Mitsubishi 2004 Lancer / Lancer Wagon Workshop Manual PDF

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Mitsubishi 2004 Lancer / Lancer Wagon Workshop Manual – PDF DOWNLOAD

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Mitsubishi 2004 Lancer / Lancer Wagon Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 788
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Mitsubishi 2004 Lancer / Lancer Wagon Workshop Manual – PDF DOWNLOAD

NOTE 416
Section titles with asterisks (*) in the table of contents in each group indicate operations requ 313
GENERAL 639
ENGINE 639
ENGINE LUBRICATION 639
GENERAL INFORMATION 201
ENGINE OILS 279
SERVICE SPECIFICATION 8
LUBRICANT 203
SEALANT 56
SPECIAL TOOLS 237
ON-VEHICLE SERVICE 10
ENGINE OIL CHECK 175
ENGINE OIL REPLACEMENT 281
ENGINE OIL FILTER REPLACEMENT 10
OIL PRESSURE CHECK 137
FUEL 639
ENGINE COOLING 639
GENERAL INFORMATION 226
SERVICE SPECIFICATIONS 56
LUBRICANT 280
SEALANTS 161
SPECIAL TOOLS 177
TROUBLESHOOTING 19
INSPECTION CHART FOR TROUBLE SYMPTOMS 113
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS 20
INSPECTION PROCEDURE 1: Cooling Fan (L H ) and Cooling Fan (R H ) <4G1 (Vehicles with A/C)> or A/ 20
DIAGNOSIS 491
STEP 1 Check the cooling fan motor (L H ) <Vehicles without A/C> 21
STEP 2 Measure the power supply voltage at cooling fan motor drive control unit connector A-18 117
STEP 3 Check the cooling fan motor drive control unit connector A-18 140
STEP 4 Check the fusible link No 2 242
STEP 5 Measure the power supply voltage at fan control relay connector A-09X 209
STEP 6 Check the fan control relay connector A-09X 22
STEP 7 Check the harness wire between fusible link No 2 and fan control relay connector A-09X te 349
STEP 8 Check the fan control relay 287
STEP 9 Check the fan control relay connector A-09X 23
STEP 10 Check the harness wire between fan control relay connector A-09X terminal 2 and cooling 650
STEP 11 Measure the terminal voltage at fan control relay connector A-09X 288
STEP 12 Check the J/C No 6 C-12 <L H drive vehicles> or C-134 <R H drive vehicles>, intermedia 24
STEP 13 Check the harness wire between J/C No 6 C-12 terminal 33 <L H drive vehicles> or C-134 245
STEP 14 Check the continuity between fan control relay connector A-09X and body earth 617
STEP 15 Check the fan control relay connector A-09X 351
STEP 16 Check the harness wire between fan control relay connector A-09X terminal 3 and body earth 617
STEP 17 Check the continuity between cooling fan motor drive control unit connector A-18 and bod 26
STEP 18 Check the cooling fan motor drive control unit connector A-18 352
STEP 19 Check the harness wire between cooling fan motor drive control unit connector A-18 termi 27
STEP 20 Check the cooling fan motor drive control unit connector A-18, intermediate connector A- 27
STEP 21 Check the harness wire between cooling fan motor drive control unit connector A-18 termi 292
STEP 22 Check the cooling fan motor drive control unit 29
STEP 23 MUT-II/III self-diag code 248
STEP 24 Check the symptoms 249
INSPECTION PROCEDURE 2: Cooling Fan (L H ) and Cooling Fan (R H ) <4G1 (Vehicles with A/C)> or A/ 399
DIAGNOSIS 400
STEP 1 Check the fan control relay 678
STEP 2 Check the fan control relay connector A-09X 356
STEP 3 Check the harness wire between fan control relay connector A-09X terminal 2 and cooling f 251
STEP 4 Check the cooling fan motor drive control unit connector A-18, intermediate connector A-1 401
STEP 5 Check the harness wire between cooling fan motor drive control unit connector A-18 termin 297
STEP 6 Check the cooling fan motor drive control unit 402
STEP 7 MUT-II/III self-diag code 695
STEP 8 Check the symptoms 299
INSPECTION PROCEDURE 3: Cooling Fan (L H ) does not Operate {When Cooling Fan (R H ) <4G1> or A/C 117
DIAGNOSIS 703
STEP 1 Check the cooling fan motor (L H ) 622
STEP 2 Check the cooling fan motor drive control unit 221
STEP 3 Check the symptoms 597
INSPECTION PROCEDURE 4: Cooling Fan (R H ) <4G1> or A/C Condenser Fan <4G6> does not Operate {Whe 53
DIAGNOSIS 406
STEP 1 Check the cooling fan motor (R H ) <4G1> or A/C condenser fan motor <4G6> 406
STEP 2 Check the cooling fan motor drive control unit 35
STEP 3 Check the symptoms 35
ON-VEHICLE SERVICE 718
ENGINE COOLANT LEAK CHECK 362
RADIATOR CAP VALVE OPENING PRESSURE CHECK 36
ENGINE COOLANT REPLACEMENT 36
CONCENTRATION MEASUREMENT 732
COOLING FAN MOTOR DRIVE CONTROL UNIT CHECK 623
FAN CONTROL RELAY CONTINUITY CHECK 38
COOLING FAN MOTOR CHECK 409
THERMOSTAT 155
REMOVAL AND INSTALLATION 40
REMOVAL SERVICE POINT 41
INSTALLATION SERVICE POINTS 41
INSPECTION 625
WATER PUMP 261
REMOVAL AND INSTALLATION <4G1> 261
INSTALLATION SERVICE POINT 253
REMOVAL AND INSTALLATION <4G6> 126
INSTALLATION SERVICE POINT 44
WATER HOSE AND WATER PIPE 45
REMOVAL AND INSTALLATION <4G1> 45
REMOVAL SERVICE POINT 525
INSTALLATION SERVICE POINTS 46
REMOVAL AND INSTALLATION <4G6> 47
REMOVAL SERVICE POINT 48
INSTALLATION SERVICE POINTS 417
INSPECTION 48
RADIATOR 49
REMOVAL AND INSTALLATION 49
REMOVAL SERVICE POINT 51
INSTALLATION SERVICE POINT 629
INTAKE AND EXHAUST 639
GENERAL INFORMATION 54
SERVICE SPECIFICATION 607
SPECIAL TOOL 54
AIR CLEANER 55
REMOVAL AND INSTALLATION 55
INLET MANIFOLD 111
REMOVAL AND INSTALLATION <4G1> 612
REMOVAL AND INSTALLATION <4G6> 113
INSPECTION 416
EXHAUST MANIFOLD 59
REMOVAL AND INSTALLATION <4G1> 231
REMOVAL SERVICE POINT 310
INSTALLATION SERVICE POINT 60
REMOVAL AND INSTALLATION <4G6> 208
REMOVAL SERVICE POINT 140
INSTALLATION SERVICE POINT 494
INSPECTION 110
EXHAUST PIPE AND MAIN MUFFLER 650
REMOVAL AND INSTALLATION 75
REMOVAL SERVICE POINT 652
INSTALLATION SERVICE POINT 395
ENGINE ELECTRICAL 639
CHARGING SYSTEM 640
GENERAL INFORMATION 237
SERVICE SPECIFICATIONS 135
SPECIAL TOOL 229
ON-VEHICLE SERVICE 67
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST 612
OUTPUT CURRENT TEST 69
REGULATED VOLTAGE TEST 71
WAVEFORM CHECK USING AN OSCILLOSCOPE 140
MEASUREMENT METHOD 73
EXAMPLE OF ABNORMAL WAVEFORMS 494
ALTERNATOR ASSEMBLY 76
REMOVAL AND INSTALLATION <4G1> 76
REMOVAL SERVICE POINT 76
REMOVAL AND INSTALLATION <4G6> 616
REMOVAL SERVICE POINT 78
DISASSEMBLY AND REASSEMBLY 79
DISASSEMBLY SERVICE POINTS 80
REASSEMBLY SERVICE POINTS 619
INSPECTION 503
STARTING SYSTEM 218
GENERAL INFORMATION 620
SYSTEM DIAGRAM 83
SERVICE SPECIFICATIONS 84
STARTER MOTOR ASSEMBLY 403
