Mitsubishi Lancer (2005) Workshop Manual

GROUP INDEX

LANCER /

LANCER WAGON

WORKSHOP MANUAL

FOREWORD

This Workshop manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Use the following manuals in combination with this manual as required.

General . . . . . . . . . . . . . . . . . . . . . . . .

Engine. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . . .

Engine and Emission Control . . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission . . . . . . . . . . . .

Automatic Transmission. . . . . . . . . .

Front Axle. . . . . . . . . . . . . . . . . . . . . .

TECHNICAL INFORMATION MANUAL

PYME0302 PYME0302-A

WORKSHOP MANUAL

CHASSIS GROUP PWME0302 BODY REPAIR MANUAL

PBME0302 PBME0302-A

PARTS CATALOGUE

B606K005A_

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tyre . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . . .

Service Brakes. . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Power Steering . . . . . . . . . . . . . . . . .

Body . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

Interior and Supplemental

. . . . . . . . . .

Restraint System (SRS)

Chassis Electrical . . . . . . . . . . . . . . .

Heater, Air Conditioner and

. . . . . . .

Ventilation

Component Locations. . . . . . . . . . . .

Mitsubishi Motors Corporation May 2004

Configration Diagrams . . . . . . . . . . .

Circuit Diagrams . . . . . . . . . . . . . . . .

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

(1) Improper service or maintenance of any component of the SRS or any SRS-related component,

can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative).

(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so

remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.

• SRS-ECU, air bag module and clock spring 93°C or more

• Seat belt with pre-tensioner: 90°C or more

(3) Service or maintenance of any SRS component or SRS-related component must be performed

only at an authorized MITSUBISHI dealer.

(4) MITSUBISHI dealer personnel must thoroughly review this Manual, and especially its GROUP

52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS or any SRS-related component.

NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

GROUP 00

GENERAL

CONTENTS

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

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

00-1

NOTES

GROUP 11

ENGINE

CONTENTS

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

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

11-1

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

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

NOTES

GROUP 12

ENGINE

LUBRICATION

CONTENTS

12-1

GENERAL INFORMATION . . . . . . . . 12-2

SERVICE SPECIFICATION . . . . . . . . 12-2

LUBRICANT. . . . . . . . . . . . . . . . . . . . 12-2

SEALANT. . . . . . . . . . . . . . . . . . . . . . 12-3

SPECIAL TOOLS . . . . . . . . . . . . . . . . 12-3

ON-VEHICLE SERVICE . . . . . . . . . . . 12-4

ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-4

ENGINE OIL REPLACEMENT . . . . . . . . . . 12-4

ENGINE OIL FILTER REPLACEMENT. . . . 12-4

OIL PRESSURE CHECK . . . . . . . . . . . . . . 12-5

12-2

ENGINE LUBRICATION

GENERAL INFORMATION

The lubrication method is a fully force-fed, full-flow filtration type. The engine oil pump is a trochoid type which is driven by the crankshaft <4G1>.The engine oil pump is a gear type which is driven by the crankshaft via the balancer timing belt <4G6>.

ENGINE OILS Health Warning

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Recommended Precautions

The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them. Other precautions:

• Avoid prolonged and repeated contact with oils, particularly used engine oils.

• Wear protective clothing, including impervious gloves where practicable.

M1121000100357

• Avoid contaminating clothes, particularly underpants, with oil.

• Do not put oily rags in pockets, the use of overalls without pockets will avoid this.

• Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separate from personal clothing.

• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

• Obtain first aid treatment immediately for open cuts and wounds.

• Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised.

• Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.

• Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work.

• If skin disorders develop, obtain medical advice without delay.

SERVICE SPECIFICATION

Item Standard value

Oil pressure kPa at idle 29 or more

at 3,500 r/min 294 − 686

LUBRICANT

Item Specification

Engine oil ACEA classification A1, A2 or A3

Engine oil API classification SG or higher

Engine oil quantity L 4G1 Oil filter 0.3

Tota l 3. 3

4G6 Oil filter 0.3

Tota l 4. 3

M1121000300232

M1121000400433

ENGINE LUBRICATION

SEALANT

M1121000500258

Item Specified sealant Remark

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

SPECIAL TOOLS

M1121000600415

Tool Number Name Use

MB991396 Oil filter wrench Removal and installation

of engine oil filter (When using the engine oil filter of MD360935)

B991396

MB991828 Oil filter wrench Removal and installation

of engine oil filter (When using the engine oil filter of MD348631 and

MB991828

MD365876)

12-3

MB991610

MB991610 Oil filter wrench Removal and installation

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

MD998054 Oil pressure switch

wrench

Removal and installation of oil pressure switch

12-4

ENGINE LUBRICATION

ON-VEHICLE SERVICE

ENGINE OIL CHECK

M1121000900342

<4G1>

Good

Maximum

<4G6>

Good

Maximum Minimum

Minimum

ACX00892AC

AC205268

1. Pull out the engine oil level gauge slowly and check that the oil level is in the illustrated range.

2. Check that the oil is not excessively dirty, that there is no coolant or petrol mixed in, and that it has sufficient viscosity.

ENGINE OIL REPLACEMENT

M1121001000416

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80 °C to 90

°C.

2. Remove the engine oil filler cap.

CAUTION

Use care as engine oil could be hot.

3. Remove the engine oil pan drain plug to drain engine oil.

Engine oip pan drain plug

Engine oil pan

4. Install a new engine oil pan drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the engine oil pan drain plug to the specified torque.

Tightening torque: 39 ± 5 N⋅m

NOTE: Install the engine oil pan drain plug gasket so it faces in the direction shown in the illustration.

AC301513

5. Refill with specified quantity of engine oil.

Specified Engine Oil (ACEA and API classification): ACEA A1, A2 or A3/API SG or higher Total quantity (Includes volume inside engine oil filter):

3.3 L <4G1>

4.3 L <4G6>

6. Install the engine oil filler cap.

7. Check engine oil level.

ENGINE OIL FILTER REPLACEMENT

M1121001100383

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80 °C to 90

°C.

2. Remove the engine oil filler cap.

CAUTION

Use care as engine oil could be hot.

3. Remove the engine oil pan drain plug to drain engine oil.

4. Remove the under cover.

Engine oil pan side

Engine oip pan drain plug

AC208299

ENGINE LUBRICATION

ON-VEHICLE SERVICE

MB991396 <4G1>, MB991828 <4G1>, MB991610 <4G6> or commerciallyavailable tool

AC000093

5. Use the respective tool in the following table to remove the engine oil filter.

Number Special tool

MD348631 <4G1> Oil filter wrench (MB991828)

MD365876 <4G1>

or equivalent

MD360935 <4G1> Oil filter wrench (MB991396)

or equivalent

MD136466 <4G6> Commercially- available tool

MD322508 <4G6>

MD356000 <4G6> Oil filter wrench (MB991610)

or equivalent

6. Clean the filter bracket side mounting surface.

12-5

Number Special tool Tightening torque

MD348631 <4G1>

MD365876 <4G1>

MD360935 <4G1>

MD136466 <4G6>

MD322508 <4G6>

MD356000 <4G6>

9. Install the engine oil pan drain plug and refill the engine oil (Refer to P.12-4).

10.Race the engine 2−3 times, and check to be sure that no engine oil leaks from installation section of the engine oil filter.

OIL PRESSURE CHECK

<4G1>

Oil filter wrench (MB991828) or equivalent

Oil filter wrench (MB991396) or equivalent

Commerciallyavailable tool

Oil filter wrench (MB991610) or equivalent

Approximately 3/4 turn (16 ± 4 N⋅m)

Approximately 1 turn (14 ± 2 N⋅m)

Approximately 3/4 turn (17 ± 3 N⋅m)

Approximately 3/4 turn (14 ± 2 N⋅m)

M1121002300368

O-ring

AC103250

7. Apply a small amount of engine oil to the O-ring of the new engine oil filter.

8. Once the O-ring of the engine oil filter is touching the flange, use the respective tool in the following table to tighten to the specified torque.

Oil pressure switch

<4G6>

Oil filter bracket

Oil pressure switch

Oil filter

AK101640

AK300647

1. Check engine oil quantity.

2. Remove the oil pressure switch terminal.

12-6

CAUTION

ENGINE LUBRICATION

ON-VEHICLE SERVICE

MD998054

AKX00294

Since sealant is applied to the thread of oil pressure switch, take care not to damage the oil pressure switch when removing it.

3. Use the special tool Oil pressure switch wrench (MD998054) to remove the oil pressure switch.

4. Install the oil pressure gauge.

NOTE: Use an adapter of PT 1/8 thread.

5. Run the engine to warm it.

6. After the engine has been warmed up, check that oil pressure is within the standard value.

Standard value: At idle: 29 kPa or more At 3,500 r/min: 294 − 686 kPa

7. Remove the oil pressure gauge.

AKX00295

8. Apply the specified sealant to the thread of oil pressure switch.

Specified sealant: 3M ATD Part No. 8660 or equivalent

CAUTION

MD998054

AKX00294

Do not start the engine within one hour after the oil pressure switch has been installed.

9. Use the special tool Oil pressure switch wrench (MD998054) to tighten the oil pressure switch to the specified torque.

Tightening torque: <4G1> 19 ± 3 N⋅m (14 ± 2 ft-lb) <4G6> 10 ± 2 N⋅m (87 ± 17 ft-lb)

10.Install the oil pressure switch terminal.

GROUP 13

FUEL

CONTENTS

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

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

13-1

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

NOTES

GROUP 14

ENGINE COOLING

CONTENTS

14-1

GENERAL INFORMATION . . . . . . . . 14-2

SERVICE SPECIFICATIONS. . . . . . . 14-2

LUBRICANT. . . . . . . . . . . . . . . . . . . . 14-2

SEALANTS . . . . . . . . . . . . . . . . . . . . 14-3

SPECIAL TOOLS. . . . . . . . . . . . . . . . 14-3

TROUBLESHOOTING . . . . . . . . . . . . 14-5

INSPECTION CHART FOR TROUBLE

SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 14-5

INSPECTION PROCEDURE FOR

TROUBLE SYMPTOMS . . . . . . . . . . . . . . . 14-6

ON-VEHICLE SERVICE. . . . . . . . . . . 14-22

ENGINE COOLANT LEAK CHECK . . . . . . 14-22

RADIATOR CAP VALVE OPENING

PRESSURE CHECK. . . . . . . . . . . . . . . . . . 14-22

ENGINE COOLANT REPLACEMENT . . . . 14-22

CONCENTRATION MEASUREMENT . . . . 14-23

COOLING FAN MOTOR DRIVE CONTROL

UNIT CHECK. . . . . . . . . . . . . . . . . . . . . . . . 14-23

FAN CONTROL RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24

COOLING FAN MOTOR CHECK . . . . . . . . 14-25

THERMOSTAT . . . . . . . . . . . . . . . . . . 14-26

REMOVAL AND INSTALLATION . . . . . . . . 14-26

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-27

WATER PUMP . . . . . . . . . . . . . . . . . . 14-29

REMOVAL AND INSTALLATION <4G1> . . 14-29

REMOVAL AND INSTALLATION <4G6> . . 14-30

WATER HOSE AND WATER PIPE . . 14-31

REMOVAL AND INSTALLATION <4G1> . . 14-31

REMOVAL AND INSTALLATION <4G6> . . 14-33

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-34

RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-35

REMOVAL AND INSTALLATION . . . . . . . . 14-35

14-2

ENGINE COOLING

GENERAL INFORMATION

The cooling system is designed to keep every part of the engine at appropriate temperature in whatever condition the engine may be operated. The cooling method is of the water-cooled, pressure forced circulation type in which the water pump pressurizes coolant and circulates it throughout the engine. If the coolant temperature exceeds the prescribed

Item Specification

Radiator Performance kJ/h 4G13 Standard vehicles 137,720

temperature, the thermostat opens to circulate the coolant through the radiator as well so that the heat absorbed by the coolant may be radiated into the air. The water pump is of the centrifugal type and is driven by the alternator drive belt from the crankshaft. The radiator is the corrugated fin, down flow type.

M1141000100371

Vehicles with capacity up radiator (option)

4G18 Standard vehicles 161,288

Vehicles with capacity up radiator (option)

4G63 181,800

A/T oil cooler Performance kJ/h 5,651

161,288

181,800

SERVICE SPECIFICATIONS

M1141000300416

Item Standard value Limit

High-pressure valve opening pressure of radiator cap kPa 93 − 123 Minimum 83

Range of coolant antifreeze concentration of radiator % 30 − 60 -

Thermostat Valve opening temperature of

thermostat °C

Full-opening temperature of thermostat °C

Valve lift mm 8.5 or more -

4G1 88 ± 1.5 -

4G6 82 ± 1.5 -

4G1 100 -

4G6 95 -

LUBRICANT

Item Specified coolant Quantity L

Engine coolant (including condense tank)

DIAQUEEN SUPER LONG LIFE COOLANT or an equivalent

4G1 5.0

4G6 7.0

M1141000400338

ENGINE COOLING

SEALANTS

Item Specified sealant

Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent

14-3

M1141000500324

Water pump <4G1>, Thermostat case <4G6>, Cooling water outlet hose fitting <4G6>

MITSUBISHI GENUINE Part No.MD970389 or equivalent

SPECIAL TOOLS

Tool Number Name Use

MB991502 MUT-II sub assembly Reading diagnosis code

B991502

M1141000600246

14-4

ENGINE COOLING

SPECIAL TOOLS

Tool Number Name Use

DO NOT USE

MB991824

MB991827

MB991910

MB991911

MB991955

A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826

MUT-III sub assembly

A: Vehicle

communication

interface (V.C.I.) B: MUT-III USB cable C: MUT-III main

harness A (Vehicles

with CAN

communication

system) D: MUT-III main

harness B (Vehicles

without CAN

communication

system) E: MUT-III

measurement

adapter F: MUT-III trigger

harness

Checking the A/T (Diagnosis display using the MUT-III)

MB991825

MB991826

MB991955

ENGINE COOLING

TROUBLESHOOTING

Tool Number Name Use

14-5

MB991223

A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set

A: Test harness B: LED harness C: LED harness

adapter D: Probe

Making voltage and resistance measurement during troubleshooting

A: Connector pin contact

pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester

connection

MB991223

MB991871 LLC changer Coolant refilling

MB991871

TROUBLESHOOTING

INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom Inspection

Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan <4G6> do not operate

Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan <4G6> do not change speed or stop

Cooling fan (L.H.) does not operate {When cooling fan (R.H.) <4G1> or A/C condenser fan <4G6> operate} <Vehicles with A/C>

Cooling fan (R.H.) <4G1> or A/C condenser fan <4G6> does not operate {When cooling fan (L.H.) operate} <Vehicles with A/C>

M1141005600360

procedure No.

