Mitsubishi Lancer 2006 User Manual

LANCER

WORKSHOP MANUAL

SUPPLEMENT

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.

TECHNICAL INFORMATION MANUAL PYME0302 PYME0302-A PYME0302-B

WORKSHOP MANUAL

CHASSIS GROUP PWME0302 PWME0302-A PWME0302-B

BODY REPAIR MANUAL PBME0302 PBME0302-A PBME0302-B

PARTS CATALOGUE

B606K006A_

GROUP INDEX

General . . . . . . . . . . . . . . . . . . . . . . . . 00

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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.

©Mitsubishi Motors Corporation

Oct. 2005

00-1

GROUP 00

GENERAL

CONTENTS

VEHICLE IDENTIFICATION . . . . . . .	00-2 GENERAL DATA AND
	SPECIFICATIONS . . . . . . . . . . . . . . .	00-3

00-2	GENERAL
	VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION

MODELS					M1001000401448
Model code		Engine model	Price class	Transmission model	Fuel supply
					system
CS9A	SRHML6	4G63-DOHC (1,997 mL)	Intense	F4A4B	MPI
				<2WD, 4A/T>

MODEL CODE

CS 9 W L N H M L 6

1 2 3 4 5 6 7 8 9

AC303950AC

No.	Item	Content
1	Development	CS: MITSUBISHI LANCER
2	Engine type	9: 1,997mL
3	Sort	A: Passenger car
4	Body style	S: 4-door sedan
5	Transmission	R: 4-speed automatic
	type	transmission
6	Trim level	H: Intense
7	Specification	M: MPI-DOHC
	engine feature
8	Steering wheel	L: Left hand
	location
9	Destination	6: For Europe

GENERAL	00-3
GENERAL DATA AND SPECIFICATIONS

GENERAL DATA AND SPECIFICATIONS

M1001000901197

7

1

2

8

3	4	5
	6

9

AC303990AB

Items					CS9A
					SRHML6
Vehicle dimensions mm	Front track			1	1,470
	Overall width			2	1,715
	Front overhang			3	965
	Wheel base			4	2,600
	Rear overhang			5	970
	Overall length			6	4,535
	Ground clearance (unladen)			7	135
	Overall height (unladen)			8	1,415
	Rear track			9	1,470
Vehicle weight kg	Kerb weight				1,295
	Max. gross vehicle weight				1,770
	Max. axle weight rating-front				930
	Max. axle weight rating-rear				840
	Max. trailer weight		With brake		1,000
			Without brake		400
	Max. trailer-nose weight				60
Seating capacity					5
Engine	Model code				4G63
	Total displacement mL				1,997
	Maximum output kW/r/min				99/5,750
	Maximum torque N m/r/min				176/4,500
Transmission	Model code				F4A4B
	Type				4-speed automatic
Fuel system	Fuel supply system				MPI
Maximum speed km/h					187
Minimum turning radius m					5.7

NOTES

13D-1

MULTIPOINT FUEL INJECTION (MPI)

<4G63>

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 6 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 10 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 90

Throttle Body (Throttle Valve Area)

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Throttle Position Sensor Adjustment . . . . . . . . . . . . 90

Basic Idle Speed Adjustment . . . . . . . . . . . . . . . . . . 91

Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . 95

Engine Control Relay Continuity Check . . . . . . . . . 96

Fuel Pump Relay Continuity Check . . . . . . . . . . . . . 96

Intake Air Temperature Sensor Check . . . . . . . . . . 97

Engine Coolant Temperature Sensor Check . . . . . 98

Throttle Position Sensor Check . . . . . . . . . . . . . . . . 98

Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . . . . 99

Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Idle Speed Control (ISC) Servo (Stepper Motor)

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Purge Control Solenoid Valve Check . . . . . . . . . . 104 EGR Control Solenoid Valve Check . . . . . . . . . . . 104

13D-2

MPI <4G63> ï General

GENERAL

OUTLINE OF CHANGE

Following service procedures have been established due to the addition of vehicles with 4G63-MPI engine for Russia.

MPI <4G63> ï General Information

13D-3

GENERAL INFORMATION

The Multipoint Fuel Injection System consists of sensors which detect the engine conditions, the engine-A/T-ECU which controls the system based on signals from these sensors, and actuators which operate under the control of the engine-A/T-ECU. The engine-A/T-ECU

FUEL INJECTION CONTROL

The injector drive times and injection timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continually-changing engine operation conditions.

A single injector is mounted at the intake port of each cylinder. Fuel is sent under pressure from the fuel tank by the fuel pump, with the pressure being regulated by the fuel pressure regulator. The fuel thus regulated is distributed to each of the injectors.

Fuel injection is normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is 1ï3ï4ï2. This is called sequential fuel injection. The

IDLE AIR CONTROL

The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in idling conditions and engine load during idling. The engine-A/T-ECU drives the idle speed control motor to keep the engine running at the pre-set idle target speed in accordance with the engine coolant temperature and air

IGNITION TIMING CONTROL

The power transistor located in the ignition primary circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition timing in order to provide the optimum ignition timing with respect to the

SELF-DIAGNOSIS FUNCTION

DWhen an abnormality is detected in one of the sensors or actuators related to

emission control, the engine warning lamp (check engine lamp) illuminates as a warning to the driver.