REMOVAL AND INSTALLATION <4G1> 403
REMOVAL SERVICE POINT 85
REMOVAL AND INSTALLATION <4G6> 221
REMOVAL SERVICE POINT 86
STARTER MOTOR ASSEMBLY INSPECTION 87
DISASSEMBLY AND REASSEMBLY 90
DISASSEMBLY SERVICE POINTS 744
STARTER MOTOR PARTS CLEANING 516
REASSEMBLY SERVICE POINTS 91
INSPECTION 624
IGNITION SYSTEM 625
GENERAL INFORMATION 94
SYSTEM DIAGRAM 261
SERVICE SPECIFICATIONS 95
SPECIAL TOOL 310
ON-VEHICLE SERVICE 96
IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK 96
SECONDARY COIL RESISTANCE CHECK 96
PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK 96
RESISTIVE CORD CHECK 96
SPARK PLUG CHECK AND CLEANING <4G1> 627
SPARK PLUG CHECK AND CLEANING <4G6> 97
CAMSHAFT POSITION SENSOR CHECK 311
CRANK ANGLE SENSOR CHECK 627
DETONATION SENSOR CHECK 97
IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE 97
MEASUREMENT METHOD 97
EXAMPLES OF ABNORMAL WAVEFORMS 100
IGNITION COIL RELAY CHECK 101
IGNITION COIL 539
REMOVAL AND INSTALLATION <4G1> 381
REMOVAL AND INSTALLATION <4G6> 630
CAMSHAFT POSITION SENSOR 104
REMOVAL AND INSTALLATION 104
CRANKSHAFT POSITION SENSOR 631
REMOVAL AND INSTALLATION <4G1> 105
REMOVAL AND INSTALLATION <4G6> 431
REMOVAL SERVICE POINT 483
DETONATION SENSOR 385
REMOVAL AND INSTALLATION 107
REMOVAL SERVICE POINT 108
INSTALLATION SERVICE POINT 108
ENGINE AND EMISSION CONTROL 639
ENGINE CONTROL 486
GENERAL INFORMATION 110
SERVICE SPECIFICATIONS 110
ON-VEHICLE SERVICE 227
ACCEL CABLE CHECK AND ADJUSTMENT 591
ACCELERATOR CABLE AND PEDAL 612
REMOVAL AND INSTALLATION 111
INSTALLATION SERVICE POINT 512
EMISSION CONTROL <MPI> 593
GENERAL INFORMATION 113
EMISSION CONTROL DEVICE REFERENCE TABLE 489
SERVICE SPECIFICATION(S) 614
VACUUM HOSE 114
VACUUM HOSE PIPING DIAGRAM 114
VACUUM CIRCUIT DIAGRAM 115
VACUUM HOSE CHECK 188
VACUUM HOSE INSTALLATION 116
CRANKCASE EMISSION CONTROL SYSTEM 208
GENERAL INFORMATION (CRANKCASE EMISSION CONTROL SYSTEM) 601
SYSTEM DIAGRAM 231
COMPONENT LOCATION (CRANKCASE EMISSION CONTROL SYSTEM) 602
POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 348
POSITIVE CRANKCASE VENTILATION (PCV) VALVE CHECK 179
EVAPORATIVE EMISSION CONTROL SYSTEM 623
GENERAL INFORMATION (EVAPORATIVE EMISSION CONTROL SYSTEM) 117
SYSTEM DIAGRAM 118
COMPONENT LOCATION (EVAPORATIVE EMISSION CONTROL SYSTEM) 118
PURGE CONTROL SYSTEM CHECK 118
PURGE PORT VACUUM CHECK 153
PURGE CONTROL SOLENOID VALVE CHECK 408
FUEL VAPOUR CANISTER REMOVAL AND INSTALLATION 258
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 121
GENERAL INFORMATION (EGR SYSTEM) 744
OPERATION 259
SYSTEM DIAGRAM 121
COMPONENT LOCATION (EGR SYSTEM) 122
EGR SYSTEM CHECK 123
EGR VALVE CHECK 123
EGR PORT VACUUM CHECK <4G1> 124
EGR PORT VACUUM CHECK <4G6> 757
EGR CONTROL SOLENOID VALVE CHECK <4G1> 124
EGR CONTROL SOLENOID VALVE CHECK <4G6> 519
EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL AND INSTALLATION 126
CATALYTIC CONVERTER 126
REMOVAL AND INSTALLATION 126
CLUTCH 639
MANUAL TRANSMISSION 639
AUTOMATIC TRANSMISSION 639
FRONT AXLE 639
GENERAL INFORMATION 588
CONSTRUCTION DIAGRAM 134
SERVICE SPECIFICATIONS 135
LUBRICANTS 135
SPECIAL TOOLS 641
ON-VEHICLE SERVICE 139
WHEEL BEARING AXIAL PLAY CHECK 139
HUB BOLT REPLACEMENT 179
FRONT AXLE HUB ASSEMBLY 140
REMOVAL AND INSTALLATION 649
REMOVAL SERVICE POINTS 141
INSTALLATION SERVICE POINT 288
INSPECTION 351
DISASSEMBLY AND REASSEMBLY 652
DISASSEMBLY SERVICE POINTS 144
REASSEMBLY SERVICE POINTS 145
INSPECTION 145
DRIVE SHAFT ASSEMBLY 294
REMOVAL AND INSTALLATION 294
REMOVAL SERVICE POINTS 401
INSTALLATION SERVICE POINTS 149
DISASSEMBLY AND REASSEMBLY 150
LUBRICATION POINTS 151
DISASSEMBLY SERVICE POINTS 151
REASSEMBLY SERVICE POINTS 362
INSPECTION 513
BJ BOOT (RESIN BOOT) REPLACEMENT 153
REAR AXLE 639
GENERAL INFORMATION 225
SERVICE SPECIFICATIONS 639
SEALANT 158
SPECIAL TOOLS 159
ON-VEHICLE SERVICE 203
WHEEL BEARING AXIAL PLAY CHECK 203
REAR HUB ROTARY-SLIDING RESISTANCE CHECK 390
HUB BOLT REPLACEMENT 160
REAR AXLE HUB ASSEMBLY 161
REMOVAL AND INSTALLATION 641
REMOVAL SERVICE POINTS 177
INSTALLATION SERVICE POINTS 488
INSPECTION 162
WHEEL AND TYRE 639
GENERAL INFORMATION 279
SPECIFICATIONS 164
SERVICE SPECIFICATIONS 184
TROUBLESHOOTING 185
DIAGNOSIS 165
WHEEL BALANCE ACCURACY 645
PURPOSE 650
PROCEDURE <Balancing Tips> 613
<Confirming Proper Balance> 613
<Wheel Balancer Calibration Checks> 392
WHEEL BALANCER CALIBRATION CHECKING FLOW CHART 168
ON-VEHICLE SERVICE 613
TYRE INFLATION PRESSURE CHECK 169
TYRE WEAR CHECK 283
WHEEL RUNOUT CHECK 169
WHEEL AND TYRE 187
INSTALLATION SERVICE POINT 179
POWER PLANT MOUNT 639
GENERAL INFORMATION 339
CONSTRUCTION DIAGRAM 172
SERVICE SPECIFICATION 279
SPECIAL TOOL 486
ENGINE MOUNTING 203
REMOVAL AND INSTALLATION 174
TRANSMISSION MOUNTING 237
REMOVAL AND INSTALLATION 280
INSTALLATION SERVICE POINT 281
ENGINE ROLL STOPPER, CENTERMEMBER 487
REMOVAL AND INSTALLATION 641
INSTALLATION SERVICE POINTS 230
CROSSMEMBER 345
REMOVAL AND INSTALLATION 613
<L H drive vehicles> 179
<R H drive vehicles> 180
REMOVAL SERVICE POINTS 181
INSTALLATION SERVICE POINTS 212
FRONT SUSPENSION 639
GENERAL INFORMATION 279
CONSTRUCTION DIAGRAM 339
SPECIFICATIONS 184
SERVICE SPECIFICATIONS 390
LUBRICANT 229
SPECIAL TOOLS 488
ON-VEHICLE SERVICE 489
FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT 648
LOWER ARM BALL JOINT AXIAL PLAY CHECK 188
LOWER ARM BALL JOINT COVER CHECK 650
STRUT ASSEMBLY 189
REMOVAL AND INSTALLATION 243
INSPECTION 264
DISASSEMBLY AND REASSEMBLY 244
DISASSEMBLY SERVICE POINTS 191
REASSEMBLY SERVICE POINTS 191
INSPECTION 499
LOWER ARM 193
REMOVAL AND INSTALLATION 193
REMOVAL SERVICE POINT 194
INSTALLATION SERVICE POINT 194
INSPECTION 194
LOWER ARM BALL JOINT COVER REPLACEMENT 194
LOWER ARM BUSHING (REAR) REPLACEMENT 195
STABILIZER BAR 619
REMOVAL AND INSTALLATION 399
REMOVAL SERVICE POINTS 198
INSTALLATION SERVICE POINTS 198
INSPECTION 199
REAR SUSPENSION 639
GENERAL INFORMATION 202
CONSTRUCTION DIAGRAM 202
SPECIFICATION 236
SERVICE SPECIFICATIONS 486
LUBRICANT 612
SPECIAL TOOLS 240
ON-VEHICLE SERVICE 613
REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT 205
CONTROL LINK PILLOW BALL BUSHING AXIAL PLAY CHECK <Sport> 345
UPPER ARM PILLOW BALL BUSHING AXIAL PLAY CHECK <Sport> 648
LOWER ARM PILLOW BALL BUSHING AXIAL PLAY CHECK 489
STABILIZER LINK BALL JOINT DUST COVER INSPECTION 648
CONTROL LINK, UPPER ARM AND LOWER ARM 648
REMOVAL AND INSTALLATION 208
REMOVAL SERVICE POINTS 604
