03 C-04 C-05 C-06 C-08 C-09

symbol Instrument panel
wiring harness C-10

C -01
thru
-36 C-36

C-35

C-11
C-34

C-33
16
C-12
C-32 6

5
C-31
J/B Control wiring
harness

C-29

Connector colour
code C-13
B : Black
BR : Brown C-27 14
G : Green
GR : Gray
L : Blue 15
None : Milk white
O : Orange
R : Red
V : Violet C-25 C-24 C-22 C-21 C-19 C-15 C-14
Y : Yellow
AC301140AB

C-01 (6) Fog lamp switch C-22 (13) Instrument panel wiring harness and floor
C-02 (1) Spare connector (for front fog lamp wiring harness (LH) combination
switch) C-24 (6-L) Instrument panel wiring harness and roof
C-03 (22-B) J/C (5) wiring harness combination
C-04 (21) Combination meter C-25 (11-B ) Instrument panel wiring harness and floor
*
C-05 (4) Stop lamp switch wiring harness (LH) combination
C-06 (21-L) Combination meter C-27 (25) Front wiring harness (LH) and instrument
C-08 (1-B) Spare connector (for audio) panel wiring harness combination
C-09 (14) Spare connector (for audio) C-29 (20) Instrument panel wiring harness and front
C-10 (1) Instrument panel wiring harness and door wiring harness (LH) combination
antenna feeder cable combination C-31 (6) Instrument panel wiring harness and roof
C-11 (16-B) Diagnosis connector wiring harness combination <Wagon>
C-12 (33) J/C (6) C-32 (22-B) J/C (4)
C-13 (25) Instrument panel wiring harness and C-33 (6-L) Rheostat
control wiring harness combination C-34 (6-GR) Headlamp levelling switch
C-14 (10-GR) Instrument panel wiring harness and C-35 (22-L) J/C (2)
control wiring harness combination C-36 (11-B) Remote controlled mirror switch
C-15 (22-L) Instrument panel wiring harness and NOTE: The connector colour marked by * is for the
control wiring harness combination female side. For the male side, the colour is grey for
C-19 (12) Diagnosis connector Sedan, and milk white for Wagon.
C-21 (3) Front wiring harness (LH) and instrument
panel wiring harness combination
 CONFIGURATION DIAGRAMS
DASH PANEL
80-17
DASH PANEL <LHD> (CONTINUED)

Connector C-101 C-102 C-103 C-104 C-106 C-107

symbol
Antenna

C -101 feeder
thru cable
-140

C-108
C-140
A/C wiring
harness

C-109
C-139

2
Instrument panel
wiring harness Control wiring C-110
harness

C-112
Connector colour
code C-133 Y
B : Black
BR : Brown
G : Green
GR : Gray C-114
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet C-132 C-131 C-130 C-128 C-126 C-124 C-122 C-119 C-116
Y : Yellow C-129 C-127 C-125 C-123
AC301143AB

C-101 (4) Hazard warning lamp switch C-123 (26-Y) Engine-ECU <M/T>
C-102 (4) Clock C-124 (26-GR) Engine-A/T-ECU <A/T>
C-103 (22-GR) J/C (1) C-125 (16-Y) Engine-ECU <M/T>
C-104 (22-GR) J/C (3) C-126 (28-GR) Engine-A/T-ECU <A/T>
C-106 (7) Instrument panel wiring harness and A/C C-127 (12-Y) Engine-ECU <M/T>
wiring harness combination C-128 (30-GR) Engine-A/T-ECU <A/T>
C-107 (7) Outside /Inside air selection damper C-129 (22-Y) Engine-ECU <M/T>
control motor C-130 (4) Engine control oxygen sensor (Rear)
C-108 (2-R) Air bag module (squib) <Passenger’s C-131 (20-Y) SRS-ECU
side> C-132 (28-Y) SRS-ECU
C-109 (4) Resistor C-133 (20-Y) SRS-ECU
C-110 (2) Blower motor C-139 (16-B) A/C-ECU or heater control unit
C-112 (16) Instrument panel wiring harness and front C-140 (6) Blower switch
door wiring harness (RH) combination NOTE: The connector colour marked by * is for the
C-114 (25) Front wiring harness (RH) and instrument female side.For the male side, the colour is grey for
panel wiring harness combination Sedan, and milk white for Wagon.
C-116 (9-GR ) Instrument panel wiring harness and floor
*
wiring harness (RH) combination
C-119 (13) Instrument panel wiring harness and floor
wiring harness (RH) combination
C-122 (35-GR) Engine-A/T-ECU <A/T>
80-18 CONFIGURATION DIAGRAMS
DASH PANEL

DASH PANEL <LHD> (CONTINUED)

JUNCTION BLOCK
Connector
symbol (Front view) (Rear view)

C -201
thru
-227
C-208 C-209 C-210 C-211 C-225

C-224 C-212
STEERING COLUMN

C-223
C-213

C-222
Clock spring
C-214

C-221
Y

C-215
C-207 C-220

C-219 C-218 C-217 C-227 C-226

Instrument panel
wiring harness

C-206

C-205 C-204 C-203 C-202 C-201

AC304413AB

C-201 (6) Ignition switch C-213 (5) Rear window defogger relay
C-202 (7) Key reminder switch C-214 (5) Blower relay
C-203 (10) Column switch C-215 (15) Floor wiring harness (LH) and J/B
C-204 (6) Clock spring combination
C-205 (4-Y) Clock spring C-217 (3) Roof wiring harness and J/B combination
C-206 (1) Horn switch C-218 (4) Rear fog lamp relay
C-207 (2) Air bag module (squib) <Driver’s side> C-219 (4) Accessory socket relay
C-208 (13) Instrument panel wiring harness and J/B C-220 (4) Fuel pump relay (2)
combination C-221 (4) Heated seat relay
C-209 (14) Instrument panel wiring harness and J/B C-222 (4) Fuel pump relay (1)
combination C-223 (5) Power window relay
C-210 (6) Instrument panel wiring harness and J/B C-224 (2) No connection
combination C-225 (20) ETACS-ECU
C-211 (1-B) Instrument panel wiring harness and J/B C-226 (24) ETACS-ECU
combination C-227 (24-GR) ETACS-ECU
C-212 (28) Instrument panel wiring harness and J/B
combination
 CONFIGURATION DIAGRAMS
DASH PANEL
80-19
DASH PANEL <RHD>
M1801000601051

Connector C-09 C-08 C-04 C-07 C-06 C-05 C-02 C-01

symbol
Instrument panel
wiring harness

C -01
thru
-37 C-36

C-32
C-10 6

C-34

C-33
2
C-11

C-31
Control wiring
harness 4
J/B
C-30
C-37

Connector colour C-28

code
B : Black Y
BR : Brown
C-16
G : Green
GR : Gray
L : Blue C-26
None : Milk white
O : Orange
R : Red
V : Violet C-17 C-18 C-19 C-35 C-20 C-23 C-24
Y : Yellow
AC301149AB

C-01 (6) Fog lamp switch C-24 (6-L) Instrument panel wiring harness and roof
C-02 (1) Spare connector (for front fog lamp wiring harness combination
switch) C-26 (9-GR) Instrument panel wiring harness and floor
C-04 (21) Combination meter wiring harness (RH) combination
C-05 (4) Stop lamp switch C-28 (25) Front wiring harness (RH) and instrument
C-06 (21-L) Combination meter panel wiring harness combination
C-07 (22-GR) J/C (3) C-30 (20) Instrument panel wiring harness and front
C-08 (1-B) Spare connector (for audio) door wiring harness (RH) combination
C-09 (14) Spare connector (for audio) C-31 (6) Instrument panel wiring harness and roof
C-10 (1) Instrument panel wiring harness and wiring harness combination <Wagon>
antenna feeder cable combination C-32 (22-B) J/C (4)
C-11 (16-B) Diagnosis connector C-33 (6-L) Rheostat
C-16 (20-Y) SRS-ECU C-34 (6-GR) Headlamp levelling switch
C-17 (28-Y) SRS-ECU C-35 (22-L) J/C (2)
C-18 (20-Y) SRS-ECU C-36 (11-B) Remote controlled mirror switch
C-19 (12) Diagnosis connector C-37 (4) Engine control oxygen sensor (Rear)
C-20 (2) No connection
C-23 (13) Instrument panel wiring harness and floor
wiring harness (RH) combination
80-20 CONFIGURATION DIAGRAMS
DASH PANEL

DASH PANEL <RHD> (CONTINUED)

Connector C-108 C-107 C-106 C-105 C-103 C-102 C-101

symbol
Antenna

C -101
thru
-140
feeder
cable

A/C wiring C-139

harness
C-109

Y
Instrument panel
wiring harness

5 C-140
C-110
3

C-111 16

C-138
Control wiring
C-113 harness

Connector colour C-115

code 15
B : Black 14 C-137
BR : Brown
G : Green
GR : Gray C-117
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet C-118 C-120 C-121 C-128 C-126 C-124 C-122 C-134 C-135 C-136
Y : Yellow C-129 C-127 C-125 C-123
AC301146AB

C-101 (4)
Hazard warning lamp switch C-121 (3) Front wiring harness (LH) and instrument
C-102 (4)
Clock panel wiring harness combination
C-103 (22-GR)
J/C (1) C-122 (35-GR) Engine-A/T-ECU <A/T>
C-105 (13)
J/C (5) C-123 (26-Y) Engine-ECU <M/T>
C-106 (7)
Instrument panel wiring harness and A/C C-124 (26-GR) Engine-A/T-ECU <A/T>
wiring harness combination C-125 (16-Y) Engine-ECU <M/T>
C-107 (7) Outside /Inside air selection damper C-126 (28-GR) Engine-A/T-ECU <A/T>
control motor C-127 (12-Y) Engine-ECU <M/T>
C-108 (2-R) Air bag module (squib) <Passenger’s C-128 (30-GR) Engine-A/T-ECU <A/T>
side> C-129 (22-Y) Engine-ECU <M/T>
C-109 (4) Resistor C-134 (33) J/C (6)
C-110 (2) Blower motor C-135 (22-L) Instrument panel wiring harness and
C-111 (12) Front wiring harness (LH) and control control wiring harness combination
wiring harness combination C-136 (10-GR) Instrument panel wiring harness and
C-113 (16) Instrument panel wiring harness and front control wiring harness combination
door wiring harness (LH) combination C-137 (25) Instrument panel wiring harness and
C-115 (25) Front wiring harness (LH) and instrument control wiring harness combination
panel wiring harness combination C-138 (3) Instrument panel wiring harness and
C-117 (11-B*) Instrument panel wiring harness and floor Instrument panel wiring harness
wiring harness (LH) combination combination
C-118 (6-L) Instrument panel wiring harness and floor C-139 (12-B) A/C-ECU or heater control unit
wiring harness (LH) combination C-140 (6) Blower switch
C-120 (13) Instrument panel wiring harness and floor NOTE: The connector colour marked by * is for the
wiring harness (LH) combination female side.For the male side, the colour is grey.
 CONFIGURATION DIAGRAMS
DASH PANEL
80-21
DASH PANEL <RHD> (CONTINUED)
JUNCTION BLOCK
Connector
symbol (Front view) (Rear view)

C -201
thru
-227
C-208 C-209 C-210 C-211 C-225

C-224 C-212

STEERING COLUMN
C-223
C-213

C-222

C-214

Clock spring C-221

Y C-216
C-207 C-220

C-219 C-218 C-217 C-227 C-226

C-206

Instrument panel
wiring harness

C-201 C-202 C-203 C-204 C-205

AC304414AB

C-201 (6) Ignition switch C-213 (5) Rear window defogger relay
C-202 (7) Key reminder switch C-214 (5) Blower relay
C-203 (10) Column switch C-216 (15) Floor wiring harness (RH) and J/B
C-204 (6) Clock spring combination
C-205 (4-Y) Clock spring C-217 (3) Roof wiring harness and J/B combination
C-206 (1) Horn switch C-218 (4) Rear fog lamp relay
C-207 (2) Air bag module (squib) <Driver’s side> C-219 (4) Accessory socket relay
C-208 (13) Instrument panel wiring harness and J/B C-220 (4) Fuel pump relay (2)
combination C-221 (4) No connection
C-209 (14) Instrument panel wiring harness and J/B C-222 (4) Fuel pump relay (1)
combination C-223 (5) Power window relay
C-210 (6) Instrument panel wiring harness and J/B C-224 (2) No connection
combination C-225 (20) ETACS-ECU
C-211 (1-B) Instrument panel wiring harness and J/B C-226 (24) ETACS-ECU
combination C-227 (24-GR) ETACS-ECU
C-212 (28) Instrument panel wiring harness and J/B
combination
80-22 CONFIGURATION DIAGRAMS
FLOOR AND ROOF

FLOOR AND ROOF

FLOOR AND ROOF <SEDAN (LHD) >
M1801000900844

Connector D-01 D-02 D-03 D-04 D-05 D-06 D-07 D-08 D-13
symbol <Vehicles with curtain air bag>

D D-35
7 D-04 D-36
Y
D-06 D-37

17 D-14

D-34 Antenna
feeder cable

Antenna Y
Y feeder cable
Floor wiring Fuel wiring
D-33 harness Y
harness (RH) Roof wiring
harness
D-15
Roof wiring
Y harness
D-32
D-16
Instrument panel Y Floor wiring
wiring harness harness (LH)
D-31

D-17

Connector colour D-30 Y

Y
code
B : Black Y
BR : Brown D-18
G : Green
GR : Gray D-29
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet D-28 D-27 D-26 D-25 D-24 D-23 D-22 D-21 D-20 D-19
Y : Yellow
AC301155AC

D-01 (2) Side impact sensor (Front: RH) D-21 (2) Side impact sensor (Front: LH)
D-02 (3) Door switch (Front: RH) D-22 (2-B) Seat belt pre-tensioner (LH)
D-03 (8) Floor wiring harness (RH) and rear door D-23 (2-R) Side air bag module (squib) (LH)
wiring harness (RH) combination D-24 (3) Heated seat assembly (LH)
D-04 (2) Front room lamp D-25 (9) Heated seat switch
D-05 (2-B) Wheel speed sensor (Rear: RH) D-26 (4) Instrument panel wiring harness and
D-06 (2-GR) Rear room lamp console wiring harness combination
D-07 (3) Door switch (Rear: RH) D-27 (6) Shift switch assembly
D-08 (2-Y) Side impact sensor (Rear: RH) D-28 (1) Cigarette lighter
D-13 (3-B) Fuel tank gauge unit D-29 (1-B) Cigarette lighter
D-14 (2-Y) Side impact sensor (Rear: LH) D-30 (2-B) Cigarette lighter illumination lamp
D-15 (3) Door switch (Rear: LH) D-31 (2-B) Ashtray illumination lamp
D-16 (5-GR) Fuel tank pump D-32 (3) Heated seat assembly (RH)
D-17 (2-B) Wheel speed sensor (Rear: LH) D-33 (2-R) Side air bag module (squib) (RH)
D-18 (8) Floor wiring harness (LH) and fuel wiring D-34 (1-B) Parking brake switch
harness combination D-35 (2-B) Seat belt pre-tensioner (RH)
D-19 (8) Floor wiring harness (LH) and rear door D-36 (2-B) Curtain air bag module (squib) (RH)
wiring harness (LH) combination D-37 (2-B) Curtain air bag module (squib) (LH)
D-20 (3) Door switch (Front: LH)
 CONFIGURATION DIAGRAMS
FLOOR AND ROOF
80-23
FLOOR AND ROOF <SEDAN (RHD) >
M1801000900855

Connector D-01 D-02 D-03 D-04 D-05 D-06 D-07 D-08 D-13
symbol <Vehicles with curtain air bag>
Antenna

D D-35
7
feeder cable
D-04 D-36

Y
D-06

Roof wiring
D-37

harness
17 D-14

D-34

Y
Y
Roof wiring Floor wiring Fuel wiring
harness harness Y
harness (RH)
D-33 Antenna
D-15 feeder cable
Y

Instrument panel Y D-16

Floor wiring
wiring harness harness (LH)
D-31

D-17

Connector colour Y
Y
code D-30 Y
B : Black
BR : Brown D-18
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange D-29
R : Red
V : Violet D-28 D-27 D-26 D-23 D-22 D-21 D-20 D-19
Y : Yellow
AC301158AB

D-01 (2) Side impact sensor (Front: RH) D-20 (3) Door switch (Front: LH)
D-02 (3) Door switch (Front: RH) D-21 (2) Side impact sensor (Front: LH)
D-03 (8) Floor wiring harness (RH) and rear door D-22 (2-B) Seat belt pre-tensioner (LH)
wiring harness (RH) combination D-23 (2-R) Side air bag module (squib) (LH)
D-04 (2) Front room lamp D-26 (4) Instrument panel wiring harness and
D-05 (2-B) Wheel speed sensor (Rear: RH) console wiring harness combination
D-06 (2-GR) Rear room lamp D-27 (6) Shift switch assembly
D-07 (3) Door switch (Rear: RH) D-28 (1) Cigarette lighter
D-08 (2-Y) Side impact sensor (Rear: RH) D-29 (1-B) Cigarette lighter
D-13 (3-B) Fuel tank gauge unit D-30 (2-B) Cigarette lighter illumination lamp
D-14 (2-Y) Side impact sensor (Rear: LH) D-31 (2-B) Ashtray illumination lamp
D-15 (3) Door switch (Rear: LH) D-33 (2-R) Side air bag module (squib) (RH)
D-16 (5-GR) Fuel tank pump D-34 (1-B) Parking brake switch
D-17 (2-B) Wheel speed sensor (Rear: LH) D-35 (2-B) Seat belt pre-tensioner (RH)
D-18 (8) Floor wiring harness (LH) and fuel wiring D-36 (2-B) Curtain air bag module (squib) (RH)
harness combination D-37 (2-B) Curtain air bag module (squib) (LH)
D-19 (8) Floor wiring harness (LH) and rear door
wiring harness (LH) combination
80-24 CONFIGURATION DIAGRAMS
FLOOR AND ROOF

FLOOR AND ROOF <WAGON (LHD) >

M1801000900866

Connector D-01 D-02 D-03 D-04 D-05 D-07 D-08 D-09 D-10 D-11 D-12
symbol
<Vehicles with curtain air bag>

D D-35
Antenna
feeder
cable
D-13
D-04 D-36 D-06 D-37

Y Y

7
D-34

Roof wiring
harness D-14
D-33 Fuel wiring
harness
Y Antenna
Y feeder cable
17
D-32 Roof wiring
harness
Floor wiring D-15
Y harness (RH)
D-27

Y Instrument panel
wiring harness
D-31

D-16
Connector colour
code D-30
B : Black Y
BR : Brown
G : Green Y Y
Floor wiring
GR : Gray harness (LH)
L : Blue D-29
None : Milk white
O : Orange
R : Red
V : Violet D-28 D-26 D-25 D-24 D-23 D-20 D-21 D-22 D-19 D-18 D-17
Y : Yellow
AC301161AB

D-01 (2) Side impact sensor (Front: RH) D-20 (3) Door switch (Front: LH)
D-02 (3) Door switch (Front: RH) D-21 (2) Side impact sensor (Front: LH)
D-03 (8) Floor wiring harness (RH) and rear door D-22 (2-B) Seat belt pre-tensioner (LH)
wiring harness (RH) combination D-23 (2-R) Side air bag module (squib) (LH)
D-04 (2) Front room lamp D-24 (3) Heated seat assembly (LH)
D-05 (2-B) Wheel speed sensor (Rear: RH) D-25 (9) Heated seat switch
D-06 (2-GR) Rear room lamp D-26 (4) Instrument panel wiring harness and
D-07 (3) Door switch (Rear: RH) console wiring harness combination
D-08 (2-Y) Side impact sensor (Rear: RH) D-27 (6) Shift switch assembly
D-09 (3) Rear personal lamp (RH) D-28 (1) Cigarette lighter
D-10 (3) Luggage room lamp D-29 (1-B) Cigarette lighter
D-11 (2-B) Diode (for luggage room lamp circuit) D-30 (2-B) Cigarette lighter illumination lamp
D-12 (3) Rear personal lamp (LH) D-31 (2-B) Ashtray illumination lamp
D-13 (3-B) Fuel tank gauge unit D-32 (3) Heated seat assembly (RH)
D-14 (2-Y) Side impact sensor (Rear: LH) D-33 (2-R) Side air bag module (squib) (RH)
D-15 (3) Door switch (Rear: LH) D-34 (1-B) Parking brake switch
D-16 (5-GR) Fuel tank pump D-35 (2-B) Seat belt pre-tensioner (RH)
D-17 (2-B) Wheel speed sensor (Rear: LH) D-36 (2-B) Curtain air bag module (squib) (RH)
D-18 (8) Floor wiring harness (LH) and fuel wiring D-37 (2-B) Curtain air bag module (squib) (LH)
harness combination
D-19 (8) Floor wiring harness (LH) and rear door
wiring harness (LH) combination
 CONFIGURATION DIAGRAMS
FLOOR AND ROOF
80-25
FLOOR AND ROOF <WAGON (RHD) >
M1801000900877

Connector
D-01 D-02 D-03 D-04 D-05 D-07 D-08 D-09 D-10 D-11 D-12
symbol
<Vehicles with curtain air bag>
D D-13
D-04 D-36 D-06 D-37
D-35 Antenna
feeder Y
cable
7

Roof wiring
D-34 harness D-14
Y
Fuel wiring
harness
Y Roof wiring
Y
harness
17
D-33

Floor wiring
Y harness (RH) D-15 Antenna
feeder cable
D-31
Y
Instrument panel
wiring harness

D-30
D-16
Connector colour
code
B : Black Y
BR : Brown
G : Green D-29 Y Y Floor wiring
GR : Gray harness (LH)
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet D-28 D-27 D-26 D-23 D-20 D-21 D-22 D-19 D-18 D-17
Y : Yellow
AC301164 AB

D-01 (2) Side impact sensor (Front: RH) D-19 (8) Floor wiring harness (LH) and rear door
D-02 (3) Door switch (Front: RH) wiring harness (LH) combination
D-03 (8) Floor wiring harness (RH) and rear door D-20 (3) Door switch (Front: LH)
wiring harness (RH) combination D-21 (2) Side impact sensor (Front: LH)
D-04 (2) Front room lamp D-22 (2-B) Seat belt pre-tensioner (LH)
D-05 (2-B) Wheel speed sensor (Rear: RH) D-23 (2-R) Side air bag module (squib) (LH)
D-06 (2-GR) Rear room lamp D-26 (4) Instrument panel wiring harness and
D-07 (3) Door switch (Rear: RH) console wiring harness combination
D-08 (2-Y) Side impact sensor (Rear: RH) D-27 (6) Shift switch assembly
D-09 (3) Rear personal lamp (RH) D-28 (1) Cigarette lighter
D-10 (3) Luggage room lamp D-29 (1-B) Cigarette lighter
D-11 (2-B) Diode (for luggage room lamp circuit) D-30 (2-B) Cigarette lighter illumination lamp
D-12 (3) Rear personal lamp (LH) D-31 (2-B) Ashtray illumination lamp
D-13 (3-B) Fuel tank gauge unit D-33 (2-R) Side air bag module (squib) (RH)
D-14 (2-Y) Side impact sensor (Rear: LH) D-34 (1-B) Parking brake switch
D-15 (3) Door switch (Rear: LH) D-35 (2-B) Seat belt pre-tensioner (RH)
D-16 (5-GR) Fuel tank pump D-36 (2-B) Curtain air bag module (squib) (RH)
D-17 (2-B) Wheel speed sensor (Rear: LH) D-37 (2-B) Curtain air bag module (squib) (LH)
D-18 (8) Floor wiring harness (LH) and fuel wiring
harness combination
80-26 CONFIGURATION DIAGRAMS
DOOR

DOOR
DOOR <LHD>
M1801001400585

Connector
symbol
Driver's side Passenger's side
E-01 E-10

E E-02 E-11

Front Front

E-06 E-05 E-04 E-03 E-16 E-15 E-14 E-13 E-12

Connector colour
Rear Rear code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
E-09 E-08 E-07 E-19 E-18 E-17 Y : Yellow
AC304415AB

E-01 (3) Remote controlled mirror (LH) <Vehicles E-11 (7) Remote controlled mirror (RH) <Vehicles
without door mirror heater> with door mirror heater>
E-02 (7) Remote controlled mirror (LH) <Vehicles E-12 (3-B) Door lock key cylinder switch
with door mirror heater> E-13 (6-B) Front door lock actuator (RH)
E-03 (2) Front door speaker (LH) E-14 (8) Front power window sub switch (RH)
E-04 (6-GR) Front power window motor (LH) E-15 (6-GR) Front power window motor (RH)
E-05 (14) Power window main switch E-16 (2) Front door speaker (RH)
E-06 (6-B) Front door lock actuator (LH) E-17 (6-B) Rear door lock actuator (RH)
E-07 (6-GR) Rear power window motor (LH) E-18 (8) Rear power window sub switch (RH)
E-08 (8) Rear power window sub switch (LH) E-19 (6-GR) Rear power window motor (RH)
E-09 (6-B) Rear door lock actuator (LH)
E-10 (3) Remote controlled mirror (RH) <Vehicles
without door mirror heater>
 CONFIGURATION DIAGRAMS
DOOR
80-27
DOOR <RHD>
M1801001400596