DWhen an abnormality is detected in one of the sensors or actuators, a diagnosis

carries out activities such as fuel injection control, idle speed control and ignition timing control. In addition, the engine-A/T-ECU is equipped with several diagnosis modes which simplify troubleshooting when a problem develops.

engine-A/T-ECU provides a richer air/fuel mixture by carrying out “open-loop” control when the engine is cold or operating under high load conditions in order to maintain engine performance. In addition, when the engine is warm or operating under normal conditions, the engine-A/T-ECU controls the air/fuel mixture by using the oxygen sensor signal to carry out “closed-loop” control in order to obtain the theoretical air/fuel mixture ratio that provides the maximum cleaning performance from the three way catalyst.

conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is idling, the idle speed control motor operates to adjust the throttle valve bypass air amount in accordance with the engine load conditions in order to avoid fluctuations in the engine speed.

engine operating conditions. The ignition timing is determined by the engine-A/T-ECU from the engine speed, intake air volume, engine coolant temperature and atmospheric pressure.

code corresponding to the abnormality is output.

DThe RAM data inside the engine-A/T-ECU that is related to the sensors and actuators can be read by means of the M.U.T.-II/III. In addition, the actuators can be force-driven under certain circumstances.

13D-4 MPI <4G63> ï General Information

OTHER CONTROL FUNCTIONS

1.Fuel Pump Control

Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running.

2.A/C Relay Control

Turns the compressor clutch of the A/C ON and OFF.

3.Fan Motor Control

The revolutions of the radiator fan and condenser fan are controlled in response to the engine coolant temperature and vehicle speed.

4.Purge Control Solenoid Valve Control

5.EGR Control Solenoid Valve Control

GENERAL SPECIFICATIONS

Item		Specification
Throttle body	Throttle bore mm	60
	Throttle position sensor	Variable resistor type
	Idle speed control servo	Stepper motor type
Engine-A/T-	Identification No.	E6T37983
ECU
Sensors	Air flow sensor	Karman vortex type
	Barometric pressure sensor	Semiconductor type
	Intake air temperature sensor	Thermistor type
	Engine coolant temperature sensor	Thermistor type
	Oxygen sensor	Zirconia type
	Inhibitor switch	Contact switch type
	Camshaft position sensor	Hall element type
	Crank angle sensor	Hall element type
	Detonation sensor	Piezoelectric type
	Power steering fluid pressure switch	Contact switch type
Actuators	Engine control relay	Contact switch type
	Fuel pump relay	Contact switch type
	Injector type and number	Electromagnetic type, 4
	Injector identification mark	HDA250E
	EGR control solenoid valve	Duty cycle type solenoid valve
	Purge control solenoid valve	Duty cycle type solenoid valve
Fuel pressure	Regulator pressure kPa	328
regulator

		MPI <4G63> ï General Information						13D-5
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM
	L1	Oxygen sensor (front)				l1 Injector
	L2	Oxygen sensor (rear)				l2 Idle speed control servo
	L3	Air flow sensor		Engine-A/T-ECU			(Stepper motor)
	L4 Intake air temperature sensor					l3 EGR control solenoid valve
	L5	Throttle position sensor				l4 Purge control solenoid valve
	L6 Camshaft position sensor
	L7 Crank angle sensor
	L8 Barometric pressure sensor					D	Engine control relay
	L9 Engine coolant temperature sensor
	L10 Detonation sensor					D	Fuel pump relay
						D	A/C compressor relay
	D	Power supply				D	Ignition	coil
						D	Fan controller
	D	Ignition switch-IG				D Air flow sensor filter reset signal
	D	Ignition switch-ST				D	Engine warning lamp
	D	A/C switch				D	Diagnosis output
	D	A/C load signal				D	Alternator G terminal
	D Power steering fluid pressure switch					D	Oxygen sensor (front) heater
	D	Alternator FR terminal				D	Oxygen sensor (rear) heater
	D	Vehicle speed sensor				D	Tachometer

		L4 Intake air temperature sensor
	l2 Idle speed control servo		L3 Air flow sensor
	(Stepper motor)		L8 Barometric
	L5 Throttle position
L6 Camshaft position sensor			pressure sensor
	sensor
Fuel pressure			Air
regulator	M M	A

To

fuel tank

L1 Oxygen sensor (front)

Catalytic converter

From fuel pump

EGR valve

			Canister
l1 Injector
L9 Engine coolant		l3 EGR control
temperature sensor		solenoid valve
L10 Detonation sensor			l4 Purge control
L7	Crank angle sensor		solenoid valve
L2	Oxygen sensor (rear)

Catalytic converter

13D-6	MPI <4G63> ï Service Specifications/Sealant
SERVICE SPECIFICATIONS
Items				Specifications
Basic idle speed	r/min			750 r 50
Throttle position sensor adjusting voltage			mV	535 ï 735
Throttle position sensor resistance k:				3.5 ï 6.5
Idle speed control servo coil resistance (at 20_C) :				28 ï 33
Intake air temperature sensor		ï20_C		13 ï 17
resistance k:
		0_C		5.3 ï 6.7
		20_C		2.3 ï 3.0
		40_C		1.0 ï 1.5
		60_C		0.56 ï0.76
		80_C		0.30 ï 0.42
Engine coolant temperature		ï20_C		14 ï 17
sensor resistance	k:
		0_C		5.1 ï 6.5
		20_C		2.1 ï 2.7
		40_C		0.9 ï 1.3
		60_C		0.48 ï 0.68
		80_C		0.26 ï 0.36
Oxygen sensor output voltage (at racing)			V	0.6 ï 1.0
Oxygen sensor heater		front		4.5 ï 8.0
resistance (at 20_C) :
		rear		11 ï 18
Fuel pressure kPa		Vacuum hose disconnection		324 ï 343 at kerb idle
		Vacuum hose connection		Approximately 265 at kerb idle
Injector coil resistance (at 20_C) :				10.5 ï 13.5

SEALANT

Item	Specified sealant	Remark
Engine coolant temperature sensor	3M Nut Locking Part No. 4171 or equivalent	Drying sealant
threaded portion

		MPI <4G63> ï Special Tools				13D-7
SPECIAL TOOLS
Tool		Number	Name	Use
		MB991502	M.U.T.-II sub	D	Reading diagnosis code
			assembly	D	MPI system inspection
				D Measurement of fuel pressure

MB991955	M.U.T.-III sub	D	Reading diagnosis code
A: MB991824	assembly	D	MPI system inspection
B: MB991827		D Measurement of fuel pressure
C: MB991910
D: MB991911
E: MB991825
F: MB991826
M.U.T.-III sub
assembly

A:Vehicle communication interface (V.C.I.)