Reference page

P.14-6

P.14-16

P.14-20

P.14-21

14-6

ENGINE COOLING

TROUBLESHOOTING

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

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

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

ENGINE-ECU <M/T> OR ENGINE-A/T-ECU <A/T>

C-123

(MU801824)

C-122

(MU803784)

A-13

(MU802611)

C-111

2 3 4

21 C-123 <M/T> 18 C-122 <A/T>

1 A-13 <LHD> 12 C-111 <RHD>

1179810

FAN CONTROL RELAY A-09X

FUSIBLE LINK No.2

B-W

R-Y

J/C (6)

C-12 <LHD> C-134 <RHD>

R-Y

8 A-13 <LHD> 11 C-111 <RHD>

R-Y

ENGINE CONTROL RELAY B-16X

A-13

(MU802611)

C-111

2 3 4

1179810

(MU802322)

COOLING FAN MOTOR DRIVE CONTROL UNIT

COOLING FAN MOTOR (R.H.) <4G1 (VEHICLES WITH A/C> OR A/C CONDENSER FAN MOTOR <4G6>

A-18-1

A-18

2211

A-18-2

COOLING FAN MOTOR (L.H.)

Wire colour code B : Black LG : Light green

G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet

AC303577

ENGINE COOLING

TROUBLESHOOTING

14-7

CIRCUIT OPERATION

• The cooling fan motor drive control unit is powered from fusible link (2).

• The engine-ECU <M/T> or engine-A/T-ECU <A/T> uses input signals from the A/C switch, the water temperature sensor unit and the vehicle speed sensor <M/T> or the output shaft speed sensor <A/T> to control the speed of the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan motor <4G6>.

• The engine-ECU <M/T> or engine-A/T-ECU <A/T> controls the cooling fan motor drive control unit to activate the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan motor <4G6>.

TECHNICAL DESCRIPTION

• The cause could be a malfunction of the cooling fan motor drive control unit power supply or earth circuit.

• If the communication line wiring harness between the cooling fan motor drive control unit and the engine-ECU <M/T> or engine-A/T-ECU <A/T> is short-circuited to earth, the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)> or the A/C condenser fan motor <4G6> will not rotate.

• The cause could also be a malfunction of the cooling fan motor (L.H.). <Vehicles without A/C>

• The cause could also be a malfunction of imput signal from the A/C switch, the water temperature sensor unit and the vehicle speed sensor <M/T> or the output shaft speed sensor <A/T> to the engine-ECU <M/T> or engine-A/T-ECU <A/T>.

• The cause could also be a malfunction of the cooling fan motor drive control unit or the engine-ECU <M/T> or engine-A/T-ECU <A/T>.

TROUBLESHOOTING HINTS

• Malfunction of fusible link (2)

• Malfunction of fan control relay

• Malfunction of cooling fan motor (L.H.) <Vehicles

without A/C>

• Malfunction of cooling fan motor drive control unit

• Malfunction of engine-ECU <M/T> or

engine-A/T-ECU <A/T>

• Damaged wiring harness or connector

DIAGNOSIS

STEP 1. Check the cooling fan motor (L.H.). <Vehicles without A/C>

Refer to P.14-25.

Q: Is the cooling fan motor (L.H.) in good condition?

Go to Step 2 .

YES : NO : Replace the cooling fan motor (L.H.) (Refer

to P.14-35). Then go to Step 24 .

STEP 2. Measure the power supply voltage at cooling fan motor drive control unit connector A-18.

Connector: A-18

A-18

3 2 1

AC100293

(1) Disconnect cooling fan motor drive control unit

connector A-18 and measure wiring harness side connector.

(2) Turn the ignition switch to the "ON" position.

A-18 Connector (Component side)

AC000246

(3) Measure the voltage between cooling fan motor

drive control unit connector A-18 terminal 3 and body earth.

• The voltage should measure system voltage.

(4) Turn the ignition switch to the "LOCK" (OFF)

position.

(5) Connect cooling fan motor drive control unit

connector A-18.

Q: Is the measured voltage system voltage?

YES : Go to Step 17 . NO : Go to Step 3 .

14-8

ENGINE COOLING

TROUBLESHOOTING

STEP 3. Check the cooling fan motor drive control unit connector A-18.

Connector: A-18

A-18

3 2 1

AC100293

Q: Is the connector in good condition?

YES : .

Go to Step 4 .

NO : . Repair or replace the connector. Then go to

Step 24 .

STEP 4. Check the fusible link No.2.

Relay box

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

(remove the fan control relay) and measure relay box side connector.

(2) Turn the ignition switch to the "ON" position.

A-09X Connector (Relay box side)

AC303511

(3) Measure the voltage between fan control relay

connector A-09X terminal 4 and body earth.

• The voltage should measure system voltage.

(4) Turn the ignition switch to the "LOCK" (OFF)

position.

(5) Connect fan control relay connector A-09X

(install the fan control relay).

Q: Is the measured voltage system voltage?

Go to Step 8 .

YES : NO : Go to Step 6 .

Fusible link No.2

AC303509

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

YES : .

Go to Step 5 .

NO : . Replace the fusible link No.2. Then go to

Step 24 .

STEP 5. Measure the power supply voltage at fan control relay connector A-09X.

Connector: A-09X

A-09X

Relay box

Fan control relay

AC303510

STEP 6. Check the fan control relay connector A-09X.

Connector: A-09X

A-09X

Q: Is the connector in good condition?

YES :

Go to Step 7 .

NO : Repair the connector or replace the relay

Relay box

Fan control relay

AC303510

box. Then go to Step 24 .

ENGINE COOLING

TROUBLESHOOTING

14-9

STEP 7. Check the harness wire between fusible link No.2 and fan control relay connector A-09X terminal 4.

Relay box

Fusible link No.2

Connector: A-09X

AC303509

Relay box

Fan control relay

A-09X

Q: Is the connector in good condition?

Go to Step 10 .

YES : NO : Repair the connector or replace the relay

box. Then go to Step 24 .

STEP 10. Check the harness wire between fan control relay connector A-09X terminal 2 and cooling fan motor drive control unit connector A-18 terminal 3.

Connector: A-09X

A-09X

Connector: A-18

Relay box

Fan control relay

AC303510

Q: Is the harness wire in good condition?

YES : .

An intermittent malfunction is suspected (Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : . Repair the damaged harness wire. Then go

to Step 24 .

STEP 8. Check the fan control relay.

Refer to P.14-24.

Q: Is the fan control relay in good condition?

Go to Step 9 .

YES : NO : Replace the fan control relay. Then go to

Step 24 .

STEP 9. Check the fan control relay connector A-09X.

Connector: A-09X

Relay box

Fan control relay

A-18

3 2 1

AC100293

Q: Is the harness wire in good condition?

Go to Step 11 .

YES : NO : Repair the damaged harness wire. Then go

to Step 24 .

STEP 11. Measure the terminal voltage at fan control relay connector A-09X.

Connector: A-09X

A-09X

Relay box

Fan control relay

A-09X

AC303510

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

(remove the fan control relay) and measure relay box side connector.

(2) Turn the ignition switch to the "ON" position.

14-10

A-09X Connector (Relay box side)

ENGINE COOLING

TROUBLESHOOTING

STEP 12. Check the J/C No.6 C-12 <L.H. drive vehicles> or C-134 <R.H. drive vehicles>, intermediate connector A-13 <L.H. drive vehicles> C-111 <R.H. drive vehicles> and fan control relay connector A-09X.

Connector: C-12 <L.H. drive vehicles>

AC303517

(3) Measure the voltage between fan control relay

connector A-09X terminal 1 and body earth.

• The voltage should measure system voltage.

(4) Turn the ignition switch to the "LOCK" (OFF)

position.

(5) Connect fan control relay connector A-09X

(install the fan control relay).

Q: Is the measured voltage system voltage?

YES : . NO : . Go to Step 12 .

Go to Step 14 .

C-12

AC303524

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

C-134

AC303525

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

A-13

AC303526

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

C-111

2 3 4

1179810

AC303527

ENGINE COOLING

TROUBLESHOOTING

14-11

Connector: A-09X

A-09X

Relay box

Fan control relay

AC303510

Q: Are there connectors in good condition?

YES : .

Go to Step 13 .

NO : . Repair or replace the connector. Then go to

Step 24 .

STEP 13. Check the harness wire between J/C No.6 C-12 terminal 33 <L.H. drive vehicles> or C-134 terminal 33 <R.H. drive vehicles> and fan control relay connector A-09X terminal 1.

Connector: C-12 <L.H. drive vehicles>

Q: Are these harness wires in good condition?

An intermittent malfunction is suspected

YES :

(Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : Repair the damaged harness wire. Then go

to Step 24 .

STEP 14. Check the continuity between fan control relay connector A-09X and body earth.

Connector: A-09X

A-09X

Relay box

Fan control relay

AC303510

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

(remove the fan control relay) and measure relay box side connector.

C-12

AC303524

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

C-134

AC303525

Connector: A-09X

Relay box

Fan control relay

A-09X Connector (Relay box side)

AC303533

(2) Measure the resistance between fan control relay

connector A-09X terminal 3 and body earth.

• Continuity exists.

(3) Connect fan control relay connector A-09X

(install the fan control relay).

Q: Does the continuity exists?

YES : An intermittent malfunction is suspected

(Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : Go to Step 15 .

A-09X

AC303510

14-12

ENGINE COOLING

TROUBLESHOOTING

STEP 15. Check the fan control relay connector A-09X.

Connector: A-09X

A-09X

Q: Is the connector in good condition?

Go to Step 16 .

YES : NO : Repair the connector or replace the relay

Relay box

Fan control relay

AC303510

box. Then go to Step 24 .

STEP 16. Check the harness wire between fan control relay connector A-09X terminal 3 and body earth.

Connector: A-09X

Relay box

STEP 17. Check the continuity between cooling fan motor drive control unit connector A-18 and body earth.

Connector: A-18

A-18

3 2 1

AC100293

(1) Disconnect cooling fan motor drive control unit

connector A-18 and measure wiring harness side connector.

A-18 Connector (Wiring harness side)

Fan control relay

A-09X

AC303510

Q: Is the harness wire in good condition?

An intermittent malfunction is suspected

YES :

(Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : Repair the damaged harness wire. Then go

to Step 24 .

AC303534

(2) Measure the resistance between cooling fan

motor drive control unit connector A-18 terminal 1 and body earth.

• Continuity exists.

(3) Connect cooling fan motor drive control unit

connector A-18.

Q: Dose the continuity exists?

YES : Go to Step 20 . NO : Go to Step 18 .

ENGINE COOLING

TROUBLESHOOTING

14-13

STEP 18. Check the cooling fan motor drive control unit connector A-18.

Connector: A-18

A-18

3 2 1

AC100293

Q: Is the connector in good condition?

Go to Step 19 .

YES : NO : Repair or replace the connector. Then go to

Step 24 .

STEP 19. Check the harness wire between cooling fan motor drive control unit connector A-18 terminal 1 and body earth.

Connector: A-18

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

Connector: A-18

A-18

3 2 1

AC100293

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

A-13

A-18

3 2 1

AC100293

Q: Is the harness wire in good condition?

An intermittent malfunction is suspected

YES :

(Refer to GROUP 00 - How to use troubleshooting P.00-5).

NO : Repair the damaged harness wire. Then go

to Step 24 .

A-13

AC303526

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

C-111

2 3 4

1179810

AC303527

14-14

ENGINE COOLING

TROUBLESHOOTING

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

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

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

C-123 <M/T>

C-122 <A/T>

AC303555

Q: Are these connectors in good condition?

Go to Step 21 .

YES : NO : Repair or replace the connector. Then go to

Step 24 .

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

Connector: A-18

A-18

3 2 1

AC100293

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

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

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

C-123 <M/T>

C-122 <A/T>

AC303555

Q: Are these harness wires in good condition?

YES : Go to Step 22 . NO : Repair the damaged harness wire. Then go

to Step 24 .

ENGINE COOLING

TROUBLESHOOTING

14-15

STEP 22. Check the cooling fan motor drive control unit.

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

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

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

C-123 <M/T>

C-122 <A/T>

AC303555

(1) Disconnect engine-ECU connector C-123 <M/T>

or engine-A/T-ECU connector C-122 <A/T>.

(5) Check for the cooling fan operation.

• The cooling fan rotates. (with connector terminal pin 21 <M/T> or 18 <A/T> disconnected)

• The cooling fan stops. (When connector terminal pin 21 <M/T> or 18 <A/T> is connected to the body earth.)

(6) Turn the ignition switch to the "OFF" position. (7) Disconnect engine-ECU connector C-123 <M/T>

or engine-A/T-ECU connector C-122 <A/T>, and push in connector terminal pin 21 <M/T> or 18 <A/T> to disconnect connector.

(8) Reconnect the connector with connector terminal

pin still installed.

Q: Does the cooling fan rotate? And when the

connector terminal pin is connected to the body earth, does the cooling fan stop?

YES :

Go to Step 23 .

