2006-2013 Mitsubishi Triton L200 Workshop Manual – PDF DOWNLOAD
SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components.
For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission.
ON-VEHICLE SERVICE “On-vehicle Service” is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed.
INSPECTION Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well. DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance.
LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time).
DANGER, WARNING, AND CAUTION DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows: •If a DANGER is not followed, the result is severe bodily harm or even death. •
If a WARNING is not followed, the result could be bodily injury. •If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment. INDICATION OF TIGHTENING TORQUE Tightening torques (units: N⋅m) are set to take into account the central value and the allowable tolerance.
The central value is the target value, and the allowable tolerance provides the checking range for tightening torques. If bolts and nuts are not provided with tightening torques, refer to P.00-37. MODEL INDICATIONS The following abbreviations are used in this manual for identification of model types. 2500: Indicates an engine with the 2,477mL <4D56> diesel engine.
3200: Indicates an engine with the 3,200mL <4M41> diesel engine. DOHC: Indicates an engine with the double overhead camshaft. M/T: Indicates the manual transmission. A/T: Indicates the automatic transmission. A/C: Indicates the air conditioner.
TABLE OF CONTENTS:
2006-2013 Mitsubishi Triton L200 Workshop Manual – PDF DOWNLOAD
00.pdf................................................................................................................................................................................................................................. 1
GENERAL............................................................................................................................................................................................................................ 1
01.pdf................................................................................................................................................................................................................................. 3
GENERAL............................................................................................................................................................................................................................ 3
HOW TO USE THIS MANUAL......................................................................................................................................................................................................... 4
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS.................................................................................................................................................................... 4
DEFINITION OF TERMS........................................................................................................................................................................................................ 4
INDICATION OF TIGHTENING TORQUE............................................................................................................................................................................................ 4
MODEL INDICATIONS.......................................................................................................................................................................................................... 4
EXPLANATION OF MANUAL CONTENTS............................................................................................................................................................................................. 5
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS........................................................................................................................................................................... 7
CONTENTS OF TROUBLESHOOTING................................................................................................................................................................................................ 7
Diagnosis method....................................................................................................................................................................................................... 8
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS..................................................................................................................................................................... 8
3. DIAGNOSIS FUNCTION.................................................................................................................................................................................................. 8
4. DIAGNOSIS CODE CHART................................................................................................................................................................................................ 8
5. DIAGNOSIS CODE PROCEDURES........................................................................................................................................................................................... 8
6. TROUBLE SYMPTOM CHART............................................................................................................................................................................................... 8
7. SYMPTOM PROCEDURES.................................................................................................................................................................................................. 9
8. SERVICE DATA REFERENCE TABLE........................................................................................................................................................................................ 9
9. ACTUATOR TEST TABLE................................................................................................................................................................................................. 9
10. CHECK AT ECU TERMINALS............................................................................................................................................................................................. 9
11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE...................................................................................................................................................................... 9
DIAGNOSIS FUNCTION......................................................................................................................................................................................................... 9
HOW TO READ DIAGNOSIS CODE............................................................................................................................................................................................. 9
ERASING DIAGNOSIS CODE................................................................................................................................................................................................. 9
HOW TO USE THE INSPECTION PROCEDURES....................................................................................................................................................................................... 10
CURRENT TROUBLE........................................................................................................................................................................................................ 11
PAST TROUBLE........................................................................................................................................................................................................... 11
HARNESS CHECK.......................................................................................................................................................................................................... 11
MEASURES TO TAKE AFTER REPLACING THE ECU............................................................................................................................................................................... 11
CONNECTOR MEASUREMENT SERVICE POINTS....................................................................................................................................................................................... 12
CONNECTOR INSPECTION SERVICE POINTS........................................................................................................................................................................................ 13
INSPECTION SERVICE POINTS FOR A BLOWN FUSE................................................................................................................................................................................. 14
HOW TO COPE WITH INTERMITTENT MALFUNCTIONS................................................................................................................................................................................. 14
HOW TO TREAT PAST TROUBLE.................................................................................................................................................................................................. 15
VEHICLE IDENTIFICATION......................................................................................................................................................................................................... 15
VEHICLE NAME PLATE......................................................................................................................................................................................................... 15
MODEL CODE................................................................................................................................................................................................................. 17
CHASSIS NUMBER............................................................................................................................................................................................................. 18
ENGINE MODEL STAMPING...................................................................................................................................................................................................... 19
GENERAL DATA AND SPECIFICATIONS................................................................................................................................................................................................ 19
CLUB CAB................................................................................................................................................................................................................... 19
<2WD>...................................................................................................................................................................................................................... 19
<4WD>...................................................................................................................................................................................................................... 21
DOUBLE CAB................................................................................................................................................................................................................. 22
<2WD>...................................................................................................................................................................................................................... 22
<4WD>...................................................................................................................................................................................................................... 24
PRECAUTIONS BEFORE SERVICE..................................................................................................................................................................................................... 25
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER....................................................................................................................................................... 25
WHAT THE COMMON RAIL ENGINE LEARNS......................................................................................................................................................................................... 26
REGISTRATION AND LEARNING PROCEDURE.................................................................................................................................................................................... 26
INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE........................................................................................................................................................................ 26
PURPOSE................................................................................................................................................................................................................ 26
REGISTRATION PROCEDURE................................................................................................................................................................................................. 27
SMALL INJECTION QUANTITY LEARNING PROCEDURE................................................................................................................................................................................ 27
PURPOSE................................................................................................................................................................................................................ 27
LEARNING PROCEDURE..................................................................................................................................................................................................... 28
SUPPLY PUMP CORRECTION LEARNING PROCEDURE.................................................................................................................................................................................. 28
PURPOSE................................................................................................................................................................................................................ 28
LEARNING PROCEDURE FOR IDLING.............................................................................................................................................................................................. 29
SERVICING ELECTRICAL SYSTEM................................................................................................................................................................................................ 29
VEHICLES WITH SEMI AUTOMATIC AIR CONDITIONER............................................................................................................................................................................... 29
APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS........................................................................................................................................................................ 29
VEHICLE WASHING............................................................................................................................................................................................................ 29
PRE-INSPECTION CONDITION................................................................................................................................................................................................... 29
MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY................................................................................................................................................................................. 30
HOW TO USE THE THROTTLE CONTROLLER......................................................................................................................................................................................... 30
IN ORDER TO PREVENT VEHICLES FROM FIRE..................................................................................................................................................................................... 31
ENGINE OILS................................................................................................................................................................................................................ 31
HEALTH WARNING......................................................................................................................................................................................................... 31
RECOMMENDED PRECAUTIONS................................................................................................................................................................................................ 31
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)............................................................................................................................................................................................ 32
SRS SERVICE PRECAUTIONS........................................................................................................................................................................................................ 33
SUPPORT LOCATIONS FOR LIFTING AND JACKING...................................................................................................................................................................................... 35
<2WD>...................................................................................................................................................................................................................... 35
<4WD>...................................................................................................................................................................................................................... 36
<2WD>...................................................................................................................................................................................................................... 37
<4WD>...................................................................................................................................................................................................................... 38
STANDARD PART/TIGHTENING-TORQUE TABLE.......................................................................................................................................................................................... 39
11.pdf................................................................................................................................................................................................................................. 41
ENGINE............................................................................................................................................................................................................................. 41
11A.pdf................................................................................................................................................................................................................................ 43
ENGINE MECHANICAL <4D5-SOHC>....................................................................................................................................................................................................... 43
GENERAL INFORMATION............................................................................................................................................................................................................ 44
SERVICE SPECIFICATIONS......................................................................................................................................................................................................... 44
SEALANTS....................................................................................................................................................................................................................... 45
SPECIAL TOOLS.................................................................................................................................................................................................................. 46
ON-VEHICLE SERVICE............................................................................................................................................................................................................. 48
DRIVE BELT TENSION CHECK AND ADJUSTMENT.................................................................................................................................................................................... 48
ALTERNATOR DRIVE BELT TENSION CHECK AND ADJUSTMENT..................................................................................................................................................................... 48
POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK....................................................................................................................................................................... 49
A/C COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT................................................................................................................................................................. 50
VALVE CLEARANCE CHECK AND ADJUSTMENT....................................................................................................................................................................................... 50
INJECTION TIMING CHECK AND ADJUSTMENT...................................................................................................................................................................................... 52
IDLE SPEED CHECK........................................................................................................................................................................................................... 54
COMPRESSION PRESSURE CHECK................................................................................................................................................................................................. 54
TIMING BELT TENSION ADJUSTMENT............................................................................................................................................................................................. 55
TIMING BELT B TENSION ADJUSTMENT........................................................................................................................................................................................... 56
CRANKSHAFT PULLEY.............................................................................................................................................................................................................. 57
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 57
REMOVAL SERVICE POINTS................................................................................................................................................................................................. 58
INSTALLATION SERVICE POINT............................................................................................................................................................................................. 59
CAMSHAFT AND VALVE STEM SEAL................................................................................................................................................................................................... 60
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 60
REMOVAL SERVICE POINTS................................................................................................................................................................................................. 61
INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 62
OIL PAN AND OIL SCREEN......................................................................................................................................................................................................... 64
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 64
REMOVAL SERVICE POINTS................................................................................................................................................................................................. 65
INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 65
CRANKSHAFT OIL SEAL............................................................................................................................................................................................................ 67
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 67
REMOVAL SERVICE POINT.................................................................................................................................................................................................. 68
INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 68
CYLINDER HEAD GASKET........................................................................................................................................................................................................... 69
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 69
REMOVAL SERVICE POINTS................................................................................................................................................................................................. 70
INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 71
TIMING BELT.................................................................................................................................................................................................................... 73
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 73
REMOVAL SERVICE POINT.................................................................................................................................................................................................. 74
INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 74
TIMING BELT B.................................................................................................................................................................................................................. 76
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 76
REMOVAL SERVICE POINT.................................................................................................................................................................................................. 76
INSTALLATION SERVICE POINT............................................................................................................................................................................................. 77
ENGINE ASSEMBLY................................................................................................................................................................................................................ 78
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 78
REMOVAL SERVICE POINTS................................................................................................................................................................................................. 80
INSTALLATION SERVICE POINT............................................................................................................................................................................................. 80
12.pdf................................................................................................................................................................................................................................. 81
ENGINE LUBRICATION................................................................................................................................................................................................................. 81
GENERAL INFORMATION............................................................................................................................................................................................................ 82
ENGINE OILS................................................................................................................................................................................................................ 82
SERVICE SPECIFICATION.......................................................................................................................................................................................................... 82
SEALANTS....................................................................................................................................................................................................................... 82
LUBRICANTS..................................................................................................................................................................................................................... 83
SPECIAL TOOLS.................................................................................................................................................................................................................. 83
ON-VEHICLE SERVICE............................................................................................................................................................................................................. 83
ENGINE OIL CHECK........................................................................................................................................................................................................... 83
ENGINE OIL REPLACEMENT..................................................................................................................................................................................................... 83
ENGINE OIL FILTER REPLACEMENT.............................................................................................................................................................................................. 84
OIL PRESSURE CHECK......................................................................................................................................................................................................... 86
ENGINE OIL COOLER.............................................................................................................................................................................................................. 87
REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................ 87
REMOVAL AND INSTALLATION <4D5-DOHC>........................................................................................................................................................................................ 88
INSTALLATION SERVICE POINT............................................................................................................................................................................................. 88
REMOVAL AND INSTALLATION <4M4>............................................................................................................................................................................................. 89
INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 90
15.pdf................................................................................................................................................................................................................................. 91