B:M.U.T.-III USB cable

C:M.U.T.-III main harness A (Vehicles with CAN communication system)

D:M.U.T.-III main harness B (Vehicles without CAN communication system)

E:M.U.T.-III measurement adapter

F:M.U.T.-III trigger harness

	MB991348	Test harness set	D Inspection using an oscilloscope

13D-8	MPI <4G63> ï Special Tools
Tool	Number	Name		Use
	MB991709	Test harness		D	Measurement of voltage during
					troubleshooting
				D	Inspection using an oscilloscope
				D	Check of idle speed control servo
	MD998478	Test harness		D	Measurement of voltage during
		(3-pin, triangle)			Troubleshooting
				D	Inspection using an oscilloscope
	MB991536	Check harness for		D	Measurement of voltage during
		throttle	position		Troubleshooting
		sensor adjustment		D	Adjusting of throttle position sensor
	MD998464	Test harness		D	Measurement of voltage during
		(4-pin, square)			Troubleshooting
				D	Inspection of oxygen sensor (front)
	MB991658	Test harness		D	Measurement of voltage during
					Troubleshooting
				D	Inspection of oxygen sensor (rear)
	MB991223	Harness set		D	Check at the ECU terminals
	A: MB991219	A: Test harness		A:	Connector pin contact pressure inspection
	B: MB991220	B: LED harness		B:	Power circuit inspection
				C:	Power circuit inspection
	C: MB991221	C: LED harness
				D:	Commercial tester connection
	D: MB991222	adapter
		D: Probe

	MPI <4G63> ï Special Tools			13D-9
Tool	Number	Name	Use
	MD998709	Adaptor hose	Measurement of fuel pressure
	MD998742	Hose adaptor
	MB991637	Fuel pressure
		gauge set
	MB991981	Fuel pressure
		gauge set
	MB992076	Injector test set	Checking the spray condition of injectors
	MB991607	Injector test
		harness
	MD998741	Injector test
		adaptor
	MB991976	Injector test holder
		assembly

13D-10

MPI <4G63> ï Troubleshooting

Engine warning lamp (check engine lamp)

TROUBLESHOOTING

DIAGNOSIS TROUBLESHOOTING FLOW

Refer to GROUP 00 ï How to Use Troubleshooting/Inspection Service Point.

NOTE

If the engine-A/T-ECU is replaced, ring antenna with built in immobilizer-ECU should be replaced, ignition key can be kept, but must be registered.

DIAGNOSIS FUNCTION

ENGINE WARNING LAMP (CHECK ENGINE LAMP)

If an abnormality occurs in any of the following items related to the MPI system, the engine warning lamp will illuminate or flash. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.

However, the warning lamp will illuminate as bulb check for five seconds whenever the ignition switch is turned to the ON position.

Engine warning lamp inspection items

Engine-A/T-ECU

Oxygen sensor (front)

Air flow sensor

Intake air temperature sensor

Throttle position sensor

Engine coolant temperature sensor

Crank angle sensor

Camshaft position sensor

Barometric pressure sensor

Detonation sensor

Ignition coil, power transistor unit

Injector

Immobilizer system

Oxygen sensor (rear)

NOTE

If the engine warning lamp illuminates because of a malfunction of the engine-A/T-ECU, communication between M.U.T.-II/III and the engine-A/T-ECU is impossible. In this case, the diagnosis code cannot be read.

MPI <4G63> ï Troubleshooting

13D-11

METHOD OF READING AND ERASING DIAGNOSIS

CODES

Refer to GROUP 00 ï How to Use Troubleshooting/Inspection

Service Points.

INSPECTION USING M.U.T.-II/III DATA LIST AND

ACTUATOR TESTING

1.Carry out inspection by means of the data list and the actuator test function. If there is an abnormality, check and repair the chassis harnesses and components.

2.After repairing, re-check using the M.U.T.-II/III and check that the abnormal input and output have returned to normal as a result of the repairs.

3.Erase the diagnosis code memory.

4.Remove the M.U.T.-II/III, and then start the engine again and carry out a road test to confirm that the problem has disappeared.

FAIL-SAFE FUNCTION REFERENCE TABLE

When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving.

Malfunctioning item	Control contents during malfunction
Air flow sensor	1. Uses the throttle position sensor signal and engine speed signal (crank angle sensor
	signal) to take reading of the basic injector drive time and basic ignition timing from
	the pre-set mapping.
	2. Fixes the ISC servo in the appointed position so idle control is not performed.
Intake air temperature	Controls as if the intake air temperature is 25_C.
sensor
Throttle position	No increase in fuel injection amount during acceleration due to the throttle position sensor
sensor (TPS)	signal.
Engine coolant	Controls as if the engine coolant temperature is 80_C.
temperature sensor
Camshaft position	Injects fuel into the cylinders in the order 1-3-4-2 with irregular timing.
sensor	(However, after the ignition switch is turned to ON, the No. 1 cylinder top dead centre is not
	detected at all.)
Barometric pressure	Controls as if the barometric pressure is 101 kPa.
sensor
Detonation sensor	Switches the ignition timing from ignition timing for super petrol to ignition timing for standard
	petrol.
Ignition coil, power	Cuts off the fuel supply to cylinders with an abnormal ignition.
transistor
Alternator FR terminal	Does not control the output of the alternator according to an electrical load. (works as a
	normal alternator)