NO : Replace the cooling fan motor drive control

unit (Refer to P.14-35). Then go to Step 24 .

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

Check if an MPI system self-diag code is set. (Refer to GROUP 13A - Trouble shooting P.13A-9) <4G1> or (Refer to GROUP 13B - Trouble shooting

P.13B-9) <4G6>.

C-123 connector <M/T> (Harness side connector: ECU side view)

C-122 connector <A/T> (Harness side connector: ECU side view)

AC303559

(2) Pull out connector terminal pin 21 <M/T> or 18

<A/T> to disconnect connector.

(3) Reconnect the connector with connector terminal

pin still removed.

(4) Turn the ignition switch to the "ON" position.

Q: Diagnosis code set?

Inspection chart for diagnosis code (Refer

YES :

to GROUP 13A - Trouble shooting

P.13A-15) <4G1> or Inspection chart for

diagnosis code (Refer to GROUP 13B Trouble shooting P.13B-15) <4G6>.

NO : Replace the engine-ECU <M/T> or

engine-A/T-ECU <A/T> (Refer to GROUP 13A P.13A-401). Then go to Step 24 .

STEP 24. Check the symptoms.

Q: Does the cooling fan motor (L.H.) and the cooling

fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan motor <4G6> operate correctly?

YES :

This symptoms is complete.

NO : Return to Step 1 .

14-16

ENGINE COOLING

TROUBLESHOOTING

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

COOLING FAN (L.H.) AND COOLING FAN (R.H.) OR A/C CONDENSER FAN DRIVE CIRCUIT

Refer to P.14-6.

CIRCUIT OPERATION

Refer to P.14-6.

TECHNICAL DESCRIPTION

• If the communication line wiring harness between the cooling fan motor drive control unit and the engine-ECU <M/T> or the engine-A/T-ECU <A/T> is open, the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)>, or the A/C condenser fan motor <4G6> rotate to prevent the engine from overheating.

• If the system voltage is continuously supplied to the cooling fan motor drive control unit by a fan motor relay malfunction and a short circuit on the cooling fan motor drive control unit power supply wiring harness, the cooling fan motor (L.H.) and the cooling fan motor (R.H.) <4G1 (Vehicles with A/C)>, or the A/C condenser fan motor <4G6> rotate.

• The cause could also be a malfunction of the cooling fan motor (L.H.). <Vehicles without A/C>

• The cause could also be a malfunction of input signal from the A/C switch, the water temperature sensor unit and the vehicle speed sensor <M/T> or the output shaft speed sensor <A/T> to the engine-ECU <M/T or engine-A/T-ECU <A/T>.

• The cause could also be a malfunction of the cooling fan motor drive control unit or the engine-ECU <M/T> or engine-A/T-ECU <A/T>.

TROUBLESHOOTING HINTS

• Malfunction of fan control relay

• Malfunction of cooling fan motor (L.H.) <Vehicles

without A/C>

• Malfunction of cooling fan motor drive control unit

• Malfunction of engine-ECU <M/T> or

engine-A/T-ECU <A/T>

• Damaged wiring harness or connector

DIAGNOSIS

STEP 1. Check the fan control relay.

Refer to P.14-24.

Q: Is the fan control relay in good condition?

Go to Step 2 .

YES : NO : Replace the fan control relay. Then go to

Step 8 .

STEP 2. Check the fan control relay connector A-09X.

Connector: A-09X

A-09X

Q: Is the connector in good condition?

YES : Go to Step 3 . NO : Repair the connector or replace the relay

box. Then go to Step 8 .

Relay box

Fan control relay

AC303510

ENGINE COOLING

TROUBLESHOOTING

14-17

STEP 3. Check the harness wire between fan control relay connector A-09X terminal 2 and cooling fan motor drive control unit connector A-18 terminal 3.

Connector: A-09X

A-09X

Connector: A-18

A-18

3 2 1

Relay box

Fan control relay

AC303510

STEP 4. Check the cooling fan motor drive control unit connector A-18, intermediate connector A-13 <L.H. drive vehicles> or C-111 <R.H. drive vehicles> and engine-ECU connector C-123 <M/T> or engine-A/T-ECU connector C-122 <A/T>.

Connector: A-18

A-18

3 2 1

AC100293

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

A-13

AC100293

Q: Is the harness wire in good condition?

Go to Step 4 .

YES : NO : Repair the damaged harness wire. Then go

to Step 8 .

A-13

AC303526

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

C-111

2 3 4

1179810

AC303527

14-18

ENGINE COOLING

TROUBLESHOOTING

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

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

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

C-123 <M/T>

C-122 <A/T>

AC303555

Q: Are these connectors in good condition?

Go to Step 5 .

YES : NO : Repair or replace the connector. Then go to

Step 8 .

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

Connector: A-18

A-18

3 2 1

AC100293

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

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

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

C-123 <M/T>

C-122 <A/T>

AC303555

Q: Are these harness wires in good condition?

YES : Go to Step 6 . NO : Repair the damaged harness wire. Then go

to Step 8 .

ENGINE COOLING

TROUBLESHOOTING

14-19

STEP 6. Check the cooling fan motor drive control unit.

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

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

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

C-123 <M/T>

C-122 <A/T>

AC303555

(1) Disconnect engine-ECU connector C-123 <M/T>

or engine-A/T-ECU connector C-122 <A/T>.

(5) Check for the cooling fan operation.

• The cooling fan rotates. (with connector terminal pin 21 <M/T> or 18 <A/T> disconnected)

• The cooling fan stops. (When connector terminal pin 21 <M/T> or 18 <A/T> is connected to the body earth.)

(6) Turn the ignition switch to the "OFF" position. (7) Disconnect engine-ECU connector C-123 <M/T>

or engine-A/T-ECU connector C-122 <A/T>, and push in connector terminal pin 21 <M/T> or 18 <A/T> to disconnect connector.

(8) Reconnect the connector with connector terminal

pin still installed.

Q: Does the cooling fan rotate? And when the

connector terminal pin is connected to the body earth, does the cooling fan stop?

YES :

Go to Step 7 .

NO : Replace the cooling fan motor drive control

unit (Refer to P.14-35). Then go to Step 8 .

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

Check if an MPI system self-diag code is set. (Refer to GROUP 13A - Trouble shooting P.13A-9) <4G1> or (Refer to GROUP 13B - Trouble shooting

P.13B-9) <4G6>.

C-123 connector <M/T> (Harness side connector: ECU side view)

C-122 connector <A/T> (Harness side connector: ECU side view)

AC303559

(2) Pull out connector terminal pin 21 <M/T> or 18

<A/T> to disconnect connector.

(3) Reconnect the connector with connector terminal

pin still removed.

(4) Turn the ignition switch to the "ON" position.

Q: Diagnosis code set?

Inspection chart for diagnosis code (Refer

YES :

to GROUP 13A - Trouble shooting

P.13A-15) <4G1> or Inspection chart for

diagnosis code (Refer to GROUP 13B Trouble shooting P.13B-15) <4G6>.

NO : Replace the engine-ECU <M/T> or

engine-A/T-ECU <A/T> (Refer to GROUP 13A P.13A-401). Then go to Step 8 .

STEP 8. Check the symptoms.

Q: Does the cooling fan motor (L.H.) and the cooling

fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C condenser fan motor <4G6> operate correctly?

YES :

This symptoms is complete.

NO : Return to Step 1 .

14-20

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

ENGINE COOLING

TROUBLESHOOTING

COOLING FAN (L.H.) AND COOLING FAN (R.H.) OR A/C CONDENSER FAN DRIVE CIRCUIT

Refer to P.14-6.

CIRCUIT OPERATION

Refer to P.14-6.

TECHNICAL DESCRIPTION

The cause could be a malfunction of the cooling fan motor (L.H.) or cooling fan motor drive control unit.

TROUBLESHOOTING HINTS

• Malfunction of cooling fan motor (L.H.)

• Malfunction of cooling fan motor drive control unit

DIAGNOSIS

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

Refer to P.14-25.

Q: Is the cooling fan motor (L.H.) in good condition?

Go to Step 2 .

YES : NO : Replace the cooling fan motor (L.H.) (Refer

to P.14-35). Then go to Step 3 .

STEP 2. Check the cooling fan motor drive control unit.

Refer to P.14-23.

Q: Is the cooling fan motor drive control unit in good

condition? YES :

Go to Step 3 .

NO : Replace the cooling fan motor drive control

unit (Refer to P.14-35). Then go to Step 3 .

STEP 3. Check the symptoms.

Q: Do the cooling fan (L.H.) operate (when the cooling

fan (R.H.) <4G1> or A/C condenser fan <4G6> operate)?

YES :

This symptoms is complete.

NO : Return to Step 1 .

ENGINE COOLING

TROUBLESHOOTING

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

14-21

COOLING FAN (L.H.) AND COOLING FAN (R.H.) OR A/C CONDENSER FAN DRIVE CIRCUIT

Refer to P.14-6.

CIRCUIT OPERATION

Refer to P.14-6.

TECHNICAL DESCRIPTION

The cause could be a malfunction of the cooling fan motor (R.H.) <4G1> or A/C condenser fan motor <4G6> or cooling fan motor drive control unit.

TROUBLESHOOTING HINTS

• Malfunction of cooling fan motor (R.H.) <4G1> or A/C condenser fan motor <4G6>

• Malfunction of cooling fan motor drive control unit

DIAGNOSIS

STEP 1. Check the cooling fan motor (R.H.) <4G1> or A/C condenser fan motor <4G6>.

Cooling fan motor (R.H.) check. (Refer to P.14-25) <4G1>. A/C condenser fan motor check. (Refer to GROUP 55 P.55-97) <4G6>.

Q: Is the cooling fan motor (R.H.) <4G1> or A/C

condenser fan motor <4G6> in good condition?

Go to Step 2 .

YES : NO : Replace the cooling fan motor (R.H.) (Refer

to P.14-35) <4G1> or A/C condenser fan motor (Refer to GROUP 55 P.55-96) <4G6>. Then go to Step 3 .

STEP 2. Check the cooling fan motor drive control unit.

Refer to P.14-23.

Q: Is the cooling fan motor drive control unit in good

condition? YES :

Go to Step 3 .

NO : Replace the cooling fan motor drive control

unit (Refer to P.14-35). Then go to Step 3 .

STEP 3. Check the symptoms.

Q: Do the cooling fan (R.H.) <4G1> or A/C condenser

fan <4G6> operate (when the cooling fan (L.H.) operate)?

YES :

This symptoms is complete.

NO : Return to Step 1 .

14-22

ENGINE COOLING

ON-VEHICLE SERVICE

ENGINE COOLANT LEAK CHECK

M1141001000300

WARNING

When pressure testing the cooling system, slowly release cooling system pressure to avoid getting burned by hot coolant.

CAUTION

• Be sure to completely clean away any moisture from the places checked.

• When the tester is taken out, be careful not to spill any coolant.

• Be careful when installing and removing the tester and when testing not to deform the filler neck of the radiator.

Cap adapter

Adapter

2. Increase the pressure until the indicator of the gauge stops moving.

Minimum limit: 83 kPa Standard value: 93 − 123 kPa

3. Replace the radiator cap if the reading does not remain at or above the limit.

ENGINE COOLANT REPLACEMENT

M1141001200434

WARNING

When removing the radiator cap, use care to avoid contact with hot coolant or steam. Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube. After relieving the steam pressure, remove the cap by slowly turning it counterclockwise.

1. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.

ACX01844

1. Check that the coolant level is up to the filler neck. Install a radiator tester and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections.

2. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP VALVE OPENING PRESSURE CHECK

M1141001300389

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

Cap adapter

AC211643 AB

1. Use a cap adapter to attach the cap to the tester.

<4G1> Inlet side

Cylinder block drain plug

AC208283

<4G6> Inlet side

Cylinder block drain plug

AC303355

2. Drain the water in the water jacket by unplugging the drain plug of the cylinder block.

3. Remove the radiator condenser tank and drain the coolant.

4. Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area.

Cylinder block drain plug

ENGINE COOLING

ON-VEHICLE SERVICE

9. Reinstall the radiator cap.

10.Start the engine and let it warm up until the thermostat opens.

11.After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.

12.Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim. Reinstall the cap.

14-23

AC200625

5. Apply the designated sealant to the screw area of the cylinder block drain plug, and then tighten to the standard torque.

Specified sealant: 3M Nut Locking Part

No.4171 or equivalent

Tightening torque:

40 ± 5 N⋅m <4G1> 44 ± 5 N⋅m <4G6>

6. Securely tighten the drain plug of the radiator.

7. Reinstall the radiator condenser tank.

CAUTION

Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminium components.

MB991871

CAUTION

Do not overfill the radiator condenser tank.

13.Add coolant to the radiator condenser tank between the "F" and "L" mark if necessary.

CONCENTRATION MEASUREMENT

M1141001100352

Measure the temperature and specific gravity of the engine coolant to check the antifreeze concentration.

Standard value: 30 − 60% (allowable

concentration range)

Recommended antifreeze: DIAQUEEN SUPER

LONG LIFE COOLANT or equivalent

CAUTION

If the concentration of the anti-freeze is below 30%, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60%, both the anti-freezing and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range.

AIR HOSE

AC303612

8. By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60%. Use special tool LLC changer (MB991871) to refill the coolant. A convenient mixture is a 50% water and 50% antifreeze solution (freezing point: −31°C).

Recommended antifreeze: DIAQUEEN SUPER

LONG LIFE COOLANT or equivalent

Quantity:

5.0 L <4G1>

7.0 L <4G6>

NOTE: For how to use special tool MB991871, refer to its manufacturer’s instructions.

COOLING FAN MOTOR DRIVE CONTROL UNIT CHECK

M1141006100216

1. Remove the cooling fan motor drive control unit connector.

Cooling fan motor

Y1716AU

drive control unit

123

AC103195

2. Turn the ignition switch to the "ON" position, and measure the voltage between terminal 1 and 3 at the harness side connector.