INSTALLATION SERVICE POINTS 243
INSPECTION 209
LOWER ARM BUSHING AND LOWER ARM PILLOW BALL BUSHING REPLACEMENT 287
TRAILING ARM ASSEMBLY 212
REMOVAL AND INSTALLATION 650
REMOVAL SERVICE POINTS 213
INSTALLATION SERVICE POINT 213
INSPECTION 499
TRAILING ARM BUSHING REPLACEMENT 213
SHOCK ABSORBER ASSEMBLY 215
REMOVAL AND INSTALLATION 397
REMOVAL SERVICE POINT 216
INSTALLATION SERVICE POINTS 667
INSPECTION 216
DISASSEMBLY AND REASSEMBLY 217
DISASSEMBLY SERVICE POINTS 218
REASSEMBLY SERVICE POINTS 218
STABILIZER BAR 253
REMOVAL AND INSTALLATION 220
INSTALLATION SERVICE POINTS 404
INSPECTION 508
STABILIZER LINK BALL JOINT DUST COVER REPLACEMENT 221
SERVICE BRAKES 639
PARKING BRAKES 639
GENERAL INFORMATION 226
CONSTRUCTION DIAGRAM 226
SERVICE SPECIFICATIONS 226
LUBRICANTS 227
ON-VEHICLE SERVICE 227
PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 227
LINING RUNNING-IN 227
PARKING BRAKE SWITCH CHECK 228
PARKING BRAKE LEVER 229
REMOVAL AND INSTALLATION 641
PARKING BRAKE CABLE 230
REMOVAL AND INSTALLATION 613
PARKING BRAKE LINING AND DRUM 282
REMOVAL AND INSTALLATION 231
REMOVAL SERVICE POINTS 615
INSTALLATION SERVICE POINTS 349
INSPECTION 233
PARKING BRAKE LINING AND DRUM CHECK 404
POWER STEERING 639
GENERAL INFORMATION 237
FEATURES 339
CONSTRUCTION DIAGRAM 612
SERVICE SPECIFICATIONS 240
LUBRICANTS 648
SEALANTS 241
SPECIAL TOOLS 242
ON-VEHICLE SERVICE 245
STEERING WHEEL FREE PLAY CHECK 245
STEERING ANGLE CHECK 245
TIE ROD END BALL JOINT TURNING TORQUE CHECK 351
STATIONARY STEERING EFFORT CHECK 617
STEERING WHEEL RETURN TO CENTRE CHECK 247
DRIVE BELT TENSION CHECK 247
FLUID LEVEL CHECK 618
FLUID REPLACEMENT 247
POWER STEERING SYSTEM AIR BLEEDING 247
OIL PUMP PRESSURE TEST 248
POWER STEERING PRESSURE SWITCH CHECK 249
TIE ROD END BALL JOINT DUST COVER CHECK 249
STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING MECHANISM CHECK 249
Inspection Procedure 250
STEERING WHEEL 251
REMOVAL AND INSTALLATION <COMFORT> 401
REMOVAL SERVICE POINTS 252
REMOVAL AND INSTALLATION <SPORT> 253
REMOVAL SERVICE POINTS 253
STEERING SHAFT 255
REMOVAL AND INSTALLATION 255
REMOVAL SERVICE POINT 255
INSTALLATION SERVICE POINT 256
DISASSEMBLY AND REASSEMBLY 256
DISASSEMBLY SERVICE POINT 257
REASSEMBLY SERVICE POINT 257
POWER STEERING GEAR BOX AND LINKAGE 407
REMOVAL AND INSTALLATION 407
INSTALLATION SERVICE POINT 624
INSPECTION 260
DISASSEMBLY AND REASSEMBLY 625
<L H drive vehicles> 261
<R H drive vehicles> 372
LUBRICATION AND SEALING POINTS 315
DISASSEMBLY SERVICE POINTS 264
REASSEMBLY SERVICE POINTS 266
TIE ROD END BALL JOINT DUST COVER REPLACEMENT 270
POWER STEERING OIL PUMP ASSEMBLY 434
REMOVAL AND INSTALLATION 271
<1300, 1600> 271
<2000> 272
REMOVAL SERVICE POINT 272
INSPECTION 272
DISASSEMBLY AND REASSEMBLY 273
<1300, 1600> 273
<2000> 274
REASSEMBLY SERVICE POINTS 275
INSPECTION 555
POWER STEERING HOSES 637
REMOVAL AND INSTALLATION 449
<LH drive vehicles> 556
<RH drive vehicles> 557
REMOVAL SERVICE POINT 559
INSTALLATION SERVICE POINTS 278
BODY 639
HOOD 281
ON-VEHICLE SERVICE 281
ADJUSTMENT OF CLEARANCE AROUND HOOD 612
ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER 341
ADJUSTMENT OF HOOD HEIGHT 281
HOOD 282
REMOVAL AND INSTALLATION 282
FENDER 283
SPECIAL TOOL 283
FENDER 284
REMOVAL AND INSTALLATION 284
REMOVAL SERVICE POINT 285
INSTALLATION SERVICE POINT 582
FUEL FILLER LID 286
REMOVAL AND INSTALLATION 614
STRUT TOWER BAR 287
REMOVAL AND INSTALLATION 615
WINDOW GLASS 650
ADHESIVE 650
SPECIAL TOOLS 287
WINDOW REPAIR 288
WINDOW GLASS INSTALLATION 289
WINDSHIELD 290
REMOVAL AND INSTALLATION 616
REMOVAL SERVICE POINT 291
INSTALLATION SERVICE POINTS 397
REAR WINDOW GLASS 294
REMOVAL AND INSTALLATION 294
REMOVAL SERVICE POINTS 295
INSTALLATION SERVICE POINTS 295
QUARTER WINDOW GLASS 297
REMOVAL AND INSTALLATION 297
REMOVAL SERVICE POINT 403
INSTALLATION SERVICE POINTS 299
TAILGATE WINDOW GLASS 300
REMOVAL AND INSTALLATION 300
REMOVAL SERVICE POINT 301
INSTALLATION SERVICE POINTS 301
DOOR 303
SERVICE SPECIFICATIONS 511
SEALANT 303
SPECIAL TOOLS 726
TROUBLESHOOTING 304
ON-VEHICLE SERVICE 305
DOOR FIT ADJUSTMENT 624
DOOR WINDOW GLASS ADJUSTMENT 306
GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT 624
POWER WINDOW OPERATING CURRENT CHECK 306
POWER WINDOW RELAY CHECK 307
CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION 307
POWER WINDOW CHECK 307
CENTRAL DOOR LOCKING SYSTEM INSPECTION 307
DOOR OUTSIDE HANDLE PLAY CHECK 307
DOOR INSIDE HANDLE PLAY ADJUSTMENT 308
DOOR ASSEMBLY 309
REMOVAL AND INSTALLATION 309
INSTALLATION SERVICE POINT 310
INSPECTION 310
DOOR SWITCH CHECK 310
DOOR GLASS AND REGULATOR 310
REMOVAL AND INSTALLATION 370
REMOVAL SERVICE POINTS 312
INSTALLATION SERVICE POINTS 312
INSPECTION 530
How to make the power window switch learn the fully closed position of the power window 312
DOOR HANDLE AND LATCH 314
REMOVAL AND INSTALLATION 314
INSTALLATION SERVICE POINTS 315
INSPECTION 315
FRONT DOOR LOCK ACTUATOR CHECK 315
REAR DOOR LOCK ACTUATOR CHECK 316
DOOR LOCK KEY CYLINDER SWITCH CHECK <PASSENGER’S 316
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP 317
REMOVAL AND INSTALLATION 382
<FRONT DOOR> 317
<REAR DOOR> 318
REMOVAL SERVICE POINT 441
INSTALLATION SERVICE POINT 319
TRUNK LID 634
SPECIAL TOOL 319
ON-VEHICLE SERVICE 319
TRUNK LID ADJUSTMENT 319
ADJUSTMENT OF CLEARANCE AROUND TRUNK LID 320
TRUNK LID STRIKER ADJUSTMENT 552
TRUNK LID HEIGHT ADJUSTMENT 445
TRUNK LID 635
REMOVAL AND INSTALLATION 321
REMOVAL SERVICE POINT 322
INSTALLATION SERVICE POINTS 450
INSPECTION 323
TRUNK LID LATCH SWITCH CONTINUITY CHECK 323
TAILGATE 324
SERVICE SPECIFICATIONS 324
SEALANTS 324
SPECIAL TOOL 324
TROUBLESHOOTING 324
ON-VEHICLE SERVICE 324
TAILGATE FIT ADJUSTMENT 324
TAILGATE HANDLE PLAY CHECK 325
TAILGATE 326
REMOVAL AND INSTALLATION 326
INSTALLATION SERVICE POINT 327
TAILGATE HANDLE AND LATCH 328
REMOVAL AND INSTALLATION 456
INSTALLATION SERVICE POINT 329
INSPECTION 329
TAILGATE LOCK ACTUATOR CHECK 329
TAILGATE LATCH CHECK <Vehicles for keyless entry system> 329
KEYLESS ENTRY SYSTEM 329
SERVICE SPECIFICATIONS 329
SPECIAL TOOLS 330
TROUBLESHOOTING 331
ON-VEHICLE SERVICE 462
KEYLESS ENTRY SYSTEM CHECK 331
KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION 331
ENABLING/DISABLING THE ANSWERBACK FUNCTION 331
ENABLING/DISABLING THE HAZARD ANSWERBACK FUNCTION 331
HOW TO REGISTER SECRET CODE 333