13D-12	MPI <4G63> ï Troubleshooting
INSPECTION CHART FOR DIAGNOSIS CODES
Code No.	Diagnosis item	Reference page
11	Oxygen sensor (front) system	13D-13
12	Air flow sensor system	13D-15
13	Intake air temperature sensor system	13D-16
14	Throttle position sensor system	13D-18
21	Engine coolant temperature sensor system	13D-20
22	Crank angle sensor system	13D-22
23	Camshaft position sensor system	13D-23
24	Vehicle speed signal system	13D-25
25	Barometric pressure sensor system	13D-26
31	Detonation sensor system	13D-28
41	Injector system	13D-29
44	Ignition coil (power transistor) system	13D-30
54	Immobilizer system	13D-31
59	Oxygen sensor (rear) system	13D-32
64	Alternator FR terminal system	13D-34

NOTE

1.Do not replace the engine-A/T-ECU until a through terminal check reveals there are no short/open circuit.

2.Check that the engine-A/T-ECU earth circuit is normal before checking for the cause of the problem.

MPI <4G63> ï Troubleshooting			13D-13
INSPECTION PROCEDURE FOR DIAGNOSIS CODE
Code No. 11 Oxygen sensor (front) system		Probable cause
Range of Check		D Malfunction of the oxygen sensor (front)
D More than 3 minutes passed after completion of start of engine		D Oxygen sensor (front) circuit disconnection,
D The engine coolant temperature is approximately more than 80_C.		short-circuit, or connector contact defect.
D Intake air temperature 0 ï 55_C.		D Malfunction of the engine-A/T-ECU
D The engine speed is more than 1,800 ï 3,500 r/min.
D The volumetric efficiency is 16 ï 60% or more.
Set Conditions
D For 30 seconds, the oxygen sensor output voltage continues to be 0.5 V or
lower, or 0.5 V or higher.
D The Engine-A/T-ECU monitors for this condition once during the drive cycle.

M.U.T.-II/III Data list

DNo. 11 Oxygen sensor (front) (Refer to P.13D-66.)

NG

Check the following connector:

B-17

OK

Measure at the B-17 oxygen sensor (front) connector.

DDisconnect connector to measure at the harness side

DResistance between terminal No. 2 and earth.

OK: Less than 2 :

OK

Measure at the B-17 oxygen sensor (front) connector.

DUsing the test harness (MD998464), connect the

connector, and measure at the pickup harness.

D Engine: After warm-up

(1)Voltage between terminal No. 2 and earth

OK: Less than 0.5 V

(2)Voltage between terminal No. 4

and the earth

D At rapid deceleration from 4,000 r/min

OK: 200 mV or less

DDuring rapid racing OK: 600 ï 1,000 mV

OK

To the next page

	OK
			Intermittent malfunction
			(Refer to GROUP 00 ï Points to Note
			for Intermittent Malfunctions.)
	NG
			Repair		NG
	NG						Repair
			Check the following connector:
			C-124
				OK
					NG
			Check the harness between the				Repair
			oxygen sensor (front) and
			engine-A/T-ECU.
				OK
					NG
			M.U.T.-II/III Data list				Replace the engine-A/T-ECU.
			D No. 11 Oxygen sensor (front)
			(Refer to P.13D-66.)
				OK
			Intermittent malfunction
			(Refer to GROUP 00 ï Points to Note
	(1) NG		for Intermittent Malfunctions.)		NG		Repair
			Check the following connector:
			C-124
				OK
					NG
			Check the harness between the				Repair
			oxygen sensor (front) and
			engine-A/T-ECU.
	(2) NG				NG
			Check the oxygen sensor (front).				Replace the oxygen sensor (front).
			(Refer to P.13D-99.)
				OK
					NG		Repair
			Check the following connector:
			C-126
				OK
					NG		Repair
			Check the harness between the
			oxygen sensor (front) and
			engine-A/T-ECU.

13D-14

MPI <4G63> ï Troubleshooting

From the previous page
		OK
			NG					NG
Measure at the C-126 engine-A/T-ECU						Check the following connector:			Repair
connector.						C-126
D Measure the engine-A/T-ECU
							OK
	terminal voltage.
D	Engine: After warm-up					Check and repair the harness between
D	Voltage between terminal No. 71
						the oxygen sensor (front) and
	and earth.
						engine-A/T-ECU.
D	At rapid deceleration from 4,000
	r/min
	OK: 200 mV or less

DDuring rapid racing OK: 600 ï 1,000 mV

	OK
		NG
Check the following connectors:				Repair
C-124, C-126
	OK
		NG
M.U.T.-II/III Data list				Replace the engine-A/T-ECU.
D No. 11 Oxygen sensor (front)
(Refer to P.13D-66.)
	OK
Intermittent malfunction
(Refer to GROUP 00 ï Points to Note
for Intermittent Malfunctions.)

MPI <4G63> ï Troubleshooting		13D-15
Code No. 12 Air flow sensor system	Probable cause
Range of Check	D Malfunction of the air flow sensor
D The engine speed is more than 500 r/min	D Air flow sensor circuit disconnection, short-circuit,
Set Condition	or connector contact defect
D The sensor output frequency is less than 3.3 Hz for 4 seconds.	D Malfunction of the engine-A/T-ECU

M.U.T.-II/III Data list

DNo. 12 Air flow sensor (Refer to P.13D-66.)

NG

Check the following connector:

B-08

OK

Measure at the B-08 air flow sensor connector.