Standard value: system voltage

14-24

ENGINE COOLING

ON-VEHICLE SERVICE

3. Connect the cooling fan motor drive control unit connector, and disconnect the cooling fan motor (L.H.) connector.

4. Ensure that the A/C switch is off, and start the engine and run it at idle.

Cooling fan motor drive control unit

AC303496

5. Measure the voltage between the cooling fan motor drive control unit side connector terminal 1 and 2.

Standard value: 1V or less

WARNING

Stay clear of the fan when the fan starts running.

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

7. Measure the voltage between the cooling fan motor drive control unit side connector terminal 1 and 2 while the fan is running. The voltage should repeat the values below.

Standard value:

1. 1 V or less

2. 8.2 ± 0.7 V

3. System voltage ± 2.6 V

8. If the voltage does not repeatedly change as indicated, replace the cooling fan motor drive control unit. (Refer to P.14-35).

FAN CONTROL RELAY CONTINUITY CHECK

M1141006200280

Fan control relay

AC211776

Battery voltage

Terminal No.to be connected to tester

Not applied 4 − 2 Open circuit

Connect

4 − 2 Less than 2 ohms terminal No.1 and battery (−) terminal. Connect terminal No.3 and battery (+) terminal.

AC301712

Continuity test results

ENGINE COOLING

ON-VEHICLE SERVICE

14-25

COOLING FAN MOTOR CHECK

Cooling fan motor drive control unit

Cooling fan motor (L.H.) connector

AC303501

Cooling fan motor Cooling fan motor drive control unit

(R.H.) connector

<4G1 with A/C>

AC303502

M1141007100060

1. Remove the cooling fan motor connector.

2. Check to see that the cooling fan motor of the radiator turns when applying battery power between the connector terminal 1 and 2 of the cooling fan motor. Also check to see that there is no abnormal sound coming from the cooling fan motor at this time.

3. If the cooling fan motor is defective, replace it. (Refer to P.14-35).

14-26

ENGINE COOLING

THERMOSTAT

REMOVAL AND INSTALLATION

M1141002400442

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).

• Air Cleaner Assembly Removal and Installation (Refer to

GROUP 15 P.15-3).

• Battery Removal and Installation

<4G1>

22 ± 4 N·m

<4G6>

AC203409

13 ± 2 N·m

AC301429

ENGINE COOLING

THERMOSTAT

14-27

Removal steps

1. Water temperature gauge unit connector <4G6>

2. Water temperature sensor unit connector <4G6>

<<A>> >B<<

3. Radiator lower hose connection

REMOVAL SERVICE POINT <<A>> RADIATOR LOWER HOSE

DISCONNECTION

Mating marks

Removal steps (Continued)

4. Engine control oxygen sensor connector and connector bracket <4G1>

5. Control wiring harness clip <4G6>

6. Cooling water inlet hose fitting

>>A<<

7. Thermostat

>>B<< RADIATOR LOWER HOSE CONNECTION

Projection

Cooling water inlet hse fitting

Mating marks

AC200642

AC200641

Make mating marks on the radiator lower hose and the hose clamp. Disconnect the radiator lower hose.

INSTALLATION SERVICE POINTS >>A<< THERMOSTAT INSTALLATION

CAUTION

Make absolutely sure that no oil adheres to the rubber ring of the thermostat. Also do not fold or scratch the rubber ring during installation.

Jiggle valve

Rubber ring

AC000279

Install the thermostat so that the jiggle valve is facing straight up. Be careful not to fold or scratch the rubber ring.

1. Insert radiator lower hose as far as the projection of the Cooling water inlet hose fitting.

2. Align the mating marks on the radiator lower hose and hose clamp, and then connect the radiator lower hose.

INSPECTION

M1141002500427

THERMOSTAT CHECK

ACX00400

1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature.

Standard value: 88 ± 1.5°C <4G1> 82 ± 1.5°C <4G6>

14-28

Valve lift

ACX00401

ENGINE COOLING

THERMOSTAT

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

standard value when the water is at the full-opening temperature.

NOTE: Measure the valve height when the thermostat is fully closed, and use this measurement to compare the valve height when the thermostat is fully open.

Standard value: 100°C <4G1> 95°C <4G6> Amount of valve lift: 8.5 mm or more

ENGINE COOLING

WATER PUMP

14-29

REMOVAL AND INSTALLATION <4G1>

M1141002700421

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).

• Valve Timing Belt Removal and Installation (Refer to

GROUP 11A P.11A-33).

23 ± 2 N·m

Bolt specifications

8 × 50

8 × 30

Screw diameter × length mm

8 × 25

24 ± 3 N·m

14 ± 1 N·m

Removal steps

1. Alternator adjusting brace

>>A<<

2. Water pump assembly

INSTALLATION SERVICE POINT >>A<< WATER PUMP ASSEMBLY

INSTALLATION

1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.

Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent

AC303372

2. Apply a bead of the specified sealant.

Specified Sealant: MITSUBISHI GENUINE PART No.MD970389 or equivalent

3. With the sealant still wet (within 15 minutes after the sealant is applied), install the water pump assembly. Do not apply the sealant in an area more than the required.

14-30

ENGINE COOLING

WATER PUMP

REMOVAL AND INSTALLATION <4G6>

M1141002700432

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Refilling (Refer to P.14-22).

• Valve Timing Belt and Balancer Timing Belt Removal and

Installation (Refer to GROUP 11C P.11C-35).

22 ± 4 N·m

Bolt specifications

8 × 70

8 × 22

23 ± 3 N·m

14 ± 1 N·m

Removal steps

1. Alternator adjusting brace

2. Water pump assembly

INSTALLATION SERVICE POINT >>A<< COOLING WATER LINE O-RING

INSTALLATION

Water pump assembly

Cooling water line O-ring

8 × 14

8 × 25

8 × 22

Screw diameter × length mm

AC301467

Removal steps (Continued)

3. Water pump gasket

>>A<<

4. Cooling water line O-ring

Fit the cooling water line O-ring to the groove in the water pump inlet pipe. Then lubricate the cooling water line O-ring and the inside of the water pump assembly with water, and then insert the water pump inlet pipe to the water pump assembly.

Water pump inlet pipe

AC103005

ENGINE COOLING

WATER HOSE AND WATER PIPE

14-31

REMOVAL AND INSTALLATION <4G1>

M1141003300415

Pre-removal and Post-installation Operation

• Under Cover Removal and Installation

• Engine Coolant Draining and Supplying (Refer to

P.14-22).

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

• Thermostat Removal and Installation (Refer to P.14-26).

23 ± 4 N·m

13 ± 2 N·m

<<A>> >>B<<

Removal steps

1. Water temperature sensor unit connector

2. Water temperature gauge unit connector

3. Control wiring harness and harness bracket

4. Radiator upper hose connection

5. Throttle body water feed hose

6. Thermostat case assembly

>>A<<

13 ± 2 N·m

AC203411

Removal steps (Continued)

7. Thermostat case gasket

8. Cooling water line O-ring

9. Control wiring harness clamp

10. Throttle body water return hose

11. Heater water hose connection

12. Water pump inlet pipe

13. Cooling water line O-ring

14-32

ENGINE COOLING

WATER HOSE AND WATER PIPE

REMOVAL SERVICE POINT <<A>> RADIATOR UPPER HOSE

DISCONNECTION

Mating marks

AC200641

After making mating marks on the radiator upper hose and hose clamp, disconnect the radiator upper hose.

INSTALLATION SERVICE POINTS >>A<< COOLING WATER LINE O-RING

INSTALLATION

>>B<< RADIATOR UPPER HOSE CONNECTION

Projection

Thermostat case assembly

1. Insert radiator upper hose as far as the projection of the thermostat case assembly.

2. Align the mating marks on the radiator upper hose and hose clamp, and then connect the radiator upper hose.

Radiator upper hose

Mating marks

AC200642

CAUTION

Water pump or thermostat case

Cooling water line O-ring

Water pump inlet pipe

AC200644

Do not allow engine oil or other grease to adhere to the O-ring

Insert the cooling water line O-ring to the water pump inlet pipe, and coat the outer portion of the cooling water line O-ring with water or engine coolant.

ENGINE COOLING

WATER HOSE AND WATER PIPE

14-33

REMOVAL AND INSTALLATION <4G6>

M1141003300426

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Supplying (Refer to

P.14-22).

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

• Thermostat Removal and Installation (Refer to P.14-26).

13 ± 2 N·m

<<A>> >>C<<

>>B<<

13 ± 2 N·m

Ø3 mm

Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent

Removal steps

1. Radiator upper hose connection

2. Cooling water outlet hose fitting

3. Throttle body water return hose

4. Throttle body water feed hose

5. Thermostat case assembly

6. Heater water hose connection

Ø3 mm

>>A<<

23 ± 4 N·m

AC303471

Removal steps (Continued)

7. Control wiring harness clamp

8. Water pump inlet pipe

9. Cooling water line O-ring

14-34

ENGINE COOLING

WATER HOSE AND WATER PIPE

REMOVAL SERVICE POINT <<A>> RADIATOR UPPER HOSE

DISCONNECTION

Mating marks

AC200641

After making mating marks on the radiator upper hose and hose clamp, disconnect the radiator upper hose.

INSTALLATION SERVICE POINTS >>A<< COOLING WATER LINE O-RING

INSTALLATION

>>B<< THERMOSTAT CASE ASSEMBLY/COOLING WATER OUTLET HOSE FITTING INSTALLATION

1. Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.

2. Apply a bead of the specified sealant.

Specified Sealant: MITSUBISHI GENUINE PART No.MD970389 or equivalent

3. With the sealant still wet (within 15 minutes after the sealant is applied), install the thermostat case assembly or cooling water outlet hose fitting. Do not apply the sealant in an area more than the required.

>>C<< RADIATOR UPPER HOSE CONNECTION

Projection

Radiator upper hose

CAUTION

Water pump or thermostat case

O-ring

Water inlet pipe

AC200644

Do not allow engine oil or other grease to adhere to the cooling water line O-ring

Insert the cooling water line O-ring to the water pump water inlet pipe, and coat the outer portion of the cooling water line O-ring with water or engine coolant.

Mating marks

Cooling water outlet hose fitting

AC200642

1. Insert radiator upper hose as far as the projection of the cooling water outlet hose fitting.

2. Align the mating marks on the radiator upper hose and hose clamp, and then connect the radiator upper hose.

INSPECTION

M1141003400296

WATER PUMP INLET PIPE AND THROTTLE BODY WATER HOSES CHECK

Check the water pipe and hoses for cracks, damage and clogs. Replace them if necessary.

ENGINE COOLING

RADIATOR

14-35

REMOVAL AND INSTALLATION

M1141001500468

Pre-removal and Post-installation Operation

• Engine Coolant Draining and Supplying (Refer to

P.14-22).

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

<4G1 (Vehicles without A/C)>

12 ± 2 N·m

AC303472

14-36

ENGINE COOLING

RADIATOR

<4G1 (Vehicles with A/C)>

12 ± 2 N·m

AC303473

<4G6>

12 ± 2 N·m

<<A>> >>A<< <<A>> >>A<<

12 ± 2 N·m

Radiator removal steps

1. Drain plug

2. Radiator cap

3. Radiator condenser tank hose

4. Radiator condenser tank assembly

5. Radiator upper hose

6. Radiator lower hose

7. Cooling fan motor drive control unit connector

AC303474

Radiator removal steps

8. T/M oil cooler line hose connection <A/T>

9. Radiator support upper insulator Radiator and cooling fan motor &

•

shroud assembly

10. Radiator support lower insulator

11. T/M oil cooler line hose <A/T>

ENGINE COOLING

RADIATOR

14-37

Radiator removal steps

12. Cooling fan motor & shroud assembly

13. A/C condenser fan motor & shroud assembly <4G6>

14. Radiator assembly

Cooling fan motor removal steps

3. Radiator condenser tank hose

<<A>> >>A<<

5. Radiator upper hose

7. Cooling fan motor drive control unit connector

REMOVAL SERVICE POINT <<A>> RADIATOR UPPER

HOSE/RADIATOR LOWER HOSE DISCONNECTION

Cooling fan motor removal steps (Continued)

12. Cooling fan motor & shroud assembly

15. Cooling fan (L.H.)

16. Cooling fan (R.H.) <4G1 (Vehicles with A/C)>

17. Cooling fan motor drive control unit

18. Cooling fan motor (L.H.)

19. Cooling fan (R.H.) motor <4G1 (Vehicles with A/C)>

20. Cooling fan shroud

INSTALLATION SERVICE POINT >>A<< RADIATOR LOWER

HOSE/RADIATOR UPPER HOSE CONNECTION

Projection

Radiator hose

Mating marks

AC200641

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hoses.

Mating marks

Cooling water hose fitting or thermostat case assembly

AC200642

1. Insert radiator lower hose as far as the projection of the cooling water inlet hose fitting.

2. Insert radiator upper hose as far as the projection of the thermostat case assembly <4G1> or the cooling water outlet hose fitting <4G6>.

3. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

NOTES

GROUP 15

INTAKE AND

EXHAUST

CONTENTS

15-1

GENERAL INFORMATION . . . . . . . . 15-2

SERVICE SPECIFICATION . . . . . . . . 15-2

SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-2

AIR CLEANER . . . . . . . . . . . . . . . . . . 15-3

REMOVAL AND INSTALLATION . . . . . . . . 15-3

INLET MANIFOLD . . . . . . . . . . . . . . . 15-5

REMOVAL AND INSTALLATION <4G1> . . 15-5

REMOVAL AND INSTALLATION <4G6> . . 15-6

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-7

EXHAUST MANIFOLD . . . . . . . . . . . . 15-7

REMOVAL AND INSTALLATION <4G1> . . 15-7

REMOVAL AND INSTALLATION <4G6> . . 15-9

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-10

EXHAUST PIPE AND MAIN

MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-11

REMOVAL AND INSTALLATION . . . . . . . . 15-11

15-2

INTAKE AND EXHAUST

GENERAL INFORMATION

The exhaust pipe is divided into three parts.