WHEN THE SPECIAL TOOL DIAGNOSIS CODE CHECK HARNESS (MB991529) IS USED 334
WHEN THE MUT-II IS USED 334
WHEN THE SPECIAL TOOL V C I (MB991824) IS USED 335
TRANSMITTER 336
DISASSEMBLY AND REASSEMBLY 336
DISASSEMBLY SERVICE POINT 337
REASSEMBLY SERVICE POINT 337
INSPECTION 337
TRANSMITTER BATTERY CHECK 423
EXTERIOR 639
FRONT BUMPER ASSEMBLY 340
ADHESIVE 340
FRONT BUMPER ASSEMBLY 340
REMOVAL AND INSTALLATION 641
DISASSEMBLY AND REASSEMBLY 341
DISASSEMBLY SERVICE POINT 342
REASSEMBLY SERVICE POINT 342
REAR BUMPER ASSEMBLY 343
REMOVAL AND INSTALLATION 343
DISASSEMBLY AND REASSEMBLY 345
DISASSEMBLY SERVICE POINT 346
ASSEMBLY SERVICE POINT 346
MOULDINGS 648
SPECIAL TOOL 347
ADHESIVE 347
MOULDINGS 348
REMOVAL AND INSTALLATION 649
REMOVAL SERVICE POINT 349
INSTALLATION SERVICE POINTS 350
REMOVAL SERVICE POINT 352
INSTALLATION SERVICE POINT 352
SIDE AIR DAM 353
ADHESIVE 397
SIDE AIR DAM 618
REMOVAL AND INSTALLATION 500
REMOVAL SERVICE POINTS 399
INSTALLATION SERVICE POINT 354
GARNISHES 355
REMOVAL AND INSTALLATION 355
REAR SPOILER 356
REMOVAL AND INSTALLATION 356
REMOVAL SERVICE POINT 356
TAILGATE SPOILER 505
REMOVAL AND INSTALLATION 357
ROOF RAIL 358
REMOVAL AND INSTALLATION 505
WINDSHIELD WIPER AND WASHER 359
GENERAL INFORMATION 621
WINDSHIELD WIPER AND WASHER OPERATION 359
SERVICE SPECIFICATION 360
TROUBLESHOOTING 360
ON-VEHICLE SERVICE 508
WINDSHIELD INTERMITTENT WIPER INSPECTION 360
WINDSHIELD WIPER AND WASHER 361
REMOVAL AND INSTALLATION 508
REMOVAL SERVICE POINT 362
INSTALLATION SERVICE POINTS 362
INSPECTION 363
FRONT WIPER MOTOR CHECK 363
FRONT WASHER MOTOR CHECK 363
WINDSHIELD WASHER FLUID EJECTION CHECK 409
WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH CHECK 409
WINDSHIELD INTERMITTENT WIPER VOLUME CHECK 365
REAR WIPER AND WASHER 746
GENERAL INFORMATION 366
REAR WIPER AND WASHER OPERATION 366
SERVICE SPECIFICATION 366
TROUBLESHOOTING 366
ON-VEHICLE SERVICE 366
CHECK OF REAR WIPER OPERATION WHEN SELECTOR LEVER IS AT THE “R” POSITION 366
REAR WIPER AND WASHER 367
REMOVAL AND INSTALLATION 367
INSTALLATION SERVICE POINTS 368
INSPECTION 626
REAR WIPER MOTOR CHECK 368
REAR WASHER MOTOR CHECK 369
REAR WASHER FLUID EJECTION CHECK 369
REAR WIPER AND WASHER SWITCH CHECK 369
HEADLAMP WASHER 370
TROUBLESHOOTING 370
HEADLAMP WASHER 370
REMOVAL AND INSTALLATION 370
INSPECTION 371
MARK 372
REMOVAL AND INSTALLATION 372
INSTALLATION SERVICE POINT 372
DOOR MIRROR 374
GENERAL INFORMATION 374
DOOR MIRROR OPERATION 374
SERVICE SPECIFICATION 417
SPECIAL TOOL 628
TROUBLESHOOTING 374
DIAGNOSIS TROUBLESHOOTING FLOW 374
TROUBLE SYMPTOM CHART 531
SYMPTOM PROCEDURES 375
INSPECTION PROCEDURE 1: All Heated Door Mirrors do not Operate 375
DIAGNOSIS PROCEDURE 376
STEP 1 Check the rear window defogger 376
STEP 2 Connector check: C-212 junction block connector 376
INSPECTION PROCEDURE 2: Right or Left Heated Door Mirror does not Operate 377
DIAGNOSIS PROCEDURE 378
Step 1 Verify the operation of each heated door mirror 378
Step 2 Connector check: E-11 door mirror assembly (RH) connector 378
Step 3 Check the door mirror assembly (RH) 378
Step 4 Resistance measurement at the E-11 door mirror assembly (RH) connector 378
Step 5 Check the wiring harness between E-11 door mirror assembly (RH) connector terminal No 4 a 379
Step 6 Voltage measurement at the E-11 door mirror assembly (RH) connector 536
Step 7 Connector check: C-212 junction block connector 630
Step 8 Check the wiring harness between E-11 door mirror assembly (RH) connector terminal No 1 a 630
Step 9 Connector check: E-02 door mirror assembly (LH) connector 380
Step 10 Check the door mirror assembly (LH) 380
Step 11 Resistance measurement at the E-02 door mirror assembly (LH) connector 381
Step 12 Check the wiring harness between E-02 door mirror assembly (LH) connector terminal No 4 381
Step 13 Connector check: C-212 junction block connector 381
Step 14 Measure the voltage at the E-02 door mirror assembly (LH) connector 382
Step 15 Check the wiring harness between E-02 door mirror assembly (LH) connector terminal No 1 630
DOOR MIRROR 427
REMOVAL AND INSTALLATION 383
REMOVAL SERVICE POINT 384
INSTALLATION SERVICE POINT 384
INSPECTION 385
ELECTRIC REMOTE CONTROL MIRROR OPERATION CHECK <VEHICLES WITHOUT HEATED DOOR MIRROR> 385
ELECTRIC REMOTE CONTROL MIRROR OPERATION CHECK <VEHICLES WITH HEATED DOOR MIRROR> 385
DOOR MIRROR CONTROL SWITCH CONTINUITY CHECK 386
HEATED DOOR MIRROR CHECK 386
INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM(SRS) 639
CHASSIS ELECTRICAL 639
BATTERY 392
SERVICE SPECIFICATIONS 489
ON-VEHICLE SERVICE 392
FLUID LEVEL AND SPECIFIC GRAVITY CHECK 596
CHARGING 392
BATTERY TEST 393
STEP 1 Check the battery cables 614
STEP 2 Check the battery post 393
STEP 3 Check the battery case and cover 393
STEP 4 Check the open circuit voltage 649
STEP 5 Charge battery 393
STEP 6 Check the load test 491
IGNITION SWITCH 394
GENERAL INFORMATION 394
IGNITION KEY REMINDER BUZZER 394
DOOR LOCK PREVENTION FUNCTION 394
IMMOBILIZER SYSTEM 394
Encrypted code registration criteria table 395
SPECIAL TOOLS 396
TROUBLESHOOTING 397
IGNITION KEY REMINDER BUZZER AND DOOR LOCK PREVENTION FUNCTION TROUBLESHOOTING 397
IMMOBILIZER SYSTEM TROUBLESHOOTING 397
DIAGNOSIS CODE CHART 499
DIAGNOSTIC TROUBLE CODE PROCEDURES 398
Code No 11: Transponder Communication System or Radio Interference of Encrypted Code 398
DIAGNOSIS PROCEDURE 399
STEP 1 Check for presence of other key near the key in the ignition 399
STEP 2 Check that the engine start using the spare ignition key which encrypted code has been re 502
STEP 3 Check whether the diagnosis code is reset 399
STEP 4 Connector check: Immobilizer-ECU connector C-202-1 669
Code No 12: Encrypted Codes are Not identical or not Registered 399
SYMPTOM CHART 399
SYMPTOM PROCEDURES 620
INSPECTION PROCEDURE 1: Communication with MUT-II/III is Impossible 400
STEP 1 Check if MUT-II/III can communicate with the MPI system and if an MPI system diagnosis co 401
STEP 2 Voltage measurement at immobilizer-ECU connector C-202-1 401
STEP 3 Connector check: Immobilizer-ECU connector C-202-1 and engine control relay connector B-16X 401
STEP 4 Check the harness wires between immobilizer-ECU connector C-202-1 (terminal 1) and engine 620
STEP 5 Resistance measurement at immobilizer-ECU connector C-202-1 403
STEP 6 Connector check: immobilizer-ECU connector C-202-1 507
STEP 7 Check the harness wire between immobilizer-ECU connector C-202-1 (terminal 4) and earth 403
STEP 8 Connector check: immobilizer-ECU connector C-202-1 and engine-ECU connector C-127 <M/T> o 404
STEP 9 Check the harness wires between immobilizer-ECU connector C-202-1 (terminal 3) and engine 404
STEP 10 Replace the immobilizer-ECU or engine-ECU <M/T> or engine-A/T-ECU <A/T> 704
STEP 11 Recheck for malfunction 405
INSPECTION PROCEDURE 2: The Ignition Key cannot be Registered 508
STEP 1 MUT-II/III diagnosis code 406
STEP 2 Retest the system 406
INSPECTION PROCEDURE 3: Engine does not Start (Cranking but no Initial Combustion) 406
STEP 1 Check the system voltage 406
STEP 2 Check the immobilizer system diagnosis code and MPI system diagnosis code 406
STEP 3 Check the starting system 406
STEP 4 Retest the system 407
DATA LIST REFERENCE TABLE 407
CHECK IMMOBILIZER-ECU 407
TERMINAL VOLTAGE CHECK TABLE 407
ON-VEHICLE SERVICE 623
HOW TO REGISTER ENCRYPTED CODE 408
POINTS TO NOTE DURING OPERATION 408
KEY ID (ENCRYPTED CODE) REGISTRATION <MUT-II> 408
KEY ID (ENCRYPTED CODE) REGISTRATION <MUT-III> 517
IGNITION SWITCH 415
REMOVAL AND INSTALLATION 415
REMOVAL SERVICE POINT 416
INSPECTION 416
IGNITION SWITCH CONTINUITY CHECK 416
KEY REMINDER SWITCH CONTINUITY CHECK 416
COMBINATION METER ASSEMBLY 417
SERVICE SPECIFICATIONS 417
SEALANT 417
SPECIAL TOOLS 417
TROUBLESHOOTING 628
SYMPTOM CHART 419
SYMPTOM PROCEDURES 420
INSPECTION PROCEDURE 1: Speedometer does not work (the other meters work) <M/T> 420
DIAGNOSIS PROCEDURE 421
STEP 1 MUT-II/III actuator test 421
STEP 2 Check the vehicle speed sensor (MUT-II/III diagnosis code) 421
STEP 3 Connector check: Combination meter connector C-04 and diagnosis connector C-11 422
STEP 4 Check the wiring harness between combination meter connector C-04 (terminal 12) and diagn 422
STEP 5 Retest the system 536
STEP 6 Check whether the diagnosis code is reset 423
STEP 7 Connector check: Combination meter connector C-04 and engine-ECU connector C-127 <RH driv 630
STEP 8 Check the wiring harness between combination meter connector C-04 (terminal 11) and engin 423
STEP 9 Retest the system 424
STEP 10 Pulse check 424
INSPECTION PROCEDURE 2: Speedometer does not work (the other meters work) <A/T> 425
DIAGNOSIS PROCEDURE 630
STEP 1 MUT-II/III actuator test 426
STEP 2 Check the output shaft speed sensor (MUT-II/III diagnosis code) 426
STEP 3 Connector check: Combination meter connector C-04 and diagnosis connector C-11 427
STEP 4 Check the wiring harness between combination meter connector C-04 (terminal 12) and diagn 427
STEP 5 Retest the system 428
STEP 6 Check whether the diagnosis code is reset 428
STEP 7 Connector check: Combination meter connector C-04 and engine-A/T-ECU connector C-124, C-126 428
STEP 8 Check the wiring harness between combination meter connector C-04 (terminal 11, 12) and e 430
STEP 9 Retest the system 431
STEP 10 Pulse check 431
INSPECTION PROCEDURE 3: Tachometer does not work (the other meters work) 432
DIAGNOSIS PROCEDURE 433
STEP 1 Check whether the diagnosis code is reset 433
STEP 2 Connector check: Combination meter connector C-04 and engine-ECU connector C-127 <M/T> or 433
STEP 3 Retest the system 433
STEP 4 Check the wiring harness between combination meter connector C-04 (terminal 11) and engin 434
INSPECTION PROCEDURE 4: Fuel gauge does not work (the other meters work) 436
DIAGNOSIS PROCEDURE 437
STEP 1 Check the fuel gauge circuit 437
STEP 2 Connector check: Combination meter connector C-06, fuel gauge unit connector D-13 437
STEP 3 Check the wiring harness between combination meter connector C-06 (terminal 51) and fuel 550
STEP 4 Retest the system 438
INSPECTION PROCEDURE 5: Engine Coolant Temperature Gauge does not Work (the other meters work) 439
DIAGNOSIS PROCEDURE 439
STEP 1 Check the engine coolant temperature gauge unit 439
STEP 2 Connector check: Combination meter connector C-06 and engine coolant temperature gauge un 440
STEP 3 Check the wiring harness between combination meter connector C-06 (terminal 50) and engin 634
STEP 4 Retest the system 441
INSPECTION PROCEDURE 6: Combination meter does not work (the instruments do not work) 551
DIAGNOSIS PROCEDURE 443
STEP 1 Voltage measurement at combination meter connector C-04 in order to check the battery cir 443
STEP 2 Connector check: Combination meter connector C-04 443
STEP 3 Check the wiring harness between combination meter connector C-04 (terminal 7) and battery 444
STEP 4 Voltage measurement at combination meter connector C-04 to check the battery circuit of p 552
STEP 5 Connector check: combination meter connector C-04 445
STEP 6 Check the wiring harness between combination meter connector C-04 (terminal 9) and igniti 446
STEP 7 Resistance measurement at combination meter connector C-04 to check the earth circuit to 447
STEP 8 Connector check: Combination meter connector C-04 447
STEP 9 Check the wiring harness between combination meter connector C-04 (terminal 1 and 2) and 448
ON-VEHICLE SERVICE 553
SPEEDOMETER CHECK 448
TACHOMETER CHECK 448
FUEL TANK GAUGE UNIT CHECK 556
FUEL TANK GAUGE UNIT RESISTANCE 449
FUEL TANK GAUGE UNIT FLOAT HEIGHT 449
ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK 449
COMBINATION METER ASSEMBLY 451
REMOVAL AND INSTALLATION 451
INSPECTION 452
VEHICLE SPEED SENSOR CHECK <M/T> 452
OUTPUT SHAFT SPEED SENSOR CHECK <A/T> 452
COMBINATION METER INTERNAL RESISTANCE CHECK 452
DISASSEMBLY AND REASSEMBLY 453
<1600 (SPORT), 2000> 453
<1300, 1600 (COMFORT)> 453
HEADLAMP 454
SERVICE SPECIFICATIONS 454
TROUBLESHOOTING 607
ON-VEHICLE SERVICE 454
HEADLAMP AIMING 454
PRE-AIMING INSTRUCTIONS 454
HEADLAMP ADJUSTMENT 455
LUMINOUS INTENSITY MEASUREMENT 455
BULB REPLACEMENT 563
Headlamp Bulb 456
Position Lamp Bulb 456
Front Turn-Signal Lamp Bulb 456
HEADLAMP 457
REMOVAL AND INSTALLATION 457
REMOVAL SERVICE POINT 457
HEADLAMP LEVELING SWITCH 458
REMOVAL AND INSTALLATION 458
INSPECTION 458
HEAD LAMP LEVELING SWITCH RESISTANCE CHECK 458
FOG LAMP 459
SERVICE SPECIFICATION 459
SPECIAL TOOL 459
TROUBLESHOOTING 459
ON-VEHICLE SERVICE 459
FRONT FOG LAMP AIMING CHECK 459
FOG LAMP 461
REMOVAL AND INSTALLATION 461
REMOVAL SERVICE POINT 461
FOG LAMP SWITCH 462
REMOVAL AND INSTALLATION 462
INSPECTION 462
FRONT FOG LAMP RELAY CHECK 463
REAR FOG LAMP 463
TROUBLESHOOTING 463
SPECIAL TOOL 463
REAR FOG LAMP 570
REMOVAL AND INSTALLATION 464
REAR FOG LAMP SWITCH 464