INTAKE AND EXHAUST................................................................................................................................................................................................................. 91
SERVICE SPECIFICATIONS......................................................................................................................................................................................................... 92
SPECIAL TOOL................................................................................................................................................................................................................... 93
ON-VEHICLE SERVICE............................................................................................................................................................................................................. 94
TURBOCHARGER SUPERCHARGING PRESSURE CHECK.................................................................................................................................................................................. 94
WASTE GATE ACTUATOR CHECK.................................................................................................................................................................................................. 95
AIR CLEANER.................................................................................................................................................................................................................... 96
REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................ 96
REMOVAL AND INSTALLATION <4D5-DOHC, 4M4>................................................................................................................................................................................... 97
INTERCOOLER <4D5-DOHC,4M4>..................................................................................................................................................................................................... 98
REMOVAL AND INSTALLATION................................................................................................................................................................................................... 98
INSTALLATION SERVICE POINT............................................................................................................................................................................................. 98
INLET AND EXHAUST MANIFOLDS <4D5-SOHC>......................................................................................................................................................................................... 99
REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................ 99
INLET MANIFOLD.................................................................................................................................................................................................................101
REMOVAL AND INSTALLATION <4D5-DOHC>........................................................................................................................................................................................101
REMOVAL SERVICE POINT..................................................................................................................................................................................................102
INSTALLATION SERVICE POINT.............................................................................................................................................................................................102
REMOVAL AND INSTALLATION <4M4>.............................................................................................................................................................................................103
EXHAUST MANIFOLD AND TURBOCHARGER..............................................................................................................................................................................................104
REMOVAL AND INSTALLATION <4D5-DOHC>........................................................................................................................................................................................104
INSTALLATION SERVICE POINTS............................................................................................................................................................................................105
REMOVAL AND INSTALLATION <4M4>.............................................................................................................................................................................................106
INSTALLATION SERVICE POINTS............................................................................................................................................................................................107
TURBOCHARGER ASSEMBLY <4D5-SOHC>...............................................................................................................................................................................................108
REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................108
INSTALLATION SERVICE POINT.............................................................................................................................................................................................109
EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER <4D5-SOHC>..................................................................................................................................................................109
REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................109
EXHAUST PIPE AND MAIN MUFFLER <4D5-DOHC, 4M4>..................................................................................................................................................................................110
REMOVAL AND INSTALLATION...................................................................................................................................................................................................110
31.pdf.................................................................................................................................................................................................................................111
WHEEL AND TYRE.....................................................................................................................................................................................................................111
GENERAL INFORMATION............................................................................................................................................................................................................112
SERVICE SPECIFICATIONS.........................................................................................................................................................................................................112
TROUBLESHOOTING................................................................................................................................................................................................................113
DIAGNOSIS..................................................................................................................................................................................................................113
WHEEL BALANCE ACCURACY.....................................................................................................................................................................................................114
PURPOSE................................................................................................................................................................................................................114
PROCEDURE <BALANCING TIPS>.............................................................................................................................................................................................115
<CONFIRMING PROPER BALANCE>............................................................................................................................................................................................115
<WHEEL BALANCER CALIBRATION CHECKS>....................................................................................................................................................................................116
WHEEL BALANCER CALIBRATION CHECKING FLOW CHART.........................................................................................................................................................................117
ON-VEHICLE SERVICE.............................................................................................................................................................................................................118
TYRE INFLATION PRESSURE CHECK..............................................................................................................................................................................................118
TYRE WEAR CHECK............................................................................................................................................................................................................118
WHEEL RUNOUT CHECK.........................................................................................................................................................................................................118
WHEEL AND TYRE.................................................................................................................................................................................................................118
INSTALLATION SERVICE POINT.................................................................................................................................................................................................118
SPARE TYRE CARRIER.............................................................................................................................................................................................................119
REMOVAL AND INSTALLATION...................................................................................................................................................................................................119
33.pdf.................................................................................................................................................................................................................................121
FRONT SUSPENSION...................................................................................................................................................................................................................121
GENERAL INFORMATION............................................................................................................................................................................................................122
SPECIFICATIONS.............................................................................................................................................................................................................123
SERVICE SPECIFICATIONS.........................................................................................................................................................................................................123
SPECIAL TOOLS..................................................................................................................................................................................................................124
ON-VEHICLE SERVICE.............................................................................................................................................................................................................125
FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT <2WD>...........................................................................................................................................................................125
FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT <4WD>...........................................................................................................................................................................126
CAMBER AND CASTER REFERENCE TABLE......................................................................................................................................................................................127
LOWER ARM BALL JOINT AXIAL PLAY CHECK......................................................................................................................................................................................128
LOWER ARM BALL JOINT COVER CHECK...........................................................................................................................................................................................128
UPPER ARM ASSEMBLY.............................................................................................................................................................................................................129
REMOVAL AND INSTALLATION <2WD>.............................................................................................................................................................................................129
REMOVAL SERVICE POINT..................................................................................................................................................................................................130
REMOVAL AND INSTALLATION <4WD>.............................................................................................................................................................................................131
REMOVAL SERVICE POINT..................................................................................................................................................................................................132
INSTALLATION SERVICE POINT.............................................................................................................................................................................................132
INSPECTION.................................................................................................................................................................................................................132
SHOCK ABSORBER AND COIL SPRING.................................................................................................................................................................................................133
REMOVAL AND INSTALLATION...................................................................................................................................................................................................133
REMOVAL SERVICE POINT..................................................................................................................................................................................................134
INSTALLATION SERVICE POINT.............................................................................................................................................................................................134
INSPECTION.................................................................................................................................................................................................................134
SHOCK ABSORBER ASSEMBLY........................................................................................................................................................................................................135
REMOVAL AND INSTALLATION <4WD>.............................................................................................................................................................................................135
INSPECTION.................................................................................................................................................................................................................135
DISASSEMBLY AND REASSEMBLY <4WD>...........................................................................................................................................................................................136
DISASSEMBLY SERVICE POINTS.............................................................................................................................................................................................136
REASSEMBLY SERVICE POINTS..............................................................................................................................................................................................137
INSPECTION.................................................................................................................................................................................................................138
LOWER ARM......................................................................................................................................................................................................................139
REMOVAL AND INSTALLATION <2WD>.............................................................................................................................................................................................139
REMOVAL SERVICE POINT..................................................................................................................................................................................................139
REMOVAL AND INSTALLATION <4WD>.............................................................................................................................................................................................140
REMOVAL SERVICE POINT..................................................................................................................................................................................................141
INSPECTION.................................................................................................................................................................................................................141
LOWER ARM BUSHING REPLACEMENT <2WD>........................................................................................................................................................................................142
LOWER ARM BUSHING REPLACEMENT <4WD>........................................................................................................................................................................................142
STRUT BAR <2WD>................................................................................................................................................................................................................144
REMOVAL AND INSTALLATION...................................................................................................................................................................................................144
INSTALLATION SERVICE POINT.............................................................................................................................................................................................144
STABILIZER BAR <4WD>...........................................................................................................................................................................................................145
REMOVAL AND INSTALLATION...................................................................................................................................................................................................145
INSTALLATION SERVICE POINTS............................................................................................................................................................................................145
INSPECTION.................................................................................................................................................................................................................145
34.pdf.................................................................................................................................................................................................................................147
REAR SUSPENSION....................................................................................................................................................................................................................147
GENERAL INFORMATION............................................................................................................................................................................................................148
SPECIFICATIONS.............................................................................................................................................................................................................149
SHOCK ABSORBER ASSEMBLY........................................................................................................................................................................................................150
REMOVAL AND INSTALLATION...................................................................................................................................................................................................150
<2WD>..................................................................................................................................................................................................................150
<4WD>..................................................................................................................................................................................................................151
INSTALLATION SERVICE POINT.............................................................................................................................................................................................151
INSPECTION.................................................................................................................................................................................................................152
42.pdf.................................................................................................................................................................................................................................153
BODY...............................................................................................................................................................................................................................153
HOOD...........................................................................................................................................................................................................................155
ON-VEHICLE SERVICE.........................................................................................................................................................................................................155
ADJUSTMENT OF CLEARANCE AROUND HOOD........................................................................................................................................................................................155
ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER...........................................................................................................................................................155
ADJUSTMENT OF HOOD HEIGHT..................................................................................................................................................................................................155
HOOD.......................................................................................................................................................................................................................156
REMOVAL AND INSTALLATION...................................................................................................................................................................................................156
FENDER.........................................................................................................................................................................................................................157
SPECIAL TOOL...............................................................................................................................................................................................................157
FENDER.....................................................................................................................................................................................................................158
REMOVAL AND INSTALLATION...................................................................................................................................................................................................158
REMOVAL SERVICE POINT..................................................................................................................................................................................................159
INSTALLATION SERVICE POINT.............................................................................................................................................................................................159
FUEL FILLER LID................................................................................................................................................................................................................160
REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................160
REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................161
SPLASH SHIELD..................................................................................................................................................................................................................162
REMOVAL AND INSTALLATION...................................................................................................................................................................................................162
WINDOW GLASS...................................................................................................................................................................................................................163
ADHESIVE...................................................................................................................................................................................................................163
SPECIAL TOOL...............................................................................................................................................................................................................163
GENERAL....................................................................................................................................................................................................................163
WINDOW GLASS INSTALLATION..............................................................................................................................................................................................164
WINDSHIELD.................................................................................................................................................................................................................165
REMOVAL AND INSTALLATION...................................................................................................................................................................................................165
REMOVAL SERVICE POINT..................................................................................................................................................................................................166
NSTALLATION SERVICE POINTS.............................................................................................................................................................................................167
SIDE WINDOW GLASS <CLUB CAB>...............................................................................................................................................................................................169
REMOVAL AND INSTALLATION...................................................................................................................................................................................................169
REMOVAL SERVICE POINT..................................................................................................................................................................................................170
INSTALLATION SERVICE POINT.............................................................................................................................................................................................170
REAR WINDOW GLASS <Vehicles without rear panel power window>...............................................................................................................................................................171
REMOVAL AND INSTALLATION...................................................................................................................................................................................................171
REMOVAL SERVICE POINT..................................................................................................................................................................................................172
INSTALLATION SERVICE POINTS............................................................................................................................................................................................172
REAR PANEL POWER WINDOW <Vehicles with rear panel power window>................................................................................................................................................................173
SEALANT....................................................................................................................................................................................................................173
SPECIAL TOOLS..............................................................................................................................................................................................................173
TROUBLESHOOTING............................................................................................................................................................................................................174
DIAGNOSIS TROUBLESHOOTING FLOW.............................................................................................................................................................................................174
DIAGNOSIS CODE CHART.......................................................................................................................................................................................................174