SERVICE SPECIFICATION

Item Standard value Limit

Manifold distortion of the installation surface mm 0.15 or less 0.20

SPECIAL TOOL

Tool Number Name Use

MD998770 Oxygen sensor wrench Removal and installation of

engine control oxygen sensor

M1151000100402

M1151000300428

M1151000600399

INTAKE AND EXHAUST

AIR CLEANER

15-3

REMOVAL AND INSTALLATION

M1151002100486

CAUTION

Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions.

• Avoid any shock or load to these parts when removing and installing them.

• When installing, securely set the air cleaner cover clamp to the air cleaner body.

NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state and local laws.

<4G1>

9.0 ± 1.0 N·m

10*

4.0 ± 1.0 N·m

12 ± 1 N·m

9.0 ± 1.0 N·m

12 ± 1 N·m

Clamp

AC303618

15-4

INTAKE AND EXHAUST

AIR CLEANER

<4G6>

10*

9.0 ± 1.0 N·m

12 ± 1 N·m

Removal steps

1. Air cleaner intake duct

2. Air cleaner air flow sensor connector <4G6>

3. Air cleaner assembly <4G1> or Air cleaner and air cleaner air flow sensor assembly <4G6>

4. Rocker cover breather hose connection

5. Air cleaner to throttle body duct

4.0 ± 1.0 N·m

12 ± 1 N·m

6. Air cleaner air flow sensor <4G6>

7. Air cleaner air flow sensor gasket

8. Air cleaner cover

9. Air cleaner element

10. Air cleaner body assembly

11. Air cleaner bracket

4.0 ± 1.0 N·m

8.8 ± 1.0 N·m

Clamp

9.0 ± 1.0 N·m

AC303619

Removal steps (Continued)

<4G6>

INTAKE AND EXHAUST

INLET MANIFOLD

15-5

REMOVAL AND INSTALLATION <4G1>

M1151003000749

Pre-removal Operation

• Fuel Line Pressure Reduction (Refer to GROUP 13A On-vehicle Service P.13A-389).

• Engine Coolant Draining (Refer to GROUP 14 On-vehicle Service P.14-22).

• Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).

• Throttle Body Assembly Removal (Refer to GROUP 13A

P.13A-400).

• Fuel Delivery Pipe and Fuel Injector Assembly Removal (Refer to GROUP 13A P.13A-398).

9.0 ± 1.0 N·m

18 ± 2 N·m

21 ± 4 N·m

9.0 ± 1.0 N·m

Post-installation Operation

• Fuel Delivery Pipe and Fuel Injector Assembly Installation (Refer to GROUP 13A P.13A-398).

• Throttle Body Assembly Installation (Refer to GROUP 13A P.13A-400).

• Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).

• Engine Coolant Supplying (Refer to GROUP 14 -

On-vehicle Service P.14-22).

• Accelerator Cable Adjustment (Refer to GROUP 17 On-vehicle Service P.17-2).

• Fuel Leak Check

18 ± 2 N·m

5.0 ± 1.0 N·m

18 ± 2 N·m

31 ± 3 N·m

49 ± 9 N·m

Removal steps

1. Inlet manifold absolute pressure sensor

2. Engine control pressure sensor O-ring

3. Engine control detonation sensor connector

4. T/M housing front lower cover stay (L.H.)

5. Battery wiring harness clamp connection

6. Inlet manifold stay

7. Brake booster vacuum hose connection

AC303642

Removal steps (Continued)

8. Emission control equip hose connection

9. Fuel vapour control hose connection

10. Inlet manifold stay

11. Inlet manifold

12. Inlet manifold gasket

13. EGR valve

14. EGR valve gasket

15. Emission vacuum hose & pipe and emission solenoid valve assembly

15-6

INTAKE AND EXHAUST

INLET MANIFOLD

REMOVAL AND INSTALLATION <4G6>

M1151003001236

Pre-removal Operation

• Fuel Line Pressure Reduction (Refer to GROUP 13A On-vehicle Service P.13A-389).

• Engine Coolant Draining (Refer to GROUP 14 On-vehicle Service P.14-22).

• Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).

• Throttle Body Assembly Removal (Refer to GROUP 13B

P.13B-336).

• Fuel Delivery Pipe and Fuel Injector Assembly Removal (Refer to GROUP 13B P.13B-334).

5.0 ± 1.0 N·m

20 ± 2 N·m

Post-installation Operation

• Fuel Delivery Pipe and Fuel Injector Assembly Installation (Refer to GROUP 13B P.13B-334).

• Throttle Body Assembly Installation (Refer to GROUP 13B P.13B-336).

• Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).

• Engine Coolant Supplying (Refer to GROUP 14 -

On-vehicle Service P.14-22).

• Accelerator Cable Adjustment (Refer to GROUP 17 On-vehicle Service P.17-2).

• Fuel Leak Check

11 ± 1 N·m

9.0 ± 1.0 N·m

36 ± 6 N·m

13 ± 1 N·m

(Engine oil)

11 ± 1 N·m

36 ± 6 N·m

20 ± 2 N·m

36 ± 6 N·m

31 ± 3 N·m

Removal steps

1. Emission control equip hose connector

2. Brake booster vacuum hose connection

3. Earth cable connection

AC303657

Removal steps (Continued)

4. Engine control detonation sensor connector

5. Engine oil level gauge and guide assembly

6. Engine oil filler O-ring

7. Emission vacuum hose connection

INTAKE AND EXHAUST

EXHAUST MANIFOLD

Removal steps (Continued)

8. Battery wiring harness clamp

9. Inlet manifold stay

10. Inlet manifold

11. Inlet manifold gasket

12. Emission vacuum hose & pipe and emission solenoid valve assembly

13. EGR valve

14. EGR valve gasket

15-7

INSPECTION

M1151003100616

Check the following points; replace the part if a problem is found.

Inlet Manifold Check

1. Check for damage or cracking of any part.

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION <4G1>

M1151003300568

29 ± 3 N·m

2. Clogging of the negative pressure (vacuum) outlet port, or clogging of the exhaust gas recirculation passages.

3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm or less Limit: 0.20 mm

29 ± 3 N·m

44 ± 5 N·m

(Engine oil)

29 ± 3 N·m

24 ± 4 N·m

35 ± 6 N·m

50 ± 10 N·m

17 ± 2 N·m

29 ± 3 N·m

AC303662

15-8

INTAKE AND EXHAUST

EXHAUST MANIFOLD

Removal steps

1. Front exhaust pipe connection

2. Exhaust pipe gasket

<<A>> >>A<<

3. Engine control oxygen sensor (front)

4. Engine oil level gauge and guide assembly

5. Engine oil filler O-ring

REMOVAL SERVICE POINT <<A>> ENGINE CONTROL OXYGEN

SENSOR (FRONT) REMOVAL

MD998770

Engine control oxygen sensor (front)

AC212566

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

Removal steps (Continued)

6. Exhaust manifold cover

7. Exhaust manifold bracket

8. Exhaust manifold

9. Exhaust manifold gasket

INSTALLATION SERVICE POINT >>A<< ENGINE CONTROL OXYGEN

SENSOR (FRONT) INSTALLATION

MD998770

Engine control oxygen sensor (front)

AC212566

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

INTAKE AND EXHAUST

EXHAUST MANIFOLD

15-9

REMOVAL AND INSTALLATION <4G6>

Pre-removal and Post-installation Operation

Under cover Removal and Installation

29 ± 3 N·m

49 ± 9 N·m

M1151003300579

49 ± 5 N·m

29 ± 3 N·m

14 ± 1 N·m

44 ± 5 N·m

<<A>> >>A<<

9.0 ± 2.0 N·m

Removal steps

1. Front exhaust pipe connection

2. Exhaust pipe gasket

3. Engine control oxygen sensor (front)

4. Exhaust manifold cover

5. Exhaust manifold bracket

49 ± 5 N·m

44 ± 5 N·m

50 ± 10 N·m

35 ± 6 N·m

14 ± 1 N·m

AC303680

Removal steps (Continued)

6. Starter cover

7. Starter cover bracket

8. Engine hanger

9. Exhaust manifold

10. Exhaust manifold gasket

15-10

INTAKE AND EXHAUST

EXHAUST MANIFOLD

REMOVAL SERVICE POINT <<A>> ENGINE CONTROL OXYGEN

SENSOR (FRONT) REMOVAL

MD998770

Engine control oxygen sensor (front)

AC212566

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

INSPECTION

M1151003400543

Check the following points; replace the part if a problem is found.

Exhaust Manifold Check

1. Check for damage or cracking of any part.

INSTALLATION SERVICE POINT >>A<< ENGINE CONTROL OXYGEN

SENSOR (FRONT) INSTALLATION

MD998770

Engine control oxygen sensor (front)

AC212566

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

2. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface.

Standard value: 0.15 mm or less Limit: 0.20 mm

INTAKE AND EXHAUST

EXHAUST PIPE AND MAIN MUFFLER

15-11

REMOVAL AND INSTALLATION

<4G1>

50 ± 10 N·m

<4G6>

45 ± 5 N·m

M1151008700301

45 ± 5 N·m

13 ± 2 N·m

59 ± 10 N·m

13 ± 2 N·m

45 ± 5 N·m

AC303694

13 ± 2 N·m

45 ± 5 N·m

50 ± 10 N·m

Exhaust main muffler removal steps

1. Exhaust main muffler

3. Exhaust pipe gasket

4. Exhaust muffler hanger

Centre exhaust pipe removal steps

2. Centre exhaust pipe

3. Exhaust pipe gasket

7. Exhaust pipe gasket

59 ± 10 N·m

<<A>> >>A<<

AC303695

Front exhaust pipe removal steps

5. Engine control oxygen sensor (rear)

6. Front exhaust pipe

7. Exhaust pipe gasket

8. Exhaust pipe gasket

9. Exhaust muffler hanger

15-12

INTAKE AND EXHAUST

EXHAUST PIPE AND MAIN MUFFLER

REMOVAL SERVICE POINT <<A>> ENGINE CONTROL OXYGEN

SENSOR (REAR) REMOVAL

MD998770

Engine control oxygen sensor (rear)

AC212566

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

INSTALLATION SERVICE POINT >>A<< ENGINE CONTROL OXYGEN

SENSOR (REAR) INSTALLATION

MD998770

Engine control oxygen sensor (rear)

AC212566

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

GROUP 16

ENGINE

ELECTRICAL

CONTENTS

16-1

CHARGING SYSTEM . . . . . . . .

16-2

GENERAL INFORMATION . . . . . . 16-2

SERVICE SPECIFICATIONS. . . . . 16-3

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

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

ALTERNATOR OUTPUT LINE VOLTAGE

DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-3

OUTPUT CURRENT TEST . . . . . . . . . . 16-5

REGULATED VOLTAGE TEST. . . . . . . 16-7

WAVEFORM CHECK USING AN

OSCILLOSCOPE. . . . . . . . . . . . . . . . . . 16-9

ALTERNATOR ASSEMBLY . . . . . 16-12

REMOVAL AND INSTALLATION

<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12

REMOVAL AND INSTALLATION

<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-13

DISASSEMBLY AND REASSEMBLY . . 16-15

INSPECTION. . . . . . . . . . . . . . . . . . . . . 16-17

STARTING SYSTEM . . . . . . . . . 16-19

GENERAL INFORMATION . . . . . .

16-19

IGNITION SYSTEM . . . . . . . . . 16-30

GENERAL INFORMATION . . . . . . 16-30

SERVICE SPECIFICATIONS . . . . . 16-31

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

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

IGNITION COIL (WITH BUILT-IN

POWER TRANSISTOR) CHECK. . . . . . 16-32

RESISTIVE CORD CHECK . . . . . . . . . . 16-32

SPARK PLUG CHECK AND

CLEANING <4G1> . . . . . . . . . . . . . . . . . 16-32

SPARK PLUG CHECK AND

CLEANING <4G6> . . . . . . . . . . . . . . . . . 16-33

CAMSHAFT POSITION SENSOR

CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . 16-33

CRANK ANGLE SENSOR CHECK . . . . 16-33

DETONATION SENSOR CHECK . . . . . 16-33

IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN

OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-33

IGNITION COIL RELAY CHECK . . . . . . 16-37

IGNITION COIL. . . . . . . . . . . . . . . . 16-38

REMOVAL AND INSTALLATION

<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-38

REMOVAL AND INSTALLATION

<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-39

SERVICE SPECIFICATIONS. . . . . 16-20

STARTER MOTOR ASSEMBLY . . 16-21

REMOVAL AND INSTALLATION

<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21

REMOVAL AND INSTALLATION

<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22

STARTER MOTOR ASSEMBLY

INSPECTION. . . . . . . . . . . . . . . . . . . . . 16-23

DISASSEMBLY AND REASSEMBLY . . 16-26

INSPECTION. . . . . . . . . . . . . . . . . . . . . 16-27

CAMSHAFT POSITION SENSOR . 16-40

REMOVAL AND INSTALLATION. . . . . . 16-40

CRANKSHAFT POSITION SENSOR 16-41

REMOVAL AND INSTALLATION

<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-41

REMOVAL AND INSTALLATION

<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42

DETONATION SENSOR . . . . . . . . 16-43

REMOVAL AND INSTALLATION. . . . . . 16-43

16-2

ENGINE ELECTRICAL

CHARGING SYSTEM

GENERAL INFORMATION

The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads.

OPERATION

Voltage

Approximately

14.4 V

Time

Rotation of the excited field coil generates AC voltage in the stator. This alternating current is recti fi ed through diodes to DC voltage having a waveform shown in the illustration.