DDisconnect the connector to measure at the harness side

(1)Voltage between terminal No. 3 and earth

(Ignition switch: ON) OK: 4.9 ï 5.1 V

(2)Voltage between terminal No. 4 and earth

(Ignition switch: ON) OK: System voltage

(3)Resistance between terminal No. 5 and earth

OK: Less than 2 :

OK

To the next page

OK

Intermittent malfunction

(Refer to GROUP 00 ï Points to Note for Intermittent Malfunctions.)

NG

Repair

	(1) NG					OK
			Measure at the C-124 engine-A/T-ECU
			connector.
			D Measure the voltage of the
				engine-A/T-ECU terminal.
			D	Ignition switch: ON
			D Voltage between terminal No. 65
				and earth.
				OK: 4.9 ï 5.1 V
					NG

Check the following connector: NG C-124

OK

NG Check the harness between the air

flow sensor and engine-A/T-ECU.

OK

NG

M.U.T.-II/III Data list

DNo. 12 Air flow sensor (Refer to P.13D-66.)

			OK
	Intermittent malfunction
	(Refer to GROUP 00 ï Points to Note
	for Intermittent Malfunctions.)
(2) NG						NG
	Check the following connector:
	B-16X
			OK
	Check the harness between the air
	flow sensor and engine control relay.
(3) NG						NG
	Check the following connector:
	C-122
			OK
						NG
	Check the harness between the air
	flow sensor and engine-A/T-ECU.
			OK			NG
	M.U.T.-II/III	Data list

DNo. 12 Air flow sensor (Refer to P.13D-66.)

OK

Intermittent malfunction

(Refer to GROUP 00 ï Points to Note for Intermittent Malfunctions.)

Check the following connector:

C-124

OK NG

Repair

Check and repair the harness between the air flow sensor and engine-A/T- ECU.

Repair

Repair

Replace the engine-A/T-ECU.

Repair

Repair

Repair

Replace the engine-A/T-ECU.

13D-16

MPI <4G63> ï Troubleshooting

From the previous page

OK

NG

NG

Measure at the B-08 air flow sensor

Check the following connector:

Repair

connector.

C-122

D

Using the test harness

OK

(MB991709), connect the

NG

connector, and measure at the

Check the harness between the air

Repair

D

pickup.

flow sensor and engine-A/T-ECU.

Ignition switch: ON

OK

D Voltage between terminal No. 7

and earth.

Replace the air flow sensor.

OK: 7 ï 8 V

OK

NG

NG

Measure at the B-08 air flow sensor

Check the following connector:

Repair

connector.

C-122

D

Using the test harness

OK

(MB991709), connect the

NG

connector, and measure at the

Repair

pickup harness.

Check the harness between air flow

sensor and engine-A/T-ECU.

D Voltage between terminal No. 7

OK

and earth.

OK: Engine: idle

NG

0 ï 1 V

M.U.T.-II/III Data list

Replace the engine-A/T-ECU.

Engine: 3,000 r/min

D No. 12 Air flow sensor

6 ï 9 V

(Refer to P.13D-66.)

OK

OK

Intermittent malfunction

(Refer to GROUP 00 ï Points to Note

for Intermittent Malfunctions.)

Measure the output waveform at the B-08 air flow sensor connector (using an analyzer).

D Using the test harness (MB991709), connect the connector, and measure at the pickup harness.

D Engine: Idle

DVoltage between terminal No. 3 and earth.

OK: Output the waveform as shown on P.13D-79 (inspection procedure by analyzer), and check that there is noise in the output waveform.

OK

M.U.T.-II/III Data list

DNo. 12 Air flow sensor (Refer to P.13D-66.)

OK

Intermittent malfunction

(Refer to GROUP 00 ï Points to Note for Intermittent Malfunctions.)

NG

Replace the air flow sensor.

		OK
Check the trouble symptom.			End
	NG
		NG
Check the following connectors:			Repair
B-16X, C-122, C-124
	OK
		NG
Check the harness between the air			Repair
flow sensor and engine control relay.
	OK

Check the harness between the air flow sensor and engine-A/T-ECU.

NG

Replace the engine-A/T-ECU.

	Code No. 13 Intake air temperature sensor system	Probable cause
	Range of Check	D Malfunction of the intake air temperature sensor
	D 60 seconds after the ignition switch is set to the “ON” position, or after the	D Intake air temperature sensor circuit disconnection,
	completion of the start of engine.	short-circuit, or connector contact defect
	Set Conditions	D Malfunction of the engine-A/T-ECU
	D The sensor output voltage is more than 4.6 V for 4 seconds (Equivalent to intake
	air temperature less than ï40_C)
	or
	D The sensor output voltage is less than 0.2 V for 4 seconds (Equivalent to intake
	air temperature of more than 120_C)