TROUBLE SYMPTOM CHART......................................................................................................................................................................................................175
DIAGNOSTIC TROUBLE CODE PROCEDURES.........................................................................................................................................................................................176
Code No.5001: P/W (RP) SW pulse1 fail, Code No.5002: P/W (RP) SW pulse2 fail...............................................................................................................................................176
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................177
STEP 1. Connector check: D-11 rear panel power window-ECU connector and D-09 rear panel power window motor connector...............................................................................................177
STEP 2. Check the wiring harness between D-11 rear panel power window-ECU connector terminal Nos.7, 8, 11 and 16 to D-09 rear panel power window motor connector terminal 2, 4, 5 and 6............................177
STEP 3. Check whether the diagnosis code is reset..................................................................................................................................................................177
Code No.5003: P/W (RP) SW position error...................................................................................................................................................................................177
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................177
STEP 1. Confirm the rear panel power window learning function......................................................................................................................................................177
STEP 2. Check whether the diagnosis code is reset..................................................................................................................................................................177
Code No.5004: P/W (RP) sensor fail.........................................................................................................................................................................................178
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................179
STEP 1. Connector check: D-11 rear panel power window-ECU connector and D-09 rear panel power window motor connector...............................................................................................179
STEP 2. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No. 8 to D-09 rear panel power window motor connector terminal 5......................................................179
STEP 3. Check whether the diagnosis code is reset..................................................................................................................................................................179
Code No.5005: P/W (RP) 3 times jumm-protection.............................................................................................................................................................................179
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................179
STEP 1. Confirm the rear panel power window learning function......................................................................................................................................................179
STEP 2. Check whether the diagnosis code is reset..................................................................................................................................................................179
Code No.5006: P/W (RP) communication error (LIN)...........................................................................................................................................................................180
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................181
STEP 1. Connector check: C-219 ETACS-ECU connector and D-11 rear panel power window-ECU connector..................................................................................................................181
STEP 2. Check the wiring harness between C-219 ETACS-ECU connector terminal No.54 to D-11 rear panel power window-ECU connector terminal No.14.....................................................................181
STEP 3. Check whether the diagnosis code is reset..................................................................................................................................................................181
Code No.5008: P/W (RP) parameter read fail, Code No.5009: P/W (RP) position read fail......................................................................................................................................182
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................182
Check whether the diagnosis code is reset..........................................................................................................................................................................182
SYMPTOM PROCEDURES.........................................................................................................................................................................................................183
Inspection Procedure 1: Rear Panel Power Window do not Work at All.........................................................................................................................................................183
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................184
STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................184
STEP 2. Check the power window sub switch..........................................................................................................................................................................184
STEP 3. Connector check: D-11 rear panel power window-ECU connector and D-09 rear panel power window motor connector...............................................................................................184
STEP 4. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.1, 2, 8 and 11 to D-09 rear panel power window motor connector terminal No.3, 1, 5 and 6...........................184
STEP 5. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.18 to fusible link (23)............................................................................................184
STEP 6. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.9 to ignition switch (IG1).........................................................................................186
STEP 7. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.10 to body earth...................................................................................................186
STEP 8. Connector check: E-03 power window main switch connector...................................................................................................................................................186
STEP 9. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.12 to E-03 power window main switch connector terminal No.11.......................................................187
STEP 10. Check the wiring harness between E-03 power window main switch connector terminal No.2 and body earth.....................................................................................................187
STEP 11. Connector check: D-22 rear panel power window switch connector............................................................................................................................................187
STEP 12. Check the rear panel power window switch..................................................................................................................................................................187
STEP 13. Check the wiring harness between D-22 rear panel power window switch connector terminal No.2 and body earth...............................................................................................188
STEP 14. Retest the system.........................................................................................................................................................................................188
Inspection Procedure 2: Any of The Rear Panel Power Window Switch Position is defective....................................................................................................................................189
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................189
STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................189
STEP 2. Connector check: D-11 rear panel power window-ECU connector and D-22 rear panel power window switch connector..............................................................................................190
STEP 3. Check the rear panel power window switch...................................................................................................................................................................190
STEP 4. Check the wiring harness between D-11 rear panel power window-ECU connector terminal Nos.4, 5 and 6 to D-22 rear panel power window switch connector terminal Nos.5, 4 and 1...............................190
STEP 5. Retest the system..........................................................................................................................................................................................190
Inspection Procedure 3: Rear Panel Power Window Anti-trap Function does not Work Normally..................................................................................................................................190
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................190
STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................190
STEP 2. Confirm the rear panel power window learning function......................................................................................................................................................191
STEP 3. Retest the system..........................................................................................................................................................................................191
Inspection Procedure 4: Rear Panel Power Window-ECU cannot Communicate with ETACS-ECU......................................................................................................................................191
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................192
STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................192
STEP 2. Connector check: C-219 ETACS-ECU connector and D-11 rear panel power window-ECU connector..................................................................................................................192
STEP 3. Check the wiring harness between C-219 ETACS-ECU connector terminal No.54 to D-11 rear panel power window-ECU connector terminal No.14.....................................................................192
STEP 4. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.18 to fusible link (23)............................................................................................193
STEP 5. Retest the system..........................................................................................................................................................................................193
Inspection Procedure 5: Rear Pnael Power Window Timer Function does not Work Normally......................................................................................................................................194
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................194
STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................194
STEP 2. Check the rear panel power window..........................................................................................................................................................................194
STEP 3. Check the power window timer function......................................................................................................................................................................194
STEP 4. Retest the system..........................................................................................................................................................................................194
ON-VEHICLE SERVICE.........................................................................................................................................................................................................194
REAR SLIDE WINDOW GLASS ADJUSTMENT.........................................................................................................................................................................................194
GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT...............................................................................................................................................................................195
REAR PANEL POWER WINDOW ANTI-TRAP FUNCTION INSPECTION......................................................................................................................................................................195
REAR PANEL POWER WINDOW INITIAL SET........................................................................................................................................................................................195
HOW TO MAKE THE REAR PANEL POWER WINDOW-ECU LEARN THE FULLY CLOSED POSITION OF THE REAR PANEL POWER WINDOW.............................................................................................................195
REAR PANEL WINDOW REGULATOR................................................................................................................................................................................................197
REMOVAL AND INSTALLATION...................................................................................................................................................................................................197
REMOVAL SERVICE POINT..................................................................................................................................................................................................199
INSTALLATION SERVICE POINT.............................................................................................................................................................................................200
INSPECTION.................................................................................................................................................................................................................200
REAR PANEL POWER WINDOW SWITCH CONTINUITY CHECK........................................................................................................................................................................200
REAR PANEL POWER WINDOW-ECU TERMINAL INSPECTION........................................................................................................................................................................201
DOOR...........................................................................................................................................................................................................................202
SERVICE SPECIFICATIONS.....................................................................................................................................................................................................202
SEALANT....................................................................................................................................................................................................................202
SPECIAL TOOLS..............................................................................................................................................................................................................202
TROUBLESHOOTING............................................................................................................................................................................................................204
DIAGNOSIS TROUBLESHOOTING FLOW.............................................................................................................................................................................................204
TROUBLE SYMPTOM CHART <CENTRAL DOOR LOCKING SYSTEM>........................................................................................................................................................................204
TROUBLE SYMPTOM CHART <POWER WINDOWS>......................................................................................................................................................................................204
SYMPTOM PROCEDURES <CENTRAL DOOR LOCKING SYSTEM>...........................................................................................................................................................................205
Inspection Procedure A-1: Central Door Locking System does not Work........................................................................................................................................................205
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................205
STEP 1. Check the power supply circuit.............................................................................................................................................................................205
STEP 2. Connector check: C-218 ETACS-ECU connector.................................................................................................................................................................206
STEP 3. Check the wiring harness between C-218 ETACS-ECU connector terminal No.1 and fusible link (20).............................................................................................................206
STEP 4. Retest the system..........................................................................................................................................................................................207
Inspection Procedure A-2: A Door cannot be Locked or Unlocked by the Central Door Locking System...........................................................................................................................208
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................209
STEP 1. Confirm which door lock actuator is defective..............................................................................................................................................................209
STEP 2. Connector check: E-04 front door lock actuator (RH) connector..............................................................................................................................................209
STEP 3. Check the front door lock actuator (RH)....................................................................................................................................................................209
STEP 4. Connector check: C-220 ETACS-ECU connector.................................................................................................................................................................209
STEP 5. Check the wiring harness from C-220 ETACS-ECU connector terminal Nos. 21 and 23 to E-04 front door lock actuator (RH) connector terminal Nos. 6 and 4......................................................210
STEP 6. Connector check: E-15 front door lock actuator (LH) connector..............................................................................................................................................210
STEP 7. Check the front door lock actuator (LH)....................................................................................................................................................................210
STEP 8. Connector check: C-220 ETACS-ECU connector.................................................................................................................................................................210
STEP 9. Check the wiring harness from C-220 ETACS-ECU connector terminal Nos. 22 and 23 to E-15 front door lock actuator (LH) connector terminal Nos. 6 and 4......................................................211
STEP 10. Connector check: E-07 rear door lock actuator (RH) connector..............................................................................................................................................211
STEP 11. Check the rear door lock actuator (RH)....................................................................................................................................................................211
STEP 12. Connector check: C-220 ETACS-ECU connector................................................................................................................................................................211
STEP 13. Check the wiring harness from C-220 ETACS-ECU connector terminal Nos. 22 and 23 to E-07 rear door lock actuator (RH) connector terminal Nos. 6 and 4......................................................212
STEP 14. Connector check: E-12 rear door lock actuator (LH) connector..............................................................................................................................................213
STEP 15. Check the rear door lock actuator (LH)....................................................................................................................................................................213
STEP 16. Connector check: C-220 ETACS-ECU connector................................................................................................................................................................213
STEP 17. Check the wiring harness from C-220 ETACS-ECU connector terminal Nos. 22 and 23 to E-12 rea door lock actuator (LH) connector terminal Nos. 6 and 4.......................................................213
Inspection Procedure A-3: Selector "P" position-linked door unlock function does not operate normally. <Vehicles with automatic transmission with keyless entry system>....................................................215
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................215
STEP 1. Checking central door unlocking operation..................................................................................................................................................................215
STEP 2. Customize function by using the M.U.T.-III.................................................................................................................................................................215
STEP 3. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................215
STEP 4. M.U.T.-III other system diagnosis code.....................................................................................................................................................................215
STEP 5. Retest the system..........................................................................................................................................................................................215
SYMPTOM PROCEDURES <POWER WINDOWS>.........................................................................................................................................................................................216
Inspection Procedure B-1: Power Windows do not Work at All.................................................................................................................................................................216
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................217
STEP 1. M.U.T.-III data list.......................................................................................................................................................................................217
STEP 2. Connector check: A-24X power window relay connector........................................................................................................................................................217
STEP 3. Check the power window relay...............................................................................................................................................................................217
STEP 4. Voltage measurement at the A-24X power window relay connector..............................................................................................................................................217
STEP 5. Check the wiring harness between A-24X power window relay connector terminal No.4 and fusible link (23)....................................................................................................218
STEP 6. Voltage measurement at the A-24X power window relay connector..............................................................................................................................................218
STEP 7. Connector check: C-219 ETACS-ECU connector.................................................................................................................................................................218
STEP 8. Check the wiring harness between C-219 ETACS-ECU connector terminal No.59 and A-24X power window relay connector terminal No.2.............................................................................219
STEP 9. Resistance measurement at the A-24X power window relay connector...........................................................................................................................................219
STEP 10. Check the wiring harness between A-24X power window relay connector terminal No.1 and body earth..........................................................................................................219
STEP 11. Connector check: E-03 power window main switch connector..................................................................................................................................................220
STEP 12. Voltage measurement at the E-03 power window main switch connector........................................................................................................................................220
STEP 13. Check the wiring harness between A-24X power window relay connector terminal No.3 and E-03 power window main switch connector terminal No.10..............................................................221
STEP 14. Resistance measurement at the E-03 power window main switch connector.....................................................................................................................................221
STEP 15. Check the wiring harness between E-03 power window main switch connector terminal No.2 and body earth.....................................................................................................222
STEP 16. Retest the system.........................................................................................................................................................................................222
Inspection Procedure B-2: Driver's Power Window does not Work by means of the Power Window Main Switch.....................................................................................................................223
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................224
STEP 1. Check the power window main switch.........................................................................................................................................................................224
STEP 2. Connector check: Connector check: E-03 power window main switch connector and E-01 power window motor (front: RH) connector................................................................................224
STEP 3. Check the wiring harness from E-03 power window main switch connector terminal Nos. 12 and 14 to E-01 power window motor (front: RH) connector terminal Nos. 2 and 1.......................................224
STEP 4. Retest the system..........................................................................................................................................................................................224
Inspection Procedure B-3: Relevant Power Window(s) do not Work by means of the Front Passenger's Power Window Sub Switch and Rear Power Window Sub Switches................................................................225
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................227
STEP 1. Check the power window main switch.........................................................................................................................................................................227
STEP 2. Determine a trouble spot...................................................................................................................................................................................227
STEP 3. Connector check: E-16 power window sub switch (front: LH) connector........................................................................................................................................227
STEP 4. Check the power window sub switch (front: LH)..............................................................................................................................................................227
STEP 5. Voltage measurement at the E-16 power window sub switch (front: LH) connector..............................................................................................................................227
STEP 6. Connector check: A-24X power window relay connector........................................................................................................................................................228
STEP 7. Check the wiring harness from E-16 power window sub switch (front: LH) connector terminal No.6 to A-24X power window relay connector terminal No.3.........................................................228
STEP 8. Connector check: E-18 power window motor (front: LH) connector.............................................................................................................................................229
STEP 9. Check the power window motor (front: LH)...................................................................................................................................................................229
STEP 10. Check the wiring harness from E-18 power window motor (front: LH) connector terminal Nos. 1 and 2 to E-16 power window sub switch (front: LH) connector terminal Nos. 4 and 7.............................229
STEP 11. Retest the system.........................................................................................................................................................................................229
STEP 12. Connector check: E-06 power window sub switch (rear: RH) connector........................................................................................................................................229
STEP 13. Check the power window sub switch (rear: RH)..............................................................................................................................................................229
STEP 14. Voltage measurement at the E-06 power window sub switch (rear: RH) connector..............................................................................................................................230
STEP 15. Connector check: A-24X power window relay connector.......................................................................................................................................................230
STEP 16. Check the wiring harness from E-06 power window sub switch (rear: RH) connector terminal No.6 to A-24X power window relay connector terminal No.3.........................................................230
STEP 17. Connector check: E-05 power window motor (rear: RH) connector.............................................................................................................................................231