AKX00183

M1161000100522

The average output voltage fluctuates slightly with the alternator load condition. When the igni tion swit ch is tur ned o n, cu rrent fl ows in the field coil and initial excitation of the field coil occurs. When the stator coil begins to generate power after the engine is started, the field coil is excited by the output current of the stator coil. The alternator output voltage rises as the field current increases and it falls as the fi eld current decreases. When the battery voltage (al ternator "S" terminal voltage) reaches a regulated voltage of approximately 14.4 V, the field current is cut off. When the battery voltage drops below the regulated voltage, the voltage regulator regulates the output voltage to a constant level by controlling the field current. In addition, when the field current is constant, the alternator output volt age rises as the engine speed increases.

SYSTEM DIAGRAM

Alternator

Stator coil

Field coil

<4G1>

V oltage regulator

Charge warning light

Engine-ECU

<M/T> or

Engine-A/T-ECU

<A/T>

Ignition switch

Battery

–

AK400308

ALTERNATOR SPECIFICATIONS

Item 4G1 4G6

Type Battery voltage sensing Rated output V/A 12/80 12/110 Voltage regulator Electronic built-in type

ENGINE ELECTRICAL

CHARGING SYSTEM

16-3

SERVICE SPECIFICATIONS

Item Standard val ue Limit

Alternator output line voltage drop (at 30 A) V Regulated voltage ambient

temperature at voltage regulat or V

−20°C 20°C 13.9 − 14.9

60°C 13.4 − 14.6 80°C 13.1 − 14.5

Output current

−

14.2 − 15.4

−

maximum 0.3

−

70 % of normal output current

SPECIAL TOOL

Tool Number Name Use

MB991519 Alternator test harness Checking the alternator

("S" terminal voltage)

M1161000300258

M1161000600163

ON-VEHICLE SE RVICE

ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

Ammeter (clamp-type)

Alternator

Voltmeter (digital-type)

"B" terminal

M1161000900346

Battery

This test determines whether the wiring from the alternator "B" terminal to the battery (+) terminal (including the fusible line) is in a good condit ion or not.

1. Always be sure to check the following before the test.

• Alternator installation

AK203361

• Drive belt tension (Refer to GROUP 11A − On-vehicle Service <4G1> P.11A-7 or GROUP 11C − On-vehicle Service <4G6> P.11C-7.)

• Fusible link

• Abnormal noise from the alternator while the

engine is running

16-4

ENGINE ELECTRICAL

CHARGING SYSTEM

2. Turn the ignition switch to the "LOCK" (OFF) position.

3. Disconnect the negative battery cable.

4. Connect a clamp-type DC test ammeter with a range of 0 − 120 A to the alternator "B" terminal output wire.

NOTE: The way of disconnecting the alternator output wire and of connecting the ammeter is possibly not found the problem that the output current is dropping due to the insufficient connection between terminal "B" and the output wire.

5. Connect a digital-type voltmeter between the alternator "B" terminal and the battery (+) terminal. [Connect the (+) lead of the vol tmeter to the "B" terminal a nd the connect the (- ) lead of th e voltmeter to the battery (+) cable].

6. Reconnect the negative battery cable.

7. Connect a tachometer or the MUT-II /III (Refer to GROUP 11 A − On-vehicle Service − Idle speed check <4G1> P.11A-11 or GROUP 11C − On-vehicle Service − Idle speed check <4G6>

P.11C-11).

8. Leave the hood open.

9. Start the engine.

10.With the engine running at 2,500 r/min, turn the headlamps and other lamps on and off to adjust the alternator load so that the value displayed on the ammeter is slightly above 30 A.

Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is 30 A. Take a reading of the value displayed on the voltmeter at this time.

Limit: maximum 0.3 V

NOTE: When the alternator output is high and the value displayed on the ammeter does not decrease until 30 A, set the value to 40 A. Read the value displayed on the voltmeter at this time. When the value range is 40 A, the limit is maximum 0.4 V.

11.If the value displayed on the voltmeter is above the limit value, there is probably a malfunct ion i n the alternator output wire, so check the wirin g between the alternator "B" termina l and the battery (+) terminal (including fusible link).

If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, repair and then test again.

12.After the test, run the engine at idle.

13.Turn off all lamps and the ignition switch.

14.Remove the tachometer or the MUT-II/III.

15.Disconnect the negative battery cable.

16.Disconnect the ammeter and voltmeter.

17.Connect the negative battery cable.

ENGINE ELECTRICAL

CHARGING SYSTEM

16-5

OUTPUT CURRENT TEST

Inition switch

Battery

Charging indicator

Brake warning light

Voltmeter

–

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

M1161001000368

Load

Ammeter (clamp-type)

L S

Alternator

This test determines whether the alternator output current is normal.

1. Before the test, always be sure to check the following.

• Alternator installation

• Battery (Refer to GROUP 54A − Battery −

On-vehicle Service P.54A-5).

NOTE: The battery should be slightly discharged.

The load needed by a fully-charged battery is insufficient for an accurate test.

• Drive belt tension

(Refer to GROUP 11A − On-vehicle Service <4G1>

P.11A-7 or GROUP 11C − On-vehicle Service

<4G6> P.11C-7.)

• Fusible link

• Abnormal noise from the alternator while the

engine is running.

2. Turn the ignition switch to the "LOCK" (OFF) position.

3. Disconnect the negative battery cable.

AK203362

CAUTION

Never use clips but tighten bolts and nuts to connect the line. Otherwise loose connections (e.g. using clips) will lead to a serious accident because of high current.

4. Connect a clamp-type DC test ammeter with a range of 0 − 120 A to the alternator "B" terminal output wire.

5. Connect a voltmeter with a range of 0 − 20 V between the alternator "B" termina l and the earth [Connect the (+) lead of the voltmeter to the "B" terminal, and then connect the (-) lead of the voltmeter to the earth].

6. Connect the negative battery cable.

16-6

ENGINE ELECTRICAL

CHARGING SYSTEM

7. Connect a tachometer or the MUT-II /III (Refer to GROUP 11 A − On-vehicle Service − Idle speed check <4G1> P.11A-11 or GROUP 11C − On-vehicle Service − Idle speed check <4G6>

P.11C-11).

8. Leave the hood open.

9. Check that the reading on the voltmeter is equal to the battery voltage.

NOTE: If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator "B" terminal and the battery (+) terminal.

10.Turn the li ght swi tch on to tur n on headlamp s and then start the engine.

11.Immediately after setting the headlamps to high beam and turning the heater blower switch to the high revolution position, increase the engine speed to 2,500 r/min and read the maximum current output value displayed on the ammeter.

Limit: 70 % of normal current output

NOTE: .

•

For the nominal current output, refer to the Alternator Specifications.

•

Because the current from the battery wi ll soon drop after the engine is started, the above step should be carried out as quickly as possible in order to obtain the maximum current output value.

•

The current output value will depend on the electrical load and the temperature of the alternator body.

•

If the electrical load is small while testing, the specified level of current may not be output even though the alternator is normal. In such cases, increase the electrical load by leaving the headlamps turned on for some time to discharge the battery or by using the lighting system in another vehicle, and then t est a gain.

•

The specified level of current also may not be output if the temperature of the alternator body or the ambient temperature is too high. In such cases, cool the alternator and then test agai n.

12.The reading on the ammeter should be above the limit value. If the reading is below the limit value and the alternator output wire is normal, remove the alternator from the engine and check the alternator.

13.Run the engine at idle after the test.

14.Turn the ignition switch to the "LOCK" (OFF) position.

15.Remove the tachometer or the MUT-II/III.

16.Disconnect the negative battery cable.

17.Disconnect the ammeter and voltmeter.

18.Connect the negative battery cable.

ENGINE ELECTRICAL

CHARGING SYSTEM

16-7

REGULATED VOLTAGE TEST

Ignition switch

Battery

Engine-ECU <M/T> Engine-A/T-ECU <A/T>

This test determines whether the voltage regulator correctly controlling the alternator output voltage.

1. Always be sure to check the following before the test.

• Alternator installation

• Check that the battery installed in the vehicle is

fully charged.

(Refer to GROUP 54A − Battery − On-vehicle

Service − Charging P.54A-4).

• Drive belt tension

(Refer to GROUP 11A − On-vehicle Service <4G1>

P.11A-7 or GROUP 11C − On-vehicle Service

<4G6> P.11C-7.)

• Fusible link

• Abnormal noise from the alternator while the

engine is running

2. Turn the ignition switch to the "LOCK" (OFF) position.

3. Disconnect the negative battery cable.

4. Use the special tool Alternator test harness (MB991519) to connect a digital volt met er between the alternator "S" terminal and earth [Connect the (+) lead of the voltmeter to the "S" terminal, and then connect the (-) lead of the voltmeter to a secure earth or to the battery (-) terminal].

5. Connect a clamp-type DC test ammeter with a range of 0 − 120 A to the alternator "B" terminal output wire.

M1161001100354

Ammeter (clamp-type)

MB991519

Black

Red

Voltmeter (digital-type)

Yellow

Blue

Load

Alternator

AK300727

6. Reconnect the negative battery cable.

7. Connect a tachometer or the MUT-II /III (Refer to GROUP 11 A − On-vehicle Service − Idle speed check <4G1> P.11A-11 or GROUP 11C − On-vehicle Service − Idle speed check <4G6>

P.11C-11).

8. Turn the ignition switch to the "ON" position and check that the readi ng on the v oltmeter is equal t o the battery voltage.

NOTE: If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator "S" terminal and the battery (+) terminal.

9. Turn all lamps and accessories off.

10.Start the engine.

11.Increase the engine speed to 2,500 r/min.

12.Read the value displayed on the voltmeter when the alternator output current alternator becomes 10 A or less.

13.If the voltage reading conforms to the value in the voltage regulation, then the voltage regulator is operating normally.

16-8

ENGINE ELECTRICAL

CHARGING SYSTEM

If the voltage is not within the st andard value, there is a malfunc tion of t he volta ge regul ator or of the alternator.

14.After the test, lower the engine speed to the idle speed.

15.Turn the ignition switch to the "LOCK" (OFF) position.

16.Remove the tachometer or the MUT-II/III.

17.Disconnect the negative battery cable.

18.Disconnect the ammeter and voltmeter.

19.Connect the alternator output wire to the alternator "B" terminal.

20.Remove the special tool, and return the connector to the original condition.

21.Connect the negative battery cable.

Voltage Regulation Table

Standard value:

Inspection terminal Voltage regulator ambient

temperature °C

Terminal "S"

−20 20 13.9 − 14.9 60 13.4 − 14.6 80 13.1 − 14.5

Voltage V

14.2 − 15.4

ENGINE ELECTRICAL

CHARGING SYSTEM

16-9

WAVEFORM CHECK USING AN OSCILLOSCOPE MEASUREMENT METHOD

Alternator

"B" terminal

CH1

AK100002

Connect the oscilloscope special patterns pick-up to the alternator "B" terminal.

STANDARD WAVEFORM

Observation Conditions

Function Special pattern

Pattern height Variable Variable knob Adjust while viewing the waveform. Pattern selector Raster Engine speed Curb idle speed

M1161001200124

Voltage at alternator "B" terminal

NOTE:

(V)

0.4

0.2

–0.2

–0.4

Time

AKX00189

(current), and is nor mal for t he alter nator. In addition, when the voltage waveform reaches an excessivel y high value (approximately 2 V or higher at idle), it often indicates an open circuit due to a brown fuse between alternato r "B" ter minal a nd bat tery, but not a defective alternator.

AKX00190

The voltage waveform of the alternator "B" terminal can undulate as shown in the illustration. This waveform is produced when the regulator operates according to fluctuations in the alternator load

16-10

ENGINE ELECTRICAL

CHARGING SYSTEM

EXAMPLE OF ABNORMAL WAVEFORMS

NOTE: .

1. The size of the waveform patterns diff ers largel y, depending on the adjustment of the vari able knob on t he oscilloscope.

2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating). (Waveforms can be observed when the headlamps are illuminated.)

3. Check the conditions of the charging warning lamp (illuminated/not illuminat ed). Also, check the chargin g system totally.

Abnormal waveform Problem cause

Example 1 Open diode

AKX00191

Example 2 Short in diode

AKX00192

ENGINE ELECTRICAL

CHARGING SYSTEM

16-11

Abnormal waveform Problem cause

Example 3 Broken wire in

stator coil

AKX00193

Example 4 Short in stator

coil

AKX00194

Example 5

At this time, the charging warning lamp is illuminat ed.

Open supplementary diode

AKX00195

16-12

ALTERNATOR ASSEMBLY

ENGINE ELECTRICAL

CHARGING SYSTEM

REMOVAL AND INSTALLATION <4G1>

M1161001400548

Pre-removal Operation

• Under Cover Removal

• Drive Belt Removal (Refer to GROUP 11A - Crankshaft

Pulley P.11A-16).

23 ± 2 N·m

44 ± 10 N·m

Post-installation Operation

• Drive Belt Installation (Refer to GROUP 11A - Crankshaft Pulley P.11A-16).

• Drive Belt Tension Adjustment (Refer to GROUP 11A On-vehicle Service P.11A-7).

• Under Cover Installation

12 ± 2 N·m

24 ± 3 N·m

Removal steps

1. Power steering pressure hose clamp

2. Alternator connector and terminal

REMOVAL SERVICE POINT <<A>> ALTERNATOR ASSEMBLY

REMOVAL

Remove the alternator assembly from above the vehicle.

<<A>>

AC303729

Removal steps (Continued)

3. Alternator adjusting brace

4. Alternator assembly

ENGINE ELECTRICAL

CHARGING SYSTEM

16-13

REMOVAL AND INSTALLATION <4G6>

M1161001400559

Pre-removal Operation

• Under Cover Removal

• Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).

• Drive Belt Removal (Refer to GROUP 11C - Crankshaft

Pulley P.11C-16).

• Air Cleaner Assembly Removal (Refer to GROUP 15

P.15-3).