REMOVAL AND INSTALATION 464
INSPECTION 464
FRONT FOG LAMP RELAY CHECK 465
SIDE TURN-SIGNAL LAMP 465
SPECIAL TOOL 465
SIDE TURN-SIGNAL LAMP 572
REMOVAL AND INSTALLATION 465
REMOVAL SERVICE POINT 465
INSTALLATION SERVICE POINT 466
ROOM LAMP 572
TROUBLESHOOTING 466
REAR COMBINATION LAMP 467
TROUBLESHOOTING 467
SPECIAL TOOL 467
REAR COMBINATION LAMP 467
REMOVAL AND INSTALLATION 573
<Sedan> 467
<Wagon> 574
HIGH-MOUNTED STOP LAMP 468
ON-VEHICLE SERVICE 468
HIGH-MOUNTED STOP LAMP BULB REPLACEMENT <WITH REAR SHELF> 468
HIGH-MOUNTED STOP LAMP 469
REMOVAL AND INSTALLATION 469
<Sedan> 469
<Wagon> 471
REMOVAL SERVICE POINT 471
LICENCE PLATE LAMP 472
REMOVAL AND INSTALLATION 472
<Sedan> 472
<Wagon> 473
HAZARD WARNING LAMP SWITCH 473
TROUBLESHOOTING 473
FLASHER TIMER FUNCTION 473
SPECIAL TOOL 473
HAZARD WARNING LAMP SWITCH 474
REMOVAL AND INSTALLATION 474
INSPECTION 474
HAZARD WARNING LAMP SWITCH CONTINUITY CHECK 474
COLUMN SWITCH 580
SPECIAL TOOL 475
COLUMN SWITCH 580
REMOVAL AND INSTALLATION 580
INSPECTION 476
TURN-SIGNAL AND LIGHTING SWITCH CHECK 476
HORN 477
REMOVAL AND INSTALLATION 477
HORN RELAY CONTINUITY CHECK 477
CLOCK 478
SPECIAL TOOL 478
CLOCK 478
REMOVAL AND INSTALLATION 478
CIGARETTE LIGHTER 585
INSPECTION 479
CIGARETTE LIGHTER CHECK 479
RHEOSTAT 479
REMOVAL AND INSTALLATION 479
INSPECTION 480
RHEOSTAT RESISTANCE CHECK 480
SPEAKER 481
REMOVAL AND INSTALLATION 481
ANTENNA 585
REMOVAL AND INSTALLATION 482
REAR WINDOW DEFOGGER 483
GENERAL INFORMATION 483
TROUBLESHOOTING 483
ON-VEHICLE SERVICE 484
PRINTED HEATER LINES CHECK 484
REAR WINDOW DEFOGGER SWITCH 484
REMOVAL AND INSTALLATION 484
INSPECTION 484
DEFOGGER RELAY CHECK 484
HEATER, AIR CONDITIONER AND VENTILATION 639
SERVICE SPECIFICATIONS 487
LUBRICANTS 487
SPECIAL TOOLS 488
TROUBLESHOOTING 489
DIAGNOSIS TROUBLESHOOTING FLOW 648
SYMPTOM CHART 489
SYMPTOM PROCEDURES 489
INSPECTION PROCEDURE 1: When the Ignition Switch is “ON” the A/C does not Operate 489
DIAGNOSIS 648
Check that the blower motor operation when the blower switch is moved to the “HI” position 489
INSPECTION PROCEDURE 2: Inside/Outside Air Selection is not possible 490
DIAGNOSIS 491
STEP 1 Check the defogger and A/C operations 491
STEP 2 Connector check: C-107 outside/inside air selection damper control motor connector 648
STEP 3 Voltage measurement at the C-107 outside/inside air selection damper control motor connec 491
STEP 4 Check the wiring harness between C-107 outside/inside air selection damper control motor 492
STEP 5 Connector check: C-139 A/C-ECU connector 493
STEP 6 Check the wiring harness between C-107 outside/inside air selection damper control motor 494
STEP 7 Check the wiring harness between C-107 outside/inside air selection damper control motor 650
STEP 8 Check the outside/inside air selection damper control motor 494
INSPECTION PROCEDURE 3: When the A/C is Operating, Temperature Inside the Passenger Compartment d 495
DIAGNOSIS 650
STEP 1 Check the defogger and outside/inside air selection damper control motor operation 496
STEP 2 Check the blower motor operation 496
STEP 3 Check the A/C compressor 496
STEP 4 Connector check: B-114 A/C compressor connector and C-123 engine-ECU connector <M/T> or C 496
STEP 5 Voltage measurement at the B-114 A/C compressor connector 497
STEP 6 Connector check: C-139 A/C-ECU connector 498
STEP 7 Voltage measurement at C-139 A/C-ECU connector 498
STEP 8 Connector check: C-109 resistor connector 498
STEP 9 Check the wiring harness between C-109 resistor connector terminal No 4 and C-139 A/C-ECU 498
STEP 10 Connector check: A-31 dual pressure switch connector 617
STEP 11 Check the dual pressure switch operation 499
STEP 12 Connector check: C-106 air thermo sensor connector 499
STEP 13 Check the wiring harness between C-106 air thermo sensor connector (terminals 4 and 5) a 499
STEP 14 Check the wiring harness between A-31 dual pressure switch connector terminal No 1 and C 500
STEP 15 Connector check: C-125 engine-ECU connector <M/T> or C-126 engine-A/T-ECU connector <A/T> 500
STEP 16 Check the wiring harness between C-125 engine-ECU connector <M/T> terminal No 45 or C-12 663
STEP 17 Connector check: C-123 engine-ECU connector <M/T> or C-124 engine-A/T-ECU connector <A/T> 502
STEP 18 Check the wiring harness between C-123 engine-ECU connectors terminal No 24 <M/T> or C-1 502
STEP 19 Check the magnetic clutch operation 503
STEP 20 Check the refrigerant temperature switch 503
STEP 21 Check the air thermo sensor 619
STEP 22 Check the refrigerant level 674
STEP 23 Replace the A/C-ECU 503
INSPECTION PROCEDURE 4: When the A/C is Operating, Temperature Inside the Passenger Compartment d 504
DIAGNOSIS 505
STEP 1 Check the defogger and outside/inside air selection damper control motor operation 505
STEP 2 Check the blower motor operation 505
STEP 3 Check the A/C compressor 505
STEP 4 Connector check: B-114 A/C compressor connector and C-123 engine-ECU connector <M/T> or C 505
STEP 5 Voltage measurement at the B-114 A/C compressor connector 506
STEP 6 Connector check: C-139 A/C-ECU connector 507
STEP 7 Voltage measurement at C-139 A/C-ECU connector 507
STEP 8 Connector check: C-109 resistor connector 697
STEP 9 Check the wiring harness between C-109 resistor connector terminal No 4 and C-139 A/C-ECU 507
STEP 10 Connector check: A-31 dual pressure switch connector 701
STEP 11 Check the dual pressure switch operation 508
STEP 12 Connector check: C-106 air thermo sensor connector 508
STEP 13 Check the wiring harness between C-106 air thermo sensor connector (terminals 4 and 5) a 508
STEP 14 Check the wiring harness between A-31 dual pressure switch connector terminal No 1 and C 597
STEP 15 Connector check: C-125 engine-ECU connector <M/T> or C-126 engine-A/T-ECU connector <A/T> 509
STEP 16 Check the wiring harness between C-125 engine-ECU connector <M/T> terminal No 45 or C-12 510
STEP 17 Connector check: C-123 engine-ECU connector <M/T> or C-124 engine-A/T-ECU connector <A/T> 511
STEP 18 Check the wiring harness between C-123 engine-ECU connectors terminal No 24 <M/T> or C-1 511
STEP 19 Check the magnetic clutch operation 512
STEP 20 Check the refrigerant temperature switch 512
STEP 21 Check the air thermo sensor 512
STEP 22 Check the refrigerant level 512
STEP 23 Replace the A/C-ECU 512
INSPECTION PROCEDURE 5: Blower Fan and Motor do not Turn 513
DIAGNOSIS 514