STEP 18. Check the power window motor (rear: RH)...................................................................................................................................................................231
STEP 19. Check the wiring harness from E-05 power window motor (rear: RH) connector terminal Nos. 1 and 2 to E-06 power window sub switch (rear: RH) connector terminal Nos. 7 and 4...............................231
STEP 20. Retest the system.........................................................................................................................................................................................232
STEP 21. Connector check: E-13 power window sub switch (rear: LH) connector........................................................................................................................................232
STEP 22. Check the power window sub switch (rear: LH)..............................................................................................................................................................232
STEP 23. Voltage measurement at the E-13 power window sub switch (rear: LH) connector..............................................................................................................................232
STEP 24. Connector check: A-24X power window relay connector.......................................................................................................................................................232
STEP 25. Check the wiring harness from E-13 power window sub switch (rear: LH) connector terminal No.6 to A-24X power window relay connector terminal No.3.........................................................233
STEP 26. Connector check: E-14 power window motor (rear: LH) connector.............................................................................................................................................234
STEP 27. Check the power window motor (rear: LH)...................................................................................................................................................................234
STEP 28. Check the wiring harness from E-14 power window motor (rear: RH) connector terminal Nos. 1 and 2 to E-13 power window sub switch (rear: LH) connector terminal Nos. 7 and 4...............................234
STEP 29. Retest the system.........................................................................................................................................................................................234
Inspection Procedure B-4: Front Passenger's Power Window do not Work by means of the Power Window Main Switch..............................................................................................................235
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................237
STEP 1. Check the power window main switch.........................................................................................................................................................................237
STEP 2. Check the power window sub switch..........................................................................................................................................................................237
STEP 3. Determine a trouble spot...................................................................................................................................................................................237
STEP 4. Connector check: E-03 power window main switch connector and E-16 power window sub switch (front: LH) connector............................................................................................237
STEP 5. Check the wiring harness between E-03 power window main switch connector terminal Nos.7 and 9 to E-16 power window sub switch (front: LH) connector terminal Nos.8 and 5...................................237
STEP 6. Retest the system..........................................................................................................................................................................................238
STEP 7. Connector check: E-03 power window main switch connector and E-06 power window sub switch (rear: RH) connector.............................................................................................238
STEP 8. Check the wiring harness between E-03 power window main switch connector terminal Nos.4 and 6 to E-06 power window sub switch (rear: RH) connector terminal Nos.8 and 5....................................238
STEP 9. Retest the system..........................................................................................................................................................................................239
STEP 10. Connector check: E-03 power window main switch connector and E-13 power window sub switch (rear: LH) connector............................................................................................239
STEP 11. Check the wiring harness between E-03 power window main switch connector terminal Nos.1 and 3 to E-13 power window sub switch (rear: LH) connector terminal Nos.8 and 5...................................239
STEP 12. Retest the system.........................................................................................................................................................................................240
Inspection procedure B-5: Power Window Timer Function does not Work Normally...............................................................................................................................................240
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................240
STEP 1. Check the power window main switch.........................................................................................................................................................................240
STEP 2. Check the power supply circuit.............................................................................................................................................................................240
STEP 3. M.U.T.-III data list.......................................................................................................................................................................................240
STEP 4. Retest the system..........................................................................................................................................................................................240
Inspection Procedure B-6: The Window Glass Lowers Automatically while it is Rising.........................................................................................................................................241
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................241
STEP 1. Check the power window operating current...................................................................................................................................................................241
STEP 2. Check that the door window glasses are installed correctly.................................................................................................................................................241
STEP 3. Retest the system..........................................................................................................................................................................................241
ON-VEHICLE SERVICE.........................................................................................................................................................................................................241
DOOR FIT ADJUSTMENT........................................................................................................................................................................................................241
FRONT DOOR WINDOW GLASS ADJUSTMENT.........................................................................................................................................................................................242
GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT...............................................................................................................................................................................243
POWER WINDOW TIMER FUNCTION CHECK..........................................................................................................................................................................................244
POWER WINDOW OPERATING CURRENT CHECK.......................................................................................................................................................................................244
POWER WINDOW RELAY CHECK...................................................................................................................................................................................................244
POWER WINDOW CHECK.........................................................................................................................................................................................................244
CENTRAL DOOR LOCKING SYSTEM INSPECTION.....................................................................................................................................................................................245
CHECK OF KEY LOCK PREVENTION FUNCTION......................................................................................................................................................................................245
SHIFT "P" INTERLINK DOOR UNLOCK FUNCTION CHECK.............................................................................................................................................................................245
DOOR OUTSIDE HANDLE PLAY CHECK.............................................................................................................................................................................................245
DOOR INSIDE HANDLE PLAY ADJUSTMENT.........................................................................................................................................................................................246
DOOR INSIDE HANDLE KNOB PLAY CHECK.....................................................................................................................................................................................246
DOOR INSIDE HANDLE LOCK KNOB STROKE CHECK..............................................................................................................................................................................246
DOOR ASSEMBLY..............................................................................................................................................................................................................247
REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................247
INSTALLATION SERVICE POINT.............................................................................................................................................................................................247
REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................248
INSTALLATION SERVICE POINT.............................................................................................................................................................................................249
INSPECTION.................................................................................................................................................................................................................249
DOOR SWITCH CHECK......................................................................................................................................................................................................249
DOOR GLASS AND REGULATOR...................................................................................................................................................................................................250
REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................250
REMOVAL SERVICE POINTS.................................................................................................................................................................................................251
INSTALLATION SERVICE POINT.............................................................................................................................................................................................251
REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................252
REMOVAL SERVICE POINTS.................................................................................................................................................................................................254
INSTALLATION SERVICE POINT.............................................................................................................................................................................................254
INSPECTION.................................................................................................................................................................................................................255
POWER WINDOW SWITCH CONTINUITY CHECK...................................................................................................................................................................................255
POWER WINDOW MOTOR CONTINUITY CHECK....................................................................................................................................................................................256
POWER WINDOW MOTOR CHECK...............................................................................................................................................................................................256
DOOR HANDLE AND LATCH......................................................................................................................................................................................................257
REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................257
INSTALLATION SERVICE POINTS............................................................................................................................................................................................258
REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................259
INSTALLATION SERVICE POINT.............................................................................................................................................................................................261
INSPECTION.................................................................................................................................................................................................................261
FRONT DOOR LOCK ACTUATOR CHECK.........................................................................................................................................................................................261
REAR DOOR LOCK ACTUATOR CHECK..........................................................................................................................................................................................262
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP......................................................................................................................................................................263
REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................263
REMOVAL SERVICE POINT..................................................................................................................................................................................................264
INSTALLATION SERVICE POINTS............................................................................................................................................................................................264
REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................265
REMOVAL SERVICE POINTS.................................................................................................................................................................................................267
INSTALLATION SERVICE POINTS............................................................................................................................................................................................267
KEYLESS ENTRY SYSTEM...........................................................................................................................................................................................................268
SERVICE SPECIFICATIONS.....................................................................................................................................................................................................268
SPECIAL TOOL...............................................................................................................................................................................................................268
TROUBLESHOOTING............................................................................................................................................................................................................269
DIAGNOSIS TROUBLESHOOTING FLOW.............................................................................................................................................................................................269
TROUBLE SYMPTOM CHART......................................................................................................................................................................................................269
INPUT SIGNAL CHART.........................................................................................................................................................................................................269
SYMPTOM PROCEDURES.........................................................................................................................................................................................................270
Inspection Procedure 1: Keyless Entry System does not Work.................................................................................................................................................................270
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................270
STEP 1. Check the operation of the central door locking system.....................................................................................................................................................270
STEP 2. Check the power supply circuit.............................................................................................................................................................................270
STEP 3. M.U.T.-III data list.......................................................................................................................................................................................271
STEP 4. Pulse check................................................................................................................................................................................................271
STEP 5. Retest the system..........................................................................................................................................................................................271
Inspection Procedure 2: Keyless Entry Hazard Lamp Answerback Function or the Room Lamp Answerback Function does not Work Normally..........................................................................................271
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................271
STEP 1. Check the operation of the hazard warning lamp.............................................................................................................................................................271
STEP 2. Check the operation of the room lamp.......................................................................................................................................................................271
STEP 3. Check the operation of the keyless entry system............................................................................................................................................................272
STEP 4. Check the customize function...............................................................................................................................................................................272
STEP 5. Check the power supply circuit.............................................................................................................................................................................272
STEP 6. Retest the system..........................................................................................................................................................................................272
Inspection Procedure 3: Encrypted Code cannot be Registered................................................................................................................................................................273
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................273
STEP 1. Check the encrypted code registration mode.................................................................................................................................................................273
STEP 2. M.U.T.-III data list.......................................................................................................................................................................................273
STEP 3. Pulse check................................................................................................................................................................................................274
STEP 4. Retest the system..........................................................................................................................................................................................274
Inspection Procedure 4: The Timer Lock Function does not Work after the Doors have been Unlocked by the Keyless Entry System...............................................................................................274
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................274
STEP 1. Check the operation of the keyless entry system............................................................................................................................................................274
STEP 2. Check the customize function...............................................................................................................................................................................274
STEP 3. Retest the system..........................................................................................................................................................................................274
INPUT SIGNAL PROCEDURES....................................................................................................................................................................................................275
Inspection Procedure 5: Each Button Signal of the Keyless Entry Transmitter is not Received................................................................................................................................275
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................275
STEP 1. Pulse check................................................................................................................................................................................................275
STEP 2. Check the transmitter battery..............................................................................................................................................................................275
STEP 3. Register the encrypted code, and then retest the system....................................................................................................................................................275
STEP 4. Retest the system..........................................................................................................................................................................................275
Inspection Procedure 6: The Key Reminder Switch Signal is not Received.....................................................................................................................................................276
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................277
STEP 1. Connector check: C-301 key reminder switch connector.......................................................................................................................................................277
STEP 2. Check the key reminder switch..............................................................................................................................................................................277
STEP 3. Resistance measurement at the C-301 key reminder switch connector..........................................................................................................................................277
STEP 4. Check the wiring harness between C-301 key reminder switch connector terminal No.4 and the body earth......................................................................................................278
STEP 5. Connector check: C-219 ETACS-ECU connector.................................................................................................................................................................278
STEP 6. Check the wiring harness between C-219 ETACS-ECU connector terminal No.53 and C-301 key reminder switch connector terminal No.6............................................................................278
STEP 7. Retest the system..........................................................................................................................................................................................278
ON-VEHICLE SERVICE.........................................................................................................................................................................................................279
KEYLESS ENTRY SYSTEM INSPECTION............................................................................................................................................................................................279
KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION........................................................................................................................................................................279
HOW TO REGISTER SECRET CODE................................................................................................................................................................................................279
WHEN THE SPECIAL TOOL V.C.I. (MB991824) IS USED........................................................................................................................................................................279
TRANSMITTER................................................................................................................................................................................................................281
DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................281
DISASSEMBLY SERVICE POINT..............................................................................................................................................................................................281
REASSEMBLY SERVICE POINT...............................................................................................................................................................................................282
INSPECTION.................................................................................................................................................................................................................282
TRANSMITTER BATTERY CHECK..............................................................................................................................................................................................282
BODY MOUNTING..................................................................................................................................................................................................................283
REMOVAL AND INSTALLATION...................................................................................................................................................................................................283
REMOVAL SERVICE POINTS.................................................................................................................................................................................................285
REAR GATE......................................................................................................................................................................................................................286
SERVICE SPECIFICATIONS.....................................................................................................................................................................................................286
ON-VEHICLE SERVICE.........................................................................................................................................................................................................286
REAR GATE PANEL FIT ADJUSTMENT.............................................................................................................................................................................................286
ALIGNMENT OF REAR GATE LATCH AND STRIKER...............................................................................................................................................................................286
ADJUSTMENT OF CLEARANCE AROUND REAR GATE...............................................................................................................................................................................286
REAR GATE OUTSIDE HANDLE ADJUSTMENT........................................................................................................................................................................................287
REAR GATE..................................................................................................................................................................................................................288
REMOVAL AND INSTALLATION...................................................................................................................................................................................................288
REAR GATE LATCH ASSEMBLY...................................................................................................................................................................................................289
REMOVAL AND INSTALLATION...................................................................................................................................................................................................289
REAR SIDE PANEL................................................................................................................................................................................................................290
REMOVAL AND INSTALLATION...................................................................................................................................................................................................290