Connector
symbol Driver's side Passenger's side
E-10 E-01
E-11

E
E-02

Front Front

E-16 E-15 E-05 E-13 E-12 E-06 E-20 E-04 E-03

Connector colour
Rear Rear code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
E-19 E-18 E-17 E-09 E-08 E-07 Y : Yellow
AC304416AB

E-01 (3) Remote controlled mirror (LH) <Vehicles E-11 (7) Remote controlled mirror (RH) <Vehicles
without door mirror heater> with door mirror heater>
E-02 (7) Remote controlled mirror (LH) <Vehicles E-12 (3-B) Door lock key cylinder switch
with door mirror heater> E-13 (6-B) Front door lock actuator (RH)
E-03 (2) Front door speaker (LH) E-15 (6-GR) Front power window motor (RH)
E-04 (6-GR) Front power window motor (LH) E-16 (2) Front door speaker (RH)
E-05 (14) Power window main switch E-17 (6-B) Rear door lock actuator (RH)
E-06 (6-B) Front door lock actuator (LH) E-18 (8) Rear power window sub switch (RH)
E-07 (6-GR) Rear power window motor (LH) E-19 (6-GR) Rear power window motor (RH)
E-08 (8) Rear power window sub switch (LH) E-20 (8) Front power window sub switch (LH)
E-09 (6-B) Rear door lock actuator (LH)
E-10 (3) Remote controlled mirror (RH) <Vehicles
without door mirror heater>
80-28 CONFIGURATION DIAGRAMS
TRUNK (LUGGAGE COMPARTMENT)

TRUNK (LUGGAGE COMPARTMENT)

TRUNK (LUGGAGE COMPARTMENT)
<SEDAN (LHD) >
M1801001500355

Connector
symbol
F-01 F-03 F-04 F-05 F-06

F Defogger
earth F-08

Antenna
feeder cable
Floor wiring
F-22 harness (RH)

F-10

F-11
Floor wiring
harness (LH)

Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue Rear bumper
None : Milk white wiring harness
O : Orange
R : Red F-21 F-20 F-19 F-18 F-16 F-15
V : Violet
Y : Yellow
AC301171AB

F-01 (2) Rear speaker (LH) F-15 (2-GR) Licence plate lamp (RH)
F-03 (1) Roof antenna F-16 (1-B) Trunk lid latch switch
F-04 (2) Luggage compartment lamp F-18 (2-GR) Licence plate lamp (LH)
F-05 (2-B) High mount stop lamp <Rear shelf> F-19 (2-GR) Floor wiring harness (LH) and rear
F-06 (1-B) Rear window defogger (−) bumper wiring harness combination
F-08 (2) Rear speaker (RH) F-20 (2) Rear fog lamp
F-10 (2) High mount stop lamp <Rear spoiler> F-21 (6-B) Rear combination lamp (LH)
F-11 (6-B) Rear combination lamp (RH) F-22 (1) Rear window defogger (+)
 CONFIGURATION DIAGRAMS
TRUNK (LUGGAGE COMPARTMENT)
80-29
TRUNK (LUGGAGE COMPARTMENT)
<SEDAN (RHD) >
M1801001500366

Connector
symbol
F-04 F-03 F-05 F-07 F-08 F-22

F Antenna
feeder cable

Defogger
earth

F-06
F-10

Floor wiring
harness (RH)
F-01

F-11

Floor wiring
harness (LH)
F-14
Connector colour
code
B : Black Rear bumper
BR : Brown wiring harness
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red F-21 F-19 F-18 F-16 F-15
V : Violet
Y : Yellow
AC301172 AB

F-01 (2) Rear speaker (LH) F-14 (2) Rear fog lamp
F-03 (1) Roof antenna F-15 (2-GR) Licence plate lamp (RH)
F-04 (2) Luggage compartment lamp F-16 (1-B) Trunk lid latch switch
F-05 (2-B) High mount stop lamp <Rear shelf> F-18 (2-GR) Licence plate lamp (LH)
F-06 (1-B) Rear window defogger (−) F-19 (2-GR) Floor wiring harness (LH) and rear
F-07 (4) No connection bumper wiring harness combination
F-08 (2) Rear speaker (RH) F-21 (6-B) Rear combination lamp (LH)
F-10 (2) High mount stop lamp <Rear spoiler> F-22 (1) Rear window defogger (+)
F-11 (6-B) Rear combination lamp (RH)
80-30 CONFIGURATION DIAGRAMS
TAILGATE

TAILGATE
TAILGATE <WAGON (LHD) >
M1801001900223

Connector
symbol

F F-01 F-06 F-02 F-03

Antenna
feeder cable
F-10 F-22

F-07

F-08
Floor wiring
harness (RH)
Floor wiring Defogger
harness (LH) earth
F-09

F-21
F-11

Tailgate wiring
harness

8 F-12

Connector colour
code
B : Black
BR : Brown Rear bumper F-13
G : Green wiring harness
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
F-20 F-19 F-18 F-17 F-15
V : Violet
Y : Yellow
AC301173 AB

F-01 (2) Rear speaker (LH) F-13 (2-B) Tailgate lock actuator
F-02 (6) Floor wiring harness (LH) and Floor F-15 (2-GR) Licence plate lamp (RH)
wiring harness (RH) combination F-17 (1) Tailgate switch
F-03 (1) Roof antenna F-18 (2-GR) Licence plate lamp (LH)
F-06 (1) Rear window defogger (−) F-19 (4-GR) Floor wiring harness (LH) and rear
F-07 (4) Rear wiper motor bumper wiring harness combination
F-08 (2) Rear speaker (RH) F-20 (2) Rear fog lamp
F-09 (2) Accessory socket F-21 (6-B) Rear combination lamp (LH)
F-10 (2) High mount stop lamp <Rear spoiler> F-22 (1) Rear window defogger (+)
F-11 (6-B) Rear combination lamp (RH)
F-12 (8) Floor wiring harness (RH) and tailgate
wiring harness combination
 CONFIGURATION DIAGRAMS
TAILGATE
80-31
TAILGATE <WAGON (RHD) >
M1801001900234

Connector
symbol

F F-01 F-06 F-03 F-10 F-22

F-07
Antenna
feeder cable Floor wiring
harness (RH)

F-08

Floor wiring Defogger

harness (LH) earth F-09

F-21 F-11

Tailgate wiring
harness F-12
8

Rear bumper
wiring harness

Connector colour F-13

code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
F-14
O : Orange
R : Red
F-19 F-18 F-17 F-15
V : Violet
Y : Yellow
AC301174 AB

F-01 (2) Rear speaker (LH) F-13 (2-B) Tailgate lock actuator
F-03 (1) Roof antenna F-14 (2) Rear fog lamp
F-06 (1) Rear window defogger (−) F-15 (2-GR) Licence plate lamp (RH)
F-07 (4) Rear wiper motor F-17 (1) Tailgate switch
F-08 (2) Rear speaker (RH) F-18 (2-GR) Licence plate lamp (LH)
F-09 (2) Accessory socket F-19 (4-GR) Floor wiring harness (LH) and rear
F-10 (2) High mount stop lamp <Rear spoiler> bumper wiring harness combination
F-11 (6-B) Rear combination lamp (RH) F-21 (6-B) Rear combination lamp (LH)
F-12 (8) Floor wiring harness (RH) and tailgate F-22 (1) Rear window defogger (+)
wiring harness combination
NOTES
 90-1

GROUP 90

CIRCUIT DIAGRAMS
CONTENTS

J/B . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4 CHARGING SYSTEM <A/T> . . . . . . . 90-28

J/C <LHD> . . . . . . . . . . . . . . . . . . . . . 90-6 ENGINE CONTROL SYSTEM

<4G1-M/T (LHD)> . . . . . . . . . . . . . . . . 90-29
J/C <RHD> . . . . . . . . . . . . . . . . . . . . . 90-8
ENGINE CONTROL SYSTEM
CENTRALIZED JUNCTION . . . . . . . . 90-10 <4G1-M/T (RHD)> . . . . . . . . . . . . . . . . 90-31

POWER DISTRIBUTION SYSTEM ENGINE CONTROL SYSTEM

<LHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-15 <4G1-A/T (LHD)> . . . . . . . . . . . . . . . . 90-33

POWER DISTRIBUTION SYSTEM ENGINE CONTROL SYSTEM

<RHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-17 <4G1-A/T (RHD)> . . . . . . . . . . . . . . . . 90-35

STARTING SYSTEM <M/T> . . . . . . . 90-19 ENGINE CONTROL SYSTEM

<4G6 (LHD)>. . . . . . . . . . . . . . . . . . . . 90-37
STARTING SYSTEM <A/T>. . . . . . . . 90-20
ENGINE CONTROL SYSTEM
IGNITION SYSTEM <4G6 (RHD)> . . . . . . . . . . . . . . . . . . . 90-39
<4G1-M/T (LHD)>. . . . . . . . . . . . . . . . 90-21
COOLING SYSTEM <LHD> . . . . . . . . 90-41
IGNITION SYSTEM
<4G1-M/T (RHD)> . . . . . . . . . . . . . . . 90-22 COOLING SYSTEM <RHD> . . . . . . . . 90-42

IGNITION SYSTEM INVECS-II 4A/T <LHD>. . . . . . . . . . . . 90-43

<4G1-A/T (LHD)> . . . . . . . . . . . . . . . . 90-23
INVECS-II 4A/T <RHD> . . . . . . . . . . . 90-45
IGNITION SYSTEM
<4G1-A/T (RHD)>. . . . . . . . . . . . . . . . 90-24 HEADLAMP <LHD> . . . . . . . . . . . . . . 90-47

IGNITION SYSTEM <4G6 (LHD)> . . . 90-25 HEADLAMP <RHD> . . . . . . . . . . . . . . 90-49

IGNITION SYSTEM <4G6 (RHD)>. . . 90-26 Continued on next page

CHARGING SYSTEM <M/T> . . . . . . . 90-27

90-2

TAIL LAMP, POSITION LAMP, LICENCE BACK-UP LAMP <RHD> . . . . . . . . . . 90-81

PLATE LAMP AND LIGHTING MONITOR
BUZZER <LHD>. . . . . . . . . . . . . . . . . 90-51 STOP LAMP <SEDAN (LHD)> . . . . . . 90-82

TAIL LAMP, POSITION LAMP, LICENCE STOP LAMP <SEDAN (RHD)>. . . . . . 90-83
PLATE LAMP AND LIGHTING MONITOR
BUZZER <RHD> . . . . . . . . . . . . . . . . 90-54 STOP LAMP <WAGON (LHD)> . . . . . 90-84

FRONT FOG LAMP <LHD>. . . . . . . . 90-57 STOP LAMP <WAGON (RHD)> . . . . . 90-85

FRONT FOG LAMP <RHD> . . . . . . . 90-59 HORN . . . . . . . . . . . . . . . . . . . . . . . . . 90-86

ROOM LAMP AND LUGGAGE METER AND GAUGE <LHD> . . . . . . 90-87

COMPARTMENT LAMP
<SEDAN (LHD)> . . . . . . . . . . . . . . . . 90-61 METER AND GAUGE <RHD> . . . . . . 90-89

ROOM LAMP AND LUGGAGE FUEL WARNING LAMP, OIL PRESSURE

COMPARTMENT LAMP WARNING LAMP AND BRAKE WARNING
<SEDAN (RHD)> . . . . . . . . . . . . . . . . 90-63 LAMP <LHD> . . . . . . . . . . . . . . . . . . . 90-91

ROOM LAMP,PERSONAL LAMP FUEL WARNING LAMP, OIL PRESSURE

AND LUGGAGE ROOM LAMP WARNING LAMP AND BRAKE WARNING
<WAGON (LHD)>. . . . . . . . . . . . . . . . 90-65 LAMP <RHD> . . . . . . . . . . . . . . . . . . . 90-92

ROOM LAMP,PERSONAL LAMP AND POWER WINDOWS <LHD> . . . . . . . . 90-93

LUGGAGE ROOM LAMP
<WAGON (RHD)> . . . . . . . . . . . . . . . 90-67 POWER WINDOWS <RHD>. . . . . . . . 90-95

REAR FOG LAMP <LHD> . . . . . . . . . 90-69 CENTRAL DOOR LOCKING SYSTEM

<LHD WITHOUT KEYLESS
REAR FOG LAMP <RHD>. . . . . . . . . 90-71 ENTRY> . . . . . . . . . . . . . . . . . . . . . . . 90-97

HEADLAMP LEVELLING SYSTEM CENTRAL DOOR LOCKING SYSTEM

<LHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-73 <RHD WITHOUT KEYLESS
ENTRY> . . . . . . . . . . . . . . . . . . . . . . . 90-99
HEADLAMP LEVELLING SYSTEM
<RHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-74 CENTRAL DOOR LOCKING SYSTEM
<SEDAN LHD WITH KEYLESS
TURN SIGNAL LAMP AND HAZARD ENTRY> . . . . . . . . . . . . . . . . . . . . . . . 90-101
WARNING LAMP <LHD> . . . . . . . . . 90-76
CENTRAL DOOR LOCKING SYSTEM
TURN SIGNAL LAMP AND HAZARD <SEDAN RHD WITH KEYLESS
WARNING LAMP <RHD> . . . . . . . . . 90-78 ENTRY> . . . . . . . . . . . . . . . . . . . . . . . 90-103

BACK-UP LAMP <LHD> . . . . . . . . . . 90-80 Continued on next page

 90-3

CENTRAL DOOR LOCKING SYSTEM REMOTE CONTROLLED MIRROR

<WAGON LHD WITH KEYLESS <RHD>. . . . . . . . . . . . . . . . . . . . . . . . . 90-130
ENTRY> . . . . . . . . . . . . . . . . . . . . . . . 90-105
HEADLAMP WASHER . . . . . . . . . . . . 90-131
CENTRAL DOOR LOCKING SYSTEM
<WAGON RHD WITH KEYLESS SPARE CONNECTOR (FOR AUDIO)
ENTRY> . . . . . . . . . . . . . . . . . . . . . . . 90-108 <LHD> . . . . . . . . . . . . . . . . . . . . . . . . . 90-132

HEATER <LHD> . . . . . . . . . . . . . . . . 90-111 SPARE CONNECTOR (FOR AUDIO)

<RHD>. . . . . . . . . . . . . . . . . . . . . . . . . 90-133
HEATER <RHD> . . . . . . . . . . . . . . . . 90-113
CLOCK . . . . . . . . . . . . . . . . . . . . . . . . 90-134
MANUAL AIR CONDITIONER
<LHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-115 CIGARETTE LIGHTER AND ASHTRAY
ILLUMINATION LAMP . . . . . . . . . . . . 90-135
MANUAL AIR CONDITIONER
<RHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-117 ACCESSORY SOCKET . . . . . . . . . . . 90-136

WINDSHIELD WIPER AND WASHER IMMOBILIZER SYSTEM <LHD> . . . . 90-137

<LHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-119
IMMOBILIZER SYSTEM <RHD> . . . . 90-138
WINDSHIELD WIPER AND WASHER
RHD> . . . . . . . . . . . . . . . . . . . . . . . . . 90-121 ABS <LHD> . . . . . . . . . . . . . . . . . . . . 90-139

REAR WIPER AND WASHER ABS <RHD> . . . . . . . . . . . . . . . . . . . . 90-141

<LHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-123
HEATED SEAT . . . . . . . . . . . . . . . . . . 90-143
REAR WIPER AND WASHER
<RHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-125 RHEOSTAT <LHD> . . . . . . . . . . . . . . 90-144

REAR WINDOW DEFOGGER AND RHEOSTAT <RHD> . . . . . . . . . . . . . . 90-145

DOOR MIRROR HEATER <LHD> . . . 90-127
SUPPLEMENTAL RESTRAINT SYSTEM
REAR WINDOW DEFOGGER AND (SRS) <LHD> . . . . . . . . . . . . . . . . . . . 90-146
DOOR MIRROR HEATER <RHD>. . . 90-128
SUPPLEMENTAL RESTRAINT SYSTEM
REMOTE CONTROLLED MIRROR (SRS) <RHD> . . . . . . . . . . . . . . . . . . . 90-148
<LHD> . . . . . . . . . . . . . . . . . . . . . . . . 90-129
SPARE CONNECTOR (FOR FRONT
FOG LAMP) . . . . . . . . . . . . . . . . . . . . 90-150
90-4 CIRCUIT DIAGRAMS
J/B

J/B
M1901000200972

POWER
WINDOW
RELAY

FUEL
PUMP
RELAY (2)

FUEL
PUMP
RELAY (1)

REAR
WINDOW
DEFOGGER BLOWER
RELAY RELAY

REAR FOG
HEATED LAMP
SEAT RELAY RELAY

ACCESSORY
SOCKET
RELAY

NOTE
· : LHD
· : RHD
· CONNECTOR NUMBERS ARE KEYED TO THE CONFIGIRATION
DIAGRAM (DASH PANEL) AND EACH CIRCUIT DIAGRAM.

J/B SIDE
 CIRCUIT DIAGRAMS
J/B
90-5

Front side Rear side

To instrument panel To instrument panel

wiring harness wiring harness

C-208 C-210
No connection

C-209 ETACS-ECU

Power
window C-224 C-211
relay C-225
Blower
relay
C-212

Fuel pump C-222 1 3 Rear

relay (1) 2 4 window
defogger
Heated seat C-221 1 3 C-223 C-214 C-213 relay
relay 2 4
1 2 3 4 5 6
C-220 1 3 19
Fuel pump
relay (2) 2 4 Fuses
7 8 9 10 11 12
(No.1 to 20)
C-219 1 3

Accessory 2 4 20
13 14 15 16 17 18
socket relay
C-218 1 3

2 4
Rear fog
lamp relay C-217 C-215 <LHD>
C-216 <RHD>

To roof wiring To floor wiring

harness harness

AC209083 AM

NOTE: .
• The triangle mark on the relay housing should face that on the J/B and the relay box.
90-6 CIRCUIT DIAGRAMS
J/C <LHD>

J/C <LHD>
M1901014201075

NOTE: IN ACTUAL VEHICLES, ANY OF THE TERMINALS CONNECTED IN J/C

ARE USED. THE TERMINAL ARRANGEMENT DESCRIBED IN THE CIRCUIT
DIAGRAM MAY NOT BE IDENTICAL TO THOSE OF THE VEHICLES.

·CENTRAL DOOR ·TAIL LAMP,

LOCKING SYSTEM POSITION LAMP, ·FRONT FOG LAMP
·FRONT FOG LICENCE PLATE ·HEADLAMP ·FRONT FOG LAMP
LAMP LAMP AND ·HEADLAMP WASHER ·HEADLAMP
·HEADLAMP LIGHTING MONITOR ·REAR FOG LAMP ·HEADLAMP LEVELLING
·HEADLAMP BUZZER ·TAIL LAMP, POSITION SYSTEM
WASHER ·TURN-SIGNAL LAMP, LICENCE PLATE ·HEADLAMP WASHER
·POWER WINDOWS LAMP AND LAMP AND LIGHTING ·REAR FOG LAMP
·REAR FOG LAMP HAZARD MONITOR BUZZER ·HEADLAMP ·TAIL LAMP, POSITION
·ROOM LAMP AND WARNING LAMP CLOCK ·TURN-SIGNAL LAMP AND LEVELLING LAMP, LICENCE PLATE
LUGGAGE ·WINDSHIELD HAZARD WARNING LAMP SYSTEM LAMP AND LIGHTING
COMPARTMENT WIPER AND ·WINDSHIELD WIPER ·WINDSHIELD MONITOR BUZZER
LAMP WASHER AND WASHER WIPER AND ·WINDSHIELD WIPER
·ROOM LAMP ·FUEL WARNING WASHER AND WASHER
PERSONAL LAMP LAMP
AND LUGGAGE ·INVECS-II ·HEATER
ROOM LAMP SPARE 4A/T ·HEADLAMP REMOTE ·MANUAL AIR
CONNECTOR ·METER AND RELAY BOX ·HEADLAMP CONTROLLED HEATED CONDITIONER
(FOR AUDIO) GAUGE (FUSE 22 ) WASHER MIRROR SEAT J/B (FUSE 5 )

HEADLAMP CIGARETTE HEATED RELAY BOX REAR WIPER ·INVECS-II

LEVELLING LIGHTER AND (FUSE 20 ) POWER AND WASHER STOP 4A/T
SEAT WINDOWS
SYSTEM ASHTRAY LAMP ·REAR WIPER
ILLUMINATION AND WASHER
LAMP INVECS-II ·STOP LAMP
·FRONT SPARE RHEOSTAT ·HEATER 4A/T
FOG LAMP CONNECTOR ·MANUAL AIR TURN-SIGNAL
·REAR (FOR AUDIO) CONDITIONER LAMP AND
FOG LAMP HAZARD WARNING
·REAR WINDOW
DEFOGGER LAMP
AND DOOR ·FRONT FOG LAMP
MIRROR HEATER ·FRONT FOG LAMP ·FRONT FOG LAMP
·HEADLAMP ·HEADLAMP ·HEADLAMP
·HEADLAMP WASHER ·HEADLAMP WASHER ·HEADLAMP WASHER
·REAR FOG LAMP ·REAR FOG LAMP ·POWER WINDOWS
·TAIL LAMP, POSITION ·REAR WIPER ·REAR FOG LAMP
LAMP, LICENCE PLATE AND WASHER ·REAR WIPER
LAMP AND LIGHTING ·TAIL LAMP, POSITION AND WASHER
MONITOR BUZZER LAMP, LICENCE PLATE ·TAIL LAMP, POSITION
·WINDSHIELD WIPER LAMP AND LIGHTING LAMP, LICENCE PLATE
AND WASHER MONITOR BUZZER LAMP AND LIGHTING
·TURN-SIGNAL LAMP MONITOR BUZZER
AND HAZARD ·TURN-SIGNAL LAMP
WARNING LAMP AND HAZARD
·WINDSHIELD WIPER WARNING LAMP
AND WASHER ·WINDSHIELD WIPER
AND WASHER
 CIRCUIT DIAGRAMS
J/C <LHD>
90-7
J/C <LHD> (CONTINUED)

·CENTRAL ·ROOM LAMP,

DOOR LOCKING PERSONAL LAMP
SYSTEM AND LUGGAGE
·FRONT FOG ROOM LAMP
LAMP ·TAIL LAMP,
·HEADLAMP POSITION LAMP,
·HEADLAMP LICENCE PLATE
WASHER LAMP AND LIGHTING ·CENTRAL
MONITOR BUZZER DOOR LOCKING
·POWER WINDOWS SYSTEM ·ROOM LAMP,
·TURN-SIGNAL
·REAR FOG LAMP AND HAZARD ·FRONT FOG PERSONAL LAMP
LAMP WARNING LAMP LAMP AND LUGGAGE
·REAR WIPER ROOM LAMP
·WINDSHIELD WIPER ·HEADLAMP
AND WASHER AND WASHER ·TAIL LAMP,
·HEADLAMP POSITION LAMP,
·ROOM LAMP AND WASHER
TURN-SIGNAL LUGGAGE LICENCE PLATE
LAMP AND COMPARTMENT ·POWER WINDOWS LAMP AND LIGHTING
HAZARD LAMP ·REAR WIPER MONITOR BUZZER
WARNING LAMP AND WASHER ·TURN-SIGNAL
·ROOM LAMP AND LAMP AND HAZARD
·HEATER LUGGAGE WARNING LAMP
FRONT FOG REAR FOG ACCESSORY ·MANUAL AIR COMPARTMENT ·WINDSHIELD WIPER
LAMP LAMP SOCKET CONDITIONER LAMP AND WASHER
HEATED DIAGNOSIS
SEAT IMMOBILIZER ·CLOCK CONNECTOR
SYSTEM ·HEADLAMP J/C (6)

·FRONT RHEOSTAT SUPPLEMENTAL DIAGNOSIS

FOG LAMP HEATED HEADLAMP ·HEATER RESTRAINT ABS ·ENGINE CONNECTOR
·REAR FOG SEAT LEVELLING SYSTEM (SRS) CONTROL
·MANUAL AIR
LAMP SYSTEM CONDITIONER SYSTEM
CIGARETTE
LIGHTER AND ·REAR WINDOW ·IMMOBILIZER
ASHTRAY DEFOGGER AND SYSTEM
·INVECS-II 4A/T ILLUMINATION DOOR MIRROR ·INVECS-II
·METER AND LAMP HEATER 4A/T
GAUGE TURN-SIGNAL
LAMP AND
HAZARD
WARNING LAMP
SPARE
CONNECTOR
(FOR AUDIO)