Post-installation Operation

• Air Cleaner Assembly Installation (Refer to GROUP 15

P.15-3).

• Drive Belt Installation (Refer to GROUP 11C - Crankshaft Pulley P.11C-16).

• Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).

• Drive Belt Tension Adjustment (Refer to GROUP 11C -

On-vehicle Service P.11C-7).

• Under Cover Installation

18 ± 3 N·m

Removal steps

1. Shift cable connection

<<A>>

AC303826

Removal steps (Continued)

2. shift cable and shift cable bracket assembly

3. Vehicle speed sensor connector

16-14

ENGINE ELECTRICAL

CHARGING SYSTEM

44 ± 10 N·m

22 ± 4 N·m

23 ± 3 N·m

8.8 ± 1.0 N·m

Removal steps

4. Battery wiring harness clamp

5. Engine oil pressure switch connection

6. Alternator connector

REMOVAL SERVICE POINT <<A>> SHIFT CABLE AND SHIFT CABLE

BRACKET ASSEMBLY REMOVAL

Remove the shift cable bracket installation bolt with the shift cable installed on the shift cable bracket, and remove the shift cable and shift cable bracket assembly from the transmission.

Removal steps (Continued)

<>

7. Alternator assembly

8. Water pump pulley

9. Alternator brace

<> ALTERNATOR ASSEMBLY REMOVAL

Alternator assemnly

AC303827

AC302930

After removing the alternator assembly installation bolts and nut, move the alternator assembly to the transmission side and remove the alternator assembly upward the engine room through the clearance between the transmission and the inlet manifold.

ENGINE ELECTRICAL

CHARGING SYSTEM

16-15

DISASSEMBLY AND REASSEMBLY

M1161001600166

4.4 ± 1.0 N·m

3.7 ± 0.7 N·m

<<A>> <>

>>B<<

189 ± 19 N·m

Disassembly steps

1. Front bracket assembly

2. Alternator pulley

3. Rotor

4. Rear bearing

5. Bearing retainer

6. Front bearing

7. Front bracket

3.7 ± 0.7 N·m

<<C>> <<C>> >>A<<

AK202845

Disassembly steps (Continued)

8. Stator

9. Plate

10. Regulator assembly

11. Brush

12. Rubber packing

13. Rectifier

14. Rear bracket

16-16

ENGINE ELECTRICAL

CHARGING SYSTEM

DISASSEMBLY SERVICE POINTS <<A>>FRONT BRACKET ASSEMBLY

REMOVAL

AK202718

CAUTION

Do not insert the screwdriver blades too deep. Doing so could damage the stator coil.

Insert the blades of screwdrivers between t he front bracket assembly and stator core, and pry and separate them with the screwdrivers.

<>ALTERNATOR PULLEY REMOVAL

CAUTION

• Use a 180 − 250 W soldering iron, and finish

unsoldering within four seconds. Diodes will be damaged by heat if unsoldering ti me is too long.

• Avoid applying undue force to the diode

leads.

1. Unsolder the stator leads from the main diode of the rectifier assembly when the stator is removed.

2. When removing the rectifier assembly from the regulator assembly, undo the soldered points on the rectifier assembly.

REASSEMBLY SERVICE POINTS >>A<<REGULATOR ASSEMBLY

INSTALLATION

Wire

AK202714

CAUTION

Perform operation carefully not to damage the rotor.

Clamp the rotor in a vise with the pulley facing up to remove the pulley.

<<C>>STATOR / REGULAT OR ASSEMBL Y REMOVAL

Rectifier assembly

Solder

AK202779

Rear bracket

Brush

AK202830

Wire

After installing the regulator assembly, insert a piece of wire through the hole in the rear bracket while pressing the brush to keep the brush against movement.

NOTE: Holding the brush with the wire facilities installation of the rotor.

Solder

AK202778

ENGINE ELECTRICAL

CHARGING SYSTEM

16-17

>>B<< ROTOR INSTALLATION

Wire

AK202779

Remove the brush holding wire after the rotor has been installed.

INSPECTION

M1161001700152

ROTOR

STATOR

AK202716

1. Check the continuity between coil leads. If there is no continuity, replace the stator.

AK202735

1. Measure the resistance bet ween the two sl ip rings of the rotor coil to check the continuity between them.

Replace the rotor if the re sist ance i s not with in the standard value range.

Standard value: 3 − 5 Ω

2. Check the continuity between the slip rings and core.

AK202736

AK202717

2. Check the continuity between coil and core. If there is no continuity, replace the stator.

RECTIFIER ASSEBMLY

AK202803

1. Check the condition of the (+) heat sink by checking continuity between the ( +) heat si nk and each of the stator coil lead connecting term inals.

If continuity is present for both terminals, the diode is shorted. Replace the rectifier ass embly.

3. If continuity is present, replace the rotor.

16-18

AK202802

2. Check the condition of the (−) heat sink by checking continuity between the (−) heat si nk and each of the stator coil lead connecting term inals.

If continuity is pr esent in both directi ons, the diod e is shorted. Replace the rectifier assembly .

ENGINE ELECTRICAL

CHARGING SYSTEM

BRUSH

Protrusion length

1. Measure the length of the protrusion of the brush. Replace the brush if the protrusion length is shorter than the limit.

Limit: 2 mm minimum

2. Unsolder the lead of the brush. The brush will come out, becoming ready for removal.

Solder

AK202808

AK202804

3. Check the condition of the diode trio by testing continuity of each of the three diodes using a circuit tester connected to both sides of th e diode. Connect in a polarity an d then rever se the pol arity for each test.

If continuity exists or no continuity exists for both polarities, the diode is defective. Replace the rectifier assembly if any of the diodes is defective.

AK202834

3. Install a new brush by pushi ng it into the holder as shown in the drawing and soldering the lead.

ENGINE ELECTRICAL

STARTING SYSTEM

16-19

GENERAL INFORMATION

If the ignition switch is tu rned to the "STA RT" position, current flows in the pull-in and holding coils provided inside magnetic switch, att racting the plunger, When the plunger is attracted, the lever connected to the plunger is actuated to engage the starter clutch. On the other hand, attracting the plunger will turn on the magnetic switch, allowing the "B" terminal and "M" terminal to conduct. Thus, current flows to engage the starter motor.

SYSTEM DIAGRAM

M1162000100202

When the ignition switch is returned to the "ON" position after starting the engine, the starter clutch is disengaged from the ring gear. An overrunning clu tch is provi ded betwee n the pinio n and the armature shaft, to prevent damage to the starter.

Holding coil

Pull-in coil

Plunger

Lever

Overrunning clutch

Ignition switch

Battery

–

Brush

Armature

Yoke

Pinion gear

AK202970

16-20

ENGINE ELECTRICAL

STARTING SYSTEM

STARTER MOTOR SPECIFICATIONS

Item 4G1 4G6

Type Reduction drive with planetary

gear Rated output kW/V 1.2/12 1.4/12 Number of pinion teeth 8 8

Reduction drive with planetary gear

SERVICE SPECIFICATIONS

M1162000300068

Item Standard value Limit

Pinion gap mm 0.5 − 2.0 Commutator run-out mm Commutator diameter mm 29.4 28.8

Undercut depth mm 0.5 0.2

−

0.05

STARTER MOTOR ASSEMBLY

ENGINE ELECTRICAL

STARTING SYSTEM

16-21

REMOVAL AND INSTALLATION <4G1>

M1162001000628

Pre-removal and Post-installation Operation

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

• Battery and Battery Tray Remov al and Inst al la tion

<M/T>

30 ± 3 N·m

18 ± 3 N·m

<A/T>

12 ± 2 N·m

Removal steps

1. Shift cable connection

<<A>> <>

2. shift cable and shift cable bracket assembly <M/T>

3. Shift cable connection <A/T>

REMOVAL SERVICE POINT <<A>> SHIFT CABLE AND SHIFT CABLE

BRACKET ASSEMBLY <M/T> REMOVAL

Remove the shift cable bracket installation bolt with the shift cable installed on the shift cable bracket, and remove the shift cable and shift cable bracket assembly from the transmission.

AC303962

Removal steps (Continued)

4. Starter connector and terminal

5. Harness bracket <M/T>

6. Harness bracket <A/T>

<<C>>

7. Starter assembly

<> SHIFT CABLE CONNECTION <A/T> REMOVAL

Disengage the transmission, and remove the shift cable assembly from the transmission.

<<C>> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from above the vehicle.

16-22

ENGINE ELECTRICAL

STARTING SYSTEM

REMOVAL AND INSTALLATION <4G6>

M1162001000617

Pre-removal and Post-installation Operation

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

• Under Cover Removal and Installation

30 ± 3 N·m

18 ± 3 N·m

49 ± 9 N·m

9.0 ± 2.0 N·m

Removal steps

1. Starter cover

2. Starter connector and terminal

3. Clutch release cylinder connecting bolts

REMOVAL SERVICE POINT <<A>> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from above the vehicle.

<<A>>

AC304005

Removal steps (Continued)

4. Clutch hose clamp

5. Starter assembly

6. Starter cover bracket

ENGINE ELECTRICAL

STARTING SYSTEM

16-23

STARTER MOTOR ASSEMBLY INSPECTION PINION GAP ADJUSTMENT

<4G1>

<4G6>

Starter motor

battery

Switch

Wire

Battery

Starter motor

AK300648

Wire

M1162001100205

AKX00199

5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket.

MAGNETIC SWITCH PULL-IN TEST

<4G1>

AKX01238

1. Disconnect the field coil wire from the M-terminal of the magnetic switch.

2. Connect a 12-volt battery between the S-terminal and M-terminal.

CAUTION

This test must be performed qui ckly (in less than 10 seconds) to prevent the coil from burning.

3. Set the switch to "ON", and the pinion will move out.

Stopper

Pinion

Pinion gap

AKX00198

Starter motor

<4G6>

Battery

Wire

Battery

Starter motor

AK300649

Wire

AKX01242

1. Disconnect the field coil wire from the M-terminal of the magnetic switch.

CAUTION

This test must be performed qui ckly (in less than 10 seconds) to prevent the coil from burning.

4. Check the pinion-to-stopper clearance (pinion gap) with a feeler gauge.

Standard value: 0.5 − 2.0 mm

2. Connect a 12-volt battery between the S-terminal and M-terminal.

3. If the pinion moves out, the pull-in coi l is good. I f it doesn't, replace the magnetic switch.

16-24

ENGINE ELECTRICAL

STARTING SYSTEM

MAGNETIC SWITCH HOLD-IN TEST

<4G1>

Starter motor

<4G6>

Battery

Wire

Battery

AK300650

Starter motor

Wire

AKX01244

FREE RUNNING TEST

<4G1>

Starter motor

<4G6>

Starter motor

Carbon-pile rheostat

Voltmeter

Carbon-pile rheostat

Voltmeter

Ammeter

Battery

AK300651

Ammeter

Battery

AKX01246

1. Disconnect the field coil wire from the M-terminal of the magnetic switch.

CAUTION

This test must be performed qui ckly (in less than 10 seconds) to prevent the coil from burning.

2. Connect a 12-volt battery between the S-terminal and body.

3. Manually pull out the pinion as far as the pinion stopper position.

4. If the pinion remains out, everything is in order. If the pinion moves in, the hold-in circuit is open. Replace the magnetic switch.

1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to the starter motor as follows:

2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the battery (+) terminal and start e r motor terminal.

3. Connect a voltmeter (15-volt scale) across the starter motor.

4. Rotate the rheostat to full-resistance position.

5. Connect the battery cable from the battery (-) terminal to the starter motor body.

6. Adjust the rheostat unti l the batter y volt age shown on the voltmeter is 11 V.

7. Confirm that the maximum amperage is within the specifications and that the st arter motor turns smoothly and freely.

Current: <4G1> maximum 95 Amps <4G6> maximum 90 Amps

ENGINE ELECTRICAL

STARTING SYSTEM

16-25

MAGNETIC SWITCH RETURN TEST

<4G1>

Starter motor

<4G6>

Battery

Wire

Battery

AK300652

Starter motor

AKX01248

Wire

1. Disconnect the field coil wire from the M-terminal of the magnetic switch.

CAUTION

This test must be performed qui ckly (in less than 10 seconds) to prevent the coil from burning.

2. Connect a 12-volt battery between the M-terminal and body.

WARNING

Be careful not to get your fingers caught when pulling out the pinion.

3. Pull the pinion out and release. If the pinion quickly retu rns to it s orig inal positio n, ever ything is operating properly. If it doesn't, replace the magnetic switch.

16-26

ENGINE ELECTRICAL

STARTING SYSTEM

DISASSEMBLY AND REASSEMBLY

M1162001200202

<<A>>

Disassembly steps

1. Screw

2. Magnetic switch

3. Screw

4. Bolt

5. Rear bracket

6. Brush holder

7. Rear bearing

8. Armature

9. Yoke assembly

10. Packing A

<> >>A<< <> >>A<<

Disassembly steps (Continued)

11. Packing B

12. Plate

13. Planetary gear

14. Lever

15. Snap ring

16. Stop ring

17. Overrunning clutch

18. Internal gear

19. Planetary gear shaft

20. Front bracket

AK201881

ENGINE ELECTRICAL

STARTING SYSTEM

16-27

DISASSEMBLY SERVICE POINTS <<A>> MAGNETIC SWITCH REMOVAL

S terminal

B terminal

M terminal

AK201882

CAUTION

Do not clamp the yoke assembly with a vise.

Disconnect the lead from the M terminal of the magnetic switch.

<> SNAP RING/STOP RING REMOVAL

Socket wrench

Stop ring

Pinion Gear

Overrunning clutch

STARTER MOTOR PARTS CLEANING

Never clean in a solvent such starter motor parts as the magnetic switch, brush holder, and armature. If they are soaked in a solvent, thei r insulation could be impaired. When these parts require cleaning, wipe off contamination with cloth.