52.pdf.................................................................................................................................................................................................................................291
INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM(SRS)....................................................................................................................................................................................291
52A.pdf................................................................................................................................................................................................................................293
INTERIOR...........................................................................................................................................................................................................................293
SPECIAL TOOL...................................................................................................................................................................................................................294
INSTRUMENT PANEL ASSEMBLY......................................................................................................................................................................................................294
REMOVAL AND INSTALLATION...................................................................................................................................................................................................294
CLIP AND CRAW POSITIONS................................................................................................................................................................................................297
REMOVAL SERVICE POINTS.................................................................................................................................................................................................298
DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................299
FLOOR CONSOLE ASSEMBLY.........................................................................................................................................................................................................300
FRONT FLOOR CONSOLE ASSEMBLY...............................................................................................................................................................................................300
REMOVAL AND INSTALLATION...................................................................................................................................................................................................300
REAR FLOOR CONSOLE ASSEMBLY................................................................................................................................................................................................301
REMOVAL AND INSTALLATION...................................................................................................................................................................................................301
<Except GL>............................................................................................................................................................................................................301
<GL>...................................................................................................................................................................................................................302
TRIMS..........................................................................................................................................................................................................................302
INTERIOR TRIM..............................................................................................................................................................................................................302
REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................302
CLIP AND CLAW POSITIONS................................................................................................................................................................................................303
REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................304
CLIP AND CLAW POSITIONS................................................................................................................................................................................................305
DOOR TRIM..................................................................................................................................................................................................................306
REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................306
CLIP AND CLAW POSITIONS................................................................................................................................................................................................307
REMOVAL SERVICE POINTS.................................................................................................................................................................................................307
REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................308
CLIP AND CLAW POSITIONS................................................................................................................................................................................................309
REMOVAL SERVICE POINTS.................................................................................................................................................................................................309
HEADLINING.....................................................................................................................................................................................................................310
REMOVAL AND INSTALLATION...................................................................................................................................................................................................310
REMOVAL SERVICE POINT..................................................................................................................................................................................................310
INSIDE REAR VIEW MIRROR........................................................................................................................................................................................................311
REMOVAL SERVICE POINT......................................................................................................................................................................................................311
FRONT SEAT ASSEMBLY............................................................................................................................................................................................................312
REMOVAL AND INSTALLATION...................................................................................................................................................................................................312
INSTALLATION SERVICE POINT.............................................................................................................................................................................................312
DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................313
<MANUAL SEAT>..........................................................................................................................................................................................................313
<POWER SEAT>...........................................................................................................................................................................................................314
DISASSEMBLY SERVICE POINT..............................................................................................................................................................................................315
REAR SEAT ASSEMBLY <DOUBLE CAB>................................................................................................................................................................................................315
REMOVAL AND INSTALLATION...................................................................................................................................................................................................315
DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................316
DISASSEMBLY SERVICE POINT..............................................................................................................................................................................................317
FRONT SEAT BELT................................................................................................................................................................................................................317
REMOVAL AND INSTALLATION...................................................................................................................................................................................................317
INSPECTION.................................................................................................................................................................................................................318
SEAT BELT BUCKLE SWITCH CONTINUITY CHECK...............................................................................................................................................................................318
REAR SEAT BELT <DOUBLE CAB>....................................................................................................................................................................................................319
REMOVAL AND INSTALLATION...................................................................................................................................................................................................319
54.pdf.................................................................................................................................................................................................................................321
CHASSIS ELECTRICAL.................................................................................................................................................................................................................321
54A.pdf................................................................................................................................................................................................................................323
CHASSIS ELECTRICAL.................................................................................................................................................................................................................323
BATTERY........................................................................................................................................................................................................................326
GENERAL INFORMATION........................................................................................................................................................................................................326
SERVICE SPECIFICATIONS.....................................................................................................................................................................................................326
ON-VEHICLE SERVICE.........................................................................................................................................................................................................326
FLUID LEVEL AND SPECIFIC GRAVITY CHECK.....................................................................................................................................................................................326
CHARGING...................................................................................................................................................................................................................327
BATTERY TEST...............................................................................................................................................................................................................327
TEST STEPS.............................................................................................................................................................................................................327
STEP 1. Battery no-load voltage check..............................................................................................................................................................................327
STEP 2. Battery charging...........................................................................................................................................................................................327
STEP 3. Load test check............................................................................................................................................................................................327
IGNITION SWITCH................................................................................................................................................................................................................328
SPECIAL TOOL...............................................................................................................................................................................................................328
REMOVAL AND INSTALLATION...................................................................................................................................................................................................329
REMOVAL SERVICE POINT..................................................................................................................................................................................................329
INSPECTION.................................................................................................................................................................................................................330
IGNITION SWITCH CONTINUITY CHECK.......................................................................................................................................................................................330
KEY REMINDER SWITCH CONTINUITY CHECK <3200>............................................................................................................................................................................330
COMBINATION METER..............................................................................................................................................................................................................331
SERVICE SPECIFICATIONS.....................................................................................................................................................................................................331
SEALANT....................................................................................................................................................................................................................331
SPECIAL TOOLS..............................................................................................................................................................................................................332
TROUBLESHOOTING............................................................................................................................................................................................................333
TROUBLE SYMPTOM CHART......................................................................................................................................................................................................333
SYMPTOM PROCEDURES.........................................................................................................................................................................................................334
Inspection Procedure 1: Power Supply Circuit System Check. Inspection Procedure 2: Odometer and Trip Meter is not Displayed. Ins...........................................................................................334
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................335
STEP 1. Connector check: Combination meter connector C-111, C-112 and C-113........................................................................................................................................335
STEP 2. Voltage measurement at combination meter connector C-112...................................................................................................................................................335
STEP 3. Check the harness wire between the battery (fusible link No.20) and combination meter connector C-112 (terminal No.42).....................................................................................336
STEP 4. Voltage measurement at combination meter connector C-112...................................................................................................................................................337
STEP 5. Check the harness wire between the ignition switch (IG1) and combination meter connector C-112 (terminal No.36)............................................................................................337
STEP 6. Resistance measurement at combination meter connector C-111 and C-113......................................................................................................................................338
STEP 7. Check the harness between combination meter connector C-111 (terminal No.57), C-113 (terminal No.13) and body earth........................................................................................338
STEP 8. Retest the system..........................................................................................................................................................................................338
Inspection Procedure 5: Speedometer does not Work (other meters work)......................................................................................................................................................339
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................339
STEP 1. M.U.T.-III other system diagnosis code.....................................................................................................................................................................339
STEP 2. M.U.T.-III other system data list..........................................................................................................................................................................339
STEP 3. Connector check: Joint connector C-127 and combination meter connector C-112...............................................................................................................................340
STEP 4. Check the wiring harness between joint connector C-127 (terminal 15) and combination meter connector C-112 (terminal 35)...................................................................................340
STEP 5. Retest the system..........................................................................................................................................................................................340
STEP 6. Pulse check................................................................................................................................................................................................341
Inspection Procedure 6: Tachometer does not Work (other meters work).......................................................................................................................................................341
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................342
STEP 1. M.U.T.-III other system diagnosis code.....................................................................................................................................................................342
STEP 2. Connector check: Combination meter connector C-112 and engine-ECU connector C-102 <2500-SOHC>, C-103 <2500-DOHC, 3200>.....................................................................................342
STEP 3. Retest the system..........................................................................................................................................................................................342
STEP 4. Check the wiring harness between combination meter connector C-112 (terminal 34) and engine ECU connector C-102 (terminal 58) <2500-SOHC>, C-103 (terminal 91) <2500-DOHC,3200>............................342
Inspection Procedure 7: Fuel Gauge does not Work (other meters work).......................................................................................................................................................343
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................343
STEP 1. Check the fuel gauge circuit...............................................................................................................................................................................343
STEP 2. Connector check: Combination meter connector C-113 and fuel pump and gauge unit connector F-09.............................................................................................................344
STEP 3. Check the wiring harness between combination meter connector C-113 (terminal 22) and fuel pump and gauge unit connector F-09 (terminal 2)..................................................................344
STEP 4. Retest the system..........................................................................................................................................................................................345
STEP 5. Check the wiring harness between fuel pump and gauge unit connector F-09 (terminal 1) and earth............................................................................................................345
STEP 6. Retest the system..........................................................................................................................................................................................345
STEP 7. Check the fuel gauge circuit...............................................................................................................................................................................345
STEP 8. Retest the system..........................................................................................................................................................................................345
Inspection Procedure 8: Engine Coolant Temperature Gauge does not Work (other meters work).................................................................................................................................346
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................347
STEP 1. Check the engine coolant temperature gauge circuit.........................................................................................................................................................347
STEP 2. Connector check: Combination meter connector C-113 and engine coolant temperature gauge unit connector A-108...............................................................................................347
STEP 3. Retest the system..........................................................................................................................................................................................348
STEP 4. Check the wiring harness between combination meter connector C-113 (terminal 21) and engine coolant temperature gauge unit connector A-108 (terminal 1)....................................................348
STEP 5. Check the engine coolant temperature gauge circuit.........................................................................................................................................................349
STEP 6. Retest the system..........................................................................................................................................................................................350
CHECK AT ECU TERMINALS.....................................................................................................................................................................................................350
ON-VEHICLE SERVICE.........................................................................................................................................................................................................352
CHECK THE SPEEDOMETER......................................................................................................................................................................................................352
TACHOMETER CHECK...........................................................................................................................................................................................................353
FUEL TANK GAUGE UNIT CHECK.................................................................................................................................................................................................353
NOMINAL RESISTANCE OF THE FUEL GAUGE UNIT..............................................................................................................................................................................353
FUEL GAUGE UNIT FLOAT HEIGHT...........................................................................................................................................................................................354
ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK................................................................................................................................................................................354
COMBINATION METER ASSEMBLY.................................................................................................................................................................................................355
REMOVAL AND INSTALLATION...................................................................................................................................................................................................355
INSPECTION.................................................................................................................................................................................................................355
CHECK OF COMBINATION METER INTERNAL RESISTANCE.........................................................................................................................................................................355
DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................356
HEADLAMP.......................................................................................................................................................................................................................357
SERVICE SPECIFICATIONS.....................................................................................................................................................................................................357
PRECAUTIONS ON HOW TO USE THE HEADLAMP ASSEMBLY........................................................................................................................................................................357
TROUBLESHOOTING............................................................................................................................................................................................................357
ON-VEHICLE SERVICE.........................................................................................................................................................................................................357
HEADLAMP AIMING............................................................................................................................................................................................................357
<USING A BEAM SETTING EQUIPMENT>.......................................................................................................................................................................................357
<USING A SCREEN>.......................................................................................................................................................................................................357
HEADLAMP INTENSITY MEASUREMENT.............................................................................................................................................................................................359
BULB REPLACEMENT...........................................................................................................................................................................................................359
HEADLAMP BULB REPLACEMENT..............................................................................................................................................................................................359
POSITION LAMP BULB REPLACEMENT.........................................................................................................................................................................................359
FRONT TURN-SIGNAL LAMP BULB REPLACEMENT................................................................................................................................................................................360
INSPECTION OF HEADLAMP AUTOMATIC-SHUTDOWN FUNCTION.........................................................................................................................................................................360
REMOVAL AND INSTALLATION...................................................................................................................................................................................................361
INSPECTION.................................................................................................................................................................................................................362
HEADLAMP RELAY (LO) CHECK..............................................................................................................................................................................................362
HEADLAMP RELAY (HI) CHECK..............................................................................................................................................................................................362
SIDE TURN-SIGNAL LAMP..........................................................................................................................................................................................................363
SPECIAL TOOL...............................................................................................................................................................................................................363
REMOVAL AND INSTALLATION...................................................................................................................................................................................................363
REMOVAL SERVICE POINT..................................................................................................................................................................................................363
INSTALLATION SERVICE POINT.............................................................................................................................................................................................363
INTERIOR LAMP..................................................................................................................................................................................................................364
SPECIAL TOOLS..............................................................................................................................................................................................................364
TROUBLESHOOTING............................................................................................................................................................................................................365
DIMMER INTERIOR LAMP CONTROL FUNCTION..................................................................................................................................................................................365
CHECK CHART FOR TROUBLE SYMPTOMS...........................................................................................................................................................................................365
SYMPTOM PROCEDURES.........................................................................................................................................................................................................367
Inspection Procedure 1: The Interior Lamps (front room lamp, rear room lamp and ignition key cylinder illumination lamp) does not Illuminate or Extinguish Normally........................................................367
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................368
STEP 1. M.U.T.-III other system diagnosis code.....................................................................................................................................................................368
STEP 2. M.U.T.-III data list.......................................................................................................................................................................................368
STEP 3. Check the door lock actuator (RH)..........................................................................................................................................................................368
STEP 4. Retest the system..........................................................................................................................................................................................368
Inspection Procedure 2: The Front Room Lamp does not Illuminate Normally...................................................................................................................................................369
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................369
STEP 1. Check that the rear room lamp and ignition key cylinder illumination lamp illuminates......................................................................................................................369
STEP 2. Retest the system..........................................................................................................................................................................................370
STEP 3. Connector check: D-03 front room lamp connector............................................................................................................................................................370
STEP 4. Check the bulb.............................................................................................................................................................................................370
STEP 5. Check the front room lamp..................................................................................................................................................................................370
STEP 6. Check the wiring harness from D-03 front room lamp connector terminal No.2 to battery......................................................................................................................370
STEP 7. Connector check: C-218 ETACS-ECU connector and D-03 front room lamp connector..............................................................................................................................371
STEP 8. Check the wiring harness from C-218 ETACS-ECU connector terminal No.18 to D-03 front room lamp connector terminal No.1.....................................................................................371
Inspection Procedure 3: The Rear Room Lamp does not Illuminate Normally....................................................................................................................................................372
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................372
STEP 1. Check if the front room lamp and ignition key cylinder illumination lamp illuminates.......................................................................................................................372
STEP 2. Retest the system..........................................................................................................................................................................................373
STEP 3. Connector check: D-06 rear room lamp connector.............................................................................................................................................................373
STEP 4. Check the bulb.............................................................................................................................................................................................373
STEP 5. Check the rear room lamp...................................................................................................................................................................................373
STEP 6. Check the wiring harness from D-06 rear room lamp connector terminal No.1 to battery.......................................................................................................................373
STEP 7. Connector check: C-218 ETACS-ECU connector and D-06 rear room lamp connector...............................................................................................................................374
STEP 8. Check the wiring harness from C-218 ETACS-ECU connector terminal No.18 to D-06 rear room lamp connector terminal No.2......................................................................................374
Inspection Procedure 4: The Ignition Key Cylinder Illumination Lamp does not Illuminate Normally...........................................................................................................................375
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................376
STEP 1. Check the operation of the front room lamp and rear room lamp..............................................................................................................................................376
STEP 2. M.U.T.-III data list.......................................................................................................................................................................................376
STEP 3. Check the key reminder switch..............................................................................................................................................................................376
STEP 4. Connector check: C-301 key reminder switch connector.......................................................................................................................................................376
STEP 5. Check the bulb of the ignition key cylinder illumination lamp..............................................................................................................................................376
STEP 6. Voltage measurement at C-301 key reminder switch connector.................................................................................................................................................376
STEP 7. Check the wiring harness from C-301 key reminder switch connector terminal No.2 to battery.................................................................................................................377
STEP 8. Connector check: C-220 ETACS-ECU connector.................................................................................................................................................................377
STEP 9. Check the wiring harness from C-220 ETACS-ECU connector terminal No.32 to C-301 key reminder switch connector terminal No.1................................................................................377
STEP 10. Retest the system.........................................................................................................................................................................................378
ON-VEHICLE SERVICE.........................................................................................................................................................................................................378
HOW TO ADJUST THE ROOM LAMP DELAY-OFF TIME.............................................................................................................................................................................378
REMOVAL AND INSTALLATION...................................................................................................................................................................................................378
REAR COMBINATION LAMP..........................................................................................................................................................................................................379
SPECIAL TOOL...............................................................................................................................................................................................................379
REMOVAL AND INSTALLATION...................................................................................................................................................................................................379
REFLECTOR......................................................................................................................................................................................................................380
SPECIFICATIONS.............................................................................................................................................................................................................380
REMOVAL AND INSTALLATION...................................................................................................................................................................................................380
HIGH-MOUNTED STOP LAMP.........................................................................................................................................................................................................381
REMOVAL AND INSTALLATION...................................................................................................................................................................................................381
LICENCE PLATE LAMP.............................................................................................................................................................................................................381
SPECIAL TOOL...............................................................................................................................................................................................................381
REMOVAL AND INSTALLATION...................................................................................................................................................................................................382
REMOVAL SERVICE POINT..................................................................................................................................................................................................382
HAZARD WARNING LAMP SWITCH.....................................................................................................................................................................................................383
SPECIAL TOOL...............................................................................................................................................................................................................383
REMOVAL AND INSTALLATION...................................................................................................................................................................................................383
INSPECTION.................................................................................................................................................................................................................383
HAZARD WARNING LAMP SWITCH CONTINUITY CHECK............................................................................................................................................................................383
HORN...........................................................................................................................................................................................................................384
REMOVAL AND INSTALLATION...................................................................................................................................................................................................384
INSPECTION.................................................................................................................................................................................................................384
HORN RELAY CONTINUITY CHECK............................................................................................................................................................................................384
CIGARETTE LIGHTER..............................................................................................................................................................................................................385
INSPECTION.................................................................................................................................................................................................................385
ACCESSORY SOCKET...............................................................................................................................................................................................................385
INSPECTION.................................................................................................................................................................................................................385
ACCESSORY SOCKET RELAY CHECK...........................................................................................................................................................................................385
COLUMN SWITCH..................................................................................................................................................................................................................386
SPECIAL TOOL...............................................................................................................................................................................................................386
REMOVAL AND INSTALLATION...................................................................................................................................................................................................386
INSPECTION.................................................................................................................................................................................................................386
LIGHTING SWITCH CONTINUITY CHECK.......................................................................................................................................................................................386
COLUMN SWITCH (SWITCH BODY) CONTINUITY CHECK...........................................................................................................................................................................387
CLOCK <VEHICLES WITHOUT RV METER>..............................................................................................................................................................................................388
REMOVAL AND INSTALLATION...................................................................................................................................................................................................388
RADIO AND TAPE PLAYER OR CD PLAYER.............................................................................................................................................................................................389
SPECIAL TOOLS..............................................................................................................................................................................................................389
TROUBLESHOOTING............................................................................................................................................................................................................389
INTRODUCTION TO AUDIO SYSTEM DIAGNOSIS.....................................................................................................................................................................................389
AUDIO ERROR CODES......................................................................................................................................................................................................389
TROUBLESHOOTING............................................................................................................................................................................................................390
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING.............................................................................................................................................................................390
TROUBLE SYMPTOM CHART......................................................................................................................................................................................................391
SYMPTOM PROCEDURES.........................................................................................................................................................................................................392
Inspection Procedure 1: Power of Radio and Tape Player or CD Player does not Turn ON when the Ignition Switch is in the "ACC" Position or "ON" Position....................................................................392
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................392
STEP 1. Check to see that the power turns ON when the power switch is turned ON....................................................................................................................................392
STEP 2. Connector check: radio and tape player or CD player connector C-125........................................................................................................................................393
STEP 3. Voltage measurement at radio and tape player or CD player connector C-125 in order to check the battery circuit of power supply system to the radio and tape player or CD player (ignition switch ACC).....393
STEP 4. Check the wiring harness between radio and tape player or CD player connector C-125 (terminal 10) and ignition switch (ACC)................................................................................394
STEP 5. Check the assembling state of the radio and tape player or CD player.......................................................................................................................................394
Inspection Procedure 2: No Sound from One Speaker..........................................................................................................................................................................395
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................396
STEP 1. Check to see which speaker the sound is not output from....................................................................................................................................................396
STEP 2. Check the front door speaker (LH)..........................................................................................................................................................................396
STEP 3. Connector check: Front door speaker (LH) connector E-19 and radio and tape player or CD player connector C-125.............................................................................................396
STEP 4. Check the wiring harness between front door speaker (LH) connector E-19 (terminal 1 and 2) and radio and tape player or CD player connector C-125 (terminals 5 and 13).....................................397
STEP 5. Check the front door speaker (RH)..........................................................................................................................................................................397
STEP 6. Connector check: Front door speaker (RH) connector E-11 and radio and tape player or CD player connector C-125.............................................................................................397
STEP 7. Check the wiring harness between front door speaker (RH) connector E-11 (terminal 1 and 2) and radio and tape player or CD player connector C-125 (terminal 6 and 14)......................................398
STEP 8. Check the rear door speaker (LH)...........................................................................................................................................................................398
STEP 9. Connector check: Rear door speaker (LH) connector E-22 and radio and tape player or CD player connector C-125..............................................................................................398
STEP 10. Check the wiring harness between rear door speaker (LH) connector E-22 (terminal 1 and 2) and radio and tape player or CD player connector C-125 (terminal 2 and 8).......................................399
STEP 11. Check the rear door speaker (RH)..........................................................................................................................................................................399
STEP 12. Connector check: Rear door speaker (RH) connector E-09 and radio and tape player or CD player connector C-125.............................................................................................399
STEP 13. Check the wiring harness between rear door speaker (RH) connector E-09 (terminals 1 and 2) and radio and tape player or CD player connector C-125 (terminals 1 and 7).....................................400
Inspection Procedure 3: Noise Appears at Certain Places when Travelling (AM)...............................................................................................................................................401
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................401
STEP 1. Check the noise occur when entering or near a particular structure (building, tunnel, mountain, etc).......................................................................................................401
STEP 2. After taking the following measures to prevent the noise, check that no noise appears......................................................................................................................401
STEP 3. Ask the owner about the state of the noise.................................................................................................................................................................401
STEP 4. Check that there is no noise...............................................................................................................................................................................401
Inspection Procedure 4: Noise is Present while Moving (FM).................................................................................................................................................................401
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................401
Inspection Procedure 5: Mixed with Noise, Only at Night (AM)...............................................................................................................................................................402
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................402
STEP 1. Check that the noise still obvious even when the lamps are off.............................................................................................................................................402
STEP 2. Check hat the following actions............................................................................................................................................................................402
STEP 3. Check that the noise fades away when the vehicle harness is moved away from the radio (if the harness is not in the proper position).......................................................................402
Inspection Procedure 6: Broadcasts can be Heard but Both AM and FM have a lot of Noise.....................................................................................................................................403
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................403
STEP 1. Check the state of the antenna.............................................................................................................................................................................403
STEP 2. Check that the noise occur when the engine is stopped or the engine is running.............................................................................................................................403
STEP 3. Check that the following actions disappear the noise.......................................................................................................................................................403
STEP 4. Check that the radio is correctly earthed..................................................................................................................................................................403
STEP 5. Check the connection of the antenna plug and radio and tape player or CD player............................................................................................................................403
STEP 6. Check that the noise is eliminated when the antenna plug is properly attached..............................................................................................................................403
STEP 7. Check that the antenna is in good condition and is it properly mounted.....................................................................................................................................403
Inspection Procedure 7: There is More Noise on Either AM or FM.............................................................................................................................................................404
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................404
STEP 1. Check that there is noise under the following state(s).....................................................................................................................................................404
STEP 2. Continue to check for static; when static is detected, check for the conditions listed above...............................................................................................................404
STEP 3. Check noise prevention on the radio side is difficult......................................................................................................................................................404
Inspection Procedure 8: There is Noise when Starting the Engine............................................................................................................................................................405
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................405
Inspection Procedure 9: Some Noise Appears when there is Vibration or Shocks During Travelling.............................................................................................................................407
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................407
STEP 1. Connector check: Radio and tape player or CD player connector C-125........................................................................................................................................407
STEP 2. Check that noise appear when the radio switch is turned on while the vehicle is stopped and the radio is tapped while tuned away from a station............................................................407
STEP 3. Check that the radio correctly earthed.....................................................................................................................................................................407
STEP 4. Check by replacing the radio and tape player or CD player..................................................................................................................................................407
Inspection Procedure 10: Noise Sometimes Appears on FM during Travelling...................................................................................................................................................408
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................408
STEP 1. Check the state of the antenna.............................................................................................................................................................................408
STEP 2. The check after adjusting the radio........................................................................................................................................................................408
STEP 3. Check with several broadcasting stations...................................................................................................................................................................408
STEP 4. Check that noise appears when the radio switch is turned on while the vehicle is stopped...................................................................................................................408
STEP 5. Check that the radio is correctly earthed..................................................................................................................................................................408
STEP 6. Check by replacing the radio and tape player or CD player..................................................................................................................................................408
Inspection Procedure 11: Ever-Present Noise................................................................................................................................................................................408
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................408
Inspection Procedure 12: There is Noise but No Reception for Both AM and FM or No Sound from AM, or No Sound from FM.......................................................................................................409
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................409
STEP 1. Check the state of the antenna.............................................................................................................................................................................409
STEP 2. Check to see if inspections are taking place is an area exposed to special electric fields.................................................................................................................409
STEP 3. Relocate and check.........................................................................................................................................................................................409
STEP 4. Tune then check............................................................................................................................................................................................409
STEP 5. Check the connection of the antenna plug and the radio and tape player or CD player........................................................................................................................409
STEP 6. Check by replacing the radio and tape player or CD player..................................................................................................................................................409
Inspection Procedure 13: Poor Reception....................................................................................................................................................................................409
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................409
STEP 1. Check the state of the antenna.............................................................................................................................................................................409
STEP 2. Check to see if inspections are taking place is an area exposed to special electric fields.................................................................................................................409
STEP 3. Relocate and check.........................................................................................................................................................................................409
STEP 4. Tune then check............................................................................................................................................................................................409
STEP 5. Check with several broadcasting stations...................................................................................................................................................................410
STEP 6. Check the connection of the antenna plug and the radio and tape player or CD player........................................................................................................................410
STEP 7. Check by replacing the radio and tape player or CD player..................................................................................................................................................410
Inspection Procedure 14: Distortion on AM or on Both AM and FM.............................................................................................................................................................410
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................410
STEP 1. Check the degree in which distortion is generated..........................................................................................................................................................410
STEP 2. Check by the transmission antenna..........................................................................................................................................................................410
STEP 3. Check how the speakers are setup...........................................................................................................................................................................410
STEP 4. Check the speakers.........................................................................................................................................................................................410
STEP 5. Check how the speakers are setup...........................................................................................................................................................................410
Inspection Procedure 15: Distortion on FM Only.............................................................................................................................................................................411
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................411
STEP 1. Check with another broadcasting station....................................................................................................................................................................411
STEP 2. Relocate the reception area and check......................................................................................................................................................................411
Inspection Procedure 16: Using the Auto Select Function, Too Few Automatic Stations are Selected...........................................................................................................................411
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................411
STEP 1. Check the state of the antenna.............................................................................................................................................................................411
STEP 2. Check the number of radio stations.........................................................................................................................................................................411
STEP 3. Check the distance from the transmission antenna...........................................................................................................................................................411
STEP 4. The check if there are not that many radio stations and when there is no transmission antenna in the vicinity..............................................................................................411
STEP 5. Check to see if inspections are taking place is an area exposed to special electric fields.................................................................................................................411
STEP 6. Relocate and check.........................................................................................................................................................................................411
STEP 7. Check the connection of the antenna plug and the radio and tape player or CD player........................................................................................................................411
Inspection Procedure 17: Preset Station are Erased.........................................................................................................................................................................412
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................412
STEP 1. Voltage measurement at radio and tape player or CD player connector C-125..................................................................................................................................412
STEP 2. Connector check: Radio and tape player or CD player connector C-125........................................................................................................................................413
STEP 3. Check the wiring harness between radio and tape player or CD player connector C-125 (terminal 11) and battery..............................................................................................413
Inspection Procedure 18: Cassette Tape can Not be Inserted.................................................................................................................................................................414
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................414
STEP 1. Check that there are any foreign objects inside the cassette player........................................................................................................................................414
STEP 2. Check that the radio with cassette player works when another tape is inserted..............................................................................................................................414
Inspection Procedure 19: Sound Quality is Poor, or Sound is Weak...........................................................................................................................................................414
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................414
STEP 1. Check that the player works normally if the tape is changed................................................................................................................................................414
STEP 2. Check that the player play OK if the tape player head is cleaned...........................................................................................................................................414
STEP 3. Check that the proper operation is obtained when the tape player is replaced...............................................................................................................................414
Inspection Procedure 20: Cassette Tape can Not be Ejected..................................................................................................................................................................414
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................414
Inspection Procedure 21: Uneven Revolution. Tape Speed is Fast or Slow.....................................................................................................................................................415
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................415
STEP 1. Check that the cassette player work normally when the tape is changed......................................................................................................................................415
STEP 2. Check that there are any foreign objects inside the cassette player........................................................................................................................................415
STEP 3. Check that the head or capstan roller is dirty.............................................................................................................................................................415
Inspection Procedure 22: Automatic Search does Not Work....................................................................................................................................................................415
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................415
STEP 1. Check that the "APS" (automatic search) button be depressed properly.......................................................................................................................................415
STEP 2. Check that the player works when the tape is changed.......................................................................................................................................................415
Inspection Procedure 23: Malfunction of the Auto Reverse...................................................................................................................................................................416
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................416
STEP 1. Check that the cassette player works normally when the tape is changed.....................................................................................................................................416
STEP 2. Check that the problem only occur while the vehicle is being driven........................................................................................................................................416
STEP 3. Check that the cassette player is properly installed to the vehicle........................................................................................................................................416
Inspection Procedure 24: Tape gets Caught in Mechanism.....................................................................................................................................................................416
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................416
Check that the player works normally if tape is changed............................................................................................................................................................416
Inspection Procedure 25: CD can Not be Inserted............................................................................................................................................................................417
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................417
STEP 1. Check that a CD has been already loaded....................................................................................................................................................................417
STEP 2. Check how a CD is inserted.................................................................................................................................................................................417
STEP 3. Check after the CD is loaded...............................................................................................................................................................................417
STEP 4. Check the CD...............................................................................................................................................................................................417
STEP 5. Check again using a normal CD, which is not dirty or scratched.............................................................................................................................................417
Inspection Procedure 26: No Sound. (CD only)...............................................................................................................................................................................417
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................417
STEP 1. Check again using a normal CD, which is not dirty or scratched.............................................................................................................................................417
STEP 2. Check power supply to the CD player when the ignition switch is at "ACC" or "ACC"..........................................................................................................................417
Inspection Procedure 27: CD Sound Skips....................................................................................................................................................................................418
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................418
STEP 1. Check the state in which the sound on the CD jumps.........................................................................................................................................................418
STEP 2. Check the surface of the CD................................................................................................................................................................................418
STEP 3. Check when replacing with a CD that can be played normally without any scratches or soiling................................................................................................................418
STEP 4. Check by tapping the radio and CD player...................................................................................................................................................................418
Inspection Procedure 28: Sound Quality is Poor.............................................................................................................................................................................418
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................418
Check to see that the CD can be played normally and that it is free of any scratches or soiling....................................................................................................................418
Inspection Procedure 29: CD can not be ejected.............................................................................................................................................................................418
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................418
Check the power of ignition switch "ACC"...........................................................................................................................................................................418
ON-VEHICLE SERVICE.........................................................................................................................................................................................................419
SPEAKER TEST...............................................................................................................................................................................................................419
RADIO AND TAPE PLAYER SPEAKER TEST.....................................................................................................................................................................................419
RADIO AND CD PLAYER SPEAKER TEST.......................................................................................................................................................................................419
RADIO AND TAPE PLAYER OR CD PLAYER.........................................................................................................................................................................................420
REMOVAL AND INSTALLATION...................................................................................................................................................................................................420
SPEAKER........................................................................................................................................................................................................................421
REMOVAL AND INSTALLATION...................................................................................................................................................................................................421
REMOVAL SERVICE POINTS.................................................................................................................................................................................................421
ANTENNA........................................................................................................................................................................................................................422
REMOVAL AND INSTALLATION...................................................................................................................................................................................................422
REMOVAL SERVICE POINT..................................................................................................................................................................................................422
RV METER.......................................................................................................................................................................................................................423
SPECIAL TOOLS..............................................................................................................................................................................................................423
TROUBLESHOOTING............................................................................................................................................................................................................424
TROUBLE DIAGMOSIS SERVICE FUNCTIONS........................................................................................................................................................................................424
BATTERY DISCONNECTION..................................................................................................................................................................................................432
DIAGNOSTIC FUNCTION........................................................................................................................................................................................................433
HOW TO READ DIAGNOSIS CODE.............................................................................................................................................................................................433
HOW TO ERASING DIAGNOSIS CODE..........................................................................................................................................................................................433
DIAGNOSIS CODE CHART.......................................................................................................................................................................................................433
DIAGNOSTIC TROUBLE CODE PROCEDURES.........................................................................................................................................................................................433
Code No. 24: Open circuit in the SWS.......................................................................................................................................................................................433
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................434
STEP 1. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................434
STEP 2. Connector check: RV meter connector C-108 and CAN adapter connector C-110..................................................................................................................................434
STEP 3. Check the harness wires between RV meter connector C-108 (terminal 26) and CAN adapter connector C-110 (terminal 2)........................................................................................435
STEP 4. Check whether the diagnosis code is reset..................................................................................................................................................................435
STEP 5. Check whether the diagnosis code is reset..................................................................................................................................................................435
Code No. 25: Open circuit in the K-LINE....................................................................................................................................................................................436
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................436
STEP 1. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................436
STEP 2. Connector check: RV meter connector C-108 and CAN adapter connector C-110..................................................................................................................................437
STEP 3. Check the harness wires between RV meter connector C-108 (terminal 35) and CAN adapter connector C-110 (terminal 8)........................................................................................437
STEP 4. Check whether the diagnosis code is reset..................................................................................................................................................................437
STEP 5. Check whether the diagnosis code is reset..................................................................................................................................................................438
SYMPTOM CHART..............................................................................................................................................................................................................438
SYMPTOM PROCEDURES.........................................................................................................................................................................................................439
Inspection Procedure 1: The RV Meter does not Show Any Information.........................................................................................................................................................439
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................440
STEP 1. Check the following connector: C-108 RV meter connector....................................................................................................................................................440
STEP 2. Measure the resistance at C-108 RV meter connector.........................................................................................................................................................440
STEP 3. Check the harness wire between C-108 RV meter connector terminal No.8 and body earth.......................................................................................................................440
STEP 4. Measure the voltage at C-108 RV meter connector............................................................................................................................................................440
STEP 5. Check the harness wire between battery (fusible link No.20) and C-108 RV meter connector terminal No.6.....................................................................................................441
STEP 6. Measure the voltage at C-108 RV meter connector............................................................................................................................................................441
STEP 7. Check the harness wire between ignition switch (ACC) and C-108 RV meter connector terminal No.5............................................................................................................442
STEP 8. Replace the RV meter temporarily and retest the system.....................................................................................................................................................442
STEP 9. Retest the system..........................................................................................................................................................................................442
Inspection Procedure 2: "Please Turn the Ignition Key to the ON Position." is continuously displayed.......................................................................................................................443
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................444
STEP 1. Check the communication and connection (ignition switch (IG1)) of the service function.....................................................................................................................444
STEP 2. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................444
STEP 3. M.U.T.-III other system diagnosis code.....................................................................................................................................................................444
STEP 4. M.U.T.-III diagnosis code..................................................................................................................................................................................444
STEP 5. Check the following connector: C-110 CAN adapter connector.................................................................................................................................................444
STEP 6. Measure the resistance at C-110 CAN adapter connector......................................................................................................................................................444
STEP 7. Check the harness wire between C-110 CAN adapter connector terminal No.4 and body earth....................................................................................................................445
STEP 8. Measure the voltage at C-110 CAN adapter connector.........................................................................................................................................................445
STEP 9. Check the harness wire between ignition switch (ACC) and C-110 CAN adapter connector terminal No.1.........................................................................................................446
STEP 10. Replace the RV meter temporarily and retest the system....................................................................................................................................................446
Inspection Procedure 3: The Low Battery Warning Screen is Displayed........................................................................................................................................................447
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................447
STEP 1.Check the RV meter power supply.............................................................................................................................................................................447
STEP 2. Check the following connector: C-108 RV meter connector....................................................................................................................................................447
STEP 3. Measure the voltage at C-108 RV meter connector............................................................................................................................................................448
STEP 4. Check the harness wire between battery (fusible link No.20) and C-108 RV meter connector terminal No.6.....................................................................................................448
STEP 5. Recheck for malfunction....................................................................................................................................................................................448
Inspection Procedure 4: The Drive Information is not Displayed Normal......................................................................................................................................................449
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................450
STEP 1. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................450
STEP 2. M.U.T-III other system diagnosis code......................................................................................................................................................................450
STEP 3. M.U.T.-III diagnosis code..................................................................................................................................................................................450
STEP 4. Connector check: Fuel pump and gauge unit connector F-09...................................................................................................................................................450
STEP 5. Check the Fuel pump and gauge unit.........................................................................................................................................................................450
STEP 6. Check the communication and connection (the fuel pump and gauge unit) of the service function..............................................................................................................450
STEP 7. Measure the resistance at F-09 fuel pump and gauge unit connector..........................................................................................................................................451