J/C <LHD> (CONTINUED)

·ENGINE
CONTROL
SYSTEM
·IGNITION
SYSTEM
·METER AND ·ENGINE
·METER AND ·ROOM LAMP AND GAUGE
LUGGAGE CONTROL
GAUGE SYSTEM
COMPARTMENT
·WINDSHIELD LAMP ·IGNITION
WIPER AND SPARE SYSTEM
WASHER ·ROOM LAMP,
PERSONAL LAMP CONNECTOR ·METER AND
AND LUGGAGE (FOR AUDIO) ENGINE GAUGE
WINDSHIELD CONTROL
WIPER AND ROOM LAMP METER AND
RELAY SYSTEM
DIAGNOSIS WASHER BOX J/C (4) GAUGE
CONNECTOR METER AND (FUSE 23 )
GAUGE CLOCK ABS

J/B ACCESSORY J/B

·ABS (FUSE 2 ) SOCKET (FUSE 11 ) ·FRONT FOG RELAY ABS
·BRAKE ·FRONT FOG FRONT FOG LAMP BOX ENGINE ·COOLING
WARNING LAMP LAMP LAMP ·SPARE (FUSE 10 ) CONTROL SYSTEM
REMOTE SYSTEM
·CHARGING ·HEADLAMP CONTROLLED CONNECTOR ·ENGINE
SPARE (FOR FRONT INVECS-II CONTROL
SYSTEM WASHER MIRROR CONNECTOR 4A/T
·ENGINE FOG LAMP) SYSTEM
·REAR FOG (FOR FRONT
CONTROL LAMP FOG LAMP)
SYSTEM ·REAR WIPER AND RELAY IMMOBILIZER
·FUEL WARNING WASHER BOX SYSTEM
LAMP ·TAIL LAMP, (FUSE 8 )
·INVECS-II POSITION LAMP,
4A/T LICENCE PLATE
·METER AND LAMP AND LIGHTING
GAUGE MONITOR BUZZER
·OIL PRESSURE ·TURN-SIGNAL
WARNING LAMP LAMP AND HAZARD
·SUPPLEMENTAL WARNING LAMP
RESTRAINT ·WINDSHIELD WIPER
SYSTEM (SRS) AND WASHER
90-8 CIRCUIT DIAGRAMS
J/C <RHD>

J/C <RHD>
M1901014201086

NOTE: IN ACTUAL VEHICLES, ANY OF THE TERMINALS CONNECTED IN J/C

ARE USED. THE TERMINAL ARRANGEMENT DESCRIBED IN THE CIRCUIT
DIAGRAM MAY NOT BE IDENTICAL TO THOSE OF THE VEHICLES. ·BACK-UP LAMP
·INVECS-II 4A/T
·FRONT FOG LAMP
REAR WIPER ·REAR WIPER
·HEADLAMP AND WASHER AND WASHER
·REAR FOG LAMP ·FRONT FOG LAMP
·REAR WIPER ·HEADLAMP
SPARE CONNECTOR AND WASHER ·HEADLAMP
BACK-UP LAMP LEVELLING
·CENTRAL DOOR ·TAIL LAMP, (FOR AUDIO) ·TAIL LAMP,
LOCKING SYSTEM POSITION LAMP, POSITION LAMP, SYSTEM
·FRONT FOG LAMP LICENCE PLATE LICENCE PLATE ·REAR FOG LAMP
·HEADLAMP LAMP AND LAMP AND ·TAIL LAMP,
LIGHTING MONITOR LIGHTING MONITOR POSITION LAMP,
·POWER WINDOWS BUZZER BUZZER LICENCE PLATE
·REAR FOG LAMP ·TURN-SIGNAL INVECS-II 4A/T LAMP AND
·TURN-SIGNAL
·REAR WIPER LAMP AND LAMP AND LIGHTING MONITOR
AND WASHER HAZARD ·FUEL WARNING HAZARD BUZZER
·ROOM LAMP WARNING LAMP LAMP WARNING LAMP ·WINDSHIELD
AND LUGGAGE ·WINDSHIELD ·INVECS-II 4A/T ·WINDSHIELD WIPER AND WASHER
COMPARTMENT WIPER AND WASHER ·METER AND GAUGE WIPER AND WASHER
LAMP
·ROOM LAMP,
PERSONAL LAMP
AND LUGGAGE
ROOM LAMP ·HEATER
·MANUAL AIR
CLOCK RELAY BOX CONDITIONER J/B
(FUSE 22 ) (FUSE 5 )

RELAY BOX
(FUSE 20 )
RHEOSTAT
·CIGARETTE ·FRONT FOG LAMP ·FRONT FOG LAMP ·FRONT FOG LAMP
LIGHTER AND ·HEADLAMP ·HEADLAMP ·HEADLAMP ACCECSSORY
HEADLAMP ASHTRAY ·REAR FOG LAMP ·REAR FOG LAMP ·POWER WINDOWS SOCKET
LEVELLING ILLUMINATION ·TAIL LAMP, ·REAR WIPER ·REAR FOG LAMP
SYSTEM LAMP POSITION LAMP, AND WASHER
LICENCE PLATE ·TAIL LAMP, ·REAR WIPER
·INVECS-II 4A/T AND WASHER REAR FOG
SPARE CONNECTOR ·METER AND GAUGE LAMP AND POSITION LAMP, LAMP
(FOR AUDIO) LIGHTING LICENCE PLATE ·TAIL LAMP,
·TAIL LAMP, POSITION LAMP,
POSITION LAMP, MONITOR LAMP AND
BUZZER LIGHTING LICENCE PLATE
·HEATER LICENCE PLATE LAMP AND
LAMP AND LIGHTING ·WINDSHIELD MONITOR HEADLAMP
·MANUAL AIR WIPER AND BUZZER LIGHTING MONITOR
MONITOR BUZZER BUZZER
CONDITIONER WASHER ·TURN-SIGNAL
·REAR WINDOW LAMP AND ·TURN-SIGNAL
DEFOGGER FRONT FOG TURN-SIGNAL HAZARD LAMP AND
AND DOOR LAMP LAMP AND WARNING LAMP HAZARD
MIRROR HAZARD ·WINDSHIELD WARNING LAMP HEADLAMP
HEATER WARNING LAMP WIPER AND ·WINDSHIELD LEVELLING
WASHER WIPER AND SYSTEM
WASHER J/C(3)
POWER
WINDOWS
 CIRCUIT DIAGRAMS
J/C <RHD>
90-9
J/C <RHD> (CONTINUED)

·ROOM LAMP, ·ROOM LAMP,

PERSONAL LAMP ·CENTRAL PERSONAL LAMP
AND LUGGAGE DOOR LOCKING AND LUGGAGE ·ROOM LAMP,
·CENTRAL ROOM LAMP
DOOR LOCKING ROOM LAMP SYSTEM PERSONAL LAMP
·TAIL LAMP, ·TAIL LAMP, ·CENTRAL
SYSTEM ·FRONT FOG LAMP DOOR LOCKING AND LUGGAGE
POSITION LAMP, POSITION LAMP, ROOM LAMP
·FRONT FOG LAMP ·HEADLAMP LICENCE PLATE SYSTEM
LICENCE PLATE ·TAIL LAMP,
·HEADLAMP LAMP AND LIGHTING ·POWER WINDOWS LAMP AND LIGHTING ·FRONT FOG LAMP POSITION LAMP,
·REAR FOG LAMP MONITOR BUZZER ·REAR FOG LAMP MONITOR BUZZER ·HEADLAMP LICENCE PLATE
·REAR WIPER ·TURN-SIGNAL ·REAR WIPER ·TURN-SIGNAL ·POWER WINDOWS LAMP AND LIGHTING
AND WASHER LAMP AND HAZARD AND WASHER LAMP AND HAZARD ·REAR FOG LAMP MONITOR BUZZER
·ROOM LAMP AND WARNING LAMP ·ROOM LAMP AND WARNING LAMP
·REAR WIPER ·TURN-SIGNAL
LUGGAGE ·WINDSHIELD WIPER LUGGAGE ·WINDSHIELD WIPER AND WASHER LAMP AND HAZARD
COMPARTMENT LAMP AND WASHER COMPARTMENT LAMP AND WASHER ACCESSORY
·ROOM LAMP AND WARNING LAMP SOCKET
LUGGAGE ·WINDSHIELD WIPER
COMPARTMENT LAMP AND WASHER SPARE
CONNECTOR ·FRONT FOG
REMOTE LAMP
·HEATER CONTROLLED (FOR FRONT FOG
REMOTE LAMP) ·SPARE
·MANUAL AIR CONTROLLED MIRROR
CONNECTOR
CONDITIONER TURN-SIGNAL MIRROR (FOR FRONT FOG
J/C (2) LAMP AND HAZARD IMMOBILIZER FRONT FOG DIAGNOSIS J/B FRONT FOG LAMP)
WARNING LAMP SYSTEM CLOCK LAMP ABS CONNECTOR (FUSE 11 ) LAMP

HEADLAMP ·FRONT FOG ·INVECS-II ABS DIAGNOSIS

SPARE LEVELLING LAMP 4A/T RHEOSTAT SUPPLEMENTAL CONNECTOR ·ROOM LAMP AND
CONNECTOR SYSTEM ·REAR FOG ·METER AND RESTRAINT LUGGAGE
(FOR AUDIO) LAMP GAUGE SYSTEM (SRS) COMPARTMENT
LAMP
·HEATER TURN-SIGNAL ·ENGINE ·ROOM LAMP,
·MANUAL AIR LAMP AND HAZARD CONTROL PERSONAL LAMP
CONDITIONER WARNING LAMP SYSTEM AND LUGGAGE
CIGARETTE ·REAR WINDOW ROOM LAMP
LIGHTER AND ·IMMOBILIZER
DEFOGGER SYSTEM
ASHTRAY AND DOOR
ILLUMINATION ·INVECS-II
MIRROR HEATER 4A/T
LAMP

J/C <RHD> (CONTINUED)

·ENGINE ·ENGINE
CONTROL CONTROL
RELAY SYSTEM SYSTEM
J/B BOX
(FUSE 16 ) ·IGNITION ·IGNITION
CLOCK (FUSE 23 ) SYSTEM SYSTEM
ABS ENGINE
REAR FOG CONTROL ·METER AND ·METER AND
REAR FOG LAMP SYSTEM GAUGE GAUGE
LAMP J/C (4) METER AND
GAUGE

ABS RELAY
SPARE RELAY BOX ENGINE
CENTRAL DOOR CONNECTOR BOX (FUSE 8 ) CONTROL
LOCKING SYSTEM (FOR AUDIO) SYSTEM
(FUSE 10 )

·ROOM LAMP AND INVECS-II IMMOBILIZER ·COOLING

LUGGAGE 4A/T SYSTEM SYSTEM
COMPARTMENT ·ENGINE
LAMP CONTROL
·ROOM LAMP, SYSTEM
PERSONAL LAMP
AND LUGGAGE
ROOM LAMP
90-10 CIRCUIT DIAGRAMS
CENTRALIZED JUNCTION

CENTRALIZED JUNCTION
M1901000300991
FUSIBLE LINK AND FUSE
ENGINE COMPARTMENT
No. Power supply circuit Name Rated Housing Load circuit
capacity (A) colour
1 Battery/ Alternator Fusible 60 Yellow Fuse No.15, 16, 19, 20 (in junction
(Fusible link No.26) link block) circuit
2 50 Red Fan controller
3 60 Yellow ABS-ECU
4 40 Green Ignition switch circuit
5 30 Pink Power window main switch and power
window sub switch
6 Fuse 15 Blue Front fog lamp, front fog lamp
indicator lamp, front fog lamp relay
and spare connector (for front fog
lamp)
7 10 Red Horn relay and horn
8 20 Yellow Air cleaner air flow sensor, camshaft
position sensor, emission solenoid
valve (EGR system), emission
solenoid valve (purge control system),
engine-A/T-ECU, engine-ECU, engine
control oxygen sensor, engine control
relay, engine crank angle sensor, fan
control relay, fuel injector, ignition coil
relay, immobilizer-ECU and throttle
body idle speed control servo
9 10 Red A/C compressor
10 15 Blue ABS-ECU, engine-A/T-ECU, high
mount stop lamp and rear combination
lamp
11 15 Blue Accessory socket
12 7.5 Brown Alternator
13 10 Red ETACS-ECU, front turn signal lamp,
rear combination lamp, side turn
signal lamp and turn signal indicator
lamp
14 20 Yellow A/T control solenoid valve assembly
and engine-A/T-ECU
15 15 Blue Fuel pump
16 Front-ECU 10 Red Headlamp (RH)
17 (Headlamp relay: HI) 10 Red Headlamp (LH) and high beam
indicator lamp
18 Front-ECU 10 Red Headlamp (RH)
19 (Headlamp relay: LO) 10 Red Headlamp (LH), headlamp assembly
and headlamp levelling switch
 CIRCUIT DIAGRAMS
CENTRALIZED JUNCTION
90-11
No. Power supply circuit Name Rated Housing Load circuit
capacity (A) colour
20 Front-ECU (Tail lamp Fuse 7.5 Brown A/C-ECU, ashtray illumination lamp,
relay) cigarette lighter illumination lamp,
combination meter, fog lamp switch,
front turn signal lamp, hazard warning
switch, headlamp assembly (RH),
headlamp levelling switch, heated
seat switch, heater control unit,
licence plate lamp, rear combination
lamp, rheostat, side turn signal lamp
and spare connector (for audio)
21 7.5 Brown Combination meter, headlamp
assembly (LH), licence plate lamp,
position lamp (LH) and rear
combination lamp (LH)
22 Battery/ Alternator 10 Red Combination meter, column switch,
(Fusible link No.26) ETACS-ECU and front-ECU
23 Ignition switch (ACC) 10 Red Clock, ETACS-ECU and spare
connector (for audio)
24 − − − −
25 Battery/ Alternator 20 Yellow Heated seat assembly and heated
(Fusible link No.26) seat switch
26 Alternator Fusible 100 <4G1> − Battery, fusible link No.1, 2, 3, 4, 5,
link 120 <4G6> fuse No.6, 7, 8, 9, 10, 11, 12, 13, 14,
15, 22 (relay box) and front-ECU

(Relay box in engine compartment)

1 24

6 25 7 8 9 10 11 12 13 14 15 4

Front of vehicle 16 18 20

17 21 23 22 5
2 3 19

AC208462 AO
90-12 CIRCUIT DIAGRAMS
CENTRALIZED JUNCTION

(Connected directly to battery positive terminal)

Front of vehicle 26

AC207745 AF

PASSENGER COMPARTMENT
No. Power supply circuit Name Rated Housing Load circuit
capacity (A) colour
1 Ignition switch (IG1) Fuse 10 Red Capacitor and ignition coil
2 7.5 Brown ABS warning lamp, brake warning
lamp, charging warning lamp, check
engine warning lamp, column switch,
combination meter, ETACS-ECU, low
fuel warning lamp, oil pressure
warning lamp, SRS air bag warning
lamp, SRS-ECU and vehicle speed
sensor
3 7.5 Brown A/T control relay, combination meter,
engine-A/T-ECU, ETACS-ECU, input
shaft speed sensor, output shaft
speed sensor, rear combination lamp
and SRS-ECU
4 − − −
5 Ignition switch (IG2) 7.5 Brown A/C compressor relay, A/C-ECU,
blower relay, rear window defogger
relay, front-ECU, heated seat relay,
heater control unit and outside/inside
air selection damper control motor
6 Rear window 7.5 Brown Remote controlled mirror
defogger relay
7 Ignition switch (ACC) 20 Yellow Front-ECU and windshield wiper
motor
8 Ignition switch (IG1) 7.5 Brown Engine-A/T-ECU, engine-ECU, fuel
pump relay (1) and fuel pump relay (2)
9 Ignition switch (ACC) 15 Blue Cigarette lighter
10 − − −
11 7.5 Brown Accessory socket relay and Remote
controlled mirror
12 Ignition switch (IG2) 7.5 Brown ABS-ECU
13 Ignition switch (ACC) − − −
14 15 Blue ETACS-ECU and rear wiper motor
 CIRCUIT DIAGRAMS
CENTRALIZED JUNCTION
90-13
No. Power supply circuit Name Rated Housing Load circuit
capacity (A) colour
15 Fusible link No.1 Fuse 15 Blue Diagnosis connector
16 10 Red Rear fog lamp, rear fog lamp indicator
lamp and rear fog lamp relay
17 − − −
18 − − −
19 30 Green A/C-ECU, blower motor, heater control
unit and resistor
20 30 Green Rear window defogger

(in junction block)

1 2 3 4 5 6
19

7 8 9 10 11 12

13 14 15 16 17 18 20

AC209082 AE
90-14 CIRCUIT DIAGRAMS
CENTRALIZED JUNCTION

CENTRALIZED RELAY
Connector No. Name Connector No. Name
A-04X Front fog lamp relay B-10X Engine speed detection
connector
A-05X Horn relay B-11X −
A-06X − B-12X −
A-07X − B-13X −
A-08X − B-14X Ignition coil relay
A-09X Fan control relay B-15X A/T control relay
A-10X Front-ECU B-16X Engine control relay
A-11X Front-ECU B-17X A/C compressor relay

(Relay box in engine compartment)

A-04X A-05X A-06X A-07X A-08X

2 1 2 1
4 3 4 3

Front of vehicle

A-10X

A-11X
A-09X

AC208462 AP

B-12X B-13X B-14X B-15X B-16X B-17X

B-11X
B-10X 2 1 2 1 2 1 2 1
Front of vehicle
4 3 4 3 4 3 4 3

AC208464 AJ

NOTE: .
• The triangle mark on the relay housing should face that on the J/B and the relay box.
 CIRCUIT DIAGRAMS
POWER DISTRIBUTION SYSTEM <LHD>
90-15
POWER DISTRIBUTION SYSTEM <LHD>
M1901000401106

BATTERY

NOTE
: 4G1
: 4G6
STARTING
SYSTEM
FUSIBLE RELAY
LINK BOX

CHARGING FRONT-ECU
SYSTEM
HEADLAMP HEADLAMP TAIL LAMP
RELAY: LO RELAY: HI RELAY

ABS
·COOLING POWER
SYSTEM WINDOWS
·MANUAL AIR
CONDITIONER

·CENTRAL DOOR ·ROOM LAMP,

LOCKING SYSTEM PERSONAL LAMP
·CLOCK AND LUGGAGE
·FRONT FOG LAMP ROOM LAMP TAIL LAMP, POSITION
·FUEL WARNING ·SPARE CONNECTOR ENGINE LAMP, LICENCE PLATE
TURN-SIGNAL ACCESSORY ·HEATER HORN ·FRONT FOG ·HEADLAMP LAMP AND LIGHTING
LAMP (FOR AUDIO) CONTROL LAMP AND SOCKET ·MANUAL AIR LAMP ·HEADLAMP HEADLAMP
·HEADLAMP ·TAIL LAMP, POSITION SYSTEM MONITOR BUZZER
HAZARD CONDITIONER ·SPARE LEVELLING
·HEADLAMP LAMP, LICENCE PLATE WARNING LAMP CONNECTOR SYSTEM
LEVELLING SYSTEM LAMP AND LIGHTING (FOR FRONT
·INVECS-II 4A/T MONITOR BUZZER INVECS-II CHARGING ·ABS ·COOLING HEATED FOG LAMP)
·KEY REMINDER ·TURN-SIGNAL LAMP 4A/T SYSTEM ·INVECS-II SYSTEM SEAT ·CIGARETTE LIGHTER ·REAR WINDOW
BUZZER AND HAZARD 4A/T ·ENGINE AND ASHTRAY DEFOGGER AND DOOR
·METER AND GAUGE WARNING LAMP ·STOP LAMP CONTROL HEADLAMP HEADLAMP ILLUMINATION LAMP MIRROR HEATER
·POWER WINDOWS ·WINDSHIELD WIPER SYSTEM LEVELLING ·FRONT FOG LAMP ·RHEOSTAT
·REAR FOG LAMP AND WASHER ·IGNITION SYSTEM SYSTEM ·HEATER ·SPARE CONNECTOR
·REAR WIPER AND ·IMMOBILIZER ·HEADLAMP (FOR AUDIO)
WASHER SYSTEM LEVELLING SYSTEM ·TAIL LAMP, POSITION
·ROOM LAMP AND ·INVECS-II 4A/T ·INVECS-II 4A/T LAMP, LICENCE PLATE
LUGGAGE COM- ·MANUAL AIR LAMP AND LIGHTING
PARTMENT LAMP CONDITIONER MONITOR BUZZER
·METER AND GAUGE ·TURN-SIGNAL LAMP AND
·REAR FOG LAMP HAZARD WARNING LAMP

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
90-16 CIRCUIT DIAGRAMS
POWER DISTRIBUTION SYSTEM <LHD>

POWER DISTRIBUTION SYSTEM <LHD> (CONTINUED)

RELAY BOX
FUSIBLE
LINK 4

RELAY
BOX
IGNITION
SWITCH

·CLOCK
·ROOM LAMP AND LUGGAGE
COMPARTMENT LAMP
·ROOM LAMP, PERSONAL LAMP
AND LUGGAGE ROOM LAMP
·SPARE CONNECTOR
(FOR AUDIO)

STARTING
SYSTEM

IGNITION ·BACK-UP LAMP ·ENGINE ABS WINDSHIELD CIGARETTE ·ACCESSORY REAR WIPER
SYSTEM ·ABS ·REAR FOG LAMP ·ENGINE CONTROL CONTROL WIPER AND LIGHTER AND SOCKET AND WASHER
·BRAKE WARNING ·REAR WIPER SYSTEM SYSTEM WASHER ASHTRAY ·REMOTE
LAMP AND WASHER ·INVECS-II 4A/T ·INVECS-II ·FRONT ILLUMINATION CONTROLLED
·CENTRAL DOOR ·ROOM LAMP 4A/T FOG LAMP LAMP MIRROR
·METER AND
LOCKING SYSTEM AND LUGGAGE GAUGE ·HEADLAMP
·CHARGING COMPARTMENT ·REAR WIPER AND ·HEADLAMP
SYSTEM LAMP WASHER LEVELLING
·ENGINE CONTROL ·ROOM LAMP, ·SUPPLEMENTAL SYSTEM
SYSTEM PERSONAL LAMP RESTRAINT SYSTEM ·HEATED SEAT
·FRONT AND LUGGAGE (SRS)
ROOM LAMP ·HEATER
FOG LAMP ·WINDSHIELD ·MANUAL AIR
·FUEL WARNING ·SUPPLEMENTAL WIPER AND WASHER CONDITIONER
LAMP RESTRAINT
SYSTEM (SRS) ·REAR
·HEADLAMP FOG LAMP
·HEADLAMP ·TAIL LAMP,
POSITION LAMP, ·TAIL LAMP,
WASHER POSITION LAMP,
LICENCE PLATE
·INVECS-II 4A/T LAMP AND LIGHTING LICENCE PLATE
·KEY REMINDER MONITOR BUZZER LAMP AND LIGHTING
BUZZER MONITOR BUZZER
·TURN-SIGNAL LAMP
·METER AND AND HAZARD ·WINDSHIELD
GAUGE WARNING LAMP WIPER AND WASHER
·OIL PRESSURE ·WINDSHIELD
WARNING LAMP WIPER AND WASHER
·POWER WINDOWS

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

POWER DISTRIBUTION SYSTEM <LHD> (CONTINUED)

RELAY BOX
(FUSIBLE LINK 1 )

FUSE 5

·ABS REAR FOG ·HEATER

·CENTRAL DOOR LAMP ·MANUAL
LOCKING SYSTEM AIR
·ENGINE CONTROL CONDITIONER
SYSTEM
·FRONT FOG LAMP
·HEADLAMP
·HEADLAMP WASHER
·IMMOBILIZER SYSTEM REAR
·INVECS-II 4A/T
·KEY REMINDER BUZZER WINDOW
·POWER WINDOWS DEFOGGER
·REAR FOG LAMP RELAY
·REAR WIPER AND
WASHER
·ROOM LAMP
AND LUGGAGE
COMPARTMENT LAMP
·ROOM LAMP,
PERSONAL LAMP AND
LUGGAGE ROOM LAMP
·SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER REAR WINDOW
·TURN-SIGNAL LAMP AND DEFOGGER AND
HAZARD WARNING LAMP DOOR MIRROR
·WINDSHIELD WIPER HEATER
AND WASHER

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
 CIRCUIT DIAGRAMS
POWER DISTRIBUTION SYSTEM <RHD>
90-17
POWER DISTRIBUTION SYSTEM <RHD>
M1901000401117

BATTERY

NOTE
: 4G1
: 4G6
STARTING
SYSTEM
FUSIBLE RELAY
LINK BOX

CHARGING FRONT-ECU
SYSTEM
HEADLAMP HEADLAMP TAIL LAMP
RELAY: LO RELAY: HI RELAY

ABS
·COOLING POWER
SYSTEM WINDOWS
·MANUAL AIR
CONDITIONER

RELAY
BOX

·CENTRAL DOOR ·ROOM LAMP,

LOCKING SYSTEM PERSONAL LAMP
·CLOCK AND LUGGAGE
·FRONT FOG LAMP ROOM LAMP TAIL LAMP, POSITION
·FUEL WARNING ·SPARE CONNECTOR ENGINE LAMP, LICENCE PLATE
TURN-SIGNAL ACCESSORY ·HEATER HORN ·FRONT FOG ·HEADLAMP LAMP AND LIGHTING
LAMP (FOR AUDIO) CONTROL LAMP AND SOCKET ·MANUAL AIR LAMP ·HEADLAMP HEADLAMP
·HEADLAMP ·TAIL LAMP, POSITION SYSTEM MONITOR BUZZER
HAZARD CONDITIONER ·SPARE LEVELLING
·HEADLAMP LAMP, LICENCE PLATE WARNING LAMP CONNECTOR SYSTEM
LEVELLING SYSTEM LAMP AND LIGHTING (FOR FRONT
·INVECS-II 4A/T MONITOR BUZZER INVECS-II CHARGING ·ABS ·COOLING FOG LAMP)
·KEY REMINDER ·TURN-SIGNAL LAMP 4A/T SYSTEM ·INVECS-II SYSTEM ·CIGARETTE LIGHTER ·REAR WINDOW
BUZZER AND HAZARD 4A/T ·ENGINE AND ASHTRAY DEFOGGER AND DOOR
·METER AND GAUGE WARNING LAMP ·STOP LAMP CONTROL ILLUMINATION LAMP MIRROR HEATER
·POWER WINDOWS ·WINDSHIELD WIPER SYSTEM ·FRONT FOG LAMP ·RHEOSTAT
·REAR FOG LAMP AND WASHER ·IGNITION SYSTEM HEADLAMP HEADLAMP ·HEATER ·SPARE CONNECTOR
·REAR WIPER AND ·IMMOBILIZER LEVELLING ·HEADLAMP (FOR AUDIO)
WASHER SYSTEM SYSTEM LEVELLING SYSTEM ·TAIL LAMP, POSITION
·ROOM LAMP AND ·INVECS-II 4A/T ·INVECS-II 4A/T LAMP, LICENCE PLATE
LUGGAGE COM- ·MANUAL AIR LAMP AND LIGHTING
PARTMENT LAMP CONDITIONER MONITOR BUZZER
·METER AND GAUGE ·TURN-SIGNAL LAMP AND
·REAR FOG LAMP HAZARD WARNING LAMP

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
90-18 CIRCUIT DIAGRAMS
POWER DISTRIBUTION SYSTEM <RHD>

POWER DISTRIBUTION SYSTEM <RHD> (CONTINUED)

RELAY BOX
FUSIBLE
LINK 4

RELAY
BOX
IGNITION
SWITCH

·CLOCK
·ROOM LAMP AND LUGGAGE
COMPARTMENT LAMP
·ROOM LAMP, PERSONAL LAMP
AND LUGGAGE ROOM LAMP
·SPARE CONNECTOR
(FOR AUDIO)

STARTING
SYSTEM

IGNITION ·BACK-UP LAMP ·ENGINE ABS WINDSHIELD CIGARETTE ·ACCESSORY REAR WIPER
SYSTEM ·ABS ·OIL PRESSURE ·ENGINE CONTROL CONTROL WIPER AND LIGHTER AND SOCKET AND WASHER
·BRAKE WARNING WARNING LAMP SYSTEM SYSTEM WASHER ASHTRAY ·REMOTE
LAMP ·POWER WINDOWS ·INVECS-II 4A/T ·INVECS-II ·FRONT ILLUMINATION CONTROLLED
·CENTRAL DOOR ·REAR FOG LAMP 4A/T FOG LAMP LAMP MIRROR
·METER AND
LOCKING SYSTEM ·REAR WIPER GAUGE ·HEADLAMP
·ENGINE CONTROL AND WASHER ·REAR WIPER AND ·HEADLAMP
SYSTEM ·SUPPLEMENTAL WASHER LEVELLING
·FRONT RESTRAINT ·SUPPLEMENTAL SYSTEM
FOG LAMP SYSTEM (SRS) RESTRAINT SYSTEM ·HEATER
·FUEL WARNING ·TAIL LAMP, (SRS) ·MANUAL AIR
LAMP POSITION LAMP, ·WINDSHIELD CONDITIONER
·HEADLAMP LICENCE PLATE WIPER AND WASHER ·REAR
·INVECS-II 4A/T LAMP AND LIGHTING FOG LAMP
MONITOR BUZZER
·KEY REMINDER ·TAIL LAMP,
BUZZER ·WINDSHIELD
WIPER AND WASHER POSITION LAMP,
·METER AND LICENCE PLATE
GAUGE LAMP AND LIGHTING
MONITOR BUZZER
·WINDSHIELD
WIPER AND WASHER

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

POWER DISTRIBUTION SYSTEM <RHD> (CONTINUED)

RELAY BOX
(FUSIBLE LINK 1 )

FUSE 5

·ABS REAR FOG ·HEATER

·CENTRAL DOOR LAMP ·MANUAL
LOCKING SYSTEM AIR
·ENGINE CONTROL CONDITIONER
SYSTEM
·FRONT FOG LAMP
·HEADLAMP
·IMMOBILIZER SYSTEM
·INVECS-II 4A/T REAR
·KEY REMINDER BUZZER
·POWER WINDOWS WINDOW
·REAR FOG LAMP DEFOGGER
·REAR WIPER AND RELAY
WASHER
·ROOM LAMP
AND LUGGAGE
COMPARTMENT LAMP
·ROOM LAMP,
PERSONAL LAMP AND
LUGGAGE ROOM LAMP
·SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP AND REAR WINDOW
HAZARD WARNING LAMP DEFOGGER AND
·WINDSHIELD WIPER DOOR MIRROR
AND WASHER HEATER

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
 CIRCUIT DIAGRAMS
STARTING SYSTEM <M/T>
90-19
STARTING SYSTEM <M/T>
M1901000501318

IGNITION
BATTERY SWITCH (ST)

ENGINE CONTROL
SYSTEM

STARTER

NOTE
: LHD
: RHD

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
90-20 CIRCUIT DIAGRAMS
STARTING SYSTEM <A/T>

STARTING SYSTEM <A/T>

M1901000501329

IGNITION
BATTERY SWITCH (ST)

INHIBITOR
SWITCH

ENGINE CONTROL
SYSTEM

STARTER

NOTE
: LHD
: RHD

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
 CIRCUIT DIAGRAMS
IGNITION SYSTEM <4G1-M/T (LHD)>
90-21
IGNITION SYSTEM <4G1-M/T (LHD)>
M1901000601832
IGNITION
SWITCH (IG1)

IGNITION IGNITION
COIL (1) COIL (2)

SPARK PLUG

ENGINE-ECU

INPUT SIGNAL
·ATMOSPHERIC ·FUEL PRESSURE SENSOR
PRESSURE SENSOR ·IGNITION SWITCH (ST)
·CAMSHAFT ·INTAKE AIR TEMPERATURE
POSITION SENSOR SENSOR
·ENGINE CONTROL ·THROTTLE BODY
DETONATION SENSOR THROTTLE SENSOR
·ENGINE CONTROL ·VEHICLE SPEED SENSOR
OXYGEN SENSOR ·WATER TEMPERATURE ENGINE SPEED
·ENGINE CRANK SENSOR UNIT
ANGLE SENSOR DETECTION
CONNECTOR
90-22 CIRCUIT DIAGRAMS
IGNITION SYSTEM <4G1-M/T (RHD)>

IGNITION SYSTEM <4G1-M/T (RHD)>

M1901000601843
IGNITION
BATTERY SWITCH (IG1)

RELAY
BOX

·ENGINE
CONTROL
SYSTEM
·IMMOBILIZER
SYSTEM
IGNITION IGNITION IGNITION
COIL (1) COIL (2) COIL RELAY

SPARK PLUG

ENGINE-ECU

INPUT SIGNAL
·ATMOSPHERIC ·FUEL PRESSURE SENSOR
PRESSURE SENSOR ·IGNITION SWITCH (ST)
·CAMSHAFT ·INTAKE AIR
POSITION SENSOR TEMPERATURE
·ENGINE CONTROL SENSOR
DETONATION SENSOR ·THROTTLE BODY
·ENGINE CONTROL THROTTLE SENSOR
OXYGEN SENSOR ·VEHICLE SPEED SENSOR ENGINE SPEED
·ENGINE CRANK
ANGLE SENSOR
·WATER TEMPERATURE DETECTION
SENSOR UNIT CONNECTOR
 CIRCUIT DIAGRAMS
IGNITION SYSTEM <4G1-A/T (LHD)>
90-23
IGNITION SYSTEM <4G1-A/T (LHD)>
M1901000601854
IGNITION
SWITCH (IG1)

IGNITION IGNITION
COIL (1) COIL (2)

SPARK PLUG

ENGINE-
A/T-ECU

INPUT SIGNAL
·ATMOSPHERIC ·FUEL PRESSURE SENSOR
PRESSURE SENSOR ·IGNITION SWITCH (ST)
·CAMSHAFT ·INHIBITOR SWITCH
POSITION SENSOR
·ENGINE CONTROL ·INTAKE AIR
DETONATION SENSOR TEMPERATURE
SENSOR
·ENGINE CONTROL
OXYGEN SENSOR ·THROTTLE BODY
THROTTLE SENSOR ENGINE SPEED
·ENGINE CRANK ·WATER TEMPERATURE DETECTION
ANGLE SENSOR SENSOR UNIT CONNECTOR
90-24 CIRCUIT DIAGRAMS
IGNITION SYSTEM <4G1-A/T (RHD)>

IGNITION SYSTEM <4G1-A/T (RHD)>

M1901000601865
IGNITION
BATTERY SWITCH (IG1)

RELAY
BOX

·ENGINE
CONTROL
SYSTEM
·IMMOBILIZER
SYSTEM
IGNITION IGNITION IGNITION
COIL (1) COIL (2) COIL RELAY

SPARK PLUG

ENGINE-
A/T-ECU

INPUT SIGNAL
·ATMOSPHERIC ·FUEL PRESSURE SENSOR
PRESSURE SENSOR ·IGNITION SWITCH (ST)
·CAMSHAFT ·INHIBITOR SWITCH
POSITION SENSOR
·ENGINE CONTROL ·INTAKE AIR
DETONATION SENSOR TEMPERATURE
SENSOR
·ENGINE CONTROL ·THROTTLE BODY
OXYGEN SENSOR THROTTLE SENSOR ENGINE SPEED
·ENGINE CRANK
ANGLE SENSOR
·WATER TEMPERATURE DETECTION
SENSOR UNIT CONNECTOR
 CIRCUIT DIAGRAMS
IGNITION SYSTEM <4G6 (LHD)>
90-25
IGNITION SYSTEM <4G6 (LHD)>
M1901000601876
IGNITION
SWITCH (IG1)

IGNITION IGNITION CAPACITOR

COIL (1) COIL (2)

SPARK PLUG

ENGINE-ECU

INPUT SIGNAL
·ATMOSPHERIC ·FUEL PRESSURE SENSOR
PRESSURE SENSOR ·IGNITION SWITCH (ST)
·CAMSHAFT ·INTAKE AIR
POSITION SENSOR TEMPERATURE
·ENGINE CONTROL SENSOR
DETONATION SENSOR ·THROTTLE BODY
·ENGINE CONTROL THROTTLE SENSOR
OXYGEN SENSOR ·VEHICLE SPEED SENSOR ENGINE SPEED
·ENGINE CRANK ·WATER TEMPERATURE
ANGLE SENSOR DETECTION
SENSOR UNIT
CONNECTOR
90-26 CIRCUIT DIAGRAMS
IGNITION SYSTEM <4G6 (RHD)>

IGNITION SYSTEM <4G6 (RHD)>

M1901000601887
IGNITION
BATTERY SWITCH (IG1)

CAPACITOR RELAY
BOX

·ENGINE
CONTROL
SYSTEM
·IMMOBILIZER
SYSTEM
IGNITION IGNITION IGNITION
COIL (1) COIL (2) COIL RELAY

SPARK PLUG

ENGINE-ECU

INPUT SIGNAL
·ATMOSPHERIC ·FUEL PRESSURE SENSOR
PRESSURE SENSOR ·IGNITION SWITCH (ST)
·CAMSHAFT ·INTAKE AIR TEMPERATURE
POSITION SENSOR SENSOR
·ENGINE CONTROL ·THROTTLE BODY
DETONATION SENSOR THROTTLE
·ENGINE CONTROL SENSOR
OXYGEN SENSOR ·VEHICLE SPEED SENSOR ENGINE SPEED
·ENGINE CRANK ·WATER TEMPERATURE
ANGLE SENSOR DETECTION
SENSOR UNIT
CONNECTOR
 CIRCUIT DIAGRAMS
CHARGING SYSTEM <M/T>
90-27
CHARGING SYSTEM <M/T>
M1901000701185
FUSIBLE IGNITION
LINK 26 BATTERY SWITCH (IG1)

RELAY BOX

·FRONT FOG
LAMP
·HEADLAMP
·REAR FOG
ENGINE- LAMP
ECU ·REAR WIPER
AND WASHER
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
COMBINATION AND HAZARD
METER WARNING LAMP
·WINDSHIELD
WIPER AND
WASHER

ALTERNATOR

FIELD
COIL
STATOR
COIL
NOTE
: LHD
IC VOLTAGE REGULATOR : RHD
<4G1>
90-28 CIRCUIT DIAGRAMS
CHARGING SYSTEM <A/T>

CHARGING SYSTEM <A/T>

M1901000701196
FUSIBLE IGNITION
LINK 26 BATTERY SWITCH (IG1)

RELAY BOX

·FRONT FOG
LAMP
·HEADLAMP
·REAR FOG
LAMP
ENGINE-A/T-ECU ·REAR WIPER
AND WASHER
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
COMBINATION AND HAZARD
METER WARNING LAMP
·WINDSHIELD
WIPER AND
WASHER

ALTERNATOR

FIELD NOTE
COIL : LHD
STATOR : RHD
COIL

IC VOLTAGE REGULATOR
 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G1-M/T (LHD)>
90-29
ENGINE CONTROL SYSTEM <4G1-M/T (LHD)>
M1901000802301

FUSIBLE IGNITION IGNITION

LINK 1 SWITCH (IG1) BATTERY SWITCH (ST)

NOTE
: SEDAN
: WAGON
RELAY
BOX

ENGINE
CONTROL
RELAY
FUEL FUEL
PUMP PUMP
RELAY RELAY
(1) (2)

STARTING
SYSTEM

FUEL
TANK
COMBINATION PUMP ·COOLING
SYSTEM
METER ·MANUAL AIR
CONDITIONER

ENGINE-ECU
POWER BACK-UP
SOURCE POWER SOURCE

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
90-30 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G1-M/T (LHD)>

ENGINE CONTROL SYSTEM <4G1-M/T (LHD)> (CONTINUED)

ENGINE CONTROL
RELAY

CAMSHAFT ENGINE
FUEL FUEL FUEL FUEL EMISSION EMISSION POSITION CRANK
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 SOLENOID SOLENOID SENSOR ANGLE
VALVE VALVE SENSOR
(PURGE (EGR
CONTROL SYSTEM)
SYSTEM)

ENGINE-
ECU

OUTPUT GND POWER

SOURCE

ENGINE CONTROL ENGINE WATER THROTTLE

INTAKE AIR BODY
OXYGEN SENSOR CONTROL TEMPERATURE TEMPERA-
(REAR) OXYGEN TURE THROTTLE
SENSOR SENSOR
SENSOR SENSOR
(FRONT) INLET MANIFOLD UNIT
ABSOLUTE PRESSURE 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 : Gray R : Red P : Pink V : Violet

ENGINE CONTROL SYSTEM <4G1-M/T (LHD)> (CONTINUED)

ENGINE-
(FUSE 2 ) ECU

·COOLING THROTTLE
CHARGING MANUAL AIR SYSTEM BODY
SYSTEM CONDITIONER ·MANUAL AIR IDLE SPEED
CONDITIONER
CONTROL
SERVO METER AND
GAUGE
(FUSE 15 )

VEHICLE
SPEED
SENSOR

ENGINE-ECU

DIAGNOSIS
CONNECTOR
IMMOBILIZER
SYSTEM IGNITION
SYSTEM

ENGINE CONTROL ENGINE DIAGNOSIS

DETONATION POWER SPEED CONNECTOR
SENSOR STEERING DETECTION
FLUID PRESSURE CONNECTOR
SWITCH

FRONT FRONT
SIDE SIDE

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
 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G1-M/T (RHD)>
90-31
ENGINE CONTROL SYSTEM <4G1-M/T (RHD)>
M1901000802312

FUSIBLE IGNITION IGNITION

LINK 1 NOTE
SWITCH (IG1) BATTERY : SEDAN
SWITCH (ST)
: WAGON
: ·FRONT FOG LAMP
·HEADLAMP
·REAR FOG LAMP
RELAY ·REAR WIPER AND WASHER
BOX ·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD WARNING LAMP
·WINDSHIELD
·IGNITION WIPER AND WASHER
SYSTEM
·IMMOBILIZER
SYSTEM

ENGINE
CONTROL
RELAY
FUEL FUEL
PUMP PUMP
RELAY RELAY
(1) (2)

STARTING
SYSTEM

COMBINATION FUEL ·COOLING

TANK SYSTEM
METER ·MANUAL AIR
PUMP CONDITIONER

ENGINE-ECU
POWER BACK-UP
SOURCE POWER SOURCE

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
90-32 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G1-M/T (RHD)>

ENGINE CONTROL SYSTEM <4G1-M/T (RHD)> (CONTINUED)

ENGINE CONTROL
RELAY

CAMSHAFT ENGINE
FUEL FUEL FUEL FUEL EMISSION EMISSION POSITION CRANK
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 SOLENOID SOLENOID SENSOR ANGLE
VALVE VALVE SENSOR
(PURGE (EGR
CONTROL SYSTEM)
SYSTEM)

ENGINE-
ECU

POWER
OUTPUT GND SOURCE

ENGINE CONTROL ENGINE WATER THROTTLE

CONTROL INTAKE AIR TEMPERA- BODY
OXYGEN SENSOR TEMPERATURE
(REAR) OXYGEN TURE THROTTLE
SENSOR SENSOR SENSOR SENSOR
(FRONT) INLET MANIFOLD UNIT
ABSOLUTE PRESSURE 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

ENGINE CONTROL SYSTEM <4G1-M/T (RHD)> (CONTINUED)

ENGINE-
(FUSE 2 ) ECU

·COOLING THROTTLE
CHARGING MANUAL AIR SYSTEM BODY
SYSTEM CONDITIONER ·MANUAL AIR IDLE SPEED
CONDITIONER
CONTROL
SERVO METER AND
GAUGE
(FUSE 15 )

VEHICLE
SPEED
SENSOR

ENGINE-ECU

DIAGNOSIS
CONNECTOR
IMMOBILIZER
SYSTEM IGNITION
SYSTEM

ENGINE CONTROL ENGINE DIAGNOSIS

DETONATION SPEED CONNECTOR
SENSOR POWER
STEERING DETECTION
FLUID PRESSURE CONNECTOR
SWITCH

FRONT FRONT
SIDE SIDE

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
 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G1-A/T (LHD)>
90-33
ENGINE CONTROL SYSTEM <4G1-A/T (LHD)>
M1901000802323

FUSIBLE IGNITION IGNITION

LINK 1 SWITCH (IG1) BATTERY SWITCH (ST)

NOTE
: SEDAN
: WAGON
RELAY
BOX

ENGINE
CONTROL
RELAY
FUEL FUEL INHIBITOR
PUMP PUMP SWITCH
RELAY RELAY
(1) (2)

FUEL
TANK
PUMP ·COOLING
COMBINATION SYSTEM
METER ·MANUAL AIR STARTING
CONDITIONER SYSTEM

ENGINE-
A/T-ECU
POWER BACK-UP
SOURCE POWER SOURCE
90-34 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G1-A/T (LHD)>

ENGINE CONTROL SYSTEM <4G1-A/T (LHD)> (CONTINUED)

ENGINE CONTROL
RELAY

CAMSHAFT ENGINE
FUEL FUEL FUEL FUEL EMISSION EMISSION POSITION CRANK
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 SOLENOID SOLENOID SENSOR ANGLE
VALVE VALVE SENSOR
(PURGE (EGR
CONTROL SYSTEM)
SYSTEM)

ENGINE-
A/T-ECU

POWER
OUTPUT GND SOURCE

ENGINE CONTROL ENGINE WATER THROTTLE

CONTROL INTAKE AIR TEMPERA- BODY
OXYGEN SENSOR TEMPERATURE
(REAR) OXYGEN TURE THROTTLE
SENSOR SENSOR SENSOR SENSOR
(FRONT) INLET MANIFOLD UNIT
ABSOLUTE PRESSURE 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

ENGINE CONTROL SYSTEM <4G1-A/T (LHD)> (CONTINUED)

ENGINE-A/T-
ECU

(FUSE 3 )

·COOLING THROTTLE
CHARGING MANUAL AIR SYSTEM BODY IDLE
SYSTEM CONDITIONER ·MANUAL AIR SPEED
CONDITIONER
CONTROL
SERVO

(FUSE 15 )
INVECS-II
4A/T

A/T
CONTROL
RELAY

ENGINE-A/T-ECU

INVECS-II
4A/T

DIAGNOSIS
CONNECTOR
IMMOBILIZER
SYSTEM IGNITION
SYSTEM OUTPUT SHAFT
SPEED SENSOR

ENGINE CONTROL ENGINE DIAGNOSIS

DETONATION POWER SPEED CONNECTOR
SENSOR STEERING DETECTION
FLUID CONNECTOR
PRESSURE
SWITCH
FRONT
SIDE FRONT
SIDE

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
 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G1-A/T (RHD)>
90-35
ENGINE CONTROL SYSTEM <4G1-A/T (RHD)>
M1901000802334
FUSIBLE IGNITION IGNITION
LINK 1 NOTE
SWITCH (IG1) BATTERY : SEDAN
SWITCH (ST)
: WAGON
: ·FRONT FOG LAMP
·HEADLAMP
·REAR FOG LAMP
RELAY ·REAR WIPER AND WASHER
BOX ·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD WARNING LAMP
·WINDSHIELD
·IGNITION WIPER AND WASHER
SYSTEM
·IMMOBILIZER
SYSTEM

ENGINE
CONTROL
RELAY
FUEL FUEL INHIBITOR
PUMP PUMP SWITCH
RELAY RELAY
(1) (2)

FUEL ·COOLING
COMBINATION TANK PUMP SYSTEM
METER ·MANUAL AIR STARTING
CONDITIONER SYSTEM

ENGINE-
A/T-ECU
POWER BACK-UP
SOURCE POWER SOURCE
90-36 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G1-A/T (RHD)>

ENGINE CONTROL SYSTEM <4G1-M/T (RHD)> (CONTINUED)

ENGINE CONTROL
RELAY

CAMSHAFT ENGINE
FUEL FUEL FUEL FUEL EMISSION EMISSION POSITION CRANK
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 SOLENOID SOLENOID SENSOR ANGLE
VALVE VALVE SENSOR
(PURGE (EGR
CONTROL SYSTEM)
SYSTEM)

ENGINE-
A/T-ECU

OUTPUT GND POWER

SOURCE

ENGINE CONTROL ENGINE WATER THROTTLE

OXYGEN SENSOR CONTROL INTAKE AIR TEMPERA- BODY
(REAR) OXYGEN TEMPERATURE TURE THROTTLE
SENSOR SENSOR SENSOR SENSOR
(FRONT) INLET MANIFOLD UNIT
ABSOLUTE PRESSURE 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

ENGINE CONTROL SYSTEM <4G1-A/T (RHD)> (CONTINUED)

ENGINE-A/T-
ECU

(FUSE 3 )

·COOLING THROTTLE
CHARGING MANUAL AIR SYSTEM BODY
SYSTEM CONDITIONER ·MANUAL AIR IDLE SPEED
CONDITIONER CONTROL
SERVO

(FUSE 15 )
INVECS-II
4A/T

A/T
CONTROL
RELAY

ENGINE-A/T-ECU

INVECS-II
4A/T

DIAGNOSIS
CONNECTOR
IMMOBILIZER
SYSTEM IGNITION
SYSTEM OUTPUT SHAFT
SPEED SENSOR

ENGINE CONTROL ENGINE DIAGNOSIS

DETONATION SPEED CONNECTOR
SENSOR POWER
STEERING DETECTION
FLUID PRESSURE CONNECTOR
SWITCH

FRONT FRONT
SIDE SIDE

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
 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G6 (LHD)>
90-37
ENGINE CONTROL SYSTEM <4G6 (LHD)>
M1901000802345