MPI <4G63> ï Troubleshooting

13D-17

			OK
M.U.T.-II/III Data list					Intermittent malfunction
D No. 13 Intake air temperature					(Refer to GROUP 00 ï Points to Note
sensor					for Intermittent Malfunctions.)
OK: Ambient temperature (More
or less the same as the air
temperature)
	NG
			NG		Repair
Check the following connector:
B-08
	OK
			NG
Check the intake air temperature					Replace the intake air temperature
sensor alone. (Refer to P.13D-97.)					sensor.
	OK
			(1) NG					NG
Measure at the B-08 air flow sensor					Check the following connector:
connector.					C-122
D Disconnect the connector to
						OK
measure at the harness side
								NG
(1) Resistance between terminal No.
					Check the harness between the air
5 and earth
					flow sensor and engine-A/T-ECU.
OK: Less than 2 :
(2) Voltage between terminal No. 6						OK
and earth								NG
(Ignition switch: ON)					M.U.T.-II/III Data list
OK: 4.5 ï 4.9 V					D No. 13 Intake air temperature
					sensor
					OK: Ambient temperature (More
					or less the same as the air
					temperature)
						OK
					Intermittent malfunction
					(Refer to GROUP 00 ï Points to Note
					for Intermittent Malfunctions.)
			(2) NG					OK
					Measure at the C-124 engine-A/T-ECU
					connector.
					D Measure the engine-A/T-ECU
					terminal voltage.
					D Disconnect the B-08 air flow
					sensor connector.
					D Ignition switch: ON
					D Voltage between terminal No. 64
					and earth.
					OK: 4.5 ï 4.9 V
						NG
								NG
					Check the following connector:
					C-124
						OK		NG
	OK
					Check the harness between the air
To the next page					flow sensor and engine-A/T-ECU.
						OK
								NG
					M.U.T.-II/III Data list
					D No. 13 intake air temperature
					sensor
					OK: Ambient temperature (More
					or less the same as air
					temperature)
						OK
					Intermittent malfunction
					(Refer to GROUP 00 ï Points to Note
					for Intermittent Malfunctions.)

Repair

Repair

Replace the engine-A/T-ECU.

Check the following connector:

C-124

OK NG

Repair

Check and repair the harness between the air flow sensor and engine-A/T- ECU.

Repair

Repair

Replace the engine-A/T-ECU.

13D-18					MPI <4G63> ï Troubleshooting
From the previous page
	OK
				NG					NG
Measure at the B-08 air flow sensor							Check the following connectors:			Repair
connector.							C-122, C-124
D Using the test harness
								OK
(MB991709), connecting only
connector terminals No. 5 and
							Check and repair the harness between
No. 6, and measure at the
							the air flow sensor and engine-A/T-
pickup harness.
							ECU.
D Ignition switch: ON

DVoltage between terminal No. 6

and earth.

OK: Ambient temperature ï20_C

3.8	ï 4.4 V
Ambient temperature 0_C
3.2	ï 3.8 V
Ambient temperature 20_C
2.3	ï 2.9 V
Ambient temperature 40_C
1.5	ï 2.1 V
Ambient temperature 60_C
0.8	ï 1.4 V
Ambient temperature 80_C
0.4	ï 1.0 V
		OK
			NG
M.U.T.-II/III	Data list				Replace the engine-A/T-ECU.
D No. 13 intake air temperature
sensor
OK: Ambient temperature (More
or less the same as the air
temperature)
		OK
Intermittent malfunction
(Refer to GROUP 00 ï Points to Note
for Intermittent Malfunctions.)

Code No. 14 Throttle position sensor system							Probable cause
Range of Check							D Malfunction of the throttle position sensor
D 60 seconds after the ignition switch is set to the “ON” position, or after the							D Improper connector contact, open circuit or
completion of start of engine.							short-circuited harness wire
Set Conditions							D Malfunction of the engine-A/T-ECU
D The sensor output voltage is 4.3 V or more for 4 seconds and volumetric
efficiency 40 % or less.
or
D The sensor output voltage is 0.2 V or less for 2 seconds
		OK
M.U.T.-II/III Data list						Intermittent malfunction
14 Throttle position sensor						(Refer to GROUP 00 ï Points to
(Refer to P.13D-66, DATA LIST						Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
	NG
		NG
Check the throttle position sensor.						Replace
(Refer to P.13D-98.)
	OK
		NG
Check the following connector:						Repair
B-06
	OK
To the next page

MPI <4G63> ï Troubleshooting

13D-19

From the previous page

OK

Measure at throttle position sensor connector B-06.

DDisconnect the connector and measure at the harness side.

(1)Voltage between terminal 1 and earth

(Ignition switch: ON) OK: 4.9 ï 5.1 V

(2)Resistance between terminal 4 and earth

OK: 2 : or less

OK

Measure at throttle position sensor connector B-06.

DUse test harness (MB991536) to connect the connector, and

measure at the pick-up harness. D Ignition switch: ON

(1)Voltage between terminal 1 and

earth

OK: 4.9 ï 5.1 V

(2)Voltage between terminal 4 and earth

OK: 0.5 V or less

(3)Voltage between terminal 2 and earth

OK: Accelerator pedal fully released: 0.335 ï 0.935 V

Accelerator pedal fully depressed: 4.4 ï 5.3 V

OK

To the next page

(1) NG

OK

Measure at engine-A/T-ECU

Check the following connector:

connector C-124.

C-124

D

Measure the voltage at the

OK

NG

engine-A/T-ECU terminals.

Repair

D

Ignition switch: ON

D

Voltage between terminal 46 and

Check the harness wire between the

earth

throttle position sensor and the

OK: 4.9 ï 5.1 V

engine-A/T-ECU, and repair if

NG

necessary.

NG

Check the following connector:

Repair

C-124

OK

NG

Check the harness wire between the

Repair

throttle position sensor and the

engine-A/T-ECU.

OK

NG

(2) NG

Check the trouble symptoms.

Replace the engine-A/T-ECU.

NG

Check the following connector:

Repair

C-124

					OK
			Check the harness wire between the
			throttle position sensor and the
			engine-A/T-ECU.
					OK
			Check the trouble symptoms.
	(1) NG		Check the following connector:
	(2) NG
			C-124
					OK

NG Repair

NG

Replace the engine-A/T-ECU.

NG

Repair

Check the harness wire between the throttle position sensor and the engine-A/T-ECU.

(3) NG

Adjust the throttle position sensor. (Refer to P.13D-98.)

			NG
	Check the following connector:
				Repair
	C-126
		OK
	Check the harness wire between the
	throttle position sensor and the
	engine-A/T-ECU, and repair if
	necessary.

13D-20

MPI <4G63> ï Troubleshooting

From the previous page

		OK
				NG
	Measure at the engine-A/T-ECU
	connector C-126

DMeasure voltage at the engine-A/T-ECU terminal.

D Ignition switch: ON

DVoltage between terminal 78 and earth

OK: Accelerator pedal fully re-

leased: 0.335 ï 0.935 V Accelerator pedal fully de- OK pressed: 4.4 ï 5.3 V

			NG
	Check the following connector:
				Repair
	C-126
		OK

Check the harness wire between the throttle position sensor and the engine-A/T-ECU, and repair if necessary.

NG

Check the following connectors: Repair

C-124, C-126

OK

Check the trouble symptoms.

NG

Replace the engine-A/T-ECU.

Code No. 21 Engine coolant temperature sensor system	Probable cause
Range of Check	D Malfunction of the engine coolant temperature
D 60 seconds after the ignition switch is set to the “ON” position, or after the	sensor
completion of start of engine.	D Open or short circuit in the engine coolant
Set Conditions	temperature sensor circuit or loose connector
D The sensor output voltage is 4.6 V or more for 4 seconds (equivalent to	contact
ï45_C or lower of engine coolant temperature)	D Malfunction of the engine-A/T-ECU
or
D The sensor output voltage is 0.1 V or less for 4 seconds (equivalent to
140_C or higher of engine coolant temperature)
Range of Check
D Engine: After starting
Set Condition
D The engine coolant temperature has reduced from over 40_C to less than
40_C, and that condition has lasted for five minutes or more.

M.U.T.-II/III Data list

21 Engine coolant temperature sensor

OK: When the engine is cold, the temperature is roughly the same as ambient temperature. If warm, it is 80 ï 120_C.

NG

Measure at engine coolant temperature sensor connector B-111.

D Disconnect the connector and measure at the sensor side.

DResistance between terminals 1 and 2

OK: At 20_C of engine coolant temperature: 2.1 ï 2.7 k: At 80_C of engine coolant temperature:

0.26ï 0.36 k:

OK

Check the following connector:

B-111

OK

To the next page

OK

Intermittent malfunction

(Refer to GROUP 00 ï Points to Note for Intermittent Malfunctions.)

NG

Replace

NG

Repair

MPI <4G63> ï Troubleshooting

13D-21

From the previous page

OK

OK

(1) NG

Measure at engine coolant

Measure at engine-A/T-ECU

Check the following connector:

C-124

temperature sensor connector B-111.

connector C-124.

D

Disconnect the connector and

D

Measure the voltage at the

OK

NG

measure at the harness side.

D

engine-A/T-ECU terminal.

Repair

(1) Voltage between terminal 1 and

Disconnect connector B-111.

earth

D

Ignition switch: ON

Check the harness wire between the

(Ignition switch: ON)

D

Voltage between terminal 44 and

engine coolant temperature sensor

OK: 4.5 ï 4.9 V

earth

and the engine-A/T-ECU, and repair

(2) Resistance between terminal 2

OK: 4.5 ï 4.9 V

if necessary.

and earth

NG

OK: 2 : or less

NG

Check the following connector:

Repair

C-124

OK

Check the harness wire between the

NG

Repair

engine coolant temperature sensor

and the engine-A/T-ECU.

OK

NG

(2) NG

Check the trouble symptoms.

Replace the engine-A/T-ECU.

NG

Check the following connector:

Repair

C-124

OK

Check the harness wire between the

NG

Repair

OK

engine coolant temperature sensor

and the engine-A/T-ECU.

OK

NG

Check the trouble symptoms.

Replace the engine-A/T-ECU.

NG

NG

Measure at engine coolant

Check the engine coolant

Repair

temperature sensor connector B-111.

temperature sensor.

D Use test harness (MB991658) to

(Refer to P.13D-98.)

connect the connector, and

OK

measure at the pick-up harness.

D

Ignition switch: ON

Check the following connector:

NG

Repair

D

Voltage between terminal 1 and

C-124

earth

OK

OK: At 0_C of engine coolant

temperature: 3.2 ï 3.8 V

Check the harness wire between the

At 20_C of engine coolant

engine coolant temperature sensor

temperature: 2.3 ï 2.9 V

and the engine-A/T-ECU, and repair

At 40_C of engine coolant

if

necessary.

temperature: 1.3 ï 1.9 V

At 80_C of engine coolant

temperature: 0.3 ï 0.9 V

OK

NG

Check the trouble symptoms.

Replace the engine-A/T-ECU.

13D-22

MPI <4G63> ï Troubleshooting

Code No. 22 Crank angle sensor system

Probable cause

Range of Check

D Malfunction of the crank angle sensor.

D

Engine is cranking

D Open or short circuit in the crank angle sensor

Set Condition

circuit or loose connector contact.

D

Sensor output voltage does not change for 4 seconds (no pulse signal input).

D

Malfunction of the engine-A/T-ECU

OK

M.U.T.-II/III Data list

Intermittent malfunction

22 Crank angle sensor

(Refer to GROUP 00 ï Points to

OK: Refer to P.13D-66, DATA

Note for Intermittent Malfunctions.)

LIST REFERENCE TABLE.

NG

NG

Check the following connector:

Repair

B-116

OK

(1) NG

Measure at the crank angle sensor

Check the harness between the

connector B-116.

crank angle sensor and earth, and

D

Disconnect the connector and

repair if necessary.

measure at the harness side.

(1) The resistance between terminal

(2) NG

OK

1 and earth

Measure at the engine-A/T-ECU

Check the following connector:

OK: 2 : or less

connector C-124.

C-124

(2) The voltage between terminal 2

D

Measure the voltage at the

OK

NG

and earth

engine-A/T-ECU terminal.

Repair

(Ignition switch: ON)

D

Disconnect the connector B-116

OK: 4.9 ï 5.1 V

D

Ignition switch: ON

Check the harness wire between the

(3) The voltage between terminal 3

D

The voltage between terminal 45

crank angle sensor and the

and earth

and earth

engine-A/T-ECU, and repair if

(Ignition switch: ON)

OK: 4.9 ï 5.1 V

necessary.

OK: System voltage

NG

NG

Check the following connector:

Repair

C-124

OK

NG

Check the harness wire between the

Repair

crank angle sensor and the

engine-A/T-ECU.

OK

NG

Check the trouble symptoms.

Replace the engine-A/T-ECU.

(3) NG

NG

Check the following connector:

Repair

B-16X

OK

Check the harness wire between the

OK

crank angle sensor and the engine

control relay, and repair if necessary.

To the next page

MPI <4G63> ï Troubleshooting

13D-23

From the previous page

OK

NG

NG

Replace

Use an analyzer to measure the

Check the crank angle sensor vane.

output waveform at the crank angle

OK

sensor connector B-116.

D

Use the test harness

Replace the crank angle sensor.

(MD998478) to connect the

connector, and measure at the

pick-up harness side.

D

Check the trouble symptoms.

Engine: Idling

D The voltage between terminal 2

NG

and earth

NG

Repair

Check the following connectors:

OK: A normal waveform should

B-16X, C-124

be displayed as described

on P.13D-81 (Inspection

OK

Procedure Using an Ana-

lyzer). Its maximum value

Check the harness wires between

should be 4.8 V or more,

the crank angle sensor and the

and its minimum value

engine-A/T-ECU, crank angle sensor

should be 0.6 V or less

and the engine control relay, and the

with no noise in waveform.

crank angle sensor and earth. Then,

OK

repair if necessary.

Check the trouble symptoms.

NG

Replace the engine-A/T-ECU.

13D-24	MPI <4G63> ï Troubleshooting
Code No. 23 Camshaft position sensor system		Probable cause
Range of Check		D Malfunction of the camshaft position sensor
D During engine cranking and driving		D Open or short circuit in the camshaft position
Set Condition		sensor circuit or loose connector contact.
D The sensor output voltage does not change for 4 seconds (no pulse signal		D Malfunction of the engine-A/T-ECU
input).

Check the following connector:

B-107

OK

Measure at camshaft position sensor connector B-107.

DDisconnect the connector and measure at the harness side.

(1)The voltage between terminal 3 and earth

(Ignition switch: ON) OK: System voltage

(2)The voltage between terminal 2 and earth

(Ignition switch: ON) OK: 4.9 ï 5.1 V

(3)The resistance between terminal 1 and earth

OK: 2 : or less

OK

NG

				Repair		NG
	(1) NG
				Check the following connector:			Repair
				B-16X
					OK

Check the harness wire between the camshaft position sensor connector and the engine control relay, and repair if necessary.

(2) NG

Measure at the engine-A/T-ECU connector C-124.

DMeasure the voltage at the engine-A/T-ECU terminal.

D Disconnect connector B-107.

D Ignition switch: ON

DThe voltage between terminal 56

and earth

OK: 4.9 ï 5.1 V

NG

Check the following connector:

C-124

OK

Check the harness wire between the intermediate connector and the engine-A/T-ECU.

OK

Check the trouble symptoms.

(3) NG

Check the harness wire between the camshaft position sensor connector and earth, and repair if necessary.

OK		Check the following connector:
		C-124
		OK	NG

Repair

Check the harness wire between the camshaft position sensor connector and the engine-A/T-ECU, and repair if necessary.

NG

Repair

NG

Repair

NG

Replace the engine-A/T-ECU.

NG

Use an analyzer to measure the output waveform at camshaft position sensor connector B-107.

DUse test harness (MB991709) to connect the connector, and

measure at the pick-up harness. D Engine: Idling

DThe voltage between terminal 2 and earth

OK: A normal waveform should be displayed as described on P.13D-81 (Inspection Procedure Using an Analyzer), its maximum value should be 4.8 V or more, and its minimum value should be 0.6 V or less with no noise in waveform.

OK

OK

Check the trouble symptoms.

NG

Replace the engine-A/T-ECU.

NG

Check the camshaft position sensing Replace cylinder.

OK

Replace the camshaft position sensor.

Check the trouble symptoms.
	NG
		NG
Check the following connectors:			Repair
B-16X, C-124
	OK

Check the harness wires between the camshaft position sensor connector and the engine-A/T-ECU, the camshaft position sensor connector and the engine control relay, and the camshaft position sensor connector and earth. Then, repair if necessary.

Intermittent malfunction

(Refer to GROUP 00 ï Points to Note for Intermittent Malfunctions.)

	MPI <4G63> ï Troubleshooting							13D-25
Code No. 24 Vehicle speed signal system						Probable cause
Range of Check						D Malfunction of the output shaft speed sensor
D 60 seconds after the ignition switch is set to the “ON” position, or after the						D	Open or short circuit in the output shaft speed
completion of start of engine.							sensor circuit or loose connector contact
D The engine speed is more than 2,300 r/min.						D	Malfunction of the engine-A/T-ECU
D Volumetric efficiency 50 % or more
Set Condition
D The vehicle speed signal does not change for 4 seconds (no pulse signal
input.)
		YES
M.U.T.-II/III Self-Diag code				D	Automatic transmission system check
D Is diagnosis code of automatic transmission system output?					(Refer to GROUP 23B ï Troubleshooting ï Inspection
					chart for diagnosis codes)
	NO	OK
Check the trouble symptoms.				Intermittent malfunction. (Refer to GROUP 00 ï Points to Note
				for	Intermittent Malfunctions.)
	NG
Replace the engine-A/T-ECU.