STEP 1 Check that the blower motor operates when the blower switch is moved to the “4 (HI) ” pos 514
STEP 2 Connector check: C-110 blower motor connector 514
STEP 3 Resistance measurement at the C-110 blower motor connector 514
STEP 4 Check the wiring harness between C-110 blower motor connector terminal No 2 and body earth 515
STEP 5 Voltage measurement at C-110 blower motor connector 515
STEP 6 Connector check: C-214 blower relay connector 743
STEP 7 Check the blower relay continuity 516
STEP 8 Voltage measurement at C-214 blower relay connector 516
STEP 9 Check the wiring harness between C-214 blower relay connector terminal No 3 and the ignit 517
STEP 10 Resistance measurement at C-214 blower relay connector 517
STEP 11 Check the wiring harness between C-214 blower relay connector terminal No 1 and earth 518
STEP 12 Check the wiring harness between C-214 blower relay connector terminal No 1 and earth 518
STEP 13 Voltage measurement at C-214 blower relay connector 519
STEP 14 Check the wiring harness between C-214 blower relay connector terminal No 5 and fusible 625
STEP 15 Check the wiring harness between C-214 blower relay connector terminal No 5 and fusible 520
STEP 16 Connector check: C-140 blower switch connector 520
STEP 17 Check the blower switch continuity 520
STEP 18 Check the wiring harness between C-140 blower switch connector terminal No 2 and C-214 b 521
STEP 19 Check the wiring harness between C-110 blower motor connector terminal No 1 and C-140 bl 522
STEP 20 Check the blower fan and motor operation 522
INSPECTION PROCEDURE 6: Blower Air Amount cannot be Changed 523
DIAGNOSIS 523
STEP 1 Check that the blower motor operates when the blower switch is moved to the “4 (HI)” posi 523
STEP 2 Connector check: C-140 blower switch connector and C-109 resistor connector 524
STEP 3 Check the blower switch continuity 524
STEP 4 Check the resistor resistance value 524
STEP 5 Check the wiring harness between C-140 blower switch connector (terminals 1, 4 and 5) and 524
STEP 6 Connector check: C-110 blower motor connector 525
STEP 7 Check the wiring harness between C-110 blower motor connector (terminal 1) and C-109 resi 525
INSPECTION PROCEDURE 7: Rear Window Defogger Function does not Operate 526
DIAGNOSIS 527
STEP 1 Check the A/C and outside/inside air selection damper control motor operation 527
STEP 2 Connector check: F-22 rear window defogger connector 527
STEP 3 Voltage measurement at F-22 rear window defogger connector 528
STEP 4 Connector check: C-213 rear window defogger relay connector 529
STEP 5 Check the rear window defogger relay continuity 529
STEP 6 Voltage measurement at C-213 rear window defogger relay connector 529
STEP 7 Check the wiring harness between C-213 rear window defogger relay connector terminal No 5 530
STEP 8 Check the wiring harness between C-213 rear window defogger relay connector terminal No 5 530
STEP 9 Voltage measurement at C-213 rear window defogger relay connector 531
STEP 10 Check the wiring harness between C-213 rear window defogger relay connector terminal No 531
STEP 11 Check the wiring harness between C-213 rear window defogger relay connector terminal No 532
STEP 12 Connector check: C-139 A/C-ECU connector or heater control unit connector 533
STEP 13 Check the wiring harness between C-213 rear window defogger relay connector terminal No 534
STEP 14 Connector check: F-06 rear window defogger connector 535
STEP 15 Resistance measurement at F-06 rear window defogger connector 535
STEP 16 Check the wiring harness between F-06 rear window defogger connector terminal No 1 and e 536
STEP 17 Check the rear window defogger 629
INSPECTION PROCEDURE 8: Rear Window Defogger Timer Function does not Operate 536
DIAGNOSIS 536
Check the performance of the rear window defogger timer operations 536
INSPECTION PROCEDURE 9: Malfunction of the A/C-ECU Power Supply System <L H D > 537
DIAGNOSIS 538
STEP 1 Connector check: C-139 A/C-ECU connector 630
STEP 2 Voltage measurement the voltage at C-139 A/C-ECU connector 630
STEP 3 Check the wiring harness between C-139 A/C-ECU connector terminal No 10 and the ignition 538
STEP 4 Resistance measurement resistance at C-139 A/C-ECU connector 539
STEP 5 Check the wiring harness between C-139 A/C-ECU connector terminal No 12 and the earth 539
INSPECTION PROCEDURE 10: Malfunction of the A/C-ECU Power Supply System <R H D > 540
DIAGNOSIS 541
STEP 1 Connector check: C-139 A/C-ECU connector 541
STEP 2 Voltage measurement at C-139 A/C-ECU connector 541
STEP 3 Check the wiring harness between C-139 A/C-ECU connector terminal No 7 and the ignition s 541
STEP 4 Resistance measurement at the C-139 A/C-ECU connector 542
STEP 5 Check the wiring harness between C-139 A/C-ECU connector terminal No 3 and the earth 542
INSPECTION PROCEDURE 11: A/C Compressor power supply system 543
STEP 1 Connector check: B-17X A/C compressor relay connector 631
STEP 2 Check the A/C compressor relay continuity 544
STEP 3 Voltage measurement at B-17X A/C compressor relay connector 544
STEP 4 Check the wiring harness between B-17X A/C compressor relay connector terminal No 2 and t 545
STEP 5 Check the wiring harness between B-17X A/C compressor relay connector terminal No 2 and t 631
STEP 6 Voltage measurement at B-17X A/C compressor relay connector 547
STEP 7 Check the wiring harness between B-17X A/C compressor relay connector terminal No 1 and t 547
STEP 8 Connector check: B-114 A/C compressor connector 548
STEP 9 Check the wiring harness between B-17X A/C compressor relay connector terminal No 4 and B 632
STEP 10 Connector check: C-123 engine-ECU connector <M/T> or C-122 engine-A/T-ECU connector <A/T> 549
STEP 11 Check the wiring harness between C-123 engine-ECU connector terminal No 8 and B-17X A/C 633
STEP 12 Check the wiring harness between C-122 engine A/T-ECU connector terminal No 20 and B-17X 550
CHECK AT ECU TERMINAL <L H D > 551
CHECK AT ECU TERMINAL <R H D > 552
ON-VEHICLE SERVICE 636
SIGHT GLASS REFRIGERANT LEVEL TEST 553
MAGNETIC CLUTCH TEST 553
COMPRESSOR DRIVE BELT ADJUSTMENT 553
<1300, 1600> 553
<2000> 636
DUAL PRESSURE SWITCH CHECK 553
CHARGING 554
CORRECTING LOW REFRIGERANT LEVEL IN CASE THE SERVICE CAN IN USED 556
DISCHARGING SYSTEM 556
REFILLING OF OIL IN THE A/C SYSTEM 556
PERFORMANCE TEST 557
REFRIGERANT LEAK REPAIR PROCEDURE 558
LOST CHARGE 558
LOW CHARGE 558
HANDLING TUBING AND FITTINGS 558
COMPRESSOR NOISE CHECK 558
ADJUSTMENT 558
POWER RELAY CHECK 559
BLOWER RELAY CONTINUITY CHECK 559
A/C COMPRESSOR RELAY CONTINUITY CHECK 559
FAN CONTROL RELAY CONTINUITY CHECK 560
IDLE-UP OPERATION CHECK 560
CLEAN AIR FILTER REPLACEMENT PROCEDURE 560
HEATER CONTROL ASSEMBLY AND A/C SWITCH 561
REMOVAL AND INSTALLATION 561
INSTALLATION SERVICE POINT 562
INSPECTION 563
BLOWER SWITCH CONTINUITY CHECK 563
DISASSEMBLY AND REASSEMBLY 563
DISASSEMBLY SERVICE POINT 564
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT 565
REMOVAL AND INSTALLATION 565
REMOVAL SERVICE POINT 566
HEATER UNIT 566
DISASSEMBLY AND REASSEMBLY <L H D > 566
DISASSEMBLY AND ASSEMBLY <R H D > 567
BLOWER ASSEMBLY 568
DISASSEMBLY AND REASSEMBLY 568
BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR 569
REMOVAL AND INSTALLATION 569
REMOVAL SERVICE POINT 570
INSPECTION 570
EVAPORATOR ASSEMBLY 572
REMOVAL AND INSTALLATION <L H D > 572
REMOVAL SERVICE POINT 572
REMOVAL AND INSTALLATION <R H D > 573
REMOVAL SERVICE POINT 574
INSPECTION 574
AIR THERMO SENSOR INSPECTION 574
COMPRESSOR ASSEMBLY AND TENSION PULLEY 575
REMOVAL AND INSTALLATION 575
REMOVAL SERVICE POINTS 576
INSTALLATION SERVICE POINT 577
INSPECTION 577
COMPRESSOR MAGNETIC CLUTCH OPERATION CHECK 577
DISASSEMBLY AND REASSEMBLY 578
DISASSEMBLY SERVICE POINT 578
REASSEMBLY SERVICE POINTS 578
INSPECTION 579
REFRIGERANT TEMPERATURE SWITCH 579
CONDENSER AND CONDENSER FAN MOTOR 580
REMOVAL AND INSTALLATION 580
REMOVAL SERVICE POINT 581
INSTALLATION SERVICE POINT 581
INSPECTION 581
CONDENSER FAN MOTOR CHECK 581
REFRIGERANT LINE 582
REMOVAL AND INSTALLATION <L H D > 582
REMOVAL SERVICE POINT 583
INSTALLATION SERVICE POINT 583
REMOVAL AND INSTALLATION <R H D > 583
REMOVAL SERVICE POINT 584
INSTALLATION SERVICE POINT 584
DUCTS 585
REMOVAL AND INSTALLATION 585
VENTILATORS 586
REMOVAL AND INSTALLATION 586
COMPONENT LOCATIONS 639
ECU 588
RELAY 591
SENSOR 592
FUSIBLE LINK AND FUSE 596
EARTH CABLE 597
SOLENOID VALVE 597
DIODE 599
EARTH 614
INSPECTION CONNECTOR AND SPARE CONNECTOR 604
CONFIGURATION DIAGRAMS 639
OVERALL CONFIGURATION DIAGRAM 608
OVERALL WIRING DIAGRAM <SEDAN (LHD) > 608
OVERALL WIRING DIAGRAM <SEDAN (RHD) > 609
OVERALL WIRING DIAGRAM <WAGON (LHD) > 610
OVERALL WIRING DIAGRAM <WAGON (RHD) > 611
ENGINE COMPARTMENT 612
ENGINE COMPARTMENT <LHD> 612
ENGINE COMPARTMENT <RHD> 613
ENGINE AND TRANSMISSION 614
ENGINE AND TRANSMISSION <4G1-MPI (LHD) > 614
ENGINE AND TRANSMISSION <4G1-MPI (RHD) > 616
ENGINE AND TRANSMISSION <4G6-MPI (LHD) > 618
ENGINE AND TRANSMISSION <4G6-MPI (RHD) > 620
DASH PANEL 622
DASH PANEL <LHD> 622
DASH PANEL <RHD> 625
FLOOR AND ROOF 628
FLOOR AND ROOF <SEDAN (LHD) > 628
FLOOR AND ROOF <SEDAN (RHD) > 629
FLOOR AND ROOF <WAGON (LHD) > 630
FLOOR AND ROOF <WAGON (RHD) > 631
DOOR 632
DOOR <LHD> 632
DOOR <RHD> 633
TRUNK (LUGGAGE COMPARTMENT) 634
TRUNK (LUGGAGE COMPARTMENT) <SEDAN (LHD) > 634
TRUNK (LUGGAGE COMPARTMENT) <SEDAN (RHD) > 635
TAILGATE 636
TAILGATE <WAGON (LHD) > 636
TAILGATE <WAGON (RHD) > 637
CIRCUIT DIAGRAMS 639
J/B 642
J/C <LHD> 644
J/C <RHD> 646
CENTRALIZED JUNCTION 648
FUSIBLE LINK AND FUSE 648
POWER DISTRIBUTION SYSTEM <LHD> 653
POWER DISTRIBUTION SYSTEM <RHD> 655
STARTING SYSTEM <M/T> 657
STARTING SYSTEM <A/T> 658
IGNITION SYSTEM <4G1-M/T (LHD)> 659
IGNITION SYSTEM <4G1-M/T (RHD)> 660
IGNITION SYSTEM <4G1-A/T (LHD)> 661
IGNITION SYSTEM <4G1-A/T (RHD)> 662
IGNITION SYSTEM <4G6 (LHD)> 663
IGNITION SYSTEM <4G6 (RHD)> 664
CHARGING SYSTEM <M/T> 665
CHARGING SYSTEM <A/T> 666
ENGINE CONTROL SYSTEM <4G1-M/T (LHD)> 667
ENGINE CONTROL SYSTEM <4G1-M/T (RHD)> 669
ENGINE CONTROL SYSTEM <4G1-A/T (LHD)> 671
ENGINE CONTROL SYSTEM <4G1-A/T (RHD)> 673
ENGINE CONTROL SYSTEM <4G6 (LHD)> 675
ENGINE CONTROL SYSTEM <4G6 (RHD)> 677
COOLING SYSTEM <LHD> 679
COOLING SYSTEM <RHD> 680
INVECS-II 4A/T <LHD> 681
INVECS-II 4A/T <RHD> 683
HEADLAMP <LHD> 685
HEADLAMP <RHD> 687
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <LHD> 689
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <RHD> 692
FRONT FOG LAMP <LHD> 695
FRONT FOG LAMP <RHD> 697
ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <SEDAN (LHD)> 699
ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <SEDAN (RHD)> 701
ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (LHD)> 703
ROOM LAMP,PERSONAL LAMP AND LUGGAGE ROOM LAMP <WAGON (RHD)> 705
REAR FOG LAMP <LHD> 707
REAR FOG LAMP <RHD> 709
HEADLAMP LEVELLING SYSTEM <LHD> 711
HEADLAMP LEVELLING SYSTEM <RHD> 712
TURN SIGNAL LAMP AND HAZARD WARNING LAMP <LHD> 714
TURN SIGNAL LAMP AND HAZARD WARNING LAMP <RHD> 716
BACK-UP LAMP <LHD> 718
BACK-UP LAMP <RHD> 719
STOP LAMP <SEDAN (LHD)> 720
STOP LAMP <SEDAN (RHD)> 721
STOP LAMP <WAGON (LHD)> 722
STOP LAMP <WAGON (RHD)> 723
HORN 724
METER AND GAUGE <LHD> 725
METER AND GAUGE <RHD> 727
FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP AND BRAKE WARNING LAMP <LHD> 729
FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP AND BRAKE WARNING LAMP <RHD> 730
POWER WINDOWS <LHD> 731
POWER WINDOWS <RHD> 733
CENTRAL DOOR LOCKING SYSTEM <LHD WITHOUT KEYLESS ENTRY> 735
CENTRAL DOOR LOCKING SYSTEM <RHD WITHOUT KEYLESS ENTRY> 737
CENTRAL DOOR LOCKING SYSTEM <SEDAN LHD WITH KEYLESS ENTRY> 739
CENTRAL DOOR LOCKING SYSTEM <SEDAN RHD WITH KEYLESS ENTRY> 741
CENTRAL DOOR LOCKING SYSTEM <WAGON LHD WITH KEYLESS ENTRY> 743
CENTRAL DOOR LOCKING SYSTEM <WAGON RHD WITH KEYLESS ENTRY> 746
HEATER <LHD> 749
HEATER <RHD> 751
MANUAL AIR CONDITIONER <LHD> 753
MANUAL AIR CONDITIONER <RHD> 755
WINDSHIELD WIPER AND WASHER <LHD> 757
WINDSHIELD WIPER AND WASHER <RHD> 759
REAR WIPER AND WASHER <LHD> 761
REAR WIPER AND WASHER <RHD> 763
REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER <LHD> 765
REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER <RHD> 766
REMOTE CONTROLLED MIRROR <LHD> 767
REMOTE CONTROLLED MIRROR <RHD> 768
HEADLAMP WASHER 769
SPARE CONNECTOR (FOR AUDIO) <LHD> 770
SPARE CONNECTOR (FOR AUDIO) <RHD> 771
CLOCK 772
CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LAMP 773
ACCESSORY SOCKET 774
IMMOBILIZER SYSTEM <LHD> 775
IMMOBILIZER SYSTEM <RHD> 776
ABS <LHD> 777
ABS <RHD> 779
HEATED SEAT 781
RHEOSTAT <LHD> 782
RHEOSTAT <RHD> 783
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <LHD> 784
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) <RHD> 786
SPARE CONNECTOR (FOR FRONT FOG LAMP) 788

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S.V 08/24