FUSIBLE IGNITION IGNITION

LINK 1 SWITCH (IG1) BATTERY SWITCH (ST)

RELAY
BOX

ENGINE
CONTROL
RELAY
FUEL FUEL
PUMP PUMP
RELAY RELAY
(1) (2)

STARTING
SYSTEM

FUEL
TANK
PUMP ·COOLING
COMBINATION SYSTEM
METER ·MANUAL AIR
CONDITIONER

NOTE
: SEDAN
: WAGON

ENGINE-
ECU
POWER BACK-UP
SOURCE POWER SOURCE

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
90-38 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G6 (LHD)>

ENGINE CONTROL SYSTEM <4G6 (LHD)> (CONTINUED)

ENGINE CONTROL
RELAY

CAMSHAFT ENGINE
FUEL FUEL FUEL FUEL EMISSION EMISSION POSITION CRANK
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 SOLENOID SOLENOID SENSOR ANGLE
VALVE VALVE SENSOR
(PURGE (EGR
CONTROL SYSTEM)
SYSTEM)

ENGINE-
ECU

BAROMETRIC
PRESSURE
SENSOR

AIR
ENGINE ENGINE FLOW WATER THROTTLE
CONTROL CONTROL INTAKE AIR SENSOR TEMPERA- BODY
OXYGEN OXYGEN TEMPERATURE TURE THROTTLE
SEMSOR
SENSOR SENSOR SENSOR SENSOR
(REAR) (FRONT)
AIR CLEANER
AIR FLOW 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

ENGINE CONTROL SYSTEM <4G6 (LHD)> (CONTINUED)

ENGINE-
(FUSE 2 ) ECU

·COOLING THROTTLE
CHARGING MANUAL AIR SYSTEM BODY
SYSTEM CONDITIONER ·MANUAL AIR IDLE SOEED
CONDITIONER CONTROL
SERVO METER AND
GAUGE
(FUSE 15 )

VEHICLE
SPEED
SENSOR

ENGINE-ECU

DIAGNOSIS
CONNECTOR
IMMOBILIZER
SYSTEM IGNITION
SYSTEM

ENGINE CONTROL ENGINE DIAGNOSIS

DETONATION SPEED CONNECTOR
SENSOR POWER
STEERING DETECTION
FLUID PRESSURE CONNECTOR
SWITCH

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G6 (RHD)>
90-39
ENGINE CONTROL SYSTEM <4G6 (RHD)>
M1901000802356

FUSIBLE IGNITION IGNITION

LINK 1 SWITCH (IG1) BATTERY SWITCH (ST)
NOTE
: ·FRONT FOG LAMP
·HEADLAMP
·REAR FOG LAMP
·REAR WIPER AND WASHER
RELAY ·TAIL LAMP, POSITION LAMP,
BOX LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD WARNING LAMP
·WINDSHIELD
WIPER AND WASHER

IGNITION
SYSTEM

ENGINE
CONTROL
RELAY
FUEL FUEL
PUMP PUMP
RELAY RELAY
(1) (2)

STARTING
SYSTEM

FUEL ·COOLING
COMBINATION TANK SYSTEM
METER PUMP ·MANUAL AIR
CONDITIONER

ENGINE-ECU
POWER BACK-UP
SOURCE POWER SOURCE

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
90-40 CIRCUIT DIAGRAMS
ENGINE CONTROL SYSTEM <4G6 (RHD)>

ENGINE CONTROL SYSTEM <4G6 (RHD)> (CONTINUED)

ENGINE CONTROL
RELAY

CAMSHAFT ENGINE
FUEL FUEL FUEL FUEL EMISSION EMISSION POSITION CRANK
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 SOLENOID SOLENOID SENSOR ANGLE
VALVE VALVE SENSOR
(PURGE (EGR
CONTROL SYSTEM)
SYSTEM)

ENGINE-
ECU

BAROMETRIC
PRESSURE
SENSOR

AIR
ENGINE CONTROL ENGINE FLOW WATER THROTTLE
OXYGEN SENSOR CONTROL INTAKE AIR SENSOR TEMPERA- BODY
(REAR) OXYGEN TEMPERATURE TURE THROTTLE
SEMSOR
SENSOR SENSOR SENSOR
(FRONT)
AIR CLEANER
AIR FLOW 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

ENGINE CONTROL SYSTEM <4G6 (RHD)> (CONTINUED)

ENGINE-
(FUSE 2 ) ECU

·COOLING THROTTLE
CHARGING MANUAL AIR SYSTEM BODY
SYSTEM CONDITIONER ·MANUAL AIR IDLE SPEED
CONDITIONER CONTROL
SERVO METER AND
GAUGE
(FUSE 15 )

VEHICLE
SPEED
SENSOR

ENGINE-ECU

DIAGNOSIS
CONNECTOR
IMMOBILIZER
SYSTEM IGNITION
SYSTEM

ENGINE CONTROL ENGINE DIAGNOSIS

DETONATION SPEED CONNECTOR
SENSOR POWER
STEERING DETECTION
FLUID PRESSURE CONNECTOR
SWITCH

FRONT FRONT
SIDE SIDE

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
 CIRCUIT DIAGRAMS
COOLING SYSTEM <LHD>
90-41
COOLING SYSTEM <LHD>
M1901001000904
ENGINE
INPUT SIGNAL CONTROL
·A/C SWITCH ·VEHICLE SPEED FUSIBLE RELAY
·OUTPUT SHAFT SENSOR <M/T> LINK 2
SPEED SENSOR ·WATER
<A/T> TEMPERATURE
SENSOR UNIT

ENGINE-
ECU <M/T>
ENGINE- ENGINE
A/T-ECU <A/T> CONTROL
SYSTEM
<M/T>
<A/T>

FAN
CONTROL
RELAY

SMOOTHING
CIRCUIT

INPUT
SIGNAL FIELD EFFECT
PROCESSING TRANSISTOR
CIRCUIT

DRIVE
CIRCUIT

TEMPERATURE CURRENT
DETECTION DETECTION

COOLING FAN MOTOR

DRIVE CONTROL UNIT

CONDENSER RADIATOR
FAN MOTOR FAN MOTOR

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
90-42 CIRCUIT DIAGRAMS
COOLING SYSTEM <RHD>

COOLING SYSTEM <RHD>

M1901001000915
ENGINE
CONTROL
INPUT SIGNAL FUSIBLE RELAY
·A/C SWITCH ·OUTPUT SHAFT LINK 2
·WATER SPEED SENSOR <A/T>
TEMPERATURE ·VEHICLE SPEED
SENSOR UNIT SENSOR <M/T>

ENGINE- ENGINE
ECU <M/T> CONTROL
SYSTEM
ENGINE-
A/T-ECU <A/T>

<M/T>
<A/T>

FAN CONTROL
RELAY

SMOOTHING
CIRCUIT

INPUT
SIGNAL FIELD EFFECT
PROCESSING TRANSISTOR
CIRCUIT

DRIVE
CIRCUIT

TEMPERATURE CURRENT
DETECTION DETECTION

COOLING FAN MOTOR

DRIVE CONTROL UNIT

CONDENSER RADIATOR
FAN MOTOR FAN MOTOR

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
 CIRCUIT DIAGRAMS
INVECS-II 4A/T <LHD>
90-43
INVECS-II 4A/T <LHD>
M1901016201264

IGNITION
SWITCH (IG1) BATTERY (FUSE 3 )

RELAY
BOX

OUTPUT INPUT
SHAFT SHAFT
SPEED SPEED
SENSOR SENSOR

ENGINE
CONTROL
STOP SYSTEM
LAMP
SWITCH

STOP LAMP ENGINE-

A/T A/T-ECU
CONTROL
RELAY

NOTE
·FRONT
FOG LAMP
·HEADLAMP
·HEADLAMP
LEVELLING SYSTEM
·HEADLAMP
WASHER
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP, METER AND
LICENCE PLATE GAUGE
ENGINE-
LAMP AND LIGHTING
A/T-ECU MONITOR BUZZER
SOLENOID VALVE
POWER SOURCE ·WINDSHIELD
WIPER AND WASHER
90-44 CIRCUIT DIAGRAMS
INVECS-II 4A/T <LHD>

INVECS-II 4A/T <LHD> (CONTINUED)

FRONT-ECU SHIFT
TAIL LAMP SWITCH INHIBITOR
RELAY ASSEMBLY ( FUSE 3 ) ( FUSE 3 ) SWITCH

RELAY
BOX

TAIL LAMP, POSITION INHIBITOR SHIFT

LAMP, LICENCE SWITCH SWITCH
PLATE LAMP AND
LIGHTING MONITOR ASSEMBLY
SHIFT SELECT
BUZZER
SWITCH SWITCH

ENGINE-
A/T-ECU

J/C (5) J/C (1)

( FUSE 2 ) ( FUSE 22 )

SHIFT
POSITION
INDICATOR CONTROL CIRCUIT

RHEOSTAT
COMBINATION
METER

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

INVECS-II 4A/T <LHD> (CONTINUED)

A/T
CONTROL FUSIBLE
RELAY LINK 1
ENGINE-
A/T-ECU

NOTE
: UNDERDRIVE
SOLENOID VALVE
: SECOND
SOLENOID VALVE
: OVERDRIVE
SOLENOID VALVE
: DAMPER CLUTCH
CONTROL
SOLENOID VALVE
: LOW AND REVERSE
SOLENOID VALVE

A/T CONTROL
SOLENOID ENGINE CONTROL
VALVE ASSEMBLY SYSTEM

A/T FLUID
TEMPERATURE THROTTLE
SENSOR BODY
THROTTLE
SENSOR

ENGINE CONTROL
SYSTEM
DIAGNOSIS
CONNECTOR

ENGINE-
A/T-ECU

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
INVECS-II 4A/T <RHD>
90-45
INVECS-II 4A/T <RHD>
M1901016201275

IGNITION
SWITCH (IG1) BATTERY (FUSE 3 )

RELAY
BOX

OUTPUT INPUT
SHAFT SHAFT
SPEED SPEED
SENSOR SENSOR

ENGINE
CONTROL
STOP SYSTEM
LAMP
SWITCH

STOP LAMP ENGINE-

A/T A/T-ECU
CONTROL
RELAY

NOTE
: ·FRONT FOG LAMP
·HEADLAMP
·REAR FOG LAMP
·REAR WIPER AND WASHER
·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·TURN-SIGNAL LAMP AND
HAZARD WARNING LAMP
·WINDSHIELD WIPER AND WASHER
: ·FRONT FOG LAMP METER AND
·HEADLAMP GAUGE
ENGINE- ·HEADLAMP LEVELLING SYSTEM
A/T-ECU ·REAR FOG LAMP
SOLENOID VALVE
POWER SOURCE ·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·WINDSHIELD WIPER AND WASHER
90-46 CIRCUIT DIAGRAMS
INVECS-II 4A/T <RHD>

INVECS-II 4A/T <RHD> (CONTINUED)

FRONT-ECU SHIFT
TAIL LAMP SWITCH INHIBITOR
RELAY ASSEMBLY ( FUSE 3 ) ( FUSE 3 ) SWITCH

RELAY
BOX

TAIL LAMP, POSITION INHIBITOR SHIFT

LAMP, LICENCE SWITCH SWITCH
PLATE LAMP AND
LIGHTING MONITOR ASSEMBLY
BUZZER SHIFT SELECT
SWITCH SWITCH

TAIL LAMP, POSITION

LAMP, LICENCE
PLATE LAMP AND ENGINE-
LIGHTING MONITOR
BUZZER A/T-ECU

J/C (1)
( FUSE 2 ) ( FUSE 22 )

SHIFT
POSITION
INDICATOR CONTROL CIRCUIT

RHEOSTAT
COMBINATION
METER

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

INVECS-II 4A/T <RHD> (CONTINUED)

A/T
CONTROL FUSIBLE
RELAY LINK 1
ENGINE-
A/T-ECU

NOTE
: UNDERDRIVE
SOLENOID VALVE
: SECOND
SOLENOID VALVE
: OVERDRIVE
SOLENOID VALVE
: DAMPER CLUTCH
CONTROL
SOLENOID VALVE
: LOW AND REVERSE
SOLENOID VALVE

A/T CONTROL
SOLENOID ENGINE CONTROL
VALVE ASSEMBLY SYSTEM

A/T FLUID
TEMPERATURE THROTTLE
SENSOR BODY
THROTTLE
SENSOR

ENGINE CONTROL
SYSTEM
DIAGNOSIS
CONNECTOR

ENGINE-
A/T-ECU

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
HEADLAMP <LHD>
90-47
HEADLAMP <LHD>
M1901001501292
IGNITION IGNITION
SWITCH (IG2) SWITCH (IG1)
BATTERY

RELAY
BOX

FRONT-ECU

( HEADLAMP
RELAY: LO )
( HEADLAMP
RELAY: HI )
POWER
SOURCE

RELAY
BOX

HEADLAMP
LEVELLING
SYSTEM
HEADLAMP
(LH) (RH) COMBINATION
METER
COLUMN-ECU

DIMMER·
( LIGHTING
SWITCH )
( )
PASSING
SWITCH
COLUMN SWITCH

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet
90-48 CIRCUIT DIAGRAMS
HEADLAMP <LHD>

HEADLAMP <LHD> (CONTINUED)

COLUMN FUSIBLE
(FUSE 22 ) SWITCH LINK 1

FUSE 2

ETACS-ECU

POWER
SOURCE

VEHICLES VEHICLES
WITHOUT DRL WITH DRL
KEY
REMINDER SWITCH
CLOCK (WHEN REMOVING
KEY: ON)

DOOR
SWITCH
(FRONT: LH)
DIAGNOSIS
CONNECTOR

NO CONNECTION

FRONT
SIDE

J/B SIDE
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
 CIRCUIT DIAGRAMS
HEADLAMP <RHD>
90-49
HEADLAMP <RHD>
M1901001501300
IGNITION IGNITION
SWITCH (IG2) SWITCH (IG1)
BATTERY

RELAY
BOX

·ABS
·BRAKE WARNING LAMP
·CHARGING SYSTEM
·ENGINE CONTROL SYSTEM
·FUEL WARNING LAMP
·INVECS-II 4A/T
·METER AND GAUGE
·OIL PRESSURE WARNING
LAMP

FRONT-ECU

( HEADLAMP
RELAY: LO )
( HEADLAMP
RELAY: HI )
POWER
SOURCE

RELAY
BOX

HEADLAMP
LEVELLING
SYSTEM
HEADLAMP
(LH) (RH) COMBINATION
METER
COLUMN-ECU

DIMMER·
( LIGHTING
SWITCH )
( )
PASSING
SWITCH
COLUMN SWITCH

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet
90-50 CIRCUIT DIAGRAMS
HEADLAMP <RHD>

HEADLAMP <RHD> (CONTINUED)

COLUMN FUSIBLE
(FUSE 22 ) SWITCH LINK 1

FUSE 2

ETACS-ECU

POWER
SOURCE

KEY
REMINDER SWITCH
(WHEN REMOVING
KEY: ON)

DOOR
SWITCH
(FRONT: RH)
DIAGNOSIS
CONNECTOR

FRONT J/B SIDE

SIDE

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
 CIRCUIT DIAGRAMS
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <LHD>
90-51
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER <LHD>
M1901001700293
IGNITION
BATTERY SWITCH (IG2)

RELAY
BOX

FRONT-ECU

( TAIL
RELAY
LAMP
)
POWER
SOURCE

RELAY
BOX

FRONT FRONT
REAR COMBINATION COMBINATION
COMBINATION LAMP LAMP
LAMP (POSITION: RH) (POSITION: LH)
(TAIL: RH)

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
90-52 CIRCUIT DIAGRAMS
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <LHD>

TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <LHD>
(CONTINUED)
IGNITION FUSIBLE
SWITCH (IG1) (FUSE 22 ) LINK 1

ETACS-ECU

POWER BUZZER
SOURCE

COLUMN
SWITCH KEY
REMINDER
SWITCH
(WHEN
REMOVING
KEY: ON)
COLUMN
SWITCH
COLUMN-ECU

LIGHTING DIAGNOSIS
SWITCH CONNECTOR

DOOR SWITCH
(FRONT: LH)

FRONT
SIDE

J/B SIDE
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
 CIRCUIT DIAGRAMS
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <LHD>
90-53
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <LHD>
(CONTINUED)

<SEDAN> <WAGON>
RELAY BOX RELAY BOX
(FUSE 21 ) (FUSE 21 )

REAR LICENCE COMBINATION REAR LICENCE COMBINATION

COMBINATION PLATE LAMP METER COMBINATION PLATE LAMP METER
LAMP (LH) (RH) LAMP (LH) (RH)
(TAIL: LH) (TAIL: LH)

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
90-54 CIRCUIT DIAGRAMS
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <RHD>

TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND

LIGHTING MONITOR BUZZER <RHD>
M1901001700301

BATTERY IGNITION
SWITCH (IG2)

RELAY
BOX

FRONT-ECU

( TAIL
RELAY
LAMP
)
POWER
SOURCE

RELAY
BOX

FRONT FRONT
COMBINATION COMBINATION
LAMP LAMP
(POSITION: LH) (POSITION:
RH)

CIGALETTOR
LIGHTER AND
ASHTRAY
ILLUMINATION
LAMP

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
 CIRCUIT DIAGRAMS
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <RHD>
90-55
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <RHD>
(CONTINUED)
IGNITION FUSIBLE
SWITCH (IG1) (FUSE 22 ) LINK 1

ETACS-ECU

POWER BUZZER
SOURCE

COLUMN KEY
SWITCH REMINDER
COLUMN-ECU SWITCH
RELAY (WHEN
BOX REMOVING
LIGHTING (FUSE 22 ) KEY: ON)
SWITCH

DIAGNOSIS
NOTE
: ·ABS
CONNECTOR
·BRAKE WARNING LAMP
·CHARGING SYSTEM
·ENGINE CONTROL
SYSTEM
·FUEL WARNING LAMP
·INVECS-II 4A/T
·METER AND GAUGE
·OIL PRESSURE WARNING
LAMP DOOR SWITCH
(FRONT: RH)

FRONT
SIDE

J/B SIDE
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
90-56 CIRCUIT DIAGRAMS
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <RHD>

TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <RHD>
(CONTINUED)

J/C (1) RELAY BOX

(FUSE 20 ) (FUSE 21 )

<WAGON>
<SEDAN>

REAR LICENCE REAR LICENCE

COMBINATION PLATE COMBINATION PLATE
LAMP LAMP LAMP LAMP
(TAIL: RH) (LH) (RH) (TAIL: LH) (LH) (RH)

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
 CIRCUIT DIAGRAMS
FRONT FOG LAMP <LHD>
90-57
FRONT FOG LAMP <LHD>
M1901011900287

IGNITION IGNITION
BATTERY SWITCH (IG2) SWITCH (IG1)

RELAY
BOX
RELAY
BOX

FRONT-
ECU

( TAIL
RELAY
LAMP
)
FRONT FOG POWER
LAMP RELAY SOURCE

RELAY
BOX
ETACS- ETACS-ECU
SPARE
CONNECTOR ECU
FOR FRONT
FOG LAMP TAIL LAMP,
POSITION LAMP,
TAIL LAMP, LICENCE PLATE
POSITION LAMP, LAMP AND
LICENCE PLATE LIGHTING
LAMP AND MONITOR
LIGHTING BUZZER
MONITOR
BUZZER

COMBINATION FOG COLUMN

FRONT FOG METER LAMP SWITCH
LAMP SWITCH COLUMN-ECU
(LH) (RH)

LIGHTING
SWITCH

RHEOSTAT

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
90-58 CIRCUIT DIAGRAMS
FRONT FOG LAMP <LHD>

FRONT FOG LAMP <LHD> (CONTINUED)

COLUMN FUSIBLE
SWITCH (FUSE 22 ) LINK 1

FUSE 2

ETACS-ECU

POWER
SOURCE

DIAGNOSIS
CONNECTOR

FRONT SIDE

J/B SIDE
 CIRCUIT DIAGRAMS
FRONT FOG LAMP <RHD>
90-59
FRONT FOG LAMP <RHD>
M1901011900298

IGNITION IGNITION
BATTERY SWITCH (IG2) SWITCH (IG1)

RELAY
BOX
RELAY
BOX

FRONT-
ECU

FRONT FOG
( TAIL
RELAY
LAMP
) ·ABS
POWER ·BRAKE WARNING LAMP
LAMP RELAY SOURCE ·CHARGING SYSTEM
·ENGINE CONTROL SYSTEM
·FUEL WARNING LAMP
·INVECS-II 4A/T
·METER AND GAUGE
·OIL PRESSURE WARNING
LAMP
RELAY
BOX
ETACS- ETACS-ECU
SPARE
CONNECTOR ECU
FOR FRONT
FOG LAMP
TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND
LIGHTING
MONITOR
BUZZER

COMBINATION FOG COLUMN

FRONT FOG METER LAMP
LAMP SWITCH
SWITCH COLUMN-ECU
(LH) (RH)

LIGHTING
SWITCH

RHEOSTAT

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
90-60 CIRCUIT DIAGRAMS
FRONT FOG LAMP <RHD>

FRONT FOG LAMP <RHD> (CONTINUED)

COLUMN FUSIBLE
SWITCH (FUSE 22 ) LINK 1

FUSE 2

ETACS-ECU

POWER
SOURCE

DIAGNOSIS
CONNECTOR

FRONT SIDE

J/B SIDE
 CIRCUIT DIAGRAMS
ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <SEDAN (LHD)>
90-61
ROOM LAMP AND LUGGAGE COMPARTMENT LAMP
<SEDAN (LHD)>
M1901017800158

IGNITION IGNITION FUSIBLE

SWITCH (ACC) SWITCH (IG1) BATTERY ·FRONT FOG LAMP LINK 1
·HEADLAMP
·HEADLAMP LEVELLING
SYSTEM
·HEADLAMP WASHER
·REAR FOG LAMP
RELAY ·TAIL LAMP,
RELAY BOX POSITION LAMP,
LICENCE PLATE
BOX LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD
WIPER AND WASHER

WITHOUT WITH
KEYLESS ENTRY KEYLESS ENTRY
POWER
SOURCE
KEEP RELAY

INTERIOR LAMP CUT BACK-UP CIRCUIT

LOAD
DETERMINATION
CIRCUIT

COMBINATION
METER REAR FRONT LUGGAGE
ROOM ROOM COMPARTMENT
LAMP LAMP LAMP

DIAGNOSIS
CONNECTOR

TRUNK LID
NOTE LATCH
: VEHICLES WITHOUT SWITCH
CURTAIN AIR BAG
: VEHICLES WITH
CURTAIN AIR BAG
FRONT
SIDE

Wire colour code

J/B SIDE 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
90-62 CIRCUIT DIAGRAMS
ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <SEDAN (LHD)>

ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <SEDAN (LHD)> (CONTINUED)

COMBINATION
METER

ETACS-
ECU

KEY
REMINDER
SWITCH
(WHEN
REMOVING
KEY: ON)

DOOR DOOR DOOR DOOR

SWITCH SWITCH SWITCH SWITCH
(FRONT: RH) (REAR: RH) (REAR: LH) (FRONT: LH)

J/B SIDE
 CIRCUIT DIAGRAMS
ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <SEDAN (RHD)>
90-63
ROOM LAMP AND LUGGAGE COMPARTMENT LAMP
<SEDAN (RHD)>
M1901017800169

IGNITION IGNITION FUSIBLE

SWITCH (ACC) SWITCH (IG1) BATTERY LINK 1

·FRONT FOG LAMP

·HEADLAMP
RELAY ·TAIL LAMP,
RELAY BOX POSITION LAMP,
LICENCE PLATE
BOX LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU

WITHOUT WITH
KEYLESS ENTRY KEYLESS ENTRY
POWER
SOURCE
KEEP RELAY

INTERIOR LAMP CUT BACK-UP CIRCUIT

LOAD
DETERMINATION
CIRCUIT

REAR FRONT LUGGAGE

ROOM ROOM COMPARTMENT
LAMP LAMP LAMP
COMBINATION
METER
DIAGNOSIS
CONNECTOR

TRUNK LID
LATCH
SWITCH

FRONT
SIDE

Wire colour code

J/B SIDE 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
90-64 CIRCUIT DIAGRAMS
ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <SEDAN (RHD)>

ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <SEDAN (RHD)> (CONTINUED)

COMBINATION
METER

ETACS-
ECU

KEY
REMINDER
SWITCH
(WHEN
REMOVING
KEY: ON)

DOOR DOOR DOOR DOOR

SWITCH SWITCH SWITCH SWITCH
(FRONT: LH) (REAR: LH) (REAR: RH) (FRONT: RH)

J/B SIDE
 CIRCUIT DIAGRAMS
ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (LHD)>
90-65
ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM
LAMP <WAGON (LHD)>
M1901017900070

IGNITION IGNITION FUSIBLE

SWITCH (ACC) SWITCH (IG1) BATTERY ·FRONT FOG LAMP LINK 1
·HEADLAMP
·HEADLAMP LEVELLING
SYSTEM
·HEADLAMP WASHER
·REAR FOG LAMP
·TAIL LAMP,
RELAY POSITION LAMP,
LICENCE PLATE
BOX LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU

WITHOUT WITH
KEYLESS ENTRY KEYLESS ENTRY

KEEP RELAY

POWER
INTERIOR LAMP CUT BACK-UP CIRCUIT SOURCE

LOAD
DETERMINATION
CIRCUIT

<VEHICLES <VEHICLES <VEHICLES <VEHICLES

WITH WITHOUT WITH WITHOUT
CURTAIN CURTAIN CURTAIN CURTAIN
AIR BAG> AIR BAG> AIR BAG> AIR BAG>
LUGGAGE COMBINATION
ROOM METER
LAMP

J/B SIDE
90-66 CIRCUIT DIAGRAMS
ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (LHD)>

ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (LHD)> (CONTINUED)
REAR REAR
PERSONAL PERSONAL COMBINATION
LAMP (RH) LAMP (LH) METER

ETACS-ECU

LUGGAGE
ROOM LAMP

(FUSE 15 )

KEY
REMINDER
SWITCH
DIODE (WHEN
REMOVING
KEY: ON)

DIAGNOSIS
CONNECTOR

TAILGATE
SWITCH
DOOR DOOR DOOR DOOR
SWITCH SWITCH SWITCH SWITCH
(FRONT: RH) (REAR: RH) (REAR: LH) (FRONT: LH)

FRONT
SIDE J/B SIDE

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

ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (LHD)> (CONTINUED)
<VEHICLES WITHOUT CURTAIN AIR BAG>

ETACS- ETACS-
ECU ECU

FRONT REAR REAR

ROOM PERSONAL PERSONAL
LAMP LAMP (LH) LAMP (RH)

<VEHICLES WITH CURTAIN AIR BAG>

ETACS- ETACS-
ECU ECU

FRONT REAR
ROOM ROOM
LAMP LAMP
 CIRCUIT DIAGRAMS
ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (RHD)>
90-67
ROOM LAMP,PERSONAL LAMP AND
LUGGAGE ROOM LAMP <WAGON (RHD)>
M1901017900081

IGNITION IGNITION FUSIBLE

SWITCH (ACC) SWITCH (IG1) BATTERY LINK 1
·FRONT FOG LAMP
·HEADLAMP
·HEADLAMP LEVELLING
SYSTEM
·REAR FOG LAMP
·TAIL LAMP,
RELAY POSITION LAMP,
LICENCE PLATE
BOX LAMP AND LIGHTING
MONITOR BUZZER
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU

WITHOUT WITH
KEYLESS ENTRY KEYLESS ENTRY

KEEP RELAY

POWER
INTERIOR LAMP CUT BACK-UP CIRCUIT SOURCE

LOAD
DETERMINATION
CIRCUIT

<VEHICLES <VEHICLES <VEHICLES <VEHICLES

WITH WITHOUT WITH WITHOUT
CURTAIN CURTAIN CURTAIN CURTAIN
AIR BAG> AIR BAG> AIR BAG> AIR BAG>
LUGGAGE
ROOM
LAMP COMBINATION
METER

J/B SIDE
90-68 CIRCUIT DIAGRAMS
ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (RHD)>

ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (RHD)> (CONTINUED)
REAR REAR
PERSONAL PERSONAL COMBINATION
LAMP (LH) LAMP (RH) METER

ETACS-ECU

LUGGAGE
ROOM LAMP

(FUSE 15 )

KEY
REMINDER
SWITCH
DIODE (WHEN
REMOVING
KEY: ON)

DIAGNOSIS
CONNECTOR

TAILGATE
SWITCH
DOOR DOOR DOOR DOOR
SWITCH SWITCH SWITCH SWITCH
(FRONT: LH) (REAR: LH) (REAR: RH) (FRONT: RH)

FRONT
SIDE J/B SIDE

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

ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (RHD)> (CONTINUED)
<VEHICLES WITHOUT CURTAIN AIR BAG>

ETACS- ETACS-
ECU ECU

FRONT REAR REAR

ROOM PERSONAL PERSONAL
LAMP LAMP (LH) LAMP (RH)

<VEHICLES WITH CURTAIN AIR BAG>

ETACS- ETACS-
ECU ECU

FRONT REAR
ROOM ROOM
LAMP LAMP
 CIRCUIT DIAGRAMS
REAR FOG LAMP <LHD>
90-69
REAR FOG LAMP <LHD>
M1901012000157

BATTERY IGNITION IGNITION REAR FOG

(FUSE 5 ) SWITCH (IG2) SWITCH (IG1) LAMP RELAY

RELAY
BOX

FRONT-ECU
TAIL ETACS-
LAMP ECU
RELAY
POWER
SOURCE POWER
SOURCE

RELAY ETACS-
BOX ECU

TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER

FOG LAMP
SWITCH

COLUMN-ECU

LIGHTING
SWITCH
COLUMN
SWITCH
RHEOSTAT

J/B SIDE
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
90-70 CIRCUIT DIAGRAMS
REAR FOG LAMP <LHD>

REAR FOG LAMP <LHD> (CONTINUED)

FUSIBLE
LINK 1
(FUSE 16 )

ETACS-ECU
REAR FOG
LAMP RELAY

REAR FOG
LAMP COMBINATION DIAGNOSIS
METER CONNECTOR

NOTE
: SEDAN
: WAGON

FRONT SIDE

J/B SIDE 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
 CIRCUIT DIAGRAMS
REAR FOG LAMP <RHD>
90-71
REAR FOG LAMP <RHD>
M1901012000168

BATTERY IGNITION IGNITION REAR FOG

(FUSE 5 ) SWITCH (IG2) SWITCH (IG1) LAMP RELAY

RELAY
BOX

ETACS-
FRONT-ECU ECU
TAIL
LAMP
RELAY POWER
POWER SOURCE
SOURCE

RELAY ETACS-
BOX ECU

TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER

FOG LAMP
SWITCH

COLUMN-ECU

NOTE
: ·ABS
·BRAKE WARNING LAMP
·CHARGING SYSTEM LIGHTING
·ENGINE CONTROL SYSTEM SWITCH
·FUEL WARNING LAMP
·INVECS-II 4A/T COLUMN
·METER AND GAUGE SWITCH
RHEOSTAT ·OIL PRESSURE WARNING LAMP

J/B SIDE 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
90-72 CIRCUIT DIAGRAMS
REAR FOG LAMP <RHD>

REAR FOG LAMP <RHD> (CONTINUED)

(FUSE 16 ) FUSIBLE
LINK 1

ETACS-ECU
REAR FOG
LAMP RELAY

REAR FOG
LAMP COMBINATION DIAGNOSIS
METER CONNECTOR

NOTE
: SEDAN
: WAGON

FRONT SIDE

J/B SIDE
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
 CIRCUIT DIAGRAMS
HEADLAMP LEVELLING SYSTEM <LHD>
90-73
HEADLAMP LEVELLING SYSTEM <LHD>
M1901012500248

IGNITION
BATTERY SWITCH (IG2)

RELAY
BOX

FRONT-ECU

HEADLAMP TAIL LAMP

RELAY: LO RELAY
POWER
SOURCE

RELAY
BOX

HEADLAMP

FRONT FRONT
COMBINATION COMBINATION
LAMP LAMP
(LEVELLING: LH) (LEVELLING: RH)

HEADLAMP NOTE
LEVELLING : ·AUDIO SYSTEM ·REAR
·CENTRAL DOOR FOG LAMP
SWITCH LOCKING SYSTEM ·REAR WIPER AND
·CLOCK WASHER
MOTOR VOLTAGE MOTOR VOLTAGE ·FRONT ·ROOM LAMP
DRIVE COMPARISON DRIVE COMPARISON FOG LAMP AND LUGGAGE
COMPARTMENT LAMP
CIRCUIT CIRCUIT CIRCUIT CIRCUIT ·FUEL
WARNING LAMP ·TAIL LAMP,
POSITION LAMP,
·HEADLAMP LICENCE PLATE LAMP
·HEADLAMP AND LIGHTING
WASHER MONITOR BUZZER
·KEY REMINDER ·TURN-SIGNAL LAMP
BUZZER AND HAZARD
·METER AND WARNING LAMP
GAUGE ·WINDSHIELD
·POWER WINDOWS WIPER AND WASHER
: ·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
RHEOSTAT MONITOR BUZZER

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
90-74 CIRCUIT DIAGRAMS
HEADLAMP LEVELLING SYSTEM <RHD>

HEADLAMP LEVELLING SYSTEM <RHD>

M1901012500259

IGNITION
BATTERY SWITCH (IG2)

RELAY
BOX

FRONT-ECU

HEADLAMP TAIL LAMP

RELAY: LO RELAY
POWER
SOURCE

RELAY
BOX

HEADLAMP

FRONT FRONT
COMBINATION COMBINATION
LAMP LAMP
(LEVELLING: LH) (LEVELLING: RH)

MOTOR VOLTAGE MOTOR VOLTAGE NOTE

DRIVE COMPARISON DRIVE COMPARISON : ·AUDIO SYSTEM ·REAR FOG LAMP
CIRCUIT CIRCUIT CIRCUIT CIRCUIT ·CENTRAL DOOR ·REAR WIPER AND
LOCKING SYSTEM WASHER
·CLOCK ·ROOM LAMP
·FRONT AND LUGGAGE
FOG LAMP COMPARTMENT LAMP
·FUEL ·TAIL LAMP,
WARNING LAMP POSITION LAMP,
LICENCE PLATE LAMP
·HEADLAMP AND LIGHTING
·HEADLAMP MONITOR BUZZER
WASHER ·TURN-SIGNAL LAMP
·KEY REMINDER AND HAZARD
BUZZER WARNING LAMP
·METER AND GAUGE ·WINDSHIELD
·POWER WINDOWS WIPER AND WASHER

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
 CIRCUIT DIAGRAMS
HEADLAMP LEVELLING SYSTEM <RHD>
90-75
HEADLAMP LEVELLING SYSTEM <RHD> (CONTINUED)
RELAY RELAY
BOX BOX
(FUSE 19 ) (FUSE 20 )

HEADLAMP
LEVELLING
SWITCH

FRONT
COMBINATION
LAMP

RHEOSTAT

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
90-76 CIRCUIT DIAGRAMS
TURN SIGNAL LAMP AND HAZARD WARNING LAMP <LHD>

TURN SIGNAL LAMP AND HAZARD WARNING LAMP

<LHD>
M1901002901129

BATTERY

RELAY
BOX

ETACS-
ECU
TURN-SIGNAL TURN-SIGNAL
LAMP RELAY: LH LAMP RELAY: RH

COMBINATION
SIDE TURN FRONT REAR REAR FRONT TURN SIDE TURN METER
SIGNAL LAMP TURN COMBINATION COMBINATION SIGNAL LAMP SIGNAL LAMP
(LH) SIGNAL LAMP (LH) LAMP (RH) (RH) (RH)
LAMP (LH)

SEDAN WAGON

J/B SIDE 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
 CIRCUIT DIAGRAMS
TURN SIGNAL LAMP AND HAZARD WARNING LAMP <LHD>
90-77
TURN SIGNAL LAMP AND HAZARD WARNING LAMP <LHD> (CONTINUED)
FRONT-ECU NOTE
TAIL LAMP IGNITION : TAIL LAMP, : ·FRONT FOG LAMP FUSIBLE
BATTERY RELAY SWITCH (IG1) POSITION LAMP, ·HEADLAMP LINK 1
LICENCE PLATE ·HEADLAMP LEVELLING
LAMP AND LIGHTING SYSTEM
MONITOR BUZZER
·HEADLAMP WASHER
·REAR FOG LAMP
·TAIL LAMP, POSITION
LAMP, LICENCE PLATE
LAMP AND LIGHTING
RELAY MONITOR BUZZER
BOX ·WINDSHIELD
WIPER AND WASHER

ETACS-ECU

POWER SOURCE

RELAY
BOX
(FUSE 22 )

COLUMN
HAZARD SWITCH
WARNING
LAMP
SWITCH
COLUMN
SWITCH DIAGNOSIS
COLUMN-ECU
CONNECTOR

TURN-SIGNAL
LAMP SWITCH

RHEOSTAT

FRONT
SIDE

J/B SIDE 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
90-78 CIRCUIT DIAGRAMS
TURN SIGNAL LAMP AND HAZARD WARNING LAMP <RHD>

TURN SIGNAL LAMP AND HAZARD WARNING LAMP

<RHD>
M1901002901130

BATTERY

RELAY
BOX

ETACS-
ECU

( TURN-SIGNAL
LAMP RELAY: LH)
(TURN-SIGNAL
LAMP RELAY: RH )

COMBINATION
SIDE TURN FRONT REAR REAR FRONT TURN SIDE TURN METER
SIGNAL LAMP TURN COMBINATION COMBINATION SIGNAL LAMP SIGNAL LAMP
(LH) SIGNAL LAMP (LH) LAMP (RH) (RH) (RH)
LAMP
(LH)

J/B SIDE 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
 CIRCUIT DIAGRAMS
TURN SIGNAL LAMP AND HAZARD WARNING LAMP <RHD>
90-79
TURN SIGNAL LAMP AND HAZARD WARNING LAMP <RHD> (CONTINUED)
FRONT-ECU NOTE
TAIL LAMP IGNITION : TAIL LAMP, : ·FRONT FOG LAMP : ·ABS FUSIBLE
BATTERY RELAY SWITCH (IG1) POSITION LAMP, ·HEADLAMP ·BRAKE WARNING LAMP LINK 1
LICENCE PLATE ·HEADLAMP LEVELLING ·CHARGING SYSTEM
LAMP AND LIGHTING SYSTEM
MONITOR BUZZER ·ENGINE CONTROL
·HEADLAMP WASHER SYSTEM
·REAR FOG LAMP ·FUEL WARNING LAMP
·TAIL LAMP, POSITION ·INVECS-II 4A/T
LAMP, LICENCE PLATE ·METER AND GAUGE
RELAY LAMP AND LIGHTING
MONITOR BUZZER ·OIL PRESSURE WARNING
BOX ·WINDSHIELD
LAMP
WIPER AND WASHER

ETACS-ECU

POWER SOURCE

RELAY
BOX
(FUSE 22 )

COLUMN
HAZARD SWITCH
WARNING
SWITCH
COLUMN
SWITCH DIAGNOSIS
COLUMN-ECU
CONNECTOR

TURN-SIGNAL
LAMP SWITCH

RHEOSTAT

FRONT
SIDE

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
90-80 CIRCUIT DIAGRAMS
BACK-UP LAMP <LHD>

BACK-UP LAMP <LHD>

M1901003101223
IGNITION
SWITCH (IG1)

A/T M/T

INHIBITOR BACK-UP
SWITCH LAMP
SWITCH

REAR REAR
COMBINATION COMBINATION
LAMP LAMP
(BACK-UP: LH) (BACK-UP: RH)

SEDAN WAGON

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
 CIRCUIT DIAGRAMS
BACK-UP LAMP <RHD>
90-81
BACK-UP LAMP <RHD>
M1901003101234
IGNITION
SWITCH (IG1)

A/T M/T

INHIBITOR BACK-UP
SWITCH LAMP
SWITCH

REAR REAR
COMBINATION COMBINATION
LAMP LAMP
(BACK-UP: LH) (BACK-UP: RH)

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
90-82 CIRCUIT DIAGRAMS
STOP LAMP <SEDAN (LHD)>

STOP LAMP <SEDAN (LHD)>

M1901003001130

BATTERY

RELAY
BOX

STOP LAMP
SWITCH

·ABS
·INVECS-II
4A/T

<REAR SHELF> <REAR SPOILER>

HIGH HIGH REAR REAR

MOUNT MOUNT COMBI- COMBI-
STOP STOP NATION NATION
LAMP LAMP LAMP LAMP
(STOP: LH) (STOP: RH)

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
 CIRCUIT DIAGRAMS
STOP LAMP <SEDAN (RHD)>
90-83
STOP LAMP <SEDAN (RHD)>
M1901003001141

BATTERY

RELAY
BOX

STOP LAMP
SWITCH

·ABS
·INVECS-II
4A/T

<REAR SHELF> <REAR SPOILER>

REAR REAR HIGH HIGH

COMBI- COMBI- MOUNT MOUNT
NATION NATION STOP STOP
LAMP LAMP LAMP LAMP
(STOP: LH) (STOP: RH)

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
90-84 CIRCUIT DIAGRAMS
STOP LAMP <WAGON (LHD)>

STOP LAMP <WAGON (LHD)>

M1901003001152

BATTERY

RELAY
BOX

STOP LAMP
SWITCH

·ABS
·INVECS-II
4A/T

REAR REAR HIGH

COMBINATION COMBINATION MOUNT
LAMP LAMP STOP LAMP
(STOP: LH) (STOP: RH)

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
 CIRCUIT DIAGRAMS
STOP LAMP <WAGON (RHD)>
90-85
STOP LAMP <WAGON (RHD)>
M1901003001163

BATTERY

RELAY
BOX

STOP LAMP
SWITCH

·ABS
·INVECS-II
4A/T

REAR REAR HIGH

COMBINATION COMBINATION MOUNT
LAMP LAMP STOP LAMP
(STOP: LH) (STOP: RH)

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
90-86 CIRCUIT DIAGRAMS
HORN

HORN
M1901003300901

BATTERY

RELAY
BOX

HORN
RELAY

CLOCK
SPRING

HORN
HORN HORN SWITCH
(LO) (HI) NOTE
: LHD
: RHD

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
 CIRCUIT DIAGRAMS
METER AND GAUGE <LHD>
90-87
METER AND GAUGE <LHD>
M1901003501072

IGNITION FRONT-ECU
SWITCH (IG1) BATTERY (TAIL LAMP RELAY)

RELAY
BOX

·FRONT FOG LAMP TAIL LAMP,

·HEADLAMP POSITION LAMP,
·HEADLAMP LICENCE PLATE
LEVELLING SYSTEM LAMP AND LIGHTING
·REAR FOG LAMP MONITOR BUZZER
·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·WINDSHIELD WIPER
AND WASHER

COMBINATION
METER
<EXCEPT
WHITE METER> ODO/TRIP

CONTROL CIRCUIT

NOTE
: SEDAN
: WAGON
: M/T
: A/T FUEL
: EXCEPT 4G6 GAUGE
: 4G6 UNIT

ENGINE ENGINE-
COOLANT ECU ENGINE
TEMPERATURE ENGINE- SPEED
GAUGE UNIT A/T-ECU DETECTION
DIAGNOSIS
CONNECTOR CONNECTOR

FRONT SIDE
90-88 CIRCUIT DIAGRAMS
METER AND GAUGE <LHD>

METER AND GAUGE <LHD> (CONTINUED)

<EXCEPT WHITE METER> <WHITE METER>

(FUSE 2 ) ENGINE-A/T-ECU (FUSE 21 ) (FUSE 21 )

(FUSE 3 )

COMBINATION
METER

COMBINATION
METER

INVECS-II 4A/T

ENGINE CONTROL
SYSTEM
A/T
CONTROL
OUTPUT RELAY
VEHICLE SHAFT
SPEED SPEED
SENSOR SENSOR

INVECS-II 4A/T

NOTE RHEOSTAT RHEOSTAT

: 4G1
: 4G6

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
 CIRCUIT DIAGRAMS
METER AND GAUGE <RHD>
90-89
METER AND GAUGE <RHD>
M1901003501083

FRONT-ECU
IGNITION TAIL
SWITCH (IG1) BATTERY LAMP RELAY

RELAY
BOX
·FRONT FOG LAMP
·HEADLAMP
·REAR FOG LAMP
·REAR WIPER AND WASHER
·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND TAIL LAMP,
LIGHTING MONITOR BUZZER POSITION LAMP,
·TURN-SIGNAL LAMP AND ·FRONT FOG LAMP LICENCE PLATE
TAIL LAMP, LAMP AND LIGHTING
HAZARD WARNING LAMP ·HEADLAMP POSITION LAMP,
·WINDSHIELD WIPER MONITOR BUZZER
·HEADLAMP LICENCE PLATE
AND WASHER LEVELLING SYSTEM LAMP AND LIGHTING
·REAR FOG LAMP MONITOR BUZZER
·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·WINDSHIELD WIPER
AND WASHER

COMBINATION
METER
ODO/TRIP

CONTROL CIRCUIT

WINDSHIELD WIPER
AND WASHER

NOTE
: SEDAN
: WAGON
: M/T
FUEL
: A/T GAUGE
: EXCEPT 4G6 UNIT
: 4G6
RHEOSTAT

ENGINE ENGINE-
COOLANT DIAGNOSIS ECU ENGINE
TEMPERATURE CONNECTOR ENGINE- SPEED
GAUGE UNIT A/T-ECU DETECTION
CONNECTOR

FRONT
SIDE
90-90 CIRCUIT DIAGRAMS
METER AND GAUGE <RHD>

METER AND GAUGE <RHD> (CONTINUED)

(FUSE 2 ) ENGINE-A/T-ECU

COMBINATION
METER (FUSE 3 )

INVECS-II 4A/T

ENGINE CONTROL
SYSTEM
A/T
CONTROL
OUTPUT RELAY
VEHICLE SHAFT
SPEED SPEED
SENSOR SENSOR

INVECS-II 4A/T

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
 CIRCUIT DIAGRAMS
FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP AND BRAKE WARNING LAMP <LHD>
90-91
FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP
AND BRAKE WARNING LAMP <LHD>
M1901018700121

IGNITION
BATTERY SWITCH (IG1)

RELAY
BOX

·FRONT
FOG LAMP
·HEADLAMP
·HEADLAMP
LEVELLING
SYSTEM
·HEADLAMP
WASHER
·REAR
FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE COMBINATION
LAMP AND LIGHTING METER
MONITOR BUZZER
·WINDSHIELD
WIPER AND
WASHER
CONTROL CIRCUIT

BRAKE FLUID
LEVEL INDICATOR
FUEL SWITCH
TANK
GAUGE
UNIT

ENGINE OIL PARKING

PRESSURE BRAKE
SWITCH SWITCH

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet
90-92 CIRCUIT DIAGRAMS
FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP AND BRAKE WARNING LAMP <RHD>

FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP

AND BRAKE WARNING LAMP <RHD>
M1901018700132

IGNITION
BATTERY SWITCH (IG1)

RELAY
BOX

·FRONT
FOG LAMP
·HEADLAMP
·REAR
FOG LAMP
·REAR WIPER
AND WASHER
·TAIL LAMP,
POSITION LAMP,
·FRONT LICENCE PLATE
FOG LAMP LAMP AND LIGHTING
·HEADLAMP MONITOR BUZZER
·HEADLAMP ·TURN-SIGNAL LAMP
LEVELLING AND HAZARD
SYSTEM WARNING LAMP
·REAR ·WINDSHIELD
FOG LAMP WIPER AND
·TAIL LAMP, WASHER
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER COMBINATION
·WINDSHIELD METER
WIPER AND
WASHER

CONTROL CIRCUIT

BRAKE FLUID
LEVEL INDICATOR
FUEL SWITCH
TANK
GAUGE
UNIT

ENGINE OIL PARKING

PRESSURE BRAKE
SWITCH SWITCH

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet
 CIRCUIT DIAGRAMS
POWER WINDOWS <LHD>
90-93
POWER WINDOWS <LHD>
M1901004601191

FUSIBLE ·FRONT IGNITION FUSIBLE

LINK 1 BATTERY FOG LAMP SWITCH (IG1) LINK 5
·HEADLAMP
·HEADLAMP LEVELLING
SYSTEM
·HEADLAMP WASHER
·REAR FOG LAMP
·TAIL LAMP,
RELAY POSITION LAMP,
LICENCE PLATE LAMP FRONT
BOX AND LIGHTING
MONITOR BUZZER POWER WINDOW
·WINDSHIELD SUB SWITCH
WIPER AND WASHER (RH)

CPU
POWER
WINDOW
RELAY
ETACS-ECU

POWER
SOURCE

HALL IC HALL IC

FRONT
POWER WINDOW
MOTOR
(RH)
DIAGNOSIS
CONNECTOR
DOOR
SWITCH
(FRONT: LH)
FRONT SIDE

Wire colour code

J/B SIDE 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
90-94 CIRCUIT DIAGRAMS
POWER WINDOWS <LHD>

POWER WINDOWS <LHD> (CONTINUED)

FRONT POWER
WINDOW
POWER WINDOW SUB SWITCH POWER WINDOW
RELAY RELAY

POWER (FRONT: RH) (REAR: RH) REAR

WINDOW POWER
MAIN WINDOW
SWITCH LOCK SUB
SWITCH SWITCH
(LH)

CPU CPU

(FRONT: LH) (REAR: LH)

FRONT FRONT
POWER POWER
WINDOW WINDOW
MOTOR MOTOR
(LH) (LH)

HALL IC HALL IC HALL IC HALL IC

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

POWER WINDOWS <LHD> (CONTINUED)

POWER
WINDOW POWER WINDOW
MAIN SWITCH RELAY

REAR
POWER
WINDOW
SUB
SWITCH
(RH)
CPU

REAR
POWER
WINDOW
MOTOR
(RH)

HALL IC HALL IC

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
 CIRCUIT DIAGRAMS
POWER WINDOWS <RHD>
90-95
POWER WINDOWS <RHD>
M1901004601209

FUSIBLE ·FRONT IGNITION FUSIBLE

LINK 1 BATTERY FOG LAMP SWITCH (IG1) LINK 5
·HEADLAMP
·HEADLAMP
LEVELLING
SYSTEM
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
RELAY LICENCE PLATE LAMP
BOX AND LIGHTING
MONITOR BUZZER FRONT POWER WINDOW
·WINDSHIELD SUB SWITCH
WIPER AND WASHER (LH)

CPU
POWER
WINDOW
RELAY
ETACS-ECU

POWER
SOURCE

HALL IC HALL IC

FRONT POWER
WINDOW MOTOR
(LH)

DIAGNOSIS
CONNECTOR
DOOR
SWITCH
(FRONT: RH)
FRONT
SIDE

Wire colour code

J/B SIDE 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
90-96 CIRCUIT DIAGRAMS
POWER WINDOWS <RHD>

POWER WINDOWS <RHD> (CONTINUED)

FRONT POWER
WINDOW
POWER WINDOW SUB SWITCH POWER WINDOW
RELAY RELAY

POWER (FRONT: RH) (REAR: RH) REAR

WINDOW POWER
MAIN LOCK WINDOW
SWITCH SWITCH SUB
SWITCH
(LH)

CPU CPU

(FRONT: LH) (REAR: LH)

FRONT REAR
POWER POWER
WINDOW WINDOW
MOTOR MOTOR
(RH) (LH)

HALL IC HALL IC HALL IC HALL IC

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

POWER WINDOWS <RHD> (CONTINUED)

POWER
WINDOW POWER WINDOW
MAIN SWITCH RELAY

REAR
POWER
WINDOW
SUB
SWITCH
(RH)

CPU

REAR
POWER
WINDOW
MOTOR
(RH)

HALL IC HALL IC

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
 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <LHD WITHOUT KEYLESS ENTRY>
90-97
CENTRAL DOOR LOCKING SYSTEM
<LHD WITHOUT KEYLESS ENTRY>
M1901004701831

FUSIBLE ·FRONT IGNITION

LINK 1 BATTERY FOG LAMP SWITCH (IG1)
·HEADLAMP
·HEADLAMP
LEVELLING
SYSTEM
·HEADLAMP
RELAY WASHER
BOX ·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU
POWER
SOURCE

DOOR LOCK
KEY CYLINDER
SWITCH

FRONT
DOOR LOCK
ACTUATOR FRONT REAR
(LH) DOOR LOCK DOOR LOCK
ACTUATOR ACTUATOR
(RH) (LH)

J/B SIDE

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
90-98 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <LHD WITHOUT KEYLESS ENTRY>

CENTRAL DOOR LOCKING SYSTEM <LHD WITHOUT KEYLESS ENTRY> (CONTINUED)

<SEDAN> <WAGON>
ETACS-ECU

ETACS-ECU ETACS-ECU

(FUSE 15 )

SRS-ECU
CRASH DETECTION
DOOR UNLOCK
SIGNAL PROCESS
DIAGNOSIS CIRCUIT
CONNECTOR

REAR REAR TAILGATE

DOOR LOCK DOOR LOCK LOCK
ACTUATOR ACTUATOR ACTUATOR
(RH) (REAR: RH)

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <RHD WITHOUT KEYLESS ENTRY>
90-99
CENTRAL DOOR LOCKING SYSTEM
<RHD WITHOUT KEYLESS ENTRY>
M1901004701842

FUSIBLE ·FRONT IGNITION

LINK 1 FOG LAMP SWITCH (IG1)
BATTERY
·HEADLAMP
·HEADLAMP
LEVELLING
SYSTEM
·REAR FOG LAMP
RELAY ·TAIL LAMP,
BOX POSITION LAMP,
LICENCE PLATE LAMP NOTE
AND LIGHTING : SEDAN
MONITOR BUZZER : WAGON
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU
POWER
SOURCE

DOOR LOCK
KEY CYLINDER
SWITCH

FRONT
DOOR LOCK
ACTUATOR
(RH) FRONT REAR
DOOR LOCK DOOR LOCK
ACTUATOR (LH) ACTUATOR (LH)

J/B SIDE
90-100 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <RHD WITHOUT KEYLESS ENTRY>

CENTRAL DOOR LOCKING SYSTEM <RHD WITHOUT KEYLESS ENTRY> (CONTINUED)

<SEDAN> <WAGON>
ETACS-ECU

ETACS-ECU ETACS-ECU

(FUSE 15 )

SRS-ECU
CRASH DETECTION
DOOR UNLOCK
SIGNAL PROCESS
DIAGNOSIS CIRCUIT
CONNECTOR

REAR DOOR REAR DOOR TAILGATE

LOCK LOCK LOCK
ACTUATOR ACTUATOR ACTUATOR
(RH) (RH)

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <SEDAN LHD WITH KEYLESS ENTRY>
90-101
CENTRAL DOOR LOCKING SYSTEM
<SEDAN LHD WITH KEYLESS ENTRY>
M1901004701853

FUSIBLE ·FRONT IGNITION

LINK 1 BATTERY FOG LAMP SWITCH (IG1)
·HEADLAMP
·HEADLAMP
LEVELLING
SYSTEM
·HEADLAMP
RELAY WASHER
·REAR FOG LAMP
BOX ·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU
POWER
SOURCE

KEY
REMINDER
SWITCH
(WHEN
REMOVING
KEY: ON)

DIAGNOSIS
CONNECTOR
FRONT
DOOR LOCK
ACTUATOR REAR FRONT REAR
(LH) DOOR LOCK DOOR LOCK DOOR LOCK
ACTUATOR ACTUATOR ACTUATOR
(RH) (RH) (LH)
FRONT SIDE

J/B SIDE
90-102 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <SEDAN LHD WITH KEYLESS ENTRY>

CENTRAL DOOR LOCKING SYSTEM <SEDAN LHD WITH KEYLESS ENTRY> (CONTINUED)

BATTERY

RELAY
BOX

KEYLESS ENTRY
TRANSMITTER

ETACS-
ECU
( TURN-SIGNAL
LAMP RELAY: LH)
(TURN-SIGNAL
LAMP RELAY: RH )
KEYLESS ENTRY
RECEIVER

TURN-SIGNAL
SIDE TURN FRONT REAR REAR FRONT TURN SIDE TURN LAMP AND HAZARD
SIGNAL LAMP TURN COMBINATION COMBINATION SIGNAL LAMP SIGNAL LAMP WARNING LAMP
SRS-ECU
(LH) SIGNAL LAMP (LH) LAMP (RH) (RH) (RH)
LAMP (LH) CRASH
DETECTION DOOR
UNLOCK SIGNAL
PROCESS CIRCUIT

J/B SIDE

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

CENTRAL DOOR LOCKING SYSTEM <SEDAN LHD WITH KEYLESS ENTRY> (CONTINUED)

ETACS-ECU

REAR FRONT
ROOM ROOM
LAMP LAMP

DOOR
LOCK KEY
CYLINDER
SWITCH

NOTE
: VEHICLES WITHOUT CARTAIN AIR BAG
: VEHICLES WITH CARTAIN AIR BAG
DOOR DOOR DOOR DOOR
SWITCH SWITCH SWITCH SWITCH
(FRONT: RH) (REAR: RH) (REAR: LH) (FRONT: LH)

J/B SIDE

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
 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <SEDAN RHD WITH KEYLESS ENTRY>
90-103
CENTRAL DOOR LOCKING SYSTEM
<SEDAN RHD WITH KEYLESS ENTRY>
M1901004701864

FUSIBLE ·FRONT IGNITION

LINK 1 FOG LAMP SWITCH (IG1)
BATTERY
·HEADLAMP
·HEADLAMP
LEVELLING
SYSTEM
·REAR FOG LAMP
RELAY ·TAIL LAMP,
BOX POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU
POWER
SOURCE

KEY
REMINDER
SWITCH
(WHEN
REMOVING
KEY: ON)

DIAGNOSIS
CONNECTOR
FRONT
DOOR LOCK
ACTUATOR
(RH) FRONT REAR DOOR REAR DOOR
DOOR LOCK LOCK LOCK
ACTUATOR ACTUATOR ACTUATOR
(LH) (LH) (RH)

FRONT SIDE

J/B SIDE
90-104 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <SEDAN RHD WITH KEYLESS ENTRY>

CENTRAL DOOR LOCKING SYSTEM <SEDAN RHD WITH KEYLESS ENTRY> (CONTINUED)

BATTERY

RELAY
BOX

KEYLESS ENTRY
TRANSMITTER

ETACS-
ECU

( TURN-SIGNAL
LAMP RELAY: LH )
(TURN-SIGNAL
LAMP RELAY: RH )
KEYLESS ENTRY
RECEIVER

TURN-SIGNAL
SIDE TURN FRONT REAR REAR FRONT TURN SIDE TURN LAMP AND HAZARD
SIGNAL LAMP TURN COMBINATION COMBINATION SIGNAL LAMP SIGNAL LAMP WARNING LAMP
SRS-ECU
(LH) SIGNAL LAMP (LH) LAMP (RH) (RH) (RH)
LAMP (LH) CRASH
DETECTION DOOR
UNLOCK SIGNAL
PROCESS CIRCUIT

J/B SIDE
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

CENTRAL DOOR LOCKING SYSTEM <SEDAN RHD WITH KEYLESS ENTRY> (CONTINUED)

ETACS-ECU

REAR FRONT
ROOM ROOM
LAMP LAMP

DOOR
LOCK KEY
CYLINDER
SWITCH

DOOR DOOR DOOR DOOR

SWITCH SWITCH SWITCH SWITCH
(FRONT: LH) (REAR: LH) (REAR: RH) (FRONT: RH)

J/B SIDE

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
 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <WAGON LHD WITH KEYLESS ENTRY>
90-105
CENTRAL DOOR LOCKING SYSTEM
<WAGON LHD WITH KEYLESS ENTRY>
M1901004701875
·FRONT
FUSIBLE FOG LAMP IGNITION
LINK 1 BATTERY ·HEADLAMP SWITCH (IG1)
·HEADLAMP
LEVELLING
SYSTEM
·HEADLAMP
WASHER
RELAY ·REAR FOG LAMP
BOX ·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU
POWER
SOURCE

DOOR FRONT
LOCK KEY DOOR LOCK
CYLINDER ACTUATOR
SWITCH (LH)

TAILGATE REAR DOOR FRONT DOOR REAR DOOR

LOCK LOCK ACTUATOR LOCK ACTUATOR LOCK ACTUATOR
ACTUATOR (RH) (RH) (LH)
J/B SIDE

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
90-106 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <WAGON LHD WITH KEYLESS ENTRY>

CENTRAL DOOR LOCKING SYSTEM <WAGON LHD WITH KEYLESS ENTRY> (CONTINUED)

ETACS-ECU

KEY REMINDER
SWITCH
(WHEN REMOVING
KEY: ON)
ROOM LAMP
AND LUGGAGE
COMPARTMENT LAMP

TAILGATE
SWITCH

DOOR DOOR DOOR DOOR

SWITCH SWITCH SWITCH SWITCH
(FRONT: RH) (REAR: RH) (REAR: LH) (FRONT: LH)

J/B SIDE

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

CENTRAL DOOR LOCKING SYSTEM <WAGON LHD WITH KEYLESS ENTRY> (CONTINUED)

BATTERY
KEYLESS ENTRY
TRANSMITTER

RELAY
BOX

ETACS-ECU FRONT
ROOM
LAMP
MAP ROOM MAP

KEYLESS ENTRY
( TURN-SIGNAL
LAMP RELAY: LH )
(TURN-SIGNAL
LAMP RELAY: RH )
RECEIVER

REAR
ROOM
LAMP

TURN-SIGNAL
LAMP AND HAZARD
WARNING LAMP
SIDE FRONT REAR REAR FRONT SIDE
TURN TURN COMBI- COMBI- TURN TURN
SIGNAL SIGNAL NATION NATION SIGNAL SIGNAL
LAMP (LH) LAMP (LH) LAMP LAMP LAMP LAMP(RH) <VEHICLES WITH
(TURN: (TURN: (RH) CARTAIN AIR BAG>
LH) RH)

J/B SIDE

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
 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <WAGON LHD WITH KEYLESS ENTRY>
90-107
CENTRAL DOOR LOCKING SYSTEM <WAGON LHD WITH KEYLESS ENTRY> (CONTINUED)

ETACS-ECU

(FUSE 15 )

SRS-ECU

DIAGNOSIS CRASH
CONNECTOR DETECTION
DOOR
UNLOCK
SIGNAL
PROCESS
CIRCUIT

FRONT
SIDE

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
90-108 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <WAGON RHD WITH KEYLESS ENTRY>

CENTRAL DOOR LOCKING SYSTEM

<WAGON RHD WITH KEYLESS ENTRY>
M1901004701886

FUSIBLE ·FRONT IGNITION

LINK 1 BATTERY FOG LAMP SWITCH (IG1)
·HEADLAMP
·HEADLAMP
LEVELLING
SYSTEM
·REAR FOG LAMP
RELAY ·TAIL LAMP,
BOX POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
·WINDSHIELD
WIPER AND WASHER

ETACS-ECU
POWER
SOURCE

DOOR FRONT
LOCK KEY DOOR LOCK
CYLINDER ACTUATOR
SWITCH (RH)

FRONT DOOR REAR DOOR REAR DOOR TAILGATE

LOCK ACTUATOR LOCK ACTUATOR LOCK ACTUATOR LOCK
(LH) (LH) (RH) ACTUATOR

J/B SIDE
 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <WAGON RHD WITH KEYLESS ENTRY>
90-109
CENTRAL DOOR LOCKING SYSTEM <WAGON RHD WITH KEYLESS ENTRY> (CONTINUED)

ETACS-ECU

KEY REMINDER
SWITCH
(WHEN REMOVING
KEY: ON)
ROOM LAMP
AND LUGGAGE
COMPARTMENT
LAMP

TAILGATE
SWITCH

DOOR DOOR DOOR DOOR

SWITCH SWITCH SWITCH SWITCH
(FRONT: LH) (REAR: LH) (REAR: RH) (FRONT: RH)

J/B SIDE

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

CENTRAL DOOR LOCKING SYSTEM <WAGON RHD WITH KEYLESS ENTRY> (CONTINUED)

BATTERY
KEYLESS ENTRY
TRANSMITTER

RELAY
BOX

ETACS-ECU FRONT
ROOM
LAMP
MAP ROOM MAP

KEYLESS ENTRY
( TURN-SIGNAL
LAMP RELAY: LH ) (TURN-SIGNAL
LAMP RELAY: RH ) RECEIVER

REAR
ROOM
LAMP

TURN-SIGNAL
LAMP AND HAZARD
WARNING LAMP
SIDE FRONT REAR REAR FRONT SIDE
TURN TURN COMBI- COMBI- TURN TURN
SIGNAL SIGNAL NATION NATION SIGNAL SIGNAL
LAMP (LH) LAMP (LH) LAMP LAMP LAMP LAMP (RH) <VEHICLES WITH
(TURN: (TURN: (RH) CARTAIN AIR BAG>
LH) RH)

J/B SIDE

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
90-110 CIRCUIT DIAGRAMS
CENTRAL DOOR LOCKING SYSTEM <WAGON RHD WITH KEYLESS ENTRY>

CENTRAL DOOR LOCKING SYSTEM <WAGON RHD WITH KEYLESS ENTRY> (CONTINUED)

ETACS-ECU

(FUSE 15 )

SRS-ECU

DIAGNOSIS CRASH
CONNECTOR DETECTION
DOOR
UNLOCK
SIGNAL
PROCESS
CIRCUIT

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
HEATER <LHD>
90-111
HEATER <LHD>
M1901013300355

FUSIBLE IGNITION FRONT-ECU

LINK 1 SWITCH (IG2) TAIL LAMP
RELAY

RELAY
BOX

TAIL LAMP, POSITION

LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER

BLOWER
RELAY
OUTSIDE/INSIDE
AIR SELECTION TAIL LAMP, POSITION
LAMP, LICENCE
DAMPER CONTROL PLATE LAMP AND
MOTOR LIGHTING MONITOR
BUZZER
NO
CONNECTION

BLOWER
SWITCH

HEATER
CONTROL
UNIT
HEATER CONTROL PANEL

RESISTOR

BLOWER REAR WINDOW

MOTOR DEFOGGER AND
DOOR MIRROR
HEATER

RHEOSTAT

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
90-112 CIRCUIT DIAGRAMS
HEATER <LHD>

HEATER <LHD> (CONTINUED)

HEATER
J/C (2) CONTROL UNIT
BATTERY (FUSE 5 )

RELAY
BOX

NO
CONNECTION
A/C
COMPRESSOR
RELAY

NO
CONNECTION

ENGINE-
ECU

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
 CIRCUIT DIAGRAMS
HEATER <RHD>
90-113
HEATER <RHD>
M1901013300366

FUSIBLE IGNITION FRONT-ECU

LINK 1 SWITCH (IG2) TAIL LAMP
RELAY

RELAY
BOX

TAIL LAMP, POSITION

LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER

BLOWER OUTSIDE/INSIDE
RELAY AIR SELECTION
DAMPER CONTROL
MOTOR
NO
CONNECTION

BLOWER
SWITCH

HEATER
CONTROL
UNIT
HEATER CONTROL PANEL

RESISTOR

BLOWER REAR WINDOW

MOTOR DEFOGGER AND
DOOR MIRROR
HEATER

RHEOSTAT

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
90-114 CIRCUIT DIAGRAMS
HEATER <RHD>

HEATER <RHD> (CONTINUED)

HEATER
CONTROL UNIT
BATTERY (FUSE 5 )

RELAY
BOX

NO
CONNECTION
A/C
COMPRESSOR
RELAY

NO
CONNECTION

ENGINE-
ECU

Wire colour code

B : Black LG : Light green G : Green L : Blue
W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Gray R : Red P : Pink V : Violet
 CIRCUIT DIAGRAMS
MANUAL AIR CONDITIONER <LHD>
90-115
MANUAL AIR CONDITIONER <LHD>
M1901005501410

FUSIBLE IGNITION AIR THERMO FRONT-ECU

LINK 1 SWITCH (IG2) SENSOR TAIL LAMP
RELAY

RELAY
BOX
TAIL LAMP, POSITION
LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER

BLOWER
RELAY
OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL
MOTOR

BLOWER
SWITCH

A/C-ECU

HEATER CONTROL PANEL

RESISTOR

BLOWER REAR WINDOW

MOTOR DEFOGGER AND
DOOR MIRROR
HEATER

RHEOSTAT

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
90-116 CIRCUIT DIAGRAMS
MANUAL AIR CONDITIONER <LHD>

MANUAL AIR CONDITIONER <LHD> (CONTINUED)

ENGINE
FUSIBLE CONTROL
A/C-ECU LINK 2 RELAY
BATTERY (FUSE 5 )

RELAY
BOX

NOTE
: M/T
: A/T
: EXCEPT 4G6
: 4G6

LOW-
PRESSURE DUAL RADIATOR
SIDE PRESSURE FAN RELAY
SWITCH

A/C COMPRESSOR COOLING FAN MOTOR

RELAY HIGH-
DRIVE CONTROL UNIT
PRESSURE
SIDE

SMOOTHING RADIATOR
CIRCUIT FAN MOTOR

INPUT
SIGNAL FIELD EFFECT
PROCESSING TRANSISTOR
CIRCUIT
DRIVE
CIRCUIT CONDENSER
A/C FAN MOTOR
REFRIGERANT
TEMPERATURE
SWITCH
TEMPERATURE CURRENT
DETECTION DETECTION

MAGNETIC
CLUTCH
ENGINE-
ECU
ENGINE-
A/T-ECU

A/C COMPRESSOR

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
 CIRCUIT DIAGRAMS
MANUAL AIR CONDITIONER <RHD>
90-117
MANUAL AIR CONDITIONER <RHD>
M1901005501421

FUSIBLE IGNITION AIR THERMO FRONT-ECU

LINK 1 SWITCH (IG2) SENSOR TAIL LAMP
RELAY

RELAY
BOX
TAIL LAMP, POSITION
LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER

BLOWER OUTSIDE/INSIDE
RELAY AIR SELECTION
DAMPER CONTROL
MOTOR

BLOWER
SWITCH

A/C-ECU

HEATER CONTROL PANEL

RESISTOR

BLOWER REAR WINDOW

MOTOR DEFOGGER AND
DOOR MIRROR
HEATER

RHEOSTAT

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
90-118 CIRCUIT DIAGRAMS
MANUAL AIR CONDITIONER <RHD>

MANUAL AIR CONDITIONER <RHD> (CONTINUED)

ENGINE
FUSIBLE CONTROL
A/C-ECU LINK 2 RELAY
BATTERY (FUSE 5 )

RELAY
BOX

NOTE
: M/T
: A/T
: EXCEPT 4G6
: 4G6

LOW-
PRESSURE DUAL RADIATOR
SIDE PRESSURE FAN RELAY
SWITCH

A/C COMPRESSOR COOLING FAN MOTOR

RELAY HIGH- DRIVE CONTROL UNIT
PRESSURE
SIDE

SMOOTHING RADIATOR
CIRCUIT FAN MOTOR

INPUT
SIGNAL FIELD EFFECT
PROCESSING TRANSISTOR
CIRCUIT
DRIVE
CIRCUIT CONDENSER
A/C
FAN MOTOR
REFRIGERANT
TEMPERATURE
SWITCH
TEMPERATURE CURRENT
DETECTION DETECTION

MAGNETIC
CLUTCH
ENGINE-
ECU
ENGINE-
A/T-ECU

A/C COMPRESSOR

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
 CIRCUIT DIAGRAMS
WINDSHIELD WIPER AND WASHER <LHD>
90-119
WINDSHIELD WIPER AND WASHER <LHD>
M1901006100995

IGNITION SWITCH (ACC) BATTERY IGNITION SWITCH (IG2) IGNITION SWITCH (IG1)

RELAY
BOX

FRONT-ECU

WIPER SPEED WIPER

WINDSHIELD AUTOMATIC
WASHER SWITCHING POWER ETACS-
RELAY STOP RELAY
SOURCE ECU

(FUSE 7 )

WINDSHIELD
WIPER MOTOR COLUMN
COLUMN-ECU SWITCH
WINDSHIELD
WASHER MOTOR CIRCUIT
BREAKER

WINDSHIELD WINDSHIELD
WASHER SWITCH INTERMITTENT
WIPER INTERVAL
(WINDSHIELD WIPER SWITCH) ADJUSTING KNOB

UPPER UPPER
SIDE SIDE
90-120 CIRCUIT DIAGRAMS
WINDSHIELD WIPER AND WASHER <LHD>

WINDSHIELD WIPER AND WASHER <LHD> (CONTINUED)

COLUMN J/C (1) FUSIBLE
SWITCH ( FUSE 22 ) LINK 1 <M/T> <A/T>

(FUSE 2 ) (FUSE 3 )

ENGINE-
FUSE 2 A/T-ECU

ETACS-ECU

INVECS-II 4A/T
POWER ENGINE
SOURCE CONTROL
SYSTEM

A/T
CONTROL
RELAY

VEHICLE OUTPUT
SPEED SHAFT
SENSOR SPEED
SENSOR

INVECS-II 4A/T

DIAGNOSIS
CONNECTOR

NOTE
: 4G1
: 4G6

FRONT
SIDE

J/B SIDE
 CIRCUIT DIAGRAMS
WINDSHIELD WIPER AND WASHER <RHD>
90-121
WINDSHIELD WIPER AND WASHER <RHD>
M1901006101006

BATTERY IGNITION SWITCH (IG2) IGNITION SWITCH (IG1)

IGNITION SWITCH (ACC)

RELAY
NOTE
: ·ABS BOX
·BRAKE WARNING LAMP
·CHARGING SYSTEM
·ENGINE CONTROL SYSTEM
·FUEL WARNING LAMP
·INVECS-II 4A/T
·METER AND GAUGE
·OIL PRESSURE WARNING LAMP

FRONT-ECU

WIPER SPEED WIPER

WINDSHIELD AUTOMATIC
WASHER SWITCHING
STOP RELAY POWER ETACS-
RELAY SOURCE ECU

ETACS-
(FUSE 7 ) ECU

WINDSHIELD
WIPER MOTOR COLUMN
COLUMN-ECU SWITCH
WINDSHIELD
WASHER MOTOR CIRCUIT
BREAKER

WINDSHIELD WINDSHIELD
WASHER SWITCH INTERMITTENT
WIPER INTERVAL
(WINDSHIELD WIPER SWITCH) ADJUSTING KNOB

Wire colour code

B : Black LG : Light green G : Green L : Blue
UPPER UPPER
SIDE SIDE W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Gray R : Red P : Pink V : Violet
90-122 CIRCUIT DIAGRAMS
WINDSHIELD WIPER AND WASHER <RHD>

WINDSHIELD WIPER AND WASHER <RHD> (CONTINUED)

COLUMN J/C (1) FUSIBLE
COMBINATION SWITCH ( FUSE 22 ) LINK 1 <M/T> <A/T>
METER
COMBINATION COMBINATION
METER (FUSE 2 ) (FUSE 3 ) METER

ENGINE-
A/T-ECU
FUSE 2

ETACS-ECU

INVECS-II 4A/T

ENGINE
POWER CONTROL
SOURCE SYSTEM

A/T
CONTROL
RELAY

VEHICLE OUTPUT
SPEED SHAFT
SENSOR SPEED
SENSOR

INVECS-II 4A/T

DIAGNOSIS
CONNECTOR

FRONT
SIDE

J/B SIDE
 CIRCUIT DIAGRAMS
REAR WIPER AND WASHER <LHD>
90-123
REAR WIPER AND WASHER <LHD>
M1901006200895

IGNITION IGNITION FUSIBLE

BATTERY SWITCH (IG1) SWITCH (ACC) LINK 1

RELAY
BOX

·FRONT
FOG LAMP
·HEADLAMP
·HEADLAMP ETACS-ECU
LEVELLING
SYSTEM REAR WASHER
·HEADLAMP RELAY REAR WIPER
WASHER RELAY
·REAR
FOG LAMP POWER
·TAIL LAMP, SOURCE
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
·WINDSHIELD
WIPER AND
WASHER

COLUMN
SWITCH

REAR
WASHER DIAGNOSIS
REAR
MOTOR CONNECTOR
REAR
WIPER WASHER
SWITCH SWITCH
REAR
WIPER
MOTOR
FRONT
SIDE

UPPER UPPER
SIDE SIDE

J/B SIDE
90-124 CIRCUIT DIAGRAMS
REAR WIPER AND WASHER <LHD>

REAR WIPER AND WASHER <LHD> (CONTINUED)

(FUSE 3 )

A/T M/T

INHIBITOR BACK-UP
SWITCH LAMP
SWITCH

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
 CIRCUIT DIAGRAMS
REAR WIPER AND WASHER <RHD>
90-125
REAR WIPER AND WASHER <RHD>
M1901006200903

IGNITION IGNITION FUSIBLE

BATTERY SWITCH (IG1) SWITCH (ACC) LINK 1

RELAY
BOX

·FRONT
FOG LAMP
·HEADLAMP ETACS-ECU
·HEADLAMP
LEVELLING REAR WASHER
SYSTEM
RELAY REAR WIPER
·REAR
FOG LAMP RELAY
·TAIL LAMP,
POSITION LAMP, POWER
LICENCE PLATE SOURCE
LAMP AND LIGHTING
MONITOR BUZZER
·WINDSHIELD
WIPER AND
WASHER

COLUMN
SWITCH

NOTE REAR
·ABS
·BRAKE WARNING LAMP WASHER DIAGNOSIS
·CHARGING SYSTEM MOTOR CONNECTOR
·ENGINE CONTROL SYSTEM
REAR REAR
·FUEL WARNING LAMP WASHER
WIPER
·INVECS-II 4A/T SWITCH SWITCH REAR
·METER AND GAUGE WIPER
·OIL PRESSURE WARNING LAMP MOTOR
FRONT
SIDE

UPPER UPPER
SIDE SIDE

J/B SIDE
90-126 CIRCUIT DIAGRAMS
REAR WIPER AND WASHER <RHD>

REAR WIPER AND WASHER <RHD> (CONTINUED)

(FUSE 3 )

A/T M/T

INHIBITOR BACK-UP
SWITCH LAMP
SWITCH

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
 CIRCUIT DIAGRAMS
REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER <LHD>
90-127
REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER
<LHD>
M1901013500672
FRONT-ECU
IGNITION FUSIBLE
( TAIL LAMP
RELAY ) SWITCH (IG2) LINK 1

(FUSE 6 )
RELAY
BOX

TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER

REAR
WINDOW
DEFOGGER
RELAY

REMOTE REMOTE
CONTROLLED CONTROLLED
MIRROR MIRROR MIRROR MIRROR
(RH) HEATER HEATER (LH)

A/C-ECU
OR
HEATER
CONTROL
UNIT

REAR WINDOW REAR WINDOW

DEFOGGER DEFOGGER
NOTE
: SEDAN
: WAGON

RHEOSTAT

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
90-128 CIRCUIT DIAGRAMS
REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER <RHD>

REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER

<RHD>
M1901013500683
FRONT-ECU
FUSIBLE
( TAIL LAMP
RELAY ) IGNITION
SWITCH (IG2) LINK 1

(FUSE 6 )
RELAY
BOX

TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER

REAR
WINDOW
DEFOGGER
RELAY

REMOTE REMOTE
CONTROLLED CONTROLLED
MIRROR MIRROR
MIRROR MIRROR (RH)
(LH) HEATER HEATER

A/C-ECU
OR
HEATER
CONTROL
UNIT

REAR
WINDOW
DEFOGGER

NOTE
: SEDAN
: WAGON
RHEOSTAT

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
 CIRCUIT DIAGRAMS
REMOTE CONTROLLED MIRROR <LHD>
90-129
REMOTE CONTROLLED MIRROR <LHD>
M1901018800054
IGNITION
SWITCH (ACC)

NOTE
: VEHICLES WITHOUT MIRROR HEATER
: VEHICLES WITH MIRROR HEATER

REMOTE
CONTROLLED
MIRROR
SWITCH

REMOTE REMOTE
CONTROLLED CONTROLLED
MIRROR (LH) MIRROR (RH)
90-130 CIRCUIT DIAGRAMS
REMOTE CONTROLLED MIRROR <RHD>

REMOTE CONTROLLED MIRROR <RHD>

M1901018800065
IGNITION
SWITCH (ACC)

NOTE
: VEHICLES WITHOUT MIRROR HEATER
: VEHICLES WITH MIRROR HEATER

REMOTE
CONTROLLED
MIRROR
SWITCH

REMOTE REMOTE
CONTROLLED CONTROLLED
MIRROR (LH) MIRROR (RH)
 CIRCUIT DIAGRAMS
HEADLAMP WASHER
90-131
HEADLAMP WASHER
M1901018900062

FUSIBLE IGNITION IGNITION FUSIBLE

LINK 5 BATTERY SWITCH (IG2) SWITCH (IG1) (FUSE 22 ) LINK 1

RELAY
BOX

ETACS-
FRONT- ECU
ECU
HEADLAMP
WASHER POWER
POWER SOURCE
SOURCE

HEADLAMP
WASHER
MOTOR

COLUMN-ECU
DIAGNOSIS
HEADLAMP CONNECTOR
WASHER
SWITCH

COLUMN SWITCH

FRONT SIDE

J/B SIDE 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
90-132 CIRCUIT DIAGRAMS
SPARE CONNECTOR (FOR AUDIO) <LHD>

SPARE CONNECTOR (FOR AUDIO) <LHD>

M1901019000147

FRONT-ECU
IGNITION TAIL LAMP
SWITCH (ACC) BATTERY RELAY

ROOF ANTENNA
NOTE
: SEDAN
RELAY : WAGON
BOX : ·FRONT
FOG LAMP
·HEADLAMP
ANTENNA ·HEADLAMP
LEVELLING
AMPLIFIER SYSTEM
·HEADLAMP
WASHER
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
TAIL LAMP, LICENCE PLATE

ANTENNA
POSITION LAMP, LAMP AND LIGHTING

FEEDER
LICENCE PLATE MONITOR BUZZER

CABLE
LAMP AND LIGHTING ·WINDSHIELD
MONITOR BUZZER WIPER AND
WASHER

SPARE CONNECTOR
(FOR AUDIO)

(LH) (RH) (LH) (RH)

RHEOSTAT REAR SPEAKER
FRONT DOOR SPEAKER

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
 CIRCUIT DIAGRAMS
SPARE CONNECTOR (FOR AUDIO) <RHD>
90-133
SPARE CONNECTOR (FOR AUDIO) <RHD>
M1901019000158

FRONT-ECU
IGNITION TAIL LAMP
SWITCH (ACC) BATTERY RELAY

ROOF ANTENNA
NOTE
: SEDAN
: WAGON
RELAY
BOX : ·FRONT
FOG LAMP
·HEADLAMP
ANTENNA ·HEADLAMP
AMPLIFIER LEVELLING
SYSTEM
·HEADLAMP
WASHER
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
TAIL LAMP,

ANTENNA
LICENCE PLATE
POSITION LAMP,

FEEDER
LAMP AND LIGHTING
LICENCE PLATE

CABLE
MONITOR BUZZER
LAMP AND LIGHTING ·WINDSHIELD
MONITOR BUZZER WIPER AND
WASHER

SPARE CONNECTOR
(FOR AUDIO)

(LH) (RH) (LH) (RH)

RHEOSTAT REAR SPEAKER
FRONT DOOR SPEAKER

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
90-134 CIRCUIT DIAGRAMS
CLOCK

CLOCK
M1901007700600
IGNITION
SWITCH (ACC) BATTERY

RELAY
BOX

·FRONT FOG LAMP

·HEADLAMP
·HEADLAMP LEVELLING SYSTEM
·HEADLAMP WASHER
·REAR FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE LAMP
AND LIGHTING
MONITOR BUZZER
·WINDSHIELD WIPER
AND WASHER

HEADLAMP

CLOCK

NOTE
: LHD
: RHD

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
 CIRCUIT DIAGRAMS
CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LAMP
90-135
CIGARETTE LIGHTER AND
ASHTRAY ILLUMINATION LAMP
M1901007800715

FRONT-ECU
IGNITION TAIL LAMP
SWITCH (ACC) RELAY

RELAY
BOX

TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING <LHD>
MONITOR BUZZER

TAIL LAMP,
CIGARETTE POSITION LAMP,
LIGHTER LICENCE PLATE <RHD>
LAMP AND LIGHTING
MONITOR BUZZER

·METER AND GAUGE

ASHTRAY CIGARETTE LIGHTER

ILLUMINATION ILLUMINATION
LAMP LAMP

NOTE
: LHD RHEOSTAT
: RHD
90-136 CIRCUIT DIAGRAMS
ACCESSORY SOCKET

ACCESSORY SOCKET
M1901019100111
IGNITION
BATTERY SWITCH (ACC)

RELAY
BOX

ACCESSORY
SOCKET
RELAY

ACCESSORY
SOCKET

NOTE
: LHD
: RHD
 CIRCUIT DIAGRAMS
IMMOBILIZER SYSTEM <LHD>
90-137
IMMOBILIZER SYSTEM <LHD>
M1901013601285

FUSIBLE
LINK 1 BATTERY
NOTE
: M/T
: A/T

RELAY
BOX

ENGINE
CONTROL
SYSTEM

ENGINE IGNITION KEY

CONTROL IGNITION
RELAY KEY RING
ANTENNA

ENGINE CONTROL
SYSTEM

ENGINE-ECU
ENGINE-
A/T-ECU

IMMOBILIZER-
ECU
POWER HIGH-FREQUENCY
SOURCE CIRCUIT

DIAGNOSIS
CONNECTOR

FRONT
SIDE

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
90-138 CIRCUIT DIAGRAMS
IMMOBILIZER SYSTEM <RHD>

IMMOBILIZER SYSTEM <RHD>

M1901013601296

FUSIBLE
LINK 1 BATTERY

NOTE
: M/T
: A/T
RELAY
BOX

·ENGINE
CONTROL
SYSTEM
·IGNITION
SYSTEM IGNITION KEY
ENGINE
CONTROL IGNITION
RELAY KEY RING
ANTENNA

ENGINE CONTROL
SYSTEM

ENGINE-ECU
ENGINE-
A/T-ECU
IMMOBILIZER-
ECU
POWER HIGH-FREQUENCY
SOURCE CIRCUIT

DIAGNOSIS
CONNECTOR

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
ABS <LHD>
90-139
ABS <LHD>
M1901019200088

FUSIBLE IGNITION IGNITION

LINK 3 SWITCH (IG2) SWITCH (IG1) BATTERY

RELAY
BOX

STOP
LAMP
SWITCH
HYDRAULIC UNIT

COMBINATION STOP LAMP

METER MOTOR SOLENOID VALVE

ABS-ECU
SOLENOID MOTOR POWER MOTOR
VALVE POWER POWER SOURCE POWER
SOURCE SOURCE SOURCE

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
90-140 CIRCUIT DIAGRAMS
ABS <LHD>

ABS <LHD> (CONTINUED)

WHEEL SPEED SENSOR FUSIBLE

LINK 1 ABS-ECU
(FRONT: LH) (FRONT: RH) (REAR: LH) (REAR: RH)

DIAGNOSIS
CONNECTOR

NOTE
ABS-ECU : SEDAN
: WAGON

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
ABS <RHD>
90-141
ABS <RHD>
M1901019200099

FUSIBLE IGNITION IGNITION

LINK 3 SWITCH (IG2) SWITCH (IG1) BATTERY

RELAY
BOX
NOTE
: TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER

STOP
LAMP
SWITCH
HYDRAULIC UNIT

COMBINATION STOP LAMP

METER MOTOR SOLENOID VALVE

ABS-ECU
SOLENOID MOTOR POWER MOTOR
VALVE POWER POWER SOURCE POWER
SOURCE SOURCE SOURCE

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
90-142 CIRCUIT DIAGRAMS
ABS <RHD>

ABS <RHD> (CONTINUED)

WHEEL SPEED SENSOR FUSIBLE

LINK 1 ABS-ECU
(FRONT: LH) (FRONT: RH) (REAR: LH) (REAR: RH)

DIAGNOSIS
CONNECTOR

ABS-ECU

FRONT
SIDE

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
 CIRCUIT DIAGRAMS
HEATED SEAT
90-143
HEATED SEAT
M1901010700406
FRONT-ECU
IGNITION TAIL LAMP HEATED SEAT
BATTERY SWITCH (IG2) RELAY SWITCH

RELAY
RELAY BOX
BOX HEATED SEAT HEATED SEAT
ASSEMBLY (LH) ASSEMBLY (RH)

SEAT SEAT
CUSHION CUSHION
HEATER HEATER
THERMOSTAT
HEATER THERMOSTAT HEATER

HEATED
SEAT THERMOSTAT
THERMOSTAT
RELAY

SEAT SEAT
BACK BACK
HEATER HEATER

HEATED
SEAT
SWITCH

HEATED HEATED
SEAT SEAT
RELAY SWITCH

NOTE
: TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER

RHEOSTAT

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
90-144 CIRCUIT DIAGRAMS
RHEOSTAT <LHD>

RHEOSTAT <LHD>
M1901011100850

FRONT-ECU
( TAILL
RELAY
LAMP
)

RELAY
BOX
·HEATER
·MANUAL AIR
CONDITIONER
·REAR WINDOW
·INVECS-II 4A/T SPARE DEFOGGER AND
·METER CONNECTOR DOOR MIRROR
HEATED SEAT AND GAUGE (FOR AUDIO) HEATER
·FRONT CIGARETTE
FOG LAMP HEADLAMP LIGHTER AND TURN-SIGNAL
·REAR LEVELLING ASHTRAY LAMP AND HAZARD
FOG LAMP SYSTEM ILLUMINATION LAMP WARNING LAMP
TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER

RHEOSTAT

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
 CIRCUIT DIAGRAMS
RHEOSTAT <RHD>
90-145
RHEOSTAT <RHD>
M1901011100861

FRONT-ECU
( TAILL
RELAY
LAMP
)

RELAY
BOX
·HEATER
·MANUAL AIR
CONDITIONER
·REAR WINDOW
TURN-SIGNAL LAMP DEFOGGER AND HEADLAMP
AND HAZARD DOOR MIRROR LEVELLING
WARNING LAMP HEATER SYSTEM
TAIL LAMP,
POSITION LAMP, ·FRONT CIGARETTE
LICENCE PLATE ·INVECS-II 4A/T FOG LAMP LIGHTER AND SPARE
LAMP AND ·METER ·REAR ASHTRAY CONNECTOR
LIGHTING MONITOR AND GAUGE FOG LAMP ILLUMINATION LAMP (FOR AUDIO)
BUZZER

RHEOSTAT

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
90-146 CIRCUIT DIAGRAMS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <LHD>

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <LHD>

M1901009701278

IGNITION
SWITCH (IG1)

NOTE
: CONNECTOR COUPLED: ON
CONNECTOR UNCOUPLED: OFF
: SEDAN
: WAGON

CONNECTOR
LOCK SWITCH

SRS-ECU

MICRO COMPUTER

SEAT BELT SEAT BELT

PRE-TENSIONER PRE-TENSIONER
DRIVE CIRCUIT DRIVE CIRCUIT

COMBINATION
METER
CONNECTOR CONNECTOR
LOCK SWITCH LOCK SWITCH

SRS-ECU

POWER SOURCE
WARNING LAMP
D.C.-D.C. CONVERTER DRIVE CIRCUIT

BACK-UP CAPACITOR

MICRO COMPUTER
CONNECTOR CONNECTOR
FRONT LOCK SWITCH LOCK SWITCH
AIR BAG FRONT AIR SIDE AIR BAG,
EEP ROM BAG SAFING CARTAIN AIR BAG
ANALOGUE
G SENSOR G SENSOR SAFING G SENSOR
SEAT BELT SEAT BELT
PRE-TENSIONER (RH) PRE-TENSIONER (LH)

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
 CIRCUIT DIAGRAMS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <LHD>
90-147
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <LHD> (CONTINUED)
<VEHICLES WITH SIDE AIR BAG AND CURTAIN AIR BAG> SIDE IMPACT SIDE IMPACT
ANALOGUE SENSOR ANALOGUE SENSOR
CONNECTOR SIDE AIR BAG CONNECTOR SIDE AIR BAG G SENSOR (REAR: LH) G SENSOR (REAR: RH)
LOCK MODULE (LH) LOCK MODULE (RH)
SWITCH (SQUIB) SWITCH (SQUIB)

CONSTANT CONSTANT
VOLTAGE VOLTAGE
CIRCUIT CIRCUIT

CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH

SRS-ECU

AIR BAG AIR BAG

DRIVE CIRCUIT DRIVE CIRCUIT SIDE IMPACT SENSOR INTERFACE CIRCUIT
MICRO
COMPUTER
AIR BAG AIR BAG SIDE IMPACT SENSOR INTERFACE CIRCUIT
DRIVE CIRCUIT DRIVE CIRCUIT

CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH

CLOCK
CONNECTOR SPRING
LOCK SIDE IMPACT SIDE IMPACT
SWITCH SENSOR SENSOR
CONSTANT (FRONT: LH) CONSTANT (FRONT: RH)
NOTE VOLTAGE VOLTAGE
: CONNECTOR CIRCUIT CIRCUIT
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF

ANALOGUE ANALOGUE
CONNECTOR CONNECTOR G SENSOR G SENSOR
LOCK LOCK
SWITCH SWITCH

AIR BAG MODULE (SQUIB) AIR BAG MODULE (SQUIB)

(DRIVER'S SIDE) (PASSENGER'S SIDE)

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

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <LHD> (CONTINUED)

FUSIBLE
LINK 1
<VEHICLES WITH SIDE AIR BAG AND CURTAIN AIR BAG>

NOTE
: CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF

SRS-ECU

MICRO COMPUTER

AIR BAG AIR BAG MUT INTERFACE

DRIVE CIRCUIT DRIVE CIRCUIT CIRCUIT

CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH

DIAGNOSIS
CONNECTOR
CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH

CURTAIN AIR BAG MODULE (LH) CURTAIN AIR BAG MODULE (RH)
(SQUIB) (SQUIB)

FRONT
SIDE

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
90-148 CIRCUIT DIAGRAMS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <RHD>

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <RHD>

M1901009701289

IGNITION
SWITCH (IG1)

NOTE
: CONNECTOR COUPLED: ON
CONNECTOR UNCOUPLED: OFF
: SEDAN
: WAGON

CONNECTOR
LOCK SWITCH

·FRONT FOG LAMP SRS-ECU

·HEADLAMP
·HEADLAMP LEVELLING SYSTEM
·HEADLAMP WASHER
·REAR FOG LAMP MICRO COMPUTER
·REAR WIPER AND
WASHER
·TAIL LAMP, COMBINATION SEAT BELT SEAT BELT
POSITION LAMP, METER PRE-TENSIONER PRE-TENSIONER
LICENCE PLATE LAMP
AND LIGHTING DRIVE CIRCUIT DRIVE CIRCUIT
MONITOR BUZZER
·TURN-SIGNAL LAMP AND
HAZARD WARNING LAMP
·WINDSHIELD WIPER
AND WASHER
CONNECTOR CONNECTOR
LOCK SWITCH LOCK SWITCH

SRS-ECU

POWER SOURCE
WARNING LAMP
D.C.-D.C. CONVERTER DRIVE CIRCUIT

BACK-UP CAPACITOR

MICRO COMPUTER
CONNECTOR CONNECTOR
FRONT LOCK SWITCH LOCK SWITCH
AIR BAG FRONT AIR SIDE AIR BAG,
EEP ROM BAG SAFING CARTAIN AIR BAG
ANALOGUE
G SENSOR G SENSOR SAFING G SENSOR
SEAT BELT SEAT BELT
PRE-TENSIONER (LH) PRE-TENSIONER (RH)

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
 CIRCUIT DIAGRAMS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <RHD>
90-149
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <RHD> (CONTINUED)
<VEHICLES WITH SIDE AIR BAG AND CURTAIN AIR BAG> SIDE IMPACT SIDE IMPACT
ANALOGUE SENSOR ANALOGUE SENSOR
CONNECTOR SIDE AIR BAG CONNECTOR SIDE AIR BAG G SENSOR (REAR: LH) G SENSOR (REAR: RH)
LOCK MODULE (LH) LOCK MODULE (RH)
SWITCH (SQUIB) SWITCH (SQUIB)

CONSTANT CONSTANT
VOLTAGE VOLTAGE
CIRCUIT CIRCUIT

CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH

SRS-ECU

AIR BAG AIR BAG

DRIVE CIRCUIT DRIVE CIRCUIT SIDE IMPACT SENSOR INTERFACE CIRCUIT
MICRO
COMPUTER
AIR BAG AIR BAG SIDE IMPACT SENSOR INTERFACE CIRCUIT
DRIVE CIRCUIT DRIVE CIRCUIT

CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH

CLOCK
CONNECTOR SPRING
LOCK SIDE IMPACT SIDE IMPACT
SWITCH SENSOR SENSOR
CONSTANT (FRONT: LH) CONSTANT (FRONT: RH)
NOTE VOLTAGE VOLTAGE
: CONNECTOR CIRCUIT CIRCUIT
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF

ANALOGUE ANALOGUE
CONNECTOR CONNECTOR G SENSOR G SENSOR
LOCK LOCK
SWITCH SWITCH

AIR BAG MODULE (SQUIB) AIR BAG MODULE (SQUIB)

(DRIVER'S SIDE) (PASSENGER'S SIDE)

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

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <RHD> (CONTINUED)

FUSIBLE
LINK 1
<VEHICLES WITH SIDE AIR BAG AND CURTAIN AIR BAG>

NOTE
: CONNECTOR
COUPLED: ON
CONNECTOR
UNCOUPLED: OFF

SRS-ECU

MICRO COMPUTER

AIR BAG AIR BAG MUT INTERFACE

DRIVE CIRCUIT DRIVE CIRCUIT CIRCUIT

CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH

DIAGNOSIS
CONNECTOR
CONNECTOR CONNECTOR
LOCK LOCK
SWITCH SWITCH

CURTAIN AIR BAG MODULE (LH) CURTAIN AIR BAG MODULE (RH)
(SQUIB) (SQUIB)

FRONT
SIDE

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
90-150 CIRCUIT DIAGRAMS
SPARE CONNECTOR (FOR FRONT FOG LAMP)

SPARE CONNECTOR (FOR FRONT FOG LAMP)

M1901019300074

BATTERY

ETACS-
ECU

RELAY
BOX

SPARE
CONNECTOR
FOR FRONT FOG
LAMP RELAY

FRONT
FOG LAMP

SPARE
CONNECTOR
FOR FRONT FOG
LAMP SWITCH

COMBINATION
SPARE METER
CONNECTOR
FOR FRONT
FOG LAMP

FRONT-ECU

NOTE
: LHD
: RHD