STEP 8. Check the harness wire between F-09 fuel pump and gauge unit connector terminal No.2 and body earth........................................................................................................451
STEP 9. Connector check: RV meter connector C-108..................................................................................................................................................................451
STEP 10. Check the wiring harness between C-108 RV meter connector terminal No.13 and F-09 fuel pump and gauge unit connector terminal No.1........................................................................451
STEP 11. Recheck for malfunction...................................................................................................................................................................................452
Inspection Procedure 5: The Ambient Air Temperature is not Displayed Normal................................................................................................................................................452
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................453
STEP 1. Check the following connector: A-36 ambient air temperature sensor.........................................................................................................................................453
STEP 2. Check the ambient air temperature sensor...................................................................................................................................................................453
STEP 3. Check the communication and connection (the ambient air temperature sensor) of the service function........................................................................................................453
STEP 4. Check the following connector: C-108 RV meter connector....................................................................................................................................................453
STEP 5. Check the harness wire between C-108 RV meter connector terminals No.3, 11 and A-36 ambient air temperature sensor connector terminals No.1, 2.............................................................454
STEP 6. M.U.T-III other system data list...........................................................................................................................................................................454
STEP 7. Check the following connector: B-01 vehicle speed sensor connector.........................................................................................................................................455
STEP 8. Check the wiring harness between B-01 vehicle speed sensor connector terminal No.3 and C-108 RV meter connector terminal No.7..............................................................................456
STEP 9. Recheck for malfunction....................................................................................................................................................................................456
Inspection Procedure 6: Icy road surface warning function does not work normally...........................................................................................................................................457
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................458
STEP 1. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................458
STEP 2. M.U.T-III other system diagnosis code......................................................................................................................................................................458
STEP 3. M.U.T.-III diagnosis code..................................................................................................................................................................................458
Step 4. Recheck for malfunction....................................................................................................................................................................................458
Inspection Procedure 7: The Compass does not Indicate Normally.............................................................................................................................................................458
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................458
STEP 1. Check the geomagnetism sensor mode in service mode.........................................................................................................................................................458
STEP 2.Check of own vehicle position...............................................................................................................................................................................458
STEP 3. Move the vehicle to the geomagnetically stable location to re-check the geomagnetism.......................................................................................................................458
STEP 4. Check of RV meter for magnetization........................................................................................................................................................................458
STEP 5. Recheck for malfunction....................................................................................................................................................................................459
Inspection Procedure 8: The Radio and CD Player Information is not Displayed Normal........................................................................................................................................459
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................460
STEP 1. Connector check: Radio and CD player connector C-126 and RV meter connector C-109..........................................................................................................................460
STEP 2. Check the wiring harness between radio and CD player connector C-126 (terminal 26, 27 and 34) and centre display unit connector C-109 (terminal 27, 37 and 28).............................................460
STEP 3. Retest the system..........................................................................................................................................................................................460
Inspection Procedure 9: Button illumination of RV meter does not illuminate................................................................................................................................................461
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................461
STEP 1.Check the RV meter power supply.............................................................................................................................................................................461
STEP 2. M.U.T-III other system diagnosis code......................................................................................................................................................................461
STEP 3. Check of combination meter trouble symptom.................................................................................................................................................................461
STEP 4. Check the following connector: C-108 RV meter connector, C-113 combination meter connector.................................................................................................................462
STEP 5. Check the harness wire between C-108 RV meter connector terminal No.12 and C-113 combination meter connector terminal No.15................................................................................462
STEP 6. Check the following connector C-220 ETACS-ECU connector....................................................................................................................................................463
STEP 7. Check the harness wire between C-108 RV meter connector terminal No.4 and C-220 ETACS-ECU connector terminal No.34.........................................................................................463
STEP 8. Recheck for malfunction....................................................................................................................................................................................463
CHECK AT ECU TERMINAL......................................................................................................................................................................................................464
RV METER...............................................................................................................................................................................................................464
CAN ADAPTER............................................................................................................................................................................................................466
ON-VEHICLE SERVICE.........................................................................................................................................................................................................467
VEHICLE MAGNETIC COMPENSATION..............................................................................................................................................................................................467
Confirmation of magnetization and demagnetization......................................................................................................................................................................467
Demagnetization and correction method..................................................................................................................................................................................468
RV METER...................................................................................................................................................................................................................470
REMOVAL AND INSTALLATION...................................................................................................................................................................................................470
AMBIENT AIR TEMPERATURE SENSOR.............................................................................................................................................................................................471
REMOVAL AND INSTALLATION...................................................................................................................................................................................................471
INSPECTION.................................................................................................................................................................................................................471
DEFOGGER.......................................................................................................................................................................................................................471
TROUBLESHOOTING............................................................................................................................................................................................................471
ON-VEHICLE SERVICE.........................................................................................................................................................................................................471
PRINTED HEATER LINES CHECK.................................................................................................................................................................................................471
REAR WINDOW DEMISTER RELAY CHECK.......................................................................................................................................................................................472
DEFOGGER SWITCH................................................................................................................................................................................................................472
REMOVAL AND INSTALLATION...................................................................................................................................................................................................472
54C.pdf................................................................................................................................................................................................................................473
CONTROLLER AREA NETWORK (CAN)......................................................................................................................................................................................................473
GENERAL INFORMATION............................................................................................................................................................................................................474
STRUCTURE..................................................................................................................................................................................................................474
SPECIAL TOOL...................................................................................................................................................................................................................475
TEST EQUIPMENT.................................................................................................................................................................................................................476
SERVICE PRECAUTIONS............................................................................................................................................................................................................477
PRECAUTIONS ON HOW TO REPAIR THE CAN BUS LINES.................................................................................................................................................................................478
EXPLANATION ABOUT THE MUT-III CAN BUS DIAGNOSTICS..............................................................................................................................................................................479
CAN BUS LINE DIAGNOSTIC FLOW...............................................................................................................................................................................................479
TROUBLESHOOTING................................................................................................................................................................................................................486
CAN BUS DIAGNOSTICS TABLE..................................................................................................................................................................................................486
CAN BUS DIAGNOSIS..........................................................................................................................................................................................................490
Diagnosis Item 1: Diagnose shorts in the power supply to CAN bus line......................................................................................................................................................490
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................491
STEP 1. Check the CAN bus lines. Voltage measurement at C-22 diagnosis connector...................................................................................................................................491
STEP 2. Check the CAN line. Voltage measurement at C-35 intermediate connector.....................................................................................................................................492
STEP 3. Check the CAN line between joint connector (CAN2) and the engine-ECU. Voltage measurement at C-01 joint connector (CAN2)...................................................................................493
STEP 4. Check the CAN line between joint connector (CAN2) and the A/T-ECU. Voltage measurement at C-01 joint connector (CAN2)......................................................................................494
STEP 5. M.U.T.-III CAN bus diagnostics [A/T-ECU connector disconnected]............................................................................................................................................494
STEP 6. M.U.T.-III CAN bus diagnostics (retest the system).........................................................................................................................................................494
STEP 7. Check the CAN line between joint connector (CAN1) and the ETACS-ECU. Voltage measurement at C-119 joint connector (CAN1)...................................................................................495
STEP 8. Check the CAN line between joint connector (CAN1) and the CAN adapter. Voltage measurement at C-119 joint connector (CAN1).................................................................................496
STEP 9. M.U.T.-III CAN bus diagnostics [CAN adapter connector disconnected]........................................................................................................................................497
STEP 10. Check the CAN line between joint connector (CAN1) and the ABS-ECU. Voltage measurement at C-119 joint connector (CAN1)....................................................................................497
STEP 11. M.U.T.-III CAN bus diagnostics [ABS-ECU connector disconnected]...........................................................................................................................................498
STEP 12. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................499
STEP 13. Check the CAN line between joint connector (CAN1) and the diagnosis connector. Voltage measurement at C-119 joint connector (CAN1)........................................................................499
STEP 14. M.U.T.-III CAN bus diagnostics [engine-ECU connector disconnected]........................................................................................................................................500
STEP 15. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................500
STEP 16. M.U.T.-III CAN bus diagnostics [ETECS-ECU connector disconnected].........................................................................................................................................500
STEP 17. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................501
Diagnosis Item 2: Diagnose shorts in the ground to CAN bus line............................................................................................................................................................502
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................504
STEP 1.Check the CAN bus lines. Resistance measurement at C-22 diagnosis connector.................................................................................................................................504
STEP 2. Check the CAN line. Resistance measurement at C-35 intermediate connector..................................................................................................................................505
STEP 3. Check the CAN line between joint connector (CAN2) and the engine-ECU. Resistance measurement at C-01 joint connector (CAN2)................................................................................506
STEP 4. Check the CAN line between joint connector (CAN2) and the A/T-ECU. Resistance measurement at C-01 joint connector (CAN2)...................................................................................507
STEP 5. M.U.T.-III CAN bus diagnostics [A/T-ECU connector disconnected]............................................................................................................................................507
STEP 6. M.U.T.-III CAN bus diagnostics (retest the system).........................................................................................................................................................508
STEP 7. Check CAN line between joint connector (CAN1) and the ETACS-ECU. Resistance measurement at C-119 joint connector (CAN1)....................................................................................509
STEP 8. Check the CAN line between joint connector (CAN1) and the CAN adapter. Resistance measurement at C-119 joint connector (CAN1)..............................................................................510
STEP 9. M.U.T.-III CAN bus diagnostics [CAN adapter connector disconnected]........................................................................................................................................510
STEP 10. Check the CAN line between joint connector (CAN1) and the ABS-ECU. Resistance measurement at C-119 joint connector (CAN1).................................................................................512
STEP 11. M.U.T.-III CAN bus diagnostics [ABS-ECU connector disconnected]...........................................................................................................................................513
STEP 12. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................513
STEP 13. Check the CAN line between joint connector (CAN1) and the diagnosis connector. Resistance measurement at C-119 joint connector (CAN1).....................................................................514
STEP 14. M.U.T.-III CAN bus diagnostics [engine-ECU connector disconnected]........................................................................................................................................515
STEP 15. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................515
STEP 16. M.U.T.-III CAN bus diagnostics [ETECS-ECU connector disconnected].........................................................................................................................................515
STEP 17. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................516
Diagnosis Item 3: Diagnose shorts between CAN_H and L lines................................................................................................................................................................517
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................518
STEP 1. Connector check: C-35 intermediate connector...............................................................................................................................................................518
STEP 2. Resistance measurement at C-35 intermediate connector......................................................................................................................................................518
STEP 3. Connector check: C-01 joint connector (CAN2)...............................................................................................................................................................519
STEP 4. Resistance measurement at C-01 joint connector (CAN2)......................................................................................................................................................519
STEP 5. Resistance measurement at C-106 <2500-SOHC> or C-103 <2500-DOHC, 3200> engine-ECU connector................................................................................................................520
STEP 6. Resistance measurement at C-01 joint connector (CAN2)......................................................................................................................................................520
STEP 7. Resistance measurement at C-18 <2WD> or C-20 <4WD> A/T-ECU connector.......................................................................................................................................522
STEP 8. Connector check: C-119 joint connector (CAN1)..............................................................................................................................................................522
STEP 9. Resistance measurement at C-119 joint connector (CAN1).....................................................................................................................................................523
STEP 10. Resistance measurement at C-219 ETACS-ECU connector.......................................................................................................................................................523
STEP 11. Resistance measurement at C-119 joint connector (CAN1)....................................................................................................................................................524
STEP 12. Resistance measurement at C-110 CAN adapter connector.....................................................................................................................................................524
STEP 13. Resistance measurement at C-119 joint connector (CAN1)....................................................................................................................................................525
STEP 14. Resistance measurement at A-01 ABS-ECU connector..........................................................................................................................................................526
STEP 15. Resistance measurement at C-119 joint connector (CAN1)....................................................................................................................................................526
Diagnosis Item 4: Diagnose the terminator resistors........................................................................................................................................................................527
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................528
STEP 1. Resistance measurement at C-219 ETACS-ECU connector........................................................................................................................................................528
STEP 2. Resistance measurement at C-106 <2500-SOHC> or C-103 <2500-DOHC, 3200> engine-ECU connector................................................................................................................529
Diagnosis Item 5: Diagnose when the M.U.T.-III cannot receive the data sent by ETACS-ECU...................................................................................................................................530
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................531
STEP 1. Connector check: C-119 joint connector (CAN1) and C-219 ETACS-ECU connector................................................................................................................................531
STEP 2. Resistance measurement at C-119 joint connector (CAN1) and C-219 ETACS-ECU connector.......................................................................................................................531
STEP 3. Resistance measurement at C-219 ETACS-ECU connector........................................................................................................................................................533
Diagnosis Item 6: Diagnose when the M.U.T.-III cannot receive the data sent by CAN adapter. <Vehicles with RV meter>.......................................................................................................534
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................535
STEP 1. Connector check: C-119 joint connector (CAN1) and C-110 CAN adapter connector..............................................................................................................................535
STEP 2. Resistance measurement at C-119 joint connector (CAN1) and C-110 CAN adapter connector.....................................................................................................................535
Diagnosis Item 7: Diagnose when the M.U.T.-III cannot receive the data sent by ABS-ECU. <Vehicles with ABS>................................................................................................................537
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................538
STEP 1. Connector check: C-13 intermediate connector, C-119 joint connector (CAN1) and A-01 ABS-ECU connector......................................................................................................538
STEP 2. Resistance measurement at C-119 joint connector (CAN1) and C-13 intermediate connector.....................................................................................................................538
STEP 3. Resistance measurement at C-13 intermediate connector and A-01 ABS-ECU connector...........................................................................................................................540
Diagnosis Item 8: Diagnose the lines between the joint connectors (CAN1 and CAN2)..........................................................................................................................................542
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................543
STEP 1. Connector check: C-35 intermediate connector, C-119 joint connector (CAN1) and C-01 joint connector (CAN2).................................................................................................543
STEP 2. Resistance measurement at C-119 joint connector (CAN1) and C-35 intermediate connector.....................................................................................................................544
STEP 3. Resistance measurement at C-01 joint connector (CAN2) and C-35 intermediate connector......................................................................................................................546
Diagnosis Item 9: Diagnose when the M.U.T.-III cannot receive the data sent by A/T-ECU. <A/T>..............................................................................................................................548
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................549
STEP 1. Connector check: C-01 joint connector (CAN2) and C-18 <2WD> or C-20 <4WD> A/T-ECU connector................................................................................................................549
STEP 2. Resistance measurement at C-01 joint connector (CAN2) and C-18 <2WD> or C-20 <4WD> A/T-ECU connector.......................................................................................................549
Diagnosis Item 10: Diagnose when the M.U.T.-III cannot receive the data sent by engine-ECU.................................................................................................................................552
DIAGNOSIS PROCEDURE....................................................................................................................................................................................................553
STEP 1. Connector check: C-01 joint connector (CAN2) and C-106 engine-ECU connector................................................................................................................................553
STEP 2. Resistance measurement at C-01 joint connector (CAN2) and C-106 <2500-SOHC> or C-103 <2500-DOHC, 3200> engine-ECU connector................................................................................554
STEP 3. Resistance measurement at C-106 <2500-SOHC> or C-103 <2500-DOHC, 3200> engine-ECU connector................................................................................................................556
CAN COMMUNICATION SIGNAL TABLE.................................................................................................................................................................................................557
CAN COMMUNICATION-RELATED DIAGNOSIS CODE (U CODE) TABLE........................................................................................................................................................................558
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