1. Never soak the drive unit in a solvent. If it is washed in a solvent, the grease having been packed in the overrunning clut ch at th e factor y will be washed out. Wipe the drive unit with cloth if it requires cleaning.

REASSEMBLY SERVICE POINTS >>A<< STOP RING/SNAP RING

INSTALLATION

Stop ring

Overrunning clutch

Snap ring

Stop ring

AK202911

AK100883

1. Apply a long socket wrench of an appropr iate siz e to the stop ring and strike the wrench to drive out the stop ring toward the pinion gear side.

Snap ring pliers

Snap ring

Pinion gear

Overrunning clutch

AK202791

2. Remove the snap ring with snap ring pliers, then remove the stop ring and overrunning clutch.

Use a suitable puller to pull the stop ri ng unti l i t gets over the snap ring.

INSPECTION

M1162001300157

COMMUTATOR

AK202712

1. Support the armature with a pair of V block and turn it to measure the runout of the surface not rubbed by the brushes using a dial gauge.

Standard val ue: 0.05 mm or less Limit: 0.1 mm

16-28

ENGINE ELECTRICAL

STARTING SYSTEM

OVERRUNNING CLUTCH

Free

AK202715

2. Measure the diameter of the commutator.

Standard value: 29.4 mm Limit: 28.8 mm

Segment

Undercut

Mica

AK202711

3. Measure the depth of the undercut between segments.

Standard value: 0.5 mm Limit: 0.2 mm

BRUSH HOLDER

Lock

AK202710

1. Make sure that the pinion cannot be turned counterclockwise and can be turned clockwise freely.

2. Check the pinion for abnormal ware and damage.

BRUSHES

Brush height

AK202846

1. Check the commutator contacting surface of each brush for abnormal roughness. Also check the height of the brush. Replace the brush holder if the height is lower than the limit.

Limit: 7.0 mm

AK201187

Push the brush into the brush holder to make sure that the spring is working on the brush. If the spring is not working, replace the brush holder.

2. When the contact surface of the brush is rectified or the brush holder is replaced, recondition the contact surface with sandpaper wrapped around the commutator.

ARMATURE COIL

1. Check the armature coil for short circuit as follows:

ENGINE ELECTRICAL

STARTING SYSTEM

16-29

Growler

AK202733

2. Set the armature in a growler.

CAUTION

Clean the surface of the armature thoroughly before performing the test.

3. While holding a thin strip of iron against the armature in parallel with its axis, turn the armature slowly. The armature is normal if the iron strip is not attracted to the armature or it does not vi brate.

MAGNETIC SWITCH

M terminal

AK202891

1. Coil open circuit test

• Check that there is continuity between the M terminal and body A.

• If there is no continuity, replace the magnetic switch.

B terminal

AK202734

4. Check the insulation between commutator segments and armature coils. The armature coils are properly insulated if no continuity is present.

AK202713

5. Check continuity betw een a segme nt and anot her. There is no open ci rcuit i n the t ested c oil i f ther e is continuity.

M terminal

AK202892

2. Contact fusion check

• Check that there is no continuity between the B terminal and M terminal.

• If there is continuity, replace the magnetic switch.

B terminal

M terminal

AK202893

3. Switch contact check

• Push the indicated end of the magnetic switch with a strong force to close the internal contacts. Without releasing the switch end, check that there is continuity between the B terminal and M terminal.

• If there is no continuity, replace the magnetic switch.

16-30

ENGINE ELECTRICAL

IGNITION SYSTEM

GENERAL INFORMATION

This system is equ ipped with two i gnitio n coils ( A and B) with built-in power transisto rs for the No. 1 and No. 4 cylinders and the No. 2 and No. 3 cylinders respectively. Interruption of the primary curr ent flowing in the primary side of ignition coil A generates a high voltage in the secondary side of igniti on coil A. The high voltage thus generated is applied to the spark plugs of No. 1 and No. 4 cylinders to generate sparks. At the time that the sparks are generated at both spark plugs, if one cylinder is at the compression stroke, the other cylinder is at the exhaust stroke, so that ignition of the compressed air/fuel mixture occurs only for the cylinder which is at the compression stroke. In the same way, when the primary current flowing in ignition coil B is interrupted, the high voltage thus generated is applied to the spark plugs of No. 2 and No. 3 cylinders.

SYSTEM DIAGRAM

M1163000100294

The engine-ECU <M/T> or engine-A/T-ECU <A/T> turns the two power transistors inside the ignition coils alternately on and off. This causes the primary currents in the ignition coils to be a lt e rnately interrupted and allowed to flow to fire the cylinders in the order 1-3-4-2. The engine-ECU <M/T> or engine-A/T-ECU <A/T> determines which ignition coil should be control led by means of the signals from the camshaft position sensor which is incorporated in the camshaft and from the crank angle sensor which i s incorporated in the crankshaft. I t also detec ts t he crank shaf t posi tion in order to provide ignition at the most appropriate timing in response to the engine operation conditions. It also detects the crankshaft position in order to provide ignition at the most appropriate timing in response to the engine operation conditions. When the engine is cold or operated at high altitudes, the ignition timing is slightly advanced to provide optimum performance. When the automatic transmission shifts gears, the ignition timing is also retarded in order to reduce output torque, thereby alleviating shifting shocks.

MAP sensor <4G1> Air flow sensor

<4G6> Intake air temperatur

sensor

Engine coolant temperature sensor

Camshaft position sensor

Crank angle sensor

Barometric pressure sonsor <4G6>

Detonatoin sensor Ignition switch-ST

Engine-ECU <M/T>

Engine-A/TECU <A/T>

Ignition coil B

Spark plug

Cylinder No.

Ignition coil A

23 4

Ignition switch

Battery

AK101074

ENGINE ELECTRICAL

IGNITION SYSTEM

IGNITION COIL SPECIFICATION

Item Specification

Type Molded 2-coil

SPARK PLUG SPECIFICATIONS

Items 4G1 4G66

NGK BKR6E-11 IGR6A11

16-31

DENSO K20PR-U11 CHAMPION RC8YC4

−

SERVICE SPECIFICATIONS

M1163000300180

IGNITION COIL

Item Standard value

Secondary coil resistance kΩ 8.5 − 11.5

SPARK PLUG

Items Standard value Limit

Spark plug gap mm 4G1 1.0 − 1.1

4G6 1.0 − 1.1 1.3

−

RESISTIVE CORD

Item Standard value Limit

Resistance kΩ

−

Maximu m 19

SPECIAL TOOL

M1163000600288

Tool Number Name Use

MD998773 Detonation sensor

wrench

Detonation sensor removal and installation

16-32

ENGINE ELECTRICAL

IGNITION SYSTEM

ON-VEHICLE SE RVICE

IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK

Check by the following procedure, and replace if there is a malfunction.

SECONDARY COIL RESISTANCE CHECK

Measure the resistance between the high-voltage terminals of the ignition coil.

Standard value: 8.5 − 11.5 kΩ

PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK

NOTE: .

–

•

M1163001200324

AKX01264

1.5 V

RESISTIVE CORD CHECK

M1163001400124

AKX00382

Measure the resistance of the all spar k plug cables.

1. Check cap and coating for cracks.

2. Measure resistance.

Limit: Maximum 19 kΩ

SPARK PLUG CHECK AND CLEANING <4G1>

M1163004300342

CAUTION

When pulling off the spark plug cable from the plug always hold the cable cap, not the cable.

1. Remove the spark plug cables.

2. Remove the spark plugs.

3. Check for burned out electrode or damaged insulator. Check for even burning.

4. Remove carbon deposits with wire brush or plug cleaner. Remove sand from plug screw with compressed air.

Plug gap gauge

AKX01265

An analogue-type circuit tester should be used.

•

Connect the nega tive (-) pr ove of the ci rcuit tes ter to terminal No. 1 .

CAUTION

This test must be performed qui ckly (in less than 10 seconds) to prevent coil from burning and power transistor from breakage.

1.5 V power supply between 2 − 3

Continuity between 1 − 2

When current is flowing Continuity When current is not

flowing No continuity

Measurement direction

AKX01272

5. Use a plug gap gauge to check that the plug gap is within the standard value range.

Standard val ue: 1.0 − 1.1 mm

If the plug gap is not within the standard value range, adjust by bending the earth electrode.

CAUTION

Be careful not to allow foreign matter in cylinders.

6. Clean the engine plug holes.

7. Install the spark plugs.

ENGINE ELECTRICAL

IGNITION SYSTEM

16-33

SPARK PLUG CHECK AND CLEANING <4G6>

M1163004300353

CAUTION

When pulling off the spark plug cable from the plug always hold the cable cap, not the cable.

1. Remove the spark plug cables.

2. Remove the spark plugs.

CAUTION

• Do not attempt to adjust the gap of the iridium

plug.

• Always use a plug cleaner and f inish cl eaning

within 20 seconds. Do not use wire brushes. Otherwise, the iridium and platinum tip may be damaged.

Iridium tip

Platinum tip

AKX00383

3. Check the plug gap and replace if the limit is exceeded.

Standard value: 1.0 − 1.1 mm Limit: 1.3 mm

CAUTION

Be careful not to allow foreign matter in cylinders.

4. Clean the engine plug holes.

5. Install the spark plugs.

CAMSHAFT POSITION SENSOR CHECK

M1163004400219

Check the camshaft position sensor circui t if self-diagnosis code No. P0340 is shown. (Refer to GROUP 13A − T roubleshooting − Inspection chart for diagnos is cod e <4G1> P.13A-15 or GROUP 13B − Troubleshooting − Inspection chart for diagnosis code <4G6> P.13B-15 ).

CRANK ANGLE SENSOR CHECK

M1163004500272

Check the crank angle sensor circui t if sel f-diagnosis code No. P0335 is shown. (Refer to GROUP 13A − Troubleshooting − Inspection chart for diagnos is cod e <4G1> P.13A-15 or GROUP 13B − Troubleshooting − Ins pection chart for diagnosis code <4G6> P.13B-15 ).

DETONATION SENSOR CHECK

M1163002900047

Check the detonation sensor circuit if se lf-diagnosis code No. P0325 is shown. (Refer to GROUP 13A − Troubleshooting − Inspection chart for diagnos is cod e <4G1> P.13A-15 or GROUP 13B − Troubleshooting − Ins pection chart for diagnosis code <4G6> P.13B-15).

IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE

M1163001700170

MEASUREMENT METHOD

1. Clamp the secondary pickup around the spark plug cable.

NOTE: .

•

The peak ignition voltage will be rever sed when the spark plug cables No. 2 and No. 4, or No. 1 and No. 3 cylinders are clamped.

•

Because of the two-cylinder simultaneous ignition system, the waveforms for two cylinders in each group appear during waveform observation (No. 1 cylinder - No. 4 cylinder, No. 2 cylinder - No. 3 cylinder). However , waveform observation is only applicable for the cylinder with the spark plug cable clamped by the secondary pickup.

•

Identifying which cylinder waveform is displayed can be difficult. For refer ence, remember that the waveform of the cylinder attached to the secondary pickup will be displayed as stable.

2. Clamp the spark plug cable with the trigger pickup.

NOTE: Clamp the trigger pickup to the same spark plug cable clamped by the secondary pickup.

16-34

STANDARD WAVEFORM

Observation Conditions

Function Secondary

Pattern height High (or Low) Pattern selector Raster Engine revolutions Curb idle speed

ENGINE ELECTRICAL

IGNITION SYSTEM

Secondary ignition voltage wave pattern

Spark line (point A)

Ignition voltage (point D)

Wave dampling reduction section (point B)

Dwell section

Point C

Time

Observation Conditions (The only change from above condition is the pattern selector.)

Pattern selector Display

AKX00278

ENGINE ELECTRICAL

IGNITION SYSTEM

16-35

NO. 2 cylinder ignition noise

Time

AKX01275

Secondary ignition voltage wave pattern

NO. 1 cylinder

0 2

Newtral section

NO. 3 cylinder ignition noise

NO. 4 cylinder

WAVEFORM OBSERVATION POINTS

Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal waveform examples, 1, 2, 3 and 4).

Spark line Plug gap Condition of

electrode

Length Long Small Normal Low Rich Advanced Leak

Short Large Large wear High Lean Retarded High

Height High Large Large wear High Lean Retarded High

Low Small Normal Low Rich Advanced Leak

Compression force

Concentration of air mixture

Ignition timing

Spark plug cable

resistance

Slope Large Plug is fouled

−−−−

Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)

Number of vibrations Coil and condenser

3 or more Normal Except above Abnormal

Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)

Number of vibrations Coil

5 − 6 or higher Normal Except above Abnormal

Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.

Ignition voltage

Plug gap Condition of

electrode

Compression force

Concentration of air mixture

Ignition timing

Spark plug cable

High Large Large wear High Lean Retarded High

resistance

Low Small Normal Low Rich Advanced Leak

16-36

ENGINE ELECTRICAL

IGNITION SYSTEM

EXAMPLES OF ABNORMAL WAVEFORMS

Example 1

• Wave characteristics Spark line is high and short.

• Cause of problem Spark plug gap is too large.

Example 3

• Wave characteristics Spark line is low and long, and is sloping.

However, there is almost no spark line distortion.

• Cause of problem Spark plug gap is fouled.

AKX00280

AKX00283

Example 4

• Wave characteristics Spark line is high and short. Difficult to di stingui sh betwee n th is and ab normal waveform example 1.

• Cause of problem Spark plug cable is nearly falling off (Causing a dual ignition).

AKX00281

Example 2

• Wave characteristics Spark line is low and long, and is sloping. Also, the se cond half of t he s p ark l ine i s di stort ed. This could be a result of misfiring.

• Cause of problem Spark plug gap is too small.

AKX00282

AKX00284

Example 5

• Wave characteristics No waves in wave damping section.

• Cause of problem Layer short in ignition coil.

Mitsubishi Lancer (2005) Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual