Page 1
GROUP 52
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM(SRS)
52-1
CONTENTS
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . 52B
Page 2
NOTES
Page 3
ALPHABETICAL INDEX
1
A
A/C-ECU
A/C-ECU removal and installation ................................. 55-180
ABS, ASC, ACD, AYC and S-AWC <M/T>
Supplemental restraint system (SRS) ........................... 90-266
Circuit diagrams............................................................. 90-266
ABS, ASC, ACD, AYC and S-AWC <TC-SST>
Supplemental restraint system (SRS) ........................... 90-276
Circuit diagrams............................................................. 90-276
Accessory socket and cigarette lighter
Supplemental restraint system (SRS) ........................... 90-264
Circuit diagrams............................................................. 90-264
Accessory socket and cigarette lighter
Diagnosis
Standard flow of diagnostic troubleshooting .............. 54A-293
General information ....................................................... 54A-291
Inspection ...................................................................... 54A-305
Removal and installation ............................................... 54A-303
Special too ls ......... ....... ....... ......................... .................. 54A-292
Symptom procedures
s
Inspection procedure 1: the accessory socket doe
cles with accessory socket> ...................................... 54A-294
Inspection procedure 2: the cigarette lighter does not wo
cles with cigarette lighter> ......................................... 54A-299
Trouble symptom chart .................................................. 54A-293
Adhesive............................................................................ 25-3
Adjustment snap ring and spacers .................................... 22B-6
Air bag module and seat belt pre-tensione
Supplemental restraint system (SRS) ........................... 52B-443
Circuit diagrams............................................................. 52B-443
Air cleaner
Removal and installation ............................................... 15-11
Air conditioning system
Supplemental restraint system (SRS) ........................... 90-204
Circuit diagrams............................................................. 90-204
Ambient air temperature sensor
Ambient air temperature sensor removal and installation 55-178
Inspection ...................................................................... 55-178
Amplifier
General information ....................................................... 54A-631
Removal and installation ............................................... 54A-632
Antenna
General information ....................................................... 54A-629
Removal and installation ............................................... 54A-630
ASC off switch
Inspection ...................................................................... 35C-297
Removal and installation ............................................... 35C-296
Audio system <vehicles with audio amplifier>
Supplemental restraint system (SRS) ........................... 90-232
Circuit diagrams............................................................. 90-232
Audio system <vehicles without audio amplifier>
Supplemental restraint system (SRS) ........................... 90-226
Circuit diagrams............................................................. 90-226
Auto A/C diagnosis
Actuator test reference table ......................................... 55-159
Check at ECU terminal .................................................. 55-160
Data list reference table................................................. 55-155
Diagnostic function ........................................................ 55-7
Diagnostic trouble code chart ........................................ 55-10
r disposal procedur
not work. <vehi-
rk.<vehi-
es
Diagnostic trouble code procedures
B1000 control panel communication error ................. 55-20
B1000 control panel communication error
<vehicles without A/C> .............................................. 55-15
B1003 mode dial sw error .......................................... 55-28
B1003 mode dial sw error <vehicles without A/C> .... 55-24
B1018 temperature control dial sw error.................... 55-34
B1018 temperature control dial sw error
<vehicles without A/C> .............................................. 55-31
B1021 fan dial sw error .............................................. 55-40
B1021 fan dial sw error <vehicles without A/C> ........ 55-37
B1031 air thermo sensor system ............................... 55-46
B1031 air thermo sensor system <vehicles without A/C> 55-43
B1034 ambient temperature sensor system .............. 55-49
B1079 refrigerant leaks.............................................. 55-52
B10C0 interior temperature sensor system ............... 55-12
B2214 control panel failure ........................................ 55-60
A/C>... 55-56
B2214 control panel failure <vehicles witho
B222C or U1415 coding not completed ..................... 55-69
B223B control panel improperly assembled .............. 55-66
B223B control panel improperly assembled
<vehicles without A/C> .............................................. 55-63
U0019 bus off (CAN-B) .............................................. 55-71
U0141 ETACS CAN time-out..................................... 55-72
U0151 SRS CAN time-out ......................................... 55-75
U0154 occupant classification ECU time out ............. 55-77
U0155 meter CAN time-out........................................ 55-80
U0168 WCM CAN time-out........................................ 55-82
U0184 audio CAN time-out ........................................ 55-85
U0195 satellite radio time out .................................... 55-87
U0197 hands free module time-out............................ 55-90
U0245 and CAN time-out........................................... 55-93
Introduction .................................................................... 55-6
Symptom chart............................................................... 55-121
Symptom chart <vehicles without A/C> ......................... 55-96
Symptom procedures
A/C outlet air temperature does not increase ............ 55-146
Air outlet vent cannot be changed. ............................ 55-148
Blower fan and motor does not run............................ 55-135
Blower fan and motor does not stop turning. ............. 55-140
Blower motor power supply system ........................... 55-151
Inside/outside air changeover is not po
Malfunction of the A/C-ECU power supply system .... 55-124
The compressor does not work.................................. 55-128
When the ignition switch is "on," the A/C does not work 55-121
Symptom procedures <vehicles without A/C>
A/C outlet air temperature does not increase
<vehicles without A/C> .............................................. 55-112
Air outlet vent cannot be changed. ............................ 55-114
Blower fan and motor does not run. <vehicles without A/C> 55-101
Blower fan and motor does not stop turning.
<vehicles without A/C> .............................................. 55-106
Blower motor power supply system <vehicles w
Inside/outside air changeover is not possible. <
C> .............................................................................. 55-109
Malfunction of the A/C-ECU power supply system <vehicles
A/C>........................................................................... 55-97
Troubleshooting strategy ............................................... 55-6
AWC-ECU
Removal and installation
Manual transaxle........................................................ 22A-133
ut
ssib
le. ........... 55-143
i
thout A/C> 55-117
vehicles without A/
without
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Page 4
2
ALPHABETICAL INDEX
Twin c lut ch-sportron ic shift transmission (TC-SST) ... 22C-434
Centralized junction
B
Backup light <M/T>
Supplemental restraint system (SRS) ........................... 90-138
Circuit diagrams............................................................. 90-138
Backup light <TC-SST>
Supplemental restraint system (SRS) ........................... 90-140
Circuit diagrams............................................................. 90-140
Basic brake system diagnosis
a
Basic brake system diagnostic troubleshooting str
Introduction to basic brake system diagnosis......
Symptom chart .............................................................. 35A-4
Symptom procedures
Inspection procedure 1: vehicle pulls to one
applied ....................................................................... 35A-5
Inspection procedure 2: insufficient braking power
Inspection procedure 3: increased pedal stroke (re
floor board clearance)................................................ 35A-6
Inspection procedure 4: brake drag ........................... 35A-7
Inspection procedure 5: scraping or grinding noise
applied ....................................................................... 35A-8
Inspection procedure 6: squealing, groaning
when brakes are applied............................................ 35A-9
Inspection procedure 7: squealing noise when
applied ....................................................................... 35A-10
Inspection procedure 8: groaning, clicking
brakes are not applied. .............................................. 35A-11
Battery
General information ....................................................... 54A-7
On-vehicle service
Battery test................................................................. 54A-9
Charging .................................................................... 54A-8
Electrolyte level and specific gravity checks
Removal and installation ............................................... 54A-10
Brake pedal
Inspection
Brake pedal distortion check...................................... 35A-26
Stoplight switch check................................................ 35A-25
Removal and installation ............................................... 35A-24
Brake warning light, fuel warning light and oil pressure
T>
Supplemental restraint system (SRS) ........................... 90-152
Circuit diagrams............................................................. 90-152
Brake warning light, fuel warning light and oil pressure warning light <TC-
SST>
Supplemental restraint system (SRS) ........................... 90-156
Circuit diagrams............................................................. 90-156
tegy 35A-4
.......... 35A-4
side
when brakes are
.... 35A-5
duced pedal-to-
when brakes are
or
chattering noise
brakes are not
or rattling noise when
....
.......... 54A-8
warning light <M/
Charge air cooler
Charging system
Charging system <M/T>
Charging system <TC-SST>
Clutch
Clutch control
Clutch housing
Clutch pedal and master cylinder
Clutch release cylinder
Column switch
C
Camshaft
Inspection ...................................................................... 11B-46
Removal and installation
Engine mechanical .................................................... 11A-25
Engine overhaul......................................................... 11B-43
CAN communication-related DTC (u-code) table.............. 54C-269
Center differential
Disassembly and assembly ........................................... 22B-52
Central door locking system
Supplemental restraint system (SRS) ........................... 90-166
Combination meter
Circuit diagrams............................................................. 90-166
Supplemental restraint system (SRS)............................ 90-20
Circuit diagrams............................................................. 90-20
Removal and installation................................................ 15-12
Charging system diagnosis............................................ 16-3
General information ....................................................... 16-2
General specifications ................................................... 16-3
Generator assembly
Disassembly and assembly ....................................... 16-16
Inspection................................................................... 16-20
Removal and installation............................................ 16-14
On-vehicle service
Generator output line voltage drop test...................... 16-7
Output current test ..................................................... 16-8
Regulated voltage test ............................................... 16-10
Wave pattern check using an oscilloscope ................ 16-11
Service specifications .................................................... 16-3
Special too l ................. ....... ....... ......................... ....... ..... 16-6
Supplemental restraint system (SRS)............................ 90-44
Circuit diagrams............................................................. 90-44
Supplemental restraint system (SRS)............................
Circuit diagrams............................................................. 90-48
Inspection ...................................................................... 21B-6
Removal and installation................................................ 21B-4
Inspection ...................................................................... 21A-10
Removal and installation................................................ 21A-9
Disassembly and assembly ........................................... 22B-44
Inspection
Clutch switch check and adjustment.......................... 21A-7
Interlock switch operating check ................................ 21A-8
Removal and installation................................................ 21A-4
Disassembly and assembly ........................................... 21B-7
Inspection ...................................................................... 21B-9
Diagnostic trouble code procedures
DTC B2350: malfunction of lighting switch, DTC B2351: malfunction
of wiper/washer switch............................................... 54A-310
General information ....................................................... 54A-306
Inspection
a
Column switch (switch body p
Wiper/washer switch continuity check ....................... 54A-313
Removal and installation................................................ 54A-312
Special too ls..... ....... ....... .................. ....... ....................... 54A-307
Troubleshooting
Diagnostic function..................................................... 54A-308
Diagnostic trouble code table..................................... 54A-310
Standard flow of diagnostic troubleshooting .............. 54A-308
Actuator test table.......................................................... 54A-89
rt) continuity check.... 54A-314
90-48
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ALPHABETICAL INDEX
3
Check at ECU terminals ................................................ 54A-96
Check procedure for each multi information display screen 54A-90
Combination meter
Disassembly and assembly ....................................... 54A-111
Removal and installation............................................ 54A-110
Diagnostic trouble code chart ........................................ 54A-32
Diagnostic trouble code procedures
DTC B1200: malfunction of odometer ....................... 54A-33
DTC B1201: abnormal fuel information ..................... 54A-34
DTC B1208: malfunction of lcd heater....................... 54A-37
DTC B1209: test mode .............................................. 54A-38
DTC B2203: vin not programmed .............................. 54A-38
DTC B2463: the sticking of rheostat switch ............... 54A-40
DTC B2464: the sticking of meter information switch 54A-41
DTC B2465: ignition switch signal error..................... 54A-44
DTC U0019: bus off (CAN-B) .................................... 54A-45
DTC U0100: engine control module CAN timeout ..... 54A-47
DTC U0141: ETACS CAN timeout............................. 54A-49
DTC U0151: SRS-ECU CAN timeout ........................ 54A-51
DTC U0154: occupant classification-ECU CAN timeout 54A-53
DTC U0164: A/C-ECU or heater control unit CAN timeout 54A-55
DTC U0168: KOS-ECU or WCM CAN timeout.......... 54A-57
DTC U0184: audio CAN timeout................................ 54A-59
DTC U0197: hands free module CAN timeout........... 54A-61
DTC U0245: audio visual navigatio
DT
C U1415: coding not completed/data fail .............. 54A-65
General information ....................................................... 54A-26
On-vehicle service
Fuel level sensor check ............................................. 54A-99
Meter information switch check ................................. 54A-100
Service reminder function set .................................... 54A-101
Speedometer check ................................................... 54A-97
Ta ch o me te r c h ec k .. ... ... .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. 54A-99
Service data................................................................... 54A-88
Service specifications .................................................... 54A-27
Special too ls ......... ....... ....... ......................... .................. 54A-28
Symptom procedures
Inspection procedure 1: power supply circuit che
Inspection procedure 2: the speedometer does not
meters work). ............................................................. 54A-74
Inspection procedure 3: the tachometer does not work (the other
meters work). ............................................................. 54A-76
Inspection procedure 4: tone alarm does not sound
normally. .................................................................... 54A-78
Inspection procedure 5: the combination meter light does not illuminate normally or the multi information display is not displayed nor-
mally........................................................................... 54A-81
Inspection procedure 6: the multi information display screen cannot
be changed with the operation of the meter
switch......................................................................... 54A-84
Trouble symptom chart .................................................. 54A-67
Troubleshooting
Diagnosis function ..................................................... 54A-29
Standard flow of diagnostic troubleshooting .............. 54A-29
Compressor assembly and tension pulley
Compressor assembly and tension pulley removal and
installation...................................................................... 55-181
Compressor assembly disasse
Inspection
Heater, air conditioning and ventilation...................... 55-183
Heater, air conditioning and ventilation...................... 55-185
Condenser assembly
n unit CAN timeout 54A-63
k. . 54A-68
c
work (the other
information meter
bly and assembly....... 55-183
m
Condenser assembly removal and installation .............. 55-186
Control housing
Disassembly and assembly ........................................... 22B-40
Control link and lower arm
Control link ball joint dust cover inspection.................... 34-15
Control link ball joint dust cover replacement ................ 34-16
Control link ball joint rotation starting torque check ....... 34-14
tion starting torque check 34-15
Control link slide bushing rot
Lower arm pillow ball bushing rotation starting torque check 34-15
Removal and installation................................................ 34-12
Control unit........................................................................ 70-4
Controller area network (CAN) <M/T>
Supplemental restraint system (SRS)............................ 90-384
Circuit diagrams............................................................. 90-384
Controller area network (CAN) <TC-SST>
Supplemental restraint system (SRS)............................ 90-388
Circuit diagrams............................................................. 90-388
Coolant .............................................................................. 14-3
Cooling system
Supplemental restraint system (SRS)............................ 90-76
Circuit diagrams............................................................. 90-76
Crankshaft and cylinder block
Inspection ...................................................................... 11B-78
Removal and installation................................................ 11B-73
Crankshaft oil seal
Removal and installation................................................ 11A-51
Crankshaft pulley
Removal and installation................................................ 11A-21
Cruise control
Cruise control switch
Removal and installation............................................ 17-68
Cruise control system diagnosis
Diagnostic function..................................................... 17-10
Diagnostic troubleshooting strategy........................... 17-10
Introduction to cruise control system diagnosis ......... 17-10
Data list reference table................................................. 17-61
Diagnostic trouble code chart ........................................ 17-13
Diagnostic trouble code procedures
DTC 15: cruise control switch system........................ 17-14
DTC 22: stoplight switch system................................ 17-27
DTC 23: ECM and its related components ................ 17-36
ECM terminal voltage reference chart for cruise control system opera-
tion ................................................................................. 17-62
General information ....................................................... 17-9
On-vehicle service
Cruise control switch check ....................................... 17-65
Cruise control system component check ................... 17-67
Special too ls..... ....... ....... .................. ....... ....................... 17-63
Symptom chart............................................................... 17-38
Symptom procedures
Inspection procedure 1: when the brake pedal is
control is not cancelled. ............................................. 17-39
Inspection procedure 2: when the clutch pedal
control is not cancelled <M/T.> .................................. 17-41
Inspection procedure 3: when the shift
tion, cruise control is not cancelled <TC-SST.> ......... 17-44
Inspection procedure 4: when the "CANCEL" switch is pressed,
cruise control is not cancelled.................................... 17-47
Inspection procedure 5: cruise control cannot be set (No response
"coast/set" switch and "acc/res" switch is pressed.) .. 17-49
a
depr
essed, cruise
is
depressed, cruise
lever is moved to "N" posi-
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4
ALPHABETICAL INDEX
Inspection procedure 6: hunting (repeated acceleration and deceler-
ation) occurs at the set vehicle speed. ...................... 17-56
Inspection procedure 7: when the "on/off" switch is turned on,
ISE" indicator light does not illuminate (however, cruise control
"CRU
system is normal.)...................................................... 17-58
Cruise control system <M/T>
Supplemental restraint system (SRS) ........................... 90-298
Circuit diagrams............................................................. 90-298
Cruise control system <TC-SST>
Supplemental restraint system (SRS) ........................... 90-304
Circuit diagrams............................................................. 90-304
Curtain air bag module(s)
Inspection
Supplemental restraint system (SRS)........................ 52B-439
Circuit diagrams......................................................... 52B-439
Removal and installation
Supplemental restraint system (SRS)........................ 52B-436
Circuit diagrams......................................................... 52B-436
Cylinder head and valves
Inspection ...................................................................... 11B-54
Removal and installation ............................................... 11B-49
Cylinder head gasket
Removal and installation ............................................... 11A-54
D
Dash panel
Configuration diagrams ................................................. 80A-10
Splice loca tions...................... ......................... ....... ........ 80B-5
Daytime running light (drl) <discharge type>
Supplemental restraint system (SRS) ........................... 90-114
Circuit diagrams............................................................. 90-114
Daytime running light (drl) <halogen type>
Supplemental restraint system (SRS) ........................... 90-110
Circuit diagrams............................................................. 90-110
Defogger
General information ....................................................... 54A-780
On-vehicle service
Printed heater check.................................................. 54A-792
Rear window defogger relay check............................ 54A-792
Removal and installation ............................................... 54A-791
Special too ls ......... ....... ....... ......................... .................. 54A-781
Symptom procedures
Rear window defogger does not operate................... 54A-782
Troubleshooting
Standard flow of diagnostic troubleshooting .............. 54A-781
Symptom chart........................................................... 54A-781
Diagnosis
ABS warning light, ASC warning/operation light and brake warning
light check...................................................................... 35C-8
Actuator test reference table ......................................... 35C-278
Actuator test table.......................................................... 42B-151
ASC diagnostic troubleshooting strategy....................... 35C-6
CAN bus diagnostics
cannot
Diagnostic item 1: diagnose when the scan tool
data sent by ETACS-ECU.......................................... 54C-28
Diagnostic item 10: diagnose when the scan tool cannot receive the
data sent by ECM. ..................................................... 54C-112
Diagnostic item 11: diagnose when the scan tool cannot receive the
data sent by TC-SST-ECU. <TC-SST> ..................... 54C-117
Diagnostic item 12: diagnose the lines between the ETACS-ECU
and joint connector (CAN2). ...................................... 54C-120
receive the
n
Diagnostic item 13: diagnose the lines betwee
(CAN2) and joint connector (CAN3)........................... 54C-125
Diagnostic item 14: diagnose the lines between
(CAN3) and joint connector (CAN4). <TC-SST> ....... 54C-129
Diagnostic item 15: diagnose when the scan tool cannot receive the
data sent by KOS-ECU. ............................................. 54C-132
Diagnostic item 16: diagnose when the scan tool cannot receive the
data sent by WCM. .................................................... 54C-135
Diagnostic item 17: diagnose when the scan tool cannot receive the
data sent by SRS-ECU. ............................................. 54C-138
Diagnostic item 18: diagnose when the scan tool cannot receive the
data sent by occupant classification-ECU.................. 54C-141
Diagnostic item 19: diagnose when the scan tool cannot receive the
a sent by A/C-
dat
<vehicles without A/C>. ............................................. 54C-144
Diagnostic item 2: malfunction of the ETACS-ECU. .. 54C-33
Diagnostic item 20: diagnose when the scan tool cannot receive the
data sent by radio and CD player or CD changer
Diagnostic item 21: diagnose when the scan tool cannot receive the
data sent by CAN box unit. ........................................ 54C-150
Diagnostic item 22: diagnose when the scan tool cannot receive the
data sent by satellite radio tuner. ............................... 54C-153
Diagnostic item 23: diagnose when the scan tool cannot receive the
data sent by hands free module................................. 54C-156
Diagnostic item 24: diagnose when the scan tool cannot receive the
data sent by combination meter................................. 54C-159
Diagnostic item 25: short to power supply or ground in both CAN_H
and CAN_L lines of the CAN-B bus lines................... 54C-162
Diagnostic item 26: diagnose the ETACS-ECU, joint connector
(CAN1) or lines between ETACS-ECU and joint connector
(CAN1). ...................................................................... 54C-205
Diagnostic item 27: short to power supply or
line-to-line short in the CAN-B bus lines. ................... 54C-210
Diagnostic item 3: abnormal short between the CAN-C
bus lines..................................................................... 54C-34
Diagnostic item 4: diagnose shorts in the ground to CAN-C
bus line....................................................................... 54C-51
Diagnostic item 5: diagnose shorts in the p
bus line....................................................................... 54C-73
Diagnostic item 6: diagnose when the scan tool cannot
data sent by AWC-ECU. ............................................ 54C-97
Diagnostic item 7: diagnose when the scan tool
data sent by steering wheel sensor............................ 54C-101
Diagnostic item 8: diagnose when the scan tool cannot
data sent by shift lever. <TC-SST>............................ 54C-105
Diagnostic item 9: diagnose when the scan tool cannot
data sent by ASC-ECU. ............................................. 54C-108
CAN bus diagnostics table............................................. 54C-15
CAN-related connector position..................................... 54C-26
Check at ECU terminals
Active stability control system (ASC) ......................... 35C-280
Wireless control module (WCM) ................................ 42C-116
Data list reference table
Active stability control system (ASC) ......................... 35C-276
Keyless operation system (KOS) ............................... 42B-150
Wireless control module (WCM) ................................ 42C-90
Diagnostic function
Active stability control system (ASC) ......................... 35C-8
Keyless operation system (KOS) ............................... 42B-9
Wireless control module (WCM) ................................ 42C-6
Diagnostic trouble code chart
Active stability control system (ASC) ......................... 35C-22
Keyless operation system (KOS) ............................... 42B-23
Wireless control module (WCM) ................................ 42C-14
Diagnostic trouble code procedures
Code No.B240E RR antenna(indoor) open ............... 42B-83
Code No.U1417 implausible coding data................... 42B-147
ECU <vehicles with A/C> or heater control unit
joint connector
joint connector
.
..... 54C-147
gr
ound, open circuit or
supply to CAN-C
ower
receive the
cannot
receive the
receive the
receive the
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ALPHABETICAL INDEX
5
DTC B1731: engine control module communication timeout
Keyless operation system (KOS)............................... 42B-25
Wireless control module (WCM) ................................ 42C-16
DTC B1761: vin code not programmed
Keyless operation system (KOS)............................... 42B-28
Wireless control module (WCM) ................................ 42C-18
B1A09: keyless/
DTC B1A08: keyless/KOS key1 performanceDT
KOS key2 performanceDTC B1A0A: keyless/KOS key3 performanceDTC B1A0B: keyless/KOS key4 performance 42B-29
DTC B1A08: keyless/KOS key1 performanceDTC
KOS key2 performanceDTC B1A0A: keyless/KOS key3 performanceDTC B1A0B: keyless/KOS key4 performanceDTC B1A0C:
keyless key 5 performanceDTC B1A ........................ 42C-20
DTC B1A10: keyless/KOS key 1 low batteryDTC B1A11: keyless/
KOS key
DTC B1A13: keyless/KOS key 4 low battery ............. 42B-30
DTC B1A10: keyless/KOS key 1 low batteryDTC B1A11: keyless/
KOS key
DTC B1A13: keyless/KOS key 4 low batteryDTC B1A14: keyless
key 5 low batteryDTC ... ............................................ 42C-21
DTC B1A24: key id not registered
Keyless operation system (KOS)............................... 42B-31
Wireless control module (WCM) ................................ 42C-22
DTC B1A25: key id unmatched
Keyless operation system (KOS)............................... 42B-32
Wireless control module (WCM) ................................ 42C-24
DTC B1A28: engine control module authenticate error
Keyless operation system (KOS)............................... 42B-34
Wireless control module (WCM) ................................ 42C-26
DTC B1A35: transponder read error
Keyless operation system (KOS)............................... 42B-36
Wireless control module (WCM) ................................ 42C-28
DTC B2101: IG sw start pos.circuit lowDTC B2102: IG SW start
pos.circuit high
Keyless operation system (KOS)............................... 42B-39
Wireless control module (WCM) ................................ 42C-31
DTC B2204: coding data mismatch
Keyless operation system (KOS)............................... 42B-42
Wireless control module (WCM) ................................ 42C-34
DTC B2206: vin code mismatch
Keyless operation system (KOS)............................... 42B-44
Wireless control module (WCM) ................................ 42C-36
DTC B2352: antenna fail
Keyless operation system (KOS)............................... 42B-46
Wireless control module (WCM) ................................ 42C-38
DTC B2400: KOS key registration fail ....................... 42B-51
DTC B2401: keyless/KOS key id not register ............ 42C-39
DTC B2401: keyless/KOS key id not registered ........ 42B-60
DTC B2402: stl unit comm.(system id)DTC B2403: stl unit
comm.(crc)DT
stl unit comm.(rolling code)DTC B2406: stl unit comm.(ptc oper-
ate)DTC B2407: stl unit comm.(EEPROM ................ 42B-62
DTC B2409 stl unit comm.(No response) .................. 42B-67
DTC B240A: dr side antenna(outdoor) open ............. 42B-72
DTC B240B: ps side antenna(outdoor) open............. 42B-75
DTC B240C: tail gate antenna(outdoor) open ........... 42B-78
DTC B240D: front antenna(indoor) open................... 42B-81
DTC B2412: lf antenna power voltage....................... 42B-86
DTC B2413: stl unit power voltage ............................ 42B-90
DTC B2414: unlock sensor fail .................................. 42B-93
DTC B2415: ra module power voltage
Keyless operation system (KOS)............................... 42B-97
Wireless control module (WCM) ................................ 42C-40
DTC B2416: ECU internal error
2 low batteryDTC B1A12: keyless/KOS key 3 low battery-
2 low batteryDTC B1A12: keyless/KOS key 3 low battery-
B2404: stl unit comm.(function code)DTC B2405:
C
C
B1A09: keyless/
Keyless operation system (KOS) ............................... 42B-106
Wireless control module (WCM) ................................ 42C-45
DTC C1000: abnormality in stoplight switch circuit.... 35C-147
speed sensor circuit 35C-25
DTC C100A: abnormality in FL w
DTC C1011: abnormality in FL wheel speed sensor signal 35C-45
DTC C1014: mutual monitoring of FL wheel speed sensor 35C-72
DTC C1015: abnormality in FR wheel speed sensor circuit 35C-30
DTC C101C: abnormality in FR wheel speed sensor signal 35C-52
DTC C101F: mutual monitoring of F
DTC C1020: abnormality in RL wheel speed sensor circuit 35C-35
DTC C1027: abnormality in RL wheel speed sensor signal 35C-59
DTC C102A: mutual monitoring of RL wheel speed sensor 35C-79
DTC C102B: abnormality in RR w
DTC C1032: abnormality in RR wheel speed sensor signal 35C-66
DTC C1035: mutual monitoring of RR wheel speed sensor 35C-82
DTC C1041: abnormality in periodical signal
sensor ........................................................................ 35C-85
DTC C1042: abnormality in periodical signal for
sensor ........................................................................ 35C-88
DTC C1043: abnormality in periodical signal for RL wheel speed
sensor ........................................................................ 35C-90
DTC C1044: abnormality in periodical signal for RR wheel speed
sensor ........................................................................ 35C-92
DTC C1046: FL wheel speed sensor contr
exceeded ................................................................... 35C-95
DTC C1047: FR wheel speed sensor control phase time
exceeded ................................................................... 35C-101
DTC C1048: RL wheel speed sensor control phase time
exceeded ................................................................... 35C-107
DTC C1049: RR wheel speed sensor contro
ed ................................................................... 35C-114
exceed
DTC C104B: abnormality in FL wheel inlet valve systemDTC
C104F:
abnormality in RL wheel inlet valve systemDTC C1057: abnormality
in RR wheel inlet valve systemDTC C105F: ... .......... 35C-120
DTC C1073: faulty motor drive circuit ........................ 35C-127
DTC C1210: abnormality in G and yaw rate se
sensor) ....................................................................... 35C-175
DTC C1219: abnormality in steering wheel sensor signal 35C-193
DTC C121A: abnormality in steering wheel sensor
initialization ................................................................ 35C-196
DTC C121C: torque request signal rejection ............. 35C-166
DTC C121D: abnormality in brake fluid pressure sensor
circuit.......................................................................... 35C-137
DTC C121E: abnormality in brake fluid pr
nal .............................................................................. 35C-139
DTC C123A: abnormality in sensor calibration .......... 35C-191
DTC C123B: prolonged operation of ASC ................. 35C-155
DTC C123C: abnormality in G and yaw rate sensor (lateral G or yaw
rate)............................................................................ 35C-180
DTC C1242: abnormality in G and yaw rate se
sensor) ....................................................................... 35C-177
DTC C1290: CAN time-out error................................ 35C-168
DTC C1395: brake fluid filling not completed............. 35C-165
DTC C1608: EEPROM error
Keyless operation system (KOS) ............................... 42B-107
Wireless control module (WCM) ................................ 42C-46
DTC C1608: implausible diagnosis data.................... 35C-199
DTC C1900: No registration
Keyless operation system (KOS) ............................... 42B-108
Wireless control module (WCM) ................................ 42C-47
DTC C1901: vehicle speed information abnormality
Keyless operation system (KOS) ............................... 42B-110
Wireless control module (WCM) ................................ 42C-48
abnormality in FR wheel inlet valve systemDTC C1053:
heel
wheel speed sensor 35C-76
R
heel speed sensor circuit 35
for
FL wheel speed
FR wheel speed
se time
ol pha
l phase time
nsor
(longitudinal G
e sensor output sig-
essur
nsor
(longitudinal G
C-40
TSB Revision
Page 8
6
ALPHABETICAL INDEX
DTC C1910: transmitter low battery voltage abnormality 1DTC
C1920: transmitter low battery voltage abnormality 2DTC C1930:
transmitter low battery voltage abnormality 3DTC C1940: transmit-
ter low battery voltage abnormality 4 ...
Keyless operation system (KOS)............................... 42B-112
Wireless control module (WCM) ................................ 42C-51
DTC C1912: tire inflation pressure warning 1DTC C1922: tire inflation pressure warning 2DTC C1932: tire inflation pressure warning
3DTC C1942: tire inflation pressure warning 4
Keyless operation system (KOS)............................... 42B-120
Wireless control module (WCM) ................................ 42C-60
DTC C1913: acceleration sensor abnor
eration sensor abnormality 2DTC C1933: acceleration sensor
abnormality 3DTC C1943: acceleration sensor abnormality 4DTC
C1914: pressure sensor abnormality 1 ...
Keyless operation system (KOS)............................... 42B-118
Wireless control module (WCM) ................................ 42C-58
DTC C1915: transmitter off mode 1DTC C1925: transmitter off
mode 2DT
off mode 4
Keyless operation system (KOS)............................... 42B-123
Wireless control module (WCM) ................................ 42C-63
DTC C2000: abnormality in wheel fluid pressure sensor
circuit ......................................................................... 35C-142
DTC C2001: abnormality in wheel fluid pressure sensor output sig-
nal.............................................................................. 35C-143
DTC C2002: abnormality in valve calibration............. 35C-206
DTC C2101: abnormality in battery voltage (high voltage) 35C-159
DTC C2104: faulty valve pow
DTC C2111: brake fluid pressure sensor power supply
input)DTC C2112: brake fluid pressure sensor power supply circuit
(high input)................................................................. 35C-185
DTC C2114: abnormality in G and yaw rate sensor operation voltage (low voltage)DTC C2115: abnormality in G and yaw rate sensor
operation voltage (high voltage) ................................ 35C-187
DTC C2116: abnormality in power supply voltage in pump
motor.......................................................................... 35C-132
DTC C2200: abnormality in ASC-ECU ...................... 35C-158
DTC C2203: vin not recorded .................................... 35C-171
DTC C2204: internal abnormality in G and yaw rate
sensor ........................................................................ 35C-183
DTC C2205: internal malfunction of steering wheel
sensor ........................................................................ 35C-197
DTC C2206: re-execution of variant coding............... 35C-173
DTC U0001: bus-off................................................... 35C-208
DTC U0019: bus off (CAN-B)
Keyless operation system (KOS)............................... 42B-124
Wireless control module (WCM) ................................ 42C-64
DTC U0100: engine time-out errorDTC U0101: TC-SST time-out
err
ETACS time-out errorDTC U0136: AWC time-out error 35C-209
DTC U0125: G and yaw rate sensor message time-out error/mes-
sage error .................................................................. 35C-212
DTC U0141: ETACS-ECU CAN timeout
Keyless operation system (KOS)............................... 42B-126
Wireless control module (WCM) ................................ 42C-66
DTC U0151: SRS-ECU CAN timeout
Keyless operation system (KOS)............................... 42B-128
Wireless control module (WCM) ................................ 42C-68
DTC U0154: occupant classification-ECU CAN timeout
Keyless operation system (KOS)............................... 42B-130
Wireless control module (WCM) ................................ 42C-70
DTC U0155: combination meter CAN timeout
Keyless operation system (KOS)............................... 42B-132
Wireless control module (WCM) ................................ 42C-72
DTC U0164: A/C-ECU CAN timeout
C
C1935: transmitter off mode 3DTC C1945: transmitter
er supply circuit
TC U0126: steering wheel sensor time-out errorDTC U0141:
orD
mality 1DTC
C1923: accel-
........... 35C-122
circuit (low
Keyless operation system (KOS) ............................... 42B-134
Wireless control module (WCM) ................................ 42C-74
DTC U0184: audio CAN timeout
Keyless operation system (KOS) ............................... 42B-136
Wireless control module (WCM) ................................ 42C-76
DTC U0195: satellite radio tuner CAN timeout
Keyless operation system (KOS) ............................... 42B-138
Wireless control module (WCM) ................................ 42C-78
DTC U0197: hands free module CAN timeout
Keyless operation system (KOS) ............................... 42B-140
Wireless control module (WCM) ................................ 42C-80
DTC U0245: audio visual navigation unit CAN timeout
Keyless operation system (KOS) ............................... 42B-142
Wireless control module (WCM) ................................ 42C-82
DTC U0251: AWC time-out error (local CAN)DTC U0440: AWC
communication
abnormality (local CAN) ............................................. 35C-219
DTC U0401: engine malfunction detected ................. 35C-215
DTC U0428: communication error in steering wheel
sensor ........................................................................ 35C-217
DTC U1003: G and yaw rate sensor bus-off.............. 35C-223
DTC U1412: implausible vehicle speed signal received
Keyless operation system (KOS) ............................... 42B-144
Wireless control module (WCM) ................................ 42C-84
DTC U1415: coding not completed/data fail
Keyless operation system (KOS) ............................... 42B-146
Wireless control module (WCM) ................................ 42C-86
DTC U1415: variant coding not completed ................ 35C-226
DTC U1417: implausible coding data ........................ 42C-87
DTC U1417: variant coding value invalid (includes faulty
installation)................................................................. 35C-228
Id codes registration judgment table
Keyless operation system (KOS) ............................... 42B-11
Wireless control module (WCM) ................................ 42C-9
Introduction to ASC diagnosis ....................................... 35C-6
Precautions for diagnosis .............................................. 35C-7
Standard flow of diagnostic t roubles hooting
Keyless operation system (KOS) ............................... 42B-9
Wireless control module (WCM) ................................ 42C-6
Symptom procedures
Inspection procedure 1: scan tool cannot
ECU. .......................................................................... 42B-152
Inspection procedure 1: scan tool cannot communicate
with WCM.................................................................. 42C-92
Inspection procedure 1: the scan tool cannot communicate with the
ABS/ASC system....................................................... 35C-233
Inspection procedure 10: driver
does not work............................................................. 42B-189
Inspection procedure 10: skid control/TCL does not
operate....................................................................... 35C-256
Inspection procedure 11: ASC-ECU
system........................................................................ 35C-258
Inspection procedure 11: front passenger's door lock switch does
not work. .................................................................... 42B-193
Inspection procedure 12: ABS/skid control/TCL operates too fre-
quently........................................................................ 35C-267
Inspection procedure 12: front passenger's door unlock
not work. .................................................................... 42B-196
Inspection procedure 13: steering wheel sensor
system........................................................................ 35C-271
Inspection procedure 13: trunk lid ope
work. .......................................................................... 42B-200
Inspection procedure 14: keyless entry
work. ......................................................................... 42B-204
e
rror in AWC (local CAN)DTC U0435: AWC signal
c
ommunicate with KOS-
unlock sensor
's door
power
supply circuit
sensor does
power supply circuit
ner switch d
system does not
oes not
TSB Revision
Page 9
ALPHABETICAL INDEX
7
Inspection procedure 15: KOS timer lock function does not
work. ......................................................................... 42B-210
Inspection procedure 16: keyless entry haza
function, the dome light answerback function or the horn answer-
back function does not work normally........................ 42B-212
Inspection procedure 17: the trunk is not opened
operation key "TRUNK" button is operated. .............. 42B-215
Inspection procedure 18: outer tone alarm does not sound.42B-220
Inspection procedure 19: power door locks with selective
does not work. ........................................................... 42B-224
Inspection procedure 2: the ignition key cannot
scan tool. ................................................................... 42C-93
Inspection procedure 2: the keyless oper
tered using scan tool.................................................. 42B-154
Inspection procedure 2: with the parking brake released,
warning light remains illuminated (ABS warning light is
turned off). ................................................................. 35C-234
Inspection procedure 3: abnormality in KOS-
ground circuits ........................................................... 42B-164
Inspection procedure 3: engine does not start (cranking but no initial
combustion). .............................................................. 42C-95
Inspection procedure 3: the ABS warning light does not illuminate
when ignition sw
stopped)..................................................................... 35C-239
Inspection procedure 4: abnormality in
ground circuits. .......................................................... 42C-97
Inspection procedure 4: keyless operation wa
disappear. .................................................................. 42B-167
Inspection procedure 4: the brake warning light
when ignition switch is turned to the on position (engine
stopped)..................................................................... 35C-242
Inspection procedure 5: IG knob will not turn
not recognized). ......................................................... 42B-169
Inspection procedure 5: keyless entr
work. .......................................................................... 42C-100
Inspection procedure 5: the ABS warning light remains illuminated
even after the engine is started. ................................ 35C-244
Inspection procedure 6: keyless entry hazar
tion, the dome light answerback function or the horn answerback
function does not work normally. ............................... 42C-107
Inspection procedure 6: the ASC warning display stays on even
after the engine is started. ......................................... 35C-246
Inspection procedure 6: the engine will not start with
operates normally). .................................................... 42B-178
Inspection procedure 7: engine does not start
(cranking but no initial combustion). .......................... 42B-180
Inspection procedure 7: the ASC off display remains illuminated
after the engine is started. ......................................... 35C-248
Inspection procedure 7: the timer lock function
the doors have been unlocked by the keyless entry
system. ...................................................................... 42C-109
Inspection procedure 8: after the ASC off switch is pressed to turn
"off," the stability control/T
Inspection procedure 8: No door will be locked or
ating a lock switch on any door, or by touching the unlock
sensor. ....................................................................... 42B-182
Inspection procedure 8: the trunk is not opened when the keyless
entry transmitter "TRUNK" button is operated. .......... 42C-110
Inspection procedure 9: abnormality in brake operation 35C-255
Inspection procedure 9: driver's door lock switch does not
work. .......................................................................... 42B-186
Inspection procedure 9: power door locks w
does not work. ........................................................... 42C-115
Te rm i na l v ol t ag e r ef e re n ce c h ar t .. ... . .. .. . .. . .. ... ... ... . .. .. . .. . . 42B-225
Trouble symptom chart
Active stability control system (ASC) ......................... 35C-232
Keyless operation system (KOS)............................... 42B-152
Wireless control module (WCM) ................................ 42C-91
Warning and warning indicator list................................. 42B-15
Warnings/alarms. ............. .............................................. 42C-12
itch is turned to the on position (engine
y
system does not
C
L cannot be cancelled.... 35C-252
rd light answerback
when the keyless
unlocking
be registered using
ation key cannot b
ECU
power supply and
WCM
power supply and
rning display does not
does not illuminate
(keyless operation is
d light answerback func-
with emergency key
does not work after
unlocked by oper-
th selective unlocking
i
e regis-
the brake
KOS (IG knob
Diagnosis <s-AWC(super all wheel control)>
CD .... 22A-116
AWD-ECU terminal voltage reference chart for
Data list reference table................................................. 22A-107
Diagnostic function ........................................................ 22A-9
Diagnostic trouble code chart ........................................ 22A-12
Diagnostic trouble code procedures
DTC C1000: stoplight switch system ......................... 22A-15
DTC C100A <FL>, C1015 <FR>, C1020 <RL>, C102B <RR>: wheel
speed sensor system (faulty circuit)........................... 22A-19
DTC C1011 <FL>, C101C <FR>, C1027 <RL>, C1032 <RR>: wheel
speed sensor system (faulty signal)........................... 22A-20
DTC C1014 <FL>, C101F <FR>, C102A <RL>, C1035 <RR>: wheel
speed sensor system (characte
DTC C1078: tire turning malfunction.......................... 22A-22
DTC C1219: steering wheel sensor system (faulty signal) 22A-24
DTC C121A: steering wheel sensor syst
mality) ........................................................................ 22A-26
DTC C123C: G and yaw rate sensor (faulty signal) ... 22A-27
DTC C1242: G and yaw rate sensor (longitudinal G output data
error) .......................................................................... 22A-29
DTC C1610: AWC actuator power supply electronic relay malfunc-
tion ............................................................................. 22A-31
DTC C1611: AWC pressure sensor system (low voltage) 22A-32
DTC C1612: AWC pressure sensor system (high voltage) 22A-34
DTC C1613: AWC mode select switch system
with steering audio remote control switch > ............... 22A-36
DTC C1613: AWC mode select switch system (
without steering audio remote control switch >.......... 22A-39
DTC C1614: parking brake switch system (clogging on) 22A-42
DTC C1615: brake control prohibition request........... 22A-44
DTC C1616: cranking signal system (on sticking)
DT
C C1617: AWC CAN main data system (data not
received) .................................................................... 22A-48
DTC C1618: AWC CAN local data system (data not
received) .................................................................... 22A-50
DTC C161C: ACD proportioning valve system
(malfunction) .............................................................. 22A-52
DTC C161D: electric pump relay circuit system
(malfunction) .............................................................. 22A-55
DTC C161E: electric pump relay circuit system (stuck) 22A-58
DTC C1622: ACD controlled system (malfunction).... 22A-60
DTC C1623: brake controlled system (malfunction) .. 22A-61
DTC C1624: AWC-ECU system (internal malfunction) 22A-62
DTC C1625: AWC pressure sensor system (abnormal power supply
voltage) ...................................................................... 22A-63
DTC C2100: battery voltage malfunction (low voltage) 22A-66
DTC C2101: battery voltage malfunction (high voltage) 22A-70
DTC C2114: G and yaw rate sensor power supply
(low voltage)............................................................... 22A-72
DTC C2115: G and yaw rate sensor power supply
(high voltage) ............................................................. 22A-75
DTC C2203: vin not recorded .................................... 22A-77
DTC C2204: G and yaw rate sensor system (internal
malfunction) ............................................................... 22A-78
DTC C2205: steering wheel sensor system (internal
malfunction) ............................................................... 22A-79
DTC U0001: bus off ................................................... 22A-80
DTC U0100: engine time-out error............................. 22A-81
DTC U0101: TC-SST time-out error .......................... 22A-82
DTC U0121: ASC time-out error ................................ 22A-83
DTC U0126: steering wheel sen
DTC U0141: ETACS time-out error............................ 22A-85
DTC U0401: engine data error................................... 22A-86
DTC U0428: steering wheel sensor data error .......... 22A-87
DTC U0431: ETACS data error.................................. 22A-88
ristics abnor
s
or time-out error .... 22A-84
A
mality) ... 22A-21
em (neutr
al learning abnor-
(
clogging) <vehicles
clogging) <vehicles
..... 22A-46
TSB Revision
Page 10
8
ALPHABETICAL INDEX
DTC U1003: bas-off (local CAN) ............................... 22A-90
DTC U1415: coding incomplete/fail ........................... 22A-91
DTC U1417: coding data malfunction........................ 22A-93
DTC U1425: TC-SST data error ................................ 22A-94
DTC U1426: ASC data error...................................... 22A-95
DTC U1427: wheel speed sensor data error ............. 22A-96
DTC U1428: G and yaw rate sensor data error ......... 22A-97
Introduction
Manual transaxle ....................................................... 22A-8
)... 22C-398
Twin c lut ch-sportron ic shift transmission (T
Special fun ction r eference ta ble ....... .................. ....... .... 22A-114
Symptom chart .............................................................. 22A-14
Symptom procedures
Inspection procedure 1: communication between the scan tool and
AWC-ECU cannot be established .............................. 22A-99
Inspection procedure 2: mode does not change even when the
C switch is pressed <vehicles with steering wheel audio remote
W
A
control switch>........................................................... 22A-99
Inspection procedure 2: mode does not change even when the
W
C switch is pressed <vehicles without steering wheel audio
A
remote control switch>............................................... 22A-102
Inspection procedure 3: AWC-ECU power supply circuit
malfunction
Troubleshooting strategy ............................................... 22A-8
Diagnosis <shift lever>
Data list reference table................................................. 22C-391
Diagnosis function ......................................................... 22C-367
Diagnostic trouble code chart ........................................ 22C-370
Diagnostic trouble code procedures
DTC P0563: power supply system ............................ 22C-370
DTC P198D: EEPROM system ................................. 22C-371
DTC P198E, P198F: lever position sensor system.... 22C-372
DTC U0001: bus-off................................................... 22C-373
DTC U0100: engine time-out error ............................ 22C-373
DTC U0101: TC-SST time-out error .......................... 22C-374
DTC U0121: ASC time-out error................................ 22C-375
DTC U0141: ETACS time-out error ........................... 22C-375
Introduction.................................................................... 22C-367
Shift lever -ECU terminalvoltage reference chart .......... 22C-394
Special fun ction ( actuator test reference table) ... .......... 22C-393
Symptom chart .............................................................. 22C-370
Symptom procedures
Inspection procedure 1: the scan tool cannot
shift lever-ECU........................................................... 22C-376
Inspection procedure 2: shift indicator light does not
illuminate.................................................................... 22C-377
Inspection procedure 3: back-up light does not
illuminate.................................................................... 22C-379
Inspection procedure 4: the driving mode cannot be
changed. .................................................................... 22C-383
Inspection procedure 5: speed change with the paddle shift is
impossible.................................................................. 22C-384
Inspection procedure 6: shift lever
mality ......................................................................... 22C-387
Troubleshooting strategy ............................................... 22C-367
Diagnosis <TC-SST>
Data list reference table................................................. 22C-359
Diagnosis function ......................................................... 22C-10
Diagnostic trouble code chart ........................................ 22C-15
Diagnostic trouble code procedures
DTC P0630: vin not recorded .................................... 22C-21
DTC P0701: EEPROM system (malfunction) ............ 22C-22
................................................................ 22A-104
C-SST
nicate with the
commu
ECU power supply circuit abnor-
-
DTC P0702: internal control module, monitoring processor system
(malfunction) .............................................................. 22C-22
DTC P0712: TC-SST-ECU temperature sensor system (output low
range out)................................................................... 22C-23
DTC P0713: TC-SST-ECU temperature sensor system (output high
range out)................................................................... 22C-25
DTC P0715: input shaft 1 (odd number gear axle) speed sensor
system (output high range out) .................................. 22C-27
DTC P0716: input shaft 1 (odd number gear axle) speed sensor
system (poor performance)........................................ 22C-29
DTC P0717: input shaft 1 (odd number gear axle) speed sensor
system (output current low range out) ....................... 22C-34
DTC P0725: engine speed signal abnormality........... 22C-36
DTC P0746: line pressure solenoid system (drive current
range out)................................................................... 22C-37
DTC P0753: shift select solenoid 1 system (open circuit) 22C-40
DTC P0758: shift select solenoid 2 system (open circuit) 22C-42
em
DTC P0776: clutch cooling flow solenoid syst
range out)................................................................... 22C-44
DTC P0777: clutch cooling flow solenoid system (stuck) 22C-46
DTC P0841: clutch 1 pressure sensor system (poor
performance).............................................................. 22C-49
DTC P0842: clutch 1 pressure sensor system (output low
range out)................................................................... 22C-51
DTC P0843: clutch 1 pressure sensor system (output high range
out)............................................................................. 22C-53
DTC P0846: clutch 2 pressure sensor system (poor
performance).............................................................. 22C-55
DTC P0847: clutch 2 pressure sensor system (output low
range out)................................................................... 22C-57
DTC P0848: clutch 2 pressure sensor system (output high range
out)............................................................................. 22C-59
DTC P0960: line pressure solenoid system (open circuit) 22C-61
DTC P0961: line pressure solenoid system (overcurrent) 22C-63
DTC P0962: line pressure solenoid system (short to
ground)....................................................................... 22C-65
DTC P0963: line pressure solenoid system (short to power
supply) ....................................................................... 22C-67
DTC P0964: clutch cooling flow solenoid system
(open circuit) .............................................................. 22C-69
DTC P0965: clutch cooling flow solenoid system
(overcurrent) .............................................................. 22C-71
DTC P0966: clutch cooling flow solenoid system (short to
ground)....................................................................... 22C-73
DTC P0967: clutch cooling flow solenoid system (short to power
supply) ....................................................................... 22C-75
DTC P0968: shift/cooling switching solenoid system
(open circuit) .............................................................. 22C-77
DTC P0970: shift/cooling switching solenoid system (short to
ground)....................................................................... 22C-79
DTC P0971: shift/cooling switching solenoid system (short to power
supply) ....................................................................... 22C-81
DTC P0973: shift select solenoid 1 system (short to
ground)....................................................................... 22C-83
DTC P0974: shift select solenoid 1 system (short to
power supply)............................................................. 22C-85
DTC P0976: shift select solenoid 2 system (short to
ground)....................................................................... 22C-87
DTC P0977: shift select solenoid 2 system (short to
power supply)............................................................. 22C-89
DTC P1637: EEPROM system (DTC storing malfunction) 22C-90
DTC P1676: coding incomplete ................................. 22C-92
DTC P1802: shift lever system (LIN communication
malfunction) ............................................................... 22C-94
DTC P1803: shift lever system (CAN, LIN time-out error) 22C-96
DTC P1804: shift fork position sensor 1 and 2 system (power supply
voltage low range out)................................................ 22C-98
DTC P1805: shift fork position sensor 1 and 2 system (power supply
voltage high range out) .............................................. 22C-100
(drive current
TSB Revision
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ALPHABETICAL INDEX
9
DTC P1806: shift fork position sensor 3 and 4 system (power supply
voltage low range out) ............................................... 22C-102
DTC P1807: shift fork position sensor 3 and 4 system (power supply
voltage high range out) .............................................. 22C-104
DTC P1808: TC-SST-ECU temperature, fluid temperature sensor
system (correlation error)........................................... 22C-106
DTC P180C: clutch pressure cut spool sticking......... 22C-108
DTC P181B: clutch 1 (pressure low range out) ......... 22C-109
DTC P181C: clutch 1 (pressure high range out)........ 22C-111
DTC P181E: clutch 2 (pressure low range out) ......... 22C-120
DTC P181F: clutch 2 (pressure high range out) ........ 22C-123
DTC P1820: shift fork position sensor 1 system (voltage low range
out)............................................................................. 22C-133
DTC P1821: shift fork position sensor 1 system (voltage high range
out)............................................................................. 22C-135
DTC P1822: shift fork position sensor 1 system (output
range out) .................................................................. 22C-137
DTC P1823: shift fork position sensor 1 system (neutral) 22C-140
DTC P1824: shift fork position sensor 1 system (poor
performance) ............................................................. 22C-143
DTC P1825: shift fork position sensor 2 system (voltage low range
out)............................................................................. 22C-147
DTC P1826: shift fork position sensor 2 system (voltage high range
out)............................................................................. 22C-149
DTC P1827: shift fork position sensor 2 system (output
range out) .................................................................. 22C-152
DTC P1828: shift fork position sensor 2 system (neutral) 22C-155
DTC P1829: shift fork position sensor 2 system (poor
performance) ............................................................. 22C-158
(volt
DTC P182A: shift fork position sensor 3 system
out)............................................................................. 22C-162
DTC P182B: shift fork position sensor 3 system (voltage high range
out)............................................................................. 22C-164
DTC P182C: shift fork position sensor 3 system (output
range out) .................................................................. 22C-166
DTC P182D: shift fork position sensor 3 system (neutral) 22C-169
DTC P182E: shift fork position sensor 3 system (
performance)
DTC P1831: shift fork position sensor 4 system (voltage low range
out)............................................................................. 22C-174
DTC P1832: shift fork position sensor 4 system (voltage high range
out)............................................................................. 22C-177
DTC P1833: shift fork position sensor 4 system (output
range out) .................................................................. 22C-179
DTC P1834: shift fork position sensor 4 system (neutral) 22C-182
DTC P1835: shift fork position sensor 4 system (poor
performance) ............................................................. 22C-185
DTC P1836: shift fork 1 malfunction .......................... 22C-188
DTC P183D: shift fork 2 malfunction ......................... 22C-196
DTC P1844: shift fork 3 malfunction .......................... 22C-204
DTC P184B: shift fork 4 malfunction.......................... 22C-211
DTC P1852: shift fork 1 or 2 opposite direction
movement .................................................................. 22C-219
DTC P1855: shift fork 3 or 4 opposite direction
movement .................................................................. 22C-222
DTC P1857: odd number gear axle interlock............. 22C-224
DTC P1858: even number gear axle interlock........... 22C-227
DTC P185D: clutch open not possible....................... 22C-229
DTC P1862: high side 1 system (overcurrent)........... 22C-230
DTC P1863: high side 1 system (open circuit) .......... 22C-232
DTC P1864: high side 1 system (short to power supply) 22C-234
DTC P1866: high side 2 system (overcurrent)........... 22C-236
DTC P1867: high side 2 system (open circuit) .......... 22C-238
DTC P1868: high side 2 system (short to power supply) 22C-240
DTC P186A: high side 3 system (overcurrent) .......... 22C-242
DTC P186B: high side 3 system (open circuit) .......... 22C-244
............................................................. 22C-172
age low range
poor
DTC P186C: high side 3 system (short to power supply) 22C-246
DTC P186D: high side 1 system (voltage low range out) 22C-248
DTC P186E: high side 2 system (voltage low range out) 22C-250
DTC P186F: high side 3 system (voltage low range out) 22C-252
DTC P1870: engine torque signal abnormality .......... 22C-254
DTC P1871: aps system (signal abnormality)............ 22C-257
DTC P1872: between shift lever and TC-SST system (q-a function
abnormality) ............................................................... 22C-260
DTC P1873: clutch 1 system (pressure abnormality) 22C-261
DTC P1874: clutch 2 system (pressure abnormality) 22C-262
DTC P1875: damper speed sensor system (poor
performance).............................................................. 22C-263
DTC P1876: gear block 1st........................................ 22C-266
DTC P1877: gear block 2nd....................................... 22C-268
DTC P1878: gear block 3rd ....................................... 22C-270
DTC P1879: gear block 4th........................................ 22C-272
DTC P187A: gear block 5th ....................................... 22C-274
DTC P187B: gear block 6th ....................................... 22C-276
DTC P187C: gear block reverse ................................ 22C-278
DTC P1880: eol mode active ..................................... 22C-279
DTC P1881: twin clutch sst control mode switch system (malfunc-
tion) ............................................................................ 22C-280
DTC P1885: shift fork 1 jump out............................... 22C-281
DTC P1886: shift fork 2 jump out............................... 22C-282
DTC P1887: shift fork 3 jump out............................... 22C-283
DTC P1888: shift fork 4 jump out............................... 22C-284
DTC P1890 teach-in not completed........................... 22C-285
DTC P2718: clutch/shift pressure solenoid 1 system
(open circuit) .............................................................. 22C-286
DTC P2719: clutch/shift pressure solenoid 1 system
(overcurrent) .............................................................. 22C-288
DTC P2720: clutch/shift pressure solenoid 1 system (short to
ground)....................................................................... 22C-290
DTC P2721: clutch/shift pressure solenoid 1 system (short to power
supply) ....................................................................... 22C-292
DTC P2727: clutch/shift pressure solenoid 2 system
(open circuit) .............................................................. 22C-294
DTC P2728: clutch/shift pressure solenoid 2 system
(overcurrent) .............................................................. 22C-296
DTC P2729: clutch/shift pressure solenoid 2 system (short to
ground)....................................................................... 22C-298
DTC P2730: clutch/shift pressure solenoid 2 system (short to power
supply) ....................................................................... 22C-300
DTC P2733: clutch/shift switching solenoid 1, spool stuck 22C-302
DTC P2736: clutch/shift switching solenoid 1 system
(open circuit) .............................................................. 22C-305
system (short to
DTC P2738: clutch/shift switching solenoid
ground)....................................................................... 22C-306
DTC P2739: clutch/shift switching solenoid 1 system (short to power
supply) ....................................................................... 22C-308
DTC P2742: fluid temperature sensor system (output low
range out)................................................................... 22C-310
DTC P2743: fluid temperature sensor system (output high range
out)............................................................................. 22C-312
DTC P2766: input shaft 2 (even number gear
system (poor performance)........................................ 22C-314
DTC P2809: clutch/shift switching solenoid 2, spool stuck 22C-319
DTC P2812: clutch/shift switching solenoid 2 system
(open circuit) .............................................................. 22C-321
DTC P2814: clutch/shift switching solenoid
ground)....................................................................... 22C-323
DTC P2815: clutch/shift switching solenoid 2 system (short to power
supply) ....................................................................... 22C-325
DTC U0001: bus-off ................................................... 22C-327
DTC U0100: engine time-out error............................. 22C-329
DTC U0103: shift lever time-out error ........................ 22C-331
1
speed sensor
axle)
system (short to
2
TSB Revision
Page 12
10
ALPHABETICAL INDEX
DTC U0121: ASC time-out error................................ 22C-332
DTC U0136: AWC time-out error............................... 22C-333
DTC U0141: ETACS time-out error ........................... 22C-334
Introduction.................................................................... 22C-6
Special fun ction .................... ......................... ....... ......... 22C-365
Symptom chart .............................................................. 22C-20
Symptom procedures
Inspection procedure 1: the scan tool cannot communicate with TC-
SST-ECU. .................................................................. 22C-335
when
Inspection procedure 10: the shock is large
stopped and the brake pedal is released with the D-range/R-range/
manual mode. ............................................................ 22C-352
Inspection procedure 11: poor acceleration............... 22C-352
Inspection procedure 12: the gear shifting does not occur. (the tran-
saxle does not upshift or downshift.) ......................... 22C-353
Inspection procedure 13: the shift shock is large....... 22C-354
Inspection procedure 14: delay occurs when the lever is shifted from
"N" to "D" or "N" to "R". .............................................. 22C-355
Inspection procedure 15: the engine stops when the lever is shifted
from "N" to "D" or "N" to "R"....................................... 22C-356
Inspection procedure 16: the vehicle moves with the n-range on the
level ground. .............................................................. 22C-357
Inspection procedure 17: judder/noise/vibration ........ 22C-357
Inspection procedure 2: the driving mode cannot be
changed. .................................................................... 22C-336
Inspection procedure 3: speed change with the paddle shift is
impossible.................................................................. 22C-338
power
Inspection procedure 4: TC-SST-ECU
tion............................................................................. 22C-341
Inspection procedure 5: the shift lever does not operate. 22C-345
Inspection procedure 6: gears cannot be changed with the manual
mode.......................................................................... 22C-348
Inspection procedure 7: the vehicle move
P-range.
Inspection procedure 8: slipping occurs w
manual mode, and engine racing occurs during gear shifting/
driving. ....................................................................... 22C-350
Inspection procedure 9: the vehicle
r-range/manual mode. ............................................... 22C-351
TC-SST teach-in............................................................ 22C-7
TC-SST-ECU terminal voltage
Troubleshooting strategy ............................................... 22C-6
Differential carrier assembly
Disassembly and reassembly........................................ 27-53
Removal and installation ............................................... 27-51
Dome light
Diagnosis
Diagnostic function .................................................... 54A-262
Standard flow of diagnostic troubleshooting .............. 54A-262
Dome light removal and installation............................... 54A-279
General information ....................................................... 54A-260
Luggage compartment light removal and installation .... 54A-281
On-vehicle service
Customization function .............................................. 54A-279
Special too ls ......... ....... ....... ......................... .................. 54A-261
Symptom procedures
Inspection procedure 1: the front dome light doe
mally........................................................................... 54A-264
Inspection procedure 2: the rear dome light does not
mally........................................................................... 54A-269
Inspection procedure 3: the luggage compartment ligh
minate normally.......................................................... 54A-273
Inspection procedure 4: the interior light auto-cut function
operate correctly........................................................ 54A-276
Trouble symptom chart .................................................. 54A-264
..................................................................... 22C-349
does not creep with the d-range/
reference
supply circuit malfunc-
s with the
i
th the D-range/R-range/
chart ............. 22C-366
the vehicle is
s not
illuminate nor-
illuminate nor-
t does not illu-
does not
Dome light, luggage compartment light and ignition key hole illumination
light
Supplemental restraint system (SRS)............................ 90-126
Circuit diagrams............................................................. 90-126
Door................................................................................... 80A-18
Door
Central door locking system diagnosis
Trouble symptom chart .................. ............................ 42A-30
Troubleshooting str ategy ................. ................... ....... 42A-30
Check at ECU terminal .................................................. 42A-110
Diagnostic trouble code procedur
Code No. L0730: p/w (dr) sw pulse 1 disconnection.. 42A-65
Code No. L0732: p/w (dr) sw pulse 2 disconnection.. 42A-67
Code No. L0734: p/w (dr) above window position ..... 42A-69
Code No. L0736: p/w (dr) sensor fail (ground)........... 42A-70
Code No. L0740: p/w (dr) 3 times jam - protection .... 42A-72
Code No. L0746: p/w (dr) parameter read failcode No. L0750: p/w
(dr) position read fail .................................................. 42A-73
Door assembly
Inspection................................................................... 42A-130
Removal and installation............................................ 42A-128
Door diagnosis
Glass and door diagnostic troubleshooting strategy .. 42A-111
Introduction to glass and door diagnosis ................... 42A-111
Symptom chart........................................................... 42A-111
Door glass and regulator
Inspection................................................................... 42A-134
Removal and installation............................................ 42A-131
Door handle and latch
Inspection................................................................... 42A-140
Removal and installation............................................ 42A-136
General information ....................................................... 42A-27
How to locate wind noise ............................................... 42A-114
On-vehicle service
Central door locking system check ............................ 42A-124
Check of key lock prevention function ....................... 42A-124
Customization function............................................... 42A-127
Door fit adjustment..................................................... 42A-118
Door inside handle check........................................... 42A-125
Door outside handle play check................................. 42A-125
Door window glass adjustment
Glass sliding mechanism check and adjustment ....... 42A-121
Ignition "lock (off)" position-linked door unloc
T, T C -S ST > . .. . .. .. . .. . .. ... . .. .. . .. . .. ... ... ... . .. .. . .. . .. ... ... ... . .. .. . . 42A-124
Learning procedures of the power window fully
<driver’s side only> .................................................... 42A-123
Power window check ................................................. 42A-121
Power window operating current check ..................... 42A-122
Power window safety mechanism check
<driver’s side only> .................................................... 42A-122
Power window timer function check........................... 42A-122
Shift "P" interlink door unlock fu
Power window diagnosis
Diagnostic trouble code chart .................................... 42A-64
Trouble symptom chart .................. ............................ 42A-64
Troubleshooting str ategy ................. ................... ....... 42A-64
Protector film <vehicles without side air dam>
Removal and installation............................................ 42A-148
Special too ls..... ....... ....... .................. ....... ....................... 42A-116
Specificati on(s)
Component identifications.......................................... 42A-27
es <pow
er window>
............................ 42A-120
......
king function check <M/
closed position
nction check <T
C-SST> 42A-124
TSB Revision
Page 13
ALPHABETICAL INDEX
11
Lubricant .................................................................... 42A-27
Sealant....................................................................... 42A-27
Service specifications ................................................ 42A-27
Symptom procedures
Inspection procedure 1: water leak through door window
glass .......................................................................... 42A-111
Inspection procedure 2: door window glass malfunction 42A-112
Inspection procedure 3: water leak through door edge 42A-112
Inspection procedure 4: water leak from door center 42A-112
Inspection procedure 5: door hard to open................ 42A-113
Inspection procedure 6: door does not open or close
completely.................................................................. 42A-113
Inspection procedure 7: uneven gap between body .. 42A-113
Inspection procedure 8: wind noise around door....... 42A-114
Symptom procedures <central d
Inspection
at all. .......................................................................... 42A-31
Inspection procedure 2: central door locking syst
ate even when door lock switch of power window main switch oper-
ated (door lock switch of front power window sub switch operate
normally). ................................................................... 42A-38
Inspection procedure 3: central door locking syst
ate even when door lock switch of front power window sub switch
operated (door lock switch of power window main switch operate
normally). ................................................................... 42A-43
Inspection procedure 4: a door cannot be locked
central door locking system. ...................................... 42A-47
Inspection procedure 5: selector "P" position-linked
function does not operate normally. <TC-SST>......... 42A-58
Inspection procedure 6: ignition "lock (off)
unlock function does not operate. <M/T, TC-SST>
Symptom procedures <power window>
Inspection procedure 1: power windows do not work at all. 42A-74
Inspection procedure 2: driver's power window does not work by
means of the power window main switch. ................. 42A-82
Inspection procedure 3: relevant power window(s)
means of the front and rear passenger's power window sub
switches. .................................................................... 42A-85
Inspection procedure 4: front and/or r
dow(s) do not work by means of the power window main
switch......................................................................... 42A-101
Inspection procedure 5: the power window timer function does not
work normally............................................................. 42A-105
Inspection procedure 6: power window anti-trap function does not
work normally. <driver’s side only>............................ 42A-107
Inspection procedure 7: the window glass lower
it is rising.................................................................... 42A-109
Window glass runchannel and door opening weatherstrip
Removal and installation............................................ 42A-142
Door ajar warning tone alarm
Supplemental restraint system (SRS) ........................... 90-366
Circuit diagrams............................................................. 90-366
Door mirror
Door mirror
Inspection .................................................................. 51-99
Removal and installation............................................ 51-97
General information ....................................................... 51-87
Heated door mirror diagnosis
Symptom chart........................................................... 51-87
Troubleshooting str ategy ........... ................... ............. 51-87
Symptom procedures
Inspection procedure 1: none of the heated door mirrors
operate....................................................................... 51-88
Inspection procedure 2: either of the heated door mirror does not
operate....................................................................... 51-91
procedure 1: central door locking system
oor locking system>
" position-linked door
ear p
assenger's power win-
s
does not work
em
does not oper-
em
does not oper-
o
r unlocked by the
door unlock
.... 42A-61
do
es not work by
automatically while
Door sash tape
Removal and installation................................................ 51-9
Special too l ................. ....... ....... ......................... ....... ..... 51-9
Door trim
Removal and installation................................................ 52A-16
Driver's air bag module and clock spring
Inspection
Supplemental restraint system (SRS)........................ 52B-419
Circuit diagrams ......................................................... 52B-419
Removal and installation
Supplemental restraint system (SRS)........................ 52B-413
Circuit diagrams ......................................................... 52B-413
Driveshaft assembly
Disassembly and assembly
Front axle ................................................................... 26-20
Rear axle.................................................................... 27-47
Ebj boot replacement
Front axle ................................................................... 26-22
Rear axle.................................................................... 27-50
Removal and installation
Front axle ................................................................... 26-15
Rear axle.................................................................... 27-42
Ducts
Duct removal and installation......................................... 55-189
E
Emission control MFI - T/C
Catalytic converter
Removal and installation............................................ 17-80
Diagnosis ....................................................................... 17-68
ank
Evaporative emission canister and fuel t
Inspection................................................................... 17-79
Removal and installation............................................ 17-78
Evaporative emission control system ............................ 17-73
Evaporative emission control system
Barometric pressure sensor check ............................ 17-77
Component location ................................................... 17-75
Crankshaft position sensor check .............................. 17-77
Engine coolant temperature sensor check................. 17-77
Evaporative emission purge solenoid
General information (evaporative em
Intake air temperature sensor 1 check....................... 17-77
Mass airflow sensor check......................................... 17-77
Purge control system check (purge flow check) ........ 17-75
Throttle position sensor check ................................... 17-77
General information ....................................................... 17-68
Positive crankcase ventilation system
Component location ................................................... 17-72
Crankcase ventilation system check.......................... 17-72
General information (positive cran
Positive crankcase ventilation (pcv) valve check ....... 17-72
Service specifications
Special too l ................. ....... ....... ......................... ....... ..... 17-68
Vac uum h oses
Vac uum cir cuit diag ram. ... ..... ......... ........... ......... ........ 17-70
Vac uum hos e check....... ......... ....... ........... ......... ........
Vac uum h ose insta lla tion ........ ..... ......... ....... ..... ......... 17-71
Vac uum h ose rou ting ........ ..... ....... ....... ....... ....... ....... . 17-69
.................................................... 17-68
pressure relief valve
.............. 17-76
check
ission system).. 17-73
kcase ven
tilation system) 17-71
17-71
TSB Revision
Page 14
12
ALPHABETICAL INDEX
Engine and transaxle
Configuration diagrams ................................................. 80A-6
Splice loca tions...................... ......................... ....... ........ 80B-4
Engine assembly
Removal and installation ............................................... 11A-76
Engine compartment
Configuration diagrams ................................................. 80A-4
Splice loca tions...................... ......................... ....... ........ 80B-4
Engine control
Accelerator pedal
Removal and installation............................................ 17-8
Engine control system diagnosis
Introduction ................................................................ 17-3
Troubleshooting str ategy ........... ................... ............. 17-3
General information ....................................................... 17-3
Special too l .... ......................... ....... ....... ......................... 17-7
Symptom chart .............................................................. 17-3
Symptom procedures
pen or
Inspection procedure 1: throttle valve will not f
close .......................................................................... 17-4
Inspection procedure 2: accelerator pedal operation not smooth
(over acceleration) ..................................................... 17-5
Engine control module (ECM)
Removal and installation ............................................... 13A-888
Engine control resistor
Removal and installation ............................................... 13A-887
Engine cooling diagnosis
Introduction.................................................................... 14-3
Symptom chart .............................................................. 14-3
Symptom procedures
Inspection procedure 1: coolant leak ......................... 14-4
Inspection procedure 2: engine overheating.............. 14-5
Inspection procedure 3: radiator fan and condenser fan do not oper-
ate.............................................................................. 14-6
Troubleshooting strategy ............................................... 14-3
Engine diagnosis ............................................................... 11A-2
Engine mounting
Removal and installation ............................................... 32-4
Engine oil cooler
Removal and installation ............................................... 12-9
Engine oil pressure switch................................................. 12-7
Engine oil pressure switch
Removal and installation ............................................... 12-7
ETACS
Check with terminal voltage........................................... 54A-742
Diagnostic trouble code chart ........................................ 54A-646
Diagnostic trouble code procedures
DTC B1761: vin not recorded .................................... 54A-684
DTC B210A: +b power supply (low input)DTC B210B: +b power
supply (high input) ..................................................... 54A-685
DTC B2206: chassis number does not match ........... 54A-690
DTC B2215: ECU internal error ................................. 54A-691
DTC B222C: coding incomplete ................................ 54A-689
DTC B2353: ignition power supply (low input)D
power supply (high input)........................................... 54A-692
DTC U0001: bus off (CAN-C)DTC U0019: bus off
(CAN-B) ..................................................................... 54A-647
DTC U0100: engine control module CAN timeout ..... 54A-649
DTC U0101: TC-SST-ECU CAN timeout................... 54A-651
DTC U0103: shift lever CAN timeout ......................... 54A-653
DTC U0121: ASC-ECU CAN timeout ........................ 54A-655
ully o
TC
B2354: ignition
DTC U0126: steering wheel sensor CAN timeout...... 54A-657
DTC U0136: AWC-ECU CAN timeout........................ 54A-659
DTC U0151: SRS-ECU CAN timeout ........................ 54A-661
DTC U0154: occupant classification-ECU CAN timeout 54A-663
DTC U0155: combination meter CAN timeout ........... 54A-665
DTC U0164: A/C-ECU or heater control unit CAN
timeout ....................................................................... 54A-667
DTC U0168: WCM or KOS-ECU CAN timeout .......... 54A-669
DTC U0184: audio CAN timeout................................ 54A-671
DTC U0195: satellite radio tuner CAN timeout .......... 54A-673
DTC U0197: hands free module CAN timeout........... 54A-675
DTC U0245: CAN box unit CAN timeout ................... 54A-677
DTC U0331: ECU internal error ................................. 54A-682
DTC U1108: excess CAN-B ECU detection............... 54A-679
DTC U1120: bus line (CAN-C) low inputDTC U1121: bus line (CAN-
C) high input............................................................... 54A-681
ETACS-ECU
Removal and installation............................................ 54A-742
General information ....................................................... 54A-640
Input signal procedures
Inspection procedure 1: malfunction of the ignition switch (acc)
input/output signal...................................................... 54A-704
Inspection procedure 10: ETACS-ECU does not receive any signal
from the hazard warning light switch.......................... 54A-732
ceive any signal
Inspection procedure 11: ETACS-ECU does not
from the column switch signal.................................... 54A-734
Inspection procedure 12: ETACS-ECU does not receive any signal
from the hood switch.................................................. 54A-735
Inspection procedure 2: malfunction of the
input/output signal...................................................... 54A-706
Inspection procedure 3: ETACS-ECU does not receive
from the key reminder switch. .................................... 54A-709
Inspection procedure 4: ETACS-ECU does not receive
from the front door lock actuator. ............................... 54A-712
Inspection procedure 5: ETACS-ECU does not
from the front door switch (LH). ................................. 54A-719
Inspection procedure 6: ETACS-ECU does not receive
from the front door switch (RH).................................. 54A-721
Inspection procedure 7: ETACS-ECU does not receive
from the rear door switch (LH). .................................. 54A-724
Inspection procedure 8: ETACS-ECU does not
from the rear door switch (RH)................................... 54A-726
Inspection procedure 9: ETACS-ECU does not receive
from the trunk lid latch................................................ 54A-729
On-vehicle service
Customization function............................................... 54A-738
Service data................................................................... 54A-694
Special too l ................. ....... ....... ......................... ....... ..... 54A-642
Symptom procedures
Malfunction of ETACS-ECU power supply circuit ...... 54A-700
Trouble symptom chart .................................................. 54A-699
Trouble symptom chart for input signal.......................... 54A-703
Troubleshooting
Diagnostic function..................................................... 54A-643
Standard flow of diagnostic troubleshooting .............. 54A-643
ETACS-ECU
Supplemental restraint system (SRS)............................ 90-10
Circuit diagrams............................................................. 90-10
Exhaust manifold
Removal and installation................................................ 11B-20
Exhaust manifold and turbocharger
Inspection ...................................................................... 15-25
Removal and installation................................................ 15-18
re
ignition
receive
receive
switch (IG1)
any signal
any signal
any signal
any signal
any signal
any signal
any signal
TSB Revision
Page 15
ALPHABETICAL INDEX
13
Exhaust pipe and main muffler
Removal and installation ............................................... 15-26
Explanation about the sCAN tool (M.U.T.-III) CAN bus
diagnostics ........................................................................ 54C-9
Exterior transmitter antenna assembly, interior transmitter antenna
s
sembly, receiver antenna module
a
Removal and installation ............................................... 42B-242
F
Fastener tightening specification....................................... 22D-2
Fastener tightening specifications
Engine overhaul............................................................. 11B-4
Manual transaxle overhaul ............................................ 22B-4
Front suspension........................................................... 33-2
Rear suspension............................................................ 34-4
Heater, air conditioning and ventilation.......................... 55-5
Fender
Removal and installation ............................................... 42A-10
Floor and roof
Configuration diagrams ................................................. 80A-16
Splice loca tions...................... ......................... ....... ........ 80B-6
Floor console assembly
Removal and installation ............................................... 52A-10
Fog light
Supplemental restraint system (SRS) ........................... 90-118
Circuit diagrams............................................................. 90-118
Fog light
Diagnosis
Diagnostic function .................................................... 54A-240
Standard flow of diagnostic troubleshooting .............. 54A-240
Inspection
Front fog light relay check.......................................... 54A-258
On-vehicle service
Front fog light aiming ................................................. 54A-255
Front fog light bulb replacement ................................ 54A-256
Removal and installation ............................................... 54A-257
Service specifications .................................................... 54A-238
Special too ls ......... ....... ....... ......................... .................. 54A-239
Symptom procedures
Inspection procedure 1: none of the front fog lights
illuminates.................................................................. 54A-243
Inspection procedure 2: one of the fog lights does not
illuminate.................................................................... 54A-249
Inspection procedure 3: the front fog light indicator does not illumi-
nate normally. ............................................................ 54A-253
Trouble symptom chart .................................................. 54A-242
Front axle diagnosis
Symptom chart .............................................................. 26-4
Symptom procedures
Inspection procedure 1: noise during wheel rotation . 26-5
Inspection procedure 2: noise due to exce
turning direction ......................................................... 26-6
Troubleshooting strategy ............................................... 26-4
Front axle hub assembly
Inspection ...................................................................... 26-13
Removal and installation ............................................... 26-9
Front bumper assembly and radiator grille
Disassembly and assembly ........................................... 51-4
Removal and installation ............................................... 51-3
ssive play o
f wheel in
Front disc brake assembly
Disassembly and assembly ........................................... 35A-32
Inspection
Basic brake system.................................................... 35A-31
Basic brake system.................................................... 35A-34
Removal and installation................................................ 35A-30
Front impact sensors
Inspection
Supplemental restraint system (SRS)........................ 52B-409
Circuit diagrams ......................................................... 52B-409
Removal and installation
Supplemental restraint system (SRS)........................ 52B-407
Circuit diagrams ......................................................... 52B-407
Front roll stopper and center member
Removal and installation................................................ 32-8
Front suspension diagnosis
Front suspension diagnosis troublesho
Introduction to front suspension diagnosis .................... 33-4
Symptom chart............................................................... 33-4
Symptom procedures
Inspection procedure 1: steering w
one side ..................................................................... 33-4
Inspection procedure 2: excessive body rolling ..
Inspection procedure 3: poor ride .............................. 33-5
Inspection procedure 4: unequal ride height.......
Inspection procedure 5: noise.................................... 33-6
Fuel filler lid
Removal and installation................................................ 42A-13
Fuel supply diagnosis
Introduction .................................................................... 13B-2
Symptom procedures..................................................... 13B-3
Troubleshooting strategy ............................................... 13B-2
Fuel tank
Disassembly and assembly ........................................... 13B-15
Disassembly and reassembly ........................................ 13B-17
Fuel tank inspection....................................................... 13B-18
Removal and installation................................................ 13B-10
Fusible link, fuse and iod or storage connector
oting strategy
heel
is heavy, vibrates or pulls to
.... 33-4
....... 33-5
....... 33-5
....... 70-13
..........
G
G and yaw rate sensor
Removal and installation................................................ 35C-304
Garnishes and moldings
Removal and installation................................................ 51-7
Special too l ................. ....... ....... ......................... ....... ..... 51-7
General data and specifications ........................................ 00-49
General description ........................................................... 22D-2
General information
Engine mechanical ........................................................ 11A-2
Engine lubrication .......................................................... 12-2
Multiport fuel injection (MFI) .......................................... 13A-2
Fuel supply .................................................................... 13B-2
Engine cooling ............................................................... 14-2
Intake and exhaust ........................................................ 15-2
Clutch............................................................................. 21A-2
Manual transaxle ........................................................... 22A-2
Manual transaxle overhaul............................................. 22B-2
Twin c lutch-sport ronic sh ift tr ansmission (TC -SS T) ... .... 22C-3
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Page 16
14
ALPHABETICAL INDEX
Propeller shaft ............................................................... 25-2
Front axle....................................................................... 26-2
Rear axle ....................................................................... 27-2
Power plant mount......................................................... 32-2
Front suspension........................................................... 33-2
Rear suspension............................................................ 34-2
Basic brake system ....................................................... 35A-2
Active stability control system (ASC)............................. 35C-3
Parking brakes............................................................... 36-2
Power steering............................................................... 37-3
Keyless operation system (KOS)................................... 42B-2
Wireless control module (WCM).................................... 42C-2
Interior ........................................................................... 52A-2
Supplemental restraint system (SRS) ........................... 52B-3
Local interconnect network (LIN)................................... 54B-2
Controller area network (CAN) ...................................... 54C-2
Heater, air conditioning and ventilation.......................... 55-3
Circuit diagrams............................................................. 52B-3
General specification......................................................... 22D-2
.
General specification(s)
General specifications
Engine overhaul............................................................. 11B-2
Clutch overhaul.............................................................. 21B-2
Manual transaxle overhaul ............................................ 22B-3
Propeller shaft ............................................................... 25-3
Front axle....................................................................... 26-3
Rear axle ....................................................................... 27-3
Wheel and tire ............................................................... 31-2
Front suspension........................................................... 33-3
Rear suspension............................................................ 34-4
Basic brake system ....................................................... 35A-3
Power steering............................................................... 37-3
Heater, air conditioning and ventilation.......................... 55-5
Generator and ignition system
Removal and installation ............................................... 11B-10
Glove box
Removal and installation ............................................... 52A-7
Grounding.......................................................................... 70-17
Grounding cable ................................................................ 70-16
.................................................... 13A-5
H
Hands free cellular phone system
Actuator test table.......................................................... 54A-574
Diagnosis
Diagnosis function ..................................................... 54A-513
Standard flow of diagnostic troubleshooting .............. 54A-513
Diagnostic trouble code chart ........................................ 54A-516
Diagnostic trouble code procedures
DTC B2468: microphone input short to batt DTC B2470: micro-
phone input short to ground....................................... 54A-517
DTC B2471: on hook button stuck DTC B2472: off hook button
stuckDTC B2473: vr button stuck .............................. 54A-520
DTC B2475: vin not programmed .............................. 54A-526
DTC No.U0184 audio CAN timeout ........................... 54A-540
DTC U0019: bus off (CAN-B) .................................... 54A-527
DTC U0141: ETACS CAN timeout............................. 54A-529
DTC U0151: SRS-ECU CAN timeout ........................ 54A-531
DTC U0154: ocm (occupant classification-ECU) CAN
timeout ...................................................................... 54A-532
DTC U0155: meter CAN timeout ............................... 54A-534
DTC U0164: A/C CAN timeout................................... 54A-536
DTC U0168: WCM/KOS CAN timeout ....................... 54A-538
DTC U0195: satellite radio CAN timeout ................... 54A-542
DTC U0245 and [audio visual navigation (HDD) unit]
CAN timeout............................................................... 54A-544
General information ....................................................... 54A-510
On-vehicle service ......................................................... 54A-571
On-vehicle service
Erase the passcode ................................................... 54A-574
Pairing a cellular phone or deleting a phone.............. 54A-571
Removal and installation................................................ 54A-575
Service data................................................................... 54A-574
Special too ls..... ....... ....... .................. ....... ....................... 54A-512
Steering wh eel voi ce control switch continu ity che ck .... 54A-576
Symptom procedures
phone
Inspection procedure 1: hands free cellular
work normally............................................................. 54A-547
Inspection procedure 2: during the conversation w
cellular phone system, the speaker’s voice cannot be heard by the
other party. ................................................................. 54A-555
Inspection procedure 3: during the conversation
cellular phone system, the voice of other party cannot
be heard.................................................................... 54A-558
Inspection procedure 4: even when the steering
switch is operated, the conversation is not possible. . 54A-559
Inspection procedure 5: the cellular phone is not
connection cannot be established.............................. 54A-564
Inspection procedure 6: steering wheel voice control
tion does not come on................................................ 54A-565
Inspection procedure 7: check the hands free module
circuit.......................................................................... 54A-569
Trouble symptom chart .................................................. 54A-546
Hands-free cellular phone system
Supplemental restraint system (SRS)............................ 90-344
Circuit diagrams............................................................. 90-344
Harness connector inspection........................................... 00E-2
Hazard warning light switch
Diagnosis
Diagnostic function..................................................... 54A-284
Standard flow of diagnostic troubleshooting .............. 54A-284
Diagnostic trouble code chart ........................................ 54A-286
Diagnostic trouble code procedures
DTC B16A6: turn-signal fuse blown........................... 54A-286
Inspection
Hazard warning light switch check............................. 54A-289
Removal and installation................................................ 54A-289
Special too ls..... ....... ....... .................. ....... ....................... 54A-283
Symptom procedures
Inspection procedure 1: the hazard warning lights do not
illuminate.................................................................... 54A-287
Trouble symptom chart .................................................. 54A-287
Headlight
Bracket repair of headlight assembly............................. 54A-210
Data list reference table................................................. 54A-192
Diagnosis
Diagnostic function..................................................... 54A-117
Standard flow of diagnostic troubleshooting .............. 54A-117
Diagnostic trouble code chart ........................................ 54A-119
Diagnostic trouble code procedures
DTC B16A2: blown turn-signal light (LH) bulb ........... 54A-120
DTC B16A3: turn-signal light (LH) short circuit .......... 54A-125
DTC B16A4: blown turn-signal light (RH) bulb........... 54A-129
system does not
ith the hands free
w
ith the hands free
wheel
voice control
recognized or the
switch illumina-
power supply
TSB Revision
Page 17
ALPHABETICAL INDEX
15
DTC B16A5: turn-signal light (RH) short circuit ......... 54A-134
DTC L0432: rls rs adaptation error ............................ 54A-137
DTC L0434: rls rain sensor errorDTC L0436: rls light
sensor error ............................................................... 54A-139
General information ....................................................... 54A-111
Headlight leveling switch removal and installation ........ 54A-205
Headlight removal and installation................................. 54A-202
Inspection
i
Headlight leveling switch check <vehicles w
eling system>............................................................. 54A-209
Headlight relay check ................................................ 54A-208
Lighting control sensor (light sensor) check .............. 54A-210
Lighting control sensor removal and installation............ 54A-206
On-vehicle service
Coming-home light function check............................. 54A-200
Customization function .............................................. 54A-200
Headlight aiming ........................................................ 54A-193
Headlight auto light function check ............................ 54A-200
Headlight automatic-shutdown function check .......... 54A-200
Luminous intensity measurement .............................. 54A-196
Replace the bulb........................................................ 54A-197
Welcome light function check .................................... 54A-200
Service precautions <discharge headlight>
Service specifications .................................................... 54A-112
Special too ls ......... ....... ....... ......................... .................. 54A-113
Symptom procedures
Inspection procedure 1: none of headlights (low-beam)
illuminates.................................................................. 54A-141
Inspection procedure 10: the auto light
mally........................................................................... 54A-180
Inspection procedure 11: none of tu
illuminates.................................................................. 54A-182
Inspection procedure 12: the comfort flashing
work normally............................................................. 54A-184
Inspection procedure 13: the turn-signal indicator light
minate. ....................................................................... 54A-186
Inspection procedure 14: the welcome light function does not work
normally. .................................................................... 54A-188
Inspection procedure 15: the coming home light function does not
work normally............................................................. 54A-190
Inspection procedure 2: none of headlights (high-beam)
illuminates.................................................................. 54A-146
Inspection procedure 3: the headlights illuminate at low-beam (high-
beam doe
positions..................................................................... 54A-150
Inspection procedure 4: headlights do
ing switch is operated. ............................................... 54A-152
Inspection procedure 5: one of the headlights does not
illuminate.................................................................... 54A-154
Inspection procedure 6: high-beam indicator
nate normally. ............................................................ 54A-158
Inspection procedure 7: the headlight automatic shutdown function
does not work normally.............................................. 54A-160
Inspection procedure 8: daytime running light function
work normally. <discharge type headlight>................ 54A-167
Inspection procedure 8: daytime running light
work normally. <halogen type headlight> .................. 54A-163
Inspection procedure 9: one of the rear side marker
light or the license plate lights does not illuminate..... 54A-174
Trouble symptom chart .................................................. 54A-140
Headlight <discharge type>
Supplemental restraint system (SRS) ........................... 90-98
Circuit diagrams............................................................. 90-98
Headlight <halogen type>
Supplemental restraint system (SRS) ........................... 90-90
illuminate) regardless of the lighting switch
s not
th headlight manual lev-
.......... 54A-115
.........
f
unction does not work nor-
rn-signal lights
function does not
s do not illu-
n
ot illuminate when the pass-
light
does not illumi-
does not
function
does not
lights, position
Circuit diagrams............................................................. 90-90
Headlight leveling system
Supplemental restraint system (SRS)............................ 90-106
Circuit diagrams............................................................. 90-106
Headlining
Removal and installation................................................ 52A-18
Heated door mirror
Supplemental restraint system (SRS)............................ 90-224
Circuit diagrams............................................................. 90-224
Heated seat
Supplemental restraint system (SRS)............................ 90-338
Circuit diagrams............................................................. 90-338
i
Heater <vehicles without air condit
Supplemental restraint system (SRS)............................ 90-194
Circuit diagrams............................................................. 90-194
Heater control unit
Heater control unit removal and installation................... 55-171
Heater unit and blower assembly
Heater unit and blower assembly disassembly and
reassembly .................................................................... 55-174
Heater unit and blower assembly removal and installation 55-172
Inspection ...................................................................... 55-175
High-mounted stoplight
Removal and installation................................................ 54A-281
Hood
Hood
Disassembly and assembly ....................................... 42A-8
Hood removal and installation.................................... 42A-7
Inspection................................................................... 42A-8
Hood diagnosis
Introduction ................................................................ 42A-4
Troubleshooting str ategy ................. ................... ....... 42A-4
On-vehicle service
Adjustment of clearance around hood ....................... 42A-5
Adjustment of hood height ......................................... 42A-6
Alignment of hood latch and striker............................ 42A-5
Symptom procedures
Inspection procedure 1: difficult lockin
Inspection procedure 2
Inspection procedure 3: uneven height
Trouble symptom chart .................................................. 42A-4
Horn
Supplemental restraint system (SRS)............................ 90-143
Circuit diagrams............................................................. 90-143
Horn
Inspection
Horn, theft-alarm horn relay check............................. 54A-291
Removal and installation................................................ 54A-289
How to diagnose
Battery handling............................................................. 00E-12
Cables and wires check................................................. 00E-12
Checking fuses .............................................................. 00E-9
Checking relays ............................................................. 00E-11
Checking switches ......................................................... 00E-10
General electrical system check
How to diagnose ............................................................ 00E-6
Information for diagnosis ............................................... 00E-6
Inspection ...................................................................... 00E-7
Inspection instruments................................................... 00E-8
oning system>
g and unlocking 42A-4
: uneven body clearance ....... 42A-5
...................... 42A-5
........
............................ 00E-12
TSB Revision
Page 18
16
ALPHABETICAL INDEX
Troubleshooting steps ................................................... 00E-6
How to read circuit diagrams
Supplemental restraint system (SRS) ........................... 90-4
Circuit diagrams............................................................. 90-4
How to read configuration diagrams.................................. 80A-3
How to read splice locations.............................................. 80B-2
How to use this manual..................................................... 00-3
oint
How to use troubleshooting/inspection service p
How to use troubleshooting/inspection service points
Connector inspection service points.............................. 00-14
Connector measurement service points ........................ 00-12
How to cope with intermittent malfunctions ................... 00-15
How to treat past trouble ............................................... 00-16
How to use the inspection procedures .......................... 00-10
Inspection service points for a blown fuse..................... 00-17
Troubleshooting contents .............................................. 00-7
Hydraulic unit..................................................................... 35C-298
Hydraulic unit
Hydraulic unit disposal
Manual transaxle ....................................................... 22A-136
Rear axle ................................................................... 27-59
Removal and installation
Manual transaxle ....................................................... 22A-136
Twin c lut ch-sportron ic shift transmission (T
Rear axle ................................................................... 27-57
Active stability control system (ASC) ......................... 35C-298
s....... 00-7
C-SST
)... 22C-434
I
Ignition key reminder tone alarm <vehicles with KOS>
Supplemental restraint system (SRS) ........................... 90-358
Circuit diagrams............................................................. 90-358
Ignition key reminder tone alarm <vehicles without KOS>
Supplemental restraint system (SRS) ........................... 90-356
Circuit diagrams............................................................. 90-356
Ignition switch
Inspection
Ignition switch continuity check.................................. 54A-25
Key reminder switch inspection ................................. 54A-25
On-vehicle service
Check of ignition key reminder warning function (steering lock
reminder tone alarm by KOS).................................... 54A-22
Removal and installation ............................................... 54A-23
Special too ls ......... ....... ....... ......................... .................. 54A-12
Symptom procedures
Inspection procedure 1: ignition key cylinder
not illuminate/extinguish normally. <vehicles with WCM> 54A-15
Inspection pr
tion switch .................................................................. 54A-20
Trouble symptom chart .................................................. 54A-15
Troubleshooting
Diagnosis function ..................................................... 54A-13
Standard flow of diagnostic trouble shooting ............. 54A-13
Ignition system
Supplemental restraint system (SRS) ........................... 90-40
Circuit diagrams............................................................. 90-40
Ignition system
Camshaft position sensor
Removal and installation............................................ 16-41
ocedure 2: defective power
illumination
supply system of the igni-
light does
Crankshaft position sensor
Removal and installation............................................ 16-42
General information ....................................................... 16-34
................................................ 16-35
General specification(s)
Ignition coil
Removal and installation............................................ 16-40
Knock sensor
Removal and installation............................................ 16-43
On-vehicle service
Camshaft position sensor check ................................ 16-39
Crankshaft position sensor check .............................. 16-39
Ignition coil check....................................................... 16-36
Knock control system check ...................................... 16-36
Spark plug check and cleaning ........ ..................... ..... 16-38
Spark plug test ........................................................... 16-37
Service specification(s).................................................. 16-35
Special too l ................. ....... ....... ......................... ....... ..... 16-36
Immobilizer system <M/T>
Supplemental restraint system (SRS)............................ 90-326
Circuit diagrams............................................................. 90-326
Immobilizer system <TC-SST>
Supplemental restraint system (SRS)............................ 90-330
Circuit diagrams............................................................. 90-330
Index.................................................................................. 80B-3
Individual component service
Supplemental restraint system (SRS)............................ 52B-404
Circuit diagrams............................................................. 52B-404
Injector
Removal and installation................................................ 13A-882
Input shaft
Disassembly and assembly ........................................... 22B-22
Inspection ...................................................................... 22B-27
Inside rear view mirror ....................................................... 52A-20
Inspection terminal ............................................................ 70-7
Instrument center panel
Removal and installation................................................ 52A-8
Instrument lower panel
Removal and installation................................................ 52A-9
Instrument panel assembly
Removal and installation................................................ 52A-3
Intake and exhaust diagnosis
Introduction .................................................................... 15-2
Symptom chart............................................................... 15-2
Symptom procedures
Inspection procedure 1: exha
Inspection procedure 2: abnormal noise.................... 15-3
Troubleshooting strategy ............................................... 15-2
Intake manifold .................................................................. 15-15
Intake manifold
Inspection ...................................................................... 15-17
Removal and installation................................................ 15-15
Intake manifold and fuel system
Removal and installation................................................ 11B-16
Interior temperature sensor
Inspection ...................................................................... 55-179
Interior temperature sensor removal and installation..... 55-179
.
ust leakage
.................. 15-3
TSB Revision
Page 19
ALPHABETICAL INDEX
17
J
Joint connector
Supplemental restraint system (SRS) ........................... 90-14
Circuit diagrams............................................................. 90-14
K
Key interlock and shift lock mechanisms
Removal and installation ............................................... 22C-408
Keyless operating system (KOS)
Supplemental restraint system (SRS) ........................... 90-178
Circuit diagrams............................................................. 90-178
Keyless operation key ....................................................... 42B-245
Keyless operation key
Disassembly and assembly ........................................... 42B-245
Knee air bag module
Inspection
Supplemental restraint system (SRS)........................ 52B-428
Circuit diagrams......................................................... 52B-428
Removal and installation
Supplemental restraint system (SRS)........................ 52B-425
Circuit diagrams......................................................... 52B-425
Knuckle
Removal and installation ............................................... 27-39
KOS-ECU
Removal and installation ............................................... 42B-241
L
License plate light
Removal and installation ............................................... 54A-282
Loose panel
Removal and installation ............................................... 42A-198
Lower arm
Inspection ...................................................................... 33-16
Lower arm ball joint dust cover replacement ................. 33-16
Removal and installation ............................................... 33-15
Lubricant
Manual transaxle ........................................................... 22A-2
Twin c lutch-sport ron ic shif
Twin c lutch sst o verhaul . ... ........... ........... ... ........... ........ 22D-3
Lubricant(s) ....................................................................... 21A-2
Lubricants
Engine lubrication .......................................................... 12-3
Clutch overhaul.............................................................. 21B-3
Manual transaxle overhaul ............................................ 22B-5
Propeller shaft ............................................................... 25-3
Front axle....................................................................... 26-4
Rear axle ....................................................................... 27-4
Front suspension........................................................... 33-3
Rear suspension............................................................ 34-5
Basic brake system ....................................................... 35A-4
Power steering............................................................... 37-4
Heater, air conditioning and ventilation.......................... 55-5
Lubrication and maintenance ............................................ 00-52
Luggage compartment
Configuration diagrams ................................................. 80A-20
Splice loca tions...................... ......................... ....... ........ 80B-6
t transmission (TC-SST)
....... 22C-3
M
Main sealant and adhesive table ....................................... 00-80
Maintenance service
1. fuel system (tank, pipe line and connection, and fuel
cap) (check for leaks) .................................................... 00-61
10. engine oil filter (replace) .......................................... 00-66
and co
11. manual transaxle oil (chec k oil level
12. twin clutch-sportronic shift transmission (T
leakage (if necessary, check the fluid level) /change].... 00-68
13. twin clutch sport-shift transmission oil filter (change) 00-70
ransfer oil (check oil level/change) ......................... 00-70
14. t
15. reserve tank fluid (for active center dif
trol system) (check fluid level) ....................................... 00-71
16. engine coolant (change) .......................................... 00-72
17. coolant hoses (radiator hose, heater hose) (
18. disk brake pads and rotors (inspect for wear).......... 00-74
19. brake hoses (check for deterioration or leaks)......... 00-77
..........
2. fuel hoses (check condition)
20. ball joint and steering linkage seals (inspect for
damage)......................................................................... 00-78
21. drive shaft boots (inspect for
22. suspension system (inspect for lo
23. rear axle oil (for differential part) (change)............... 00-78
24. rear axle oil (for torque transfer mechanism part) (change) 00-79
25. tires (rotate) ............................................................. 00-79
26. air purifier filter (replace).......................................... 00-79
3. air cleaner element (replace) ..................................... 00-61
4. evaporative emission control system (except
canister) (check for leaks and clogging) ........................ 00-61
5. spark plugs (replace) ................................................. 00-62
6. intake and exhaust valve clearance (inspect and adjust) 00-62
7. drive belt (for the generator and power steering oil pump)
(replace)......................................................................... 00-64
8. exhaust system (connections portion of muf
converter heat shields) (check and service) .................. 00-65
9. engine oil (change) .................................................... 00-65
Manual transaxle diagnosis <manual transaxle>
Introduction .................................................................... 22A-5
Symptom chart............................................................... 22A-5
Symptom procedures
Inspection procedure 1: noise, vibration .................... 22A-5
Inspection procedure 2: oil leaks ............................... 22A-6
Inspection procedure 3: hard shifting......................... 22A-7
Inspection procedure 4: jumps out of gear................. 22A-8
Troubleshooting strategy ............................................... 22A-5
Mark
Removal and installation................................................ 51-85
Master cylinder assembly and brake booster assembly
Removal and installation................................................ 35A-26
Mechatronic assembly, manual control lever
Removal and installation................................................ 22C-421
Meter and gauge <M/T>
Supplemental restraint system (SRS)............................ 90-144
Circuit diagrams............................................................. 90-144
Meter and gauge <TC-SST>
Supplemental restraint system (SRS)............................ 90-148
Circuit diagrams............................................................. 90-148
MFI system <M/T>
Supplemental restraint system (SRS)............................ 90-52
Circuit diagrams............................................................. 90-52
............................ 00-61
grease leaks and
oseness and damage) 00-78
ndition/rchange) 00-66
C-SST) [check the fluid
ferential and active yaw con-
tank filler tube
inspect) 00-74
grease leaks and
damage) 00-78
evaporative
fler
, muffler pipes and
emission
TSB Revision
Page 20
18
ALPHABETICAL INDEX
MFI system <TC-SST>
Supplemental restraint system (SRS) ........................... 90-64
Circuit diagrams............................................................. 90-64
Mitsubishi multi-communication system (MMCS)
Supplemental restraint system (SRS) ........................... 90-244
Circuit diagrams............................................................. 90-244
MMCS
Diagnosis
Diagnosis function ..................................................... 54A-428
Error message ........................................................... 54A-426
Precautions on servicing MMCS................................ 54A-412
Service mode............................................................. 54A-413
Standard flow of diagnostic troubleshooting .............. 54A-412
Diagnostic trouble code chart ........................................ 54A-430
Diagnostic trouble code procedures
DTC B2226: and error ............................................... 54A-430
DTC B2240: communication error with CAN box ...... 54A-432
DTC B2477: vin not programmed .............................. 54A-435
DTC No.U1417 implausible coding data.................... 54A-455
DTC U0019: bus off (CAN-B) .................................... 54A-436
DTC U0141: ETACS CAN timeout............................. 54A-438
DTC U0151: SRS-ECU CAN timeout ........................ 54A-440
DTC U0154: ocm (occupant classification-ECU) CAN
timeout ...................................................................... 54A-442
DTC U0155: meter CAN timeout ............................... 54A-444
DTC U0164: A/C CAN timeout .................................. 54A-446
DTC U0168: WCM/KOS CAN timeout....................... 54A-448
DTC U0195: satellite radio CAN timeout ................... 54A-450
DTC U0197: hands free module CAN timeout........... 54A-452
DTC U1415: coding not completed/data fail .............. 54A-454
ETACS function customization function......................... 54A-504
Inspection
Audio and video adapter inspection........................... 54A-509
Mitsubishi multi communication sysyem........................ 54A-409
Removal and installation ............................................... 54A-507
Special too ls ......... ....... ....... ......................... .................. 54A-411
Symptom procedures .................................................... 54A-458
Symptom procedures
Inspection procedure 1: No navigation screen is
displayed.................................................................... 54A-458
Inspection procedure 10: sound of a DVD can be
image is played.......................................................... 54A-495
Inspection procedure 11: the picture and sound of extern
not played. ................................................................. 54A-496
Inspection procedure 12: check the CAN box
cuit. ............................................................................ 54A-499
Inspection procedure 2: No sound is heard. <vehicles
amplifier> ................................................................... 54A-465
Inspection procedure 3: No sound is heard from one
ers. <vehicles with audio amplifier>........................... 54A-475
Inspection procedure 4: the navigation system can be operated
while the vehicle is driven. ......................................... 54A-484
Inspection procedure 5: the screen is not normal
mode. (the own vehicle mark is dislocated.).............. 54A-487
Inspection procedure 6: the AM/FM radio broadcasting cannot be
received. .................................................................... 54A-490
Inspection procedure 7: GPS signal can not be received. 54A-492
Inspection procedure 8: CD/DVD cannot be played. . 54A-493
Inspection procedure 9: image of a DVD is played,
played. ....................................................................... 54A-494
Trouble symptom chart .................................................. 54A-457
Motors and transistor
Inspection ...................................................................... 55-177
played, but no
al input are
unit power supply cir-
with audio
of the speak-
in
the navigation
but
no sound is
Motors and transistor removal and installation .............. 55-176
Multiport fuel injection (MFI) diagnosis
Actuator test reference table.......................................... 13A-840
Check at the engine control module (ECM)................... 13A-841
Data list reference table................................................. 13A-818
Diagnostic function ........................................................ 13A-9
Diagnostic trouble code chart ........................................ 13A-48
Diagnostic trouble code procedures
DTC P0010: intake engine oil control valve circuit..... 13A-56
DTC P0011: intake variable valve timing system target error13A-62
DTC P0012: camshaft position − timing over-retarded 13A-66
DTC P0013: exhaust engine oil contr
DTC P0014: exhaust variable valve timing system target
error ........................................................................... 13A-73
DTC P0016: crankshaft/camshaft (intake) p
problem ...................................................................... 13A-76
DTC P0017: crankshaft/camshaft (exhaust) position sensor phase
problem ...................................................................... 13A-80
DTC P0031: heated oxygen sensor (
low.............................................................................. 13A-84
DTC P0032: heated oxygen sensor (front)
high ............................................................................ 13A-91
DTC P0037: heated oxygen sensor (rear) heater circuit
low.............................................................................. 13A-95
DTC P0038: heated oxygen sensor (rear) heater circuit
high ............................................................................ 13A-102
DTC P0069: abnormal correlation between manifold absolute pres-
sure sensor and barometric pressure sensor ............ 13A-106
DTC P0096: intake air temperature circuit range/performance prob-
lem (sensor 2) ............................................................ 13A-110
DTC P0097: intake air temperature circuit low input
(sensor 2)................................................................... 13A-117
DTC P0098: intake air temperature circuit high input
(sensor 2)................................................................... 13A-121
DTC P0101: mass airflow circuit range/performance
problem ...................................................................... 13A-127
DTC P0102: mass airflow circuit low input................. 13A-133
DTC P0103: mass airflow circuit high input ............... 13A-140
DTC P0106: manifold absolute pressure circuit range/
performance problem................................................. 13A-145
DTC P0107: manifold absolute pressure circuit low input 13A-154
DTC P0108: manifold absolute pressu
DTC P0111: intake air temperature circuit range/performance
problem (sensor 1)..................................................... 13A-167
DTC P0112: intake air temperature circuit low input
(sensor 1)................................................................... 13A-173
DTC P0113: intake air temperature circuit high input
(sensor 1)................................................................... 13A-177
DTC P0116: engine coolant temperature circuit range/
performance problem................................................. 13A-183
DTC P0117: engine coolant temperature circuit low input 13A-189
DTC P0118: engine coolant temperature circuit high
input .......................................................................... 13A-194
DTC P0122: throttle position sensor (main) circuit low
input ........................................................................... 13A-201
DTC P0123: throttle position sensor (main) circuit high
input ........................................................................... 13A-205
DTC P0125: insufficient coolant temperature for closed loop fuel
control ........................................................................ 13A-212
DTC P0128: coolant thermostat (coolant temperature below thermo-
stat regulating temperature)....................................... 13A-220
DTC P0131: heated oxygen sensor (front) circuit low
voltage ....................................................................... 13A-223
DTC P0132: heated oxygen sensor (front) circuit high
voltage ....................................................................... 13A-231
DTC P0133: heated oxygen sensor (front) circuit slow
responce .................................................................... 13A-235
ol valve circuit
front)
heater circuit
heater circuit
re cir
.. 13A-67
osition sensor phase
cuit high input 13A-162
TSB Revision
Page 21
ALPHABETICAL INDEX
19
DTC P0134: heated oxygen sensor (front) circuit No activity
detected ..................................................................... 13A-240
DTC P0137: heated oxygen sensor (rear) circuit low
voltage ....................................................................... 13A-246
DTC P0138: heated oxygen sensor (rear) circuit high
voltage ....................................................................... 13A-254
DTC P0139: heated oxygen sensor (rear) circuit slow
responce .................................................................... 13A-258
activity
DTC P0140: heated oxygen sensor (rear) circuit
detected ..................................................................... 13A-263
DTC P0171: system too lean..................................... 13A-267
DTC P0172: system too rich...................................... 13A-273
DTC P0181: fuel tank temperatur
performance............................................................... 13A-279
DTC P0182: fuel tank temperatur
input .......................................................................... 13A-286
DTC P0183: fuel tank temperature sensor
input .......................................................................... 13A-291
DTC P0201: injector circuit-cylinder 1 ....................... 13A-298
DTC P0202: injector circuit-cylinder 2 ....................... 13A-308
DTC P0203: injector circuit-cylinder 3 ....................... 13A-318
DTC P0204: injector circuit-cylinder 4 ....................... 13A-328
DTC P0219: engine over speed condition ................. 13A-338
DTC P0222: throttle position senso
input........................................................................... 13A-339
DTC P0223: throttle position senso
input........................................................................... 13A-345
DTC P0234: turbocharger wastegate system malfunction 13A-350
DTC P0243: turbocharger wastegate solenoid 1 circuit 13A-352
DTC P0247: turbocharger wastegate solenoid 2 circuit 13A-359
DTC P0300: random/multiple cylinder misfire detected 13A-365
DTC P0301: cylinder 1 misfire detected .................... 13A-370
DTC P0302: cylinder 2 misfire detected .................... 13A-373
DTC P0303: cylinder 3 misfire detected .................... 13A-376
DTC P0304: cylinder 4 misfire detected .................... 13A-379
DTC P0327: knock sensor circuit low
DTC P0328: knock sensor circuit high.............
DTC P0335: crankshaft position sensor circuit.......... 13A-389
C P0340: intake camshaft position sensor circuit . 13A-399
DT
DTC P0365: exhaust camshaft position sensor circ
DTC P0420: warm up catalyst efficiency below threshold 13A-416
DTC P0441: evaporative emission control system incorrect
purge flow .................................................................. 13A-418
DTC P0442: evaporative emission control syst
(small leak) ................................................................ 13A-422
DTC P0443: evaporative emission control system
valve circuit ................................................................ 13A-434
DTC P0446: evaporative emission control system vent contr
cuit ............................................................................. 13A-441
DTC P0450: evaporative emission control system pr
malfunction ................................................................ 13A-448
DTC P0451: evaporative emission control system pr
range/performance .................................................... 13A-456
DTC P0452: evaporative emission control system pr
low input..................................................................... 13A-465
DTC P0453: evaporative emission control system
high input ................................................................... 13A-475
DTC P0455: evaporative emission control syst
(gross leak) ................................................................ 13A-483
DTC P0456: evaporative emission control syst
(very small leak)......................................................... 13A-494
DTC P0461: fuel level sensor (
performance............................................................... 13A-505
DTC P0462: fuel level sensor circuit low input .......... 13A-508
DTC P0463: fuel level sensor circuit high input ......... 13A-511
C P0500: vehicle speed signal malfunction .......... 13A-513
DT
e sensor
e sensor
m
ain) circuit range/
circuit range/
circuit low
circuit high
(sub) circuit low
r
r
(sub) circuit high
..............
.......... 13A-383
.......... 13A-386
No
uit 13A-407
em leak detected
purge control
ol cir-
essure sensor
essure sensor
essure sensor
pr
essure sensor
em leak detected
em leak detected
DTC P0506: idle control sytem rpm lower than expected 13A-516
DTC P0507: idle control sytem rpm higher than expected 13A-519
DTC P050B: ignition timing retard insufficient ........... 13A-522
DTC P0513: immobilizer malfunction......................... 13A-525
DTC P0551: power steering pressure switch circuit range/
performance............................................................... 13A-527
DTC P0554: power steering pressure switch circuit
intermittent ................................................................. 13A-534
DTC P0603: EEPROM malfunction ........................... 13A-538
DTC P0606: engine control module main processor
malfunction................................................................. 13A-540
DTC P0622: generator FR terminal circuit malfunction 13A-546
icatio
DTC P0630: vehicle identif
malfunction................................................................. 13A-551
DTC P0638: throttle actuator control motor circuit
mance ........................................................................ 13A-553
DTC P0642: throttle position sensor power supply.... 13A-556
DTC P0657: throttle actuator control motor relay circuit
malfunction................................................................. 13A-558
DTC P0830: clutch pedal position switch circuit range/
performance <M/T> ................................................... 13A-566
DTC P1231: active stability co
DTC P1232: fail safe system ..................................... 13A-572
DTC P1233: throttle position sensor (main) p
DTC P1234: throttle position sensor (sub)
DTC P1235: mass airflow sensor plausibility............. 13A-580
DTC P1236: a/d converter ......................................... 13A-583
DTC P1237: accelerator pedal position sensor plausibility 13A-584
DTC P1238: mass airflow sensor plausibility
(torque monitor) ......................................................... 13A-587
DTC P1239: engine rpm plausibility........................... 13A-590
DTC P1240: ignition angle ......................................... 13A-593
DTC P1241: torque monitor ....................................... 13A-594
DTC P1242: fail safe control monitor ......................... 13A-598
DTC P1243: inquiry/response error ........................... 13A-600
DTC P1244: ram test for all area ............................... 13A-601
DTC P1245: cycle ram test (engine).......................... 13A-602
DTC P1247: TC-SST plausibility <TC-SST> ............. 13A-603
DTC P1506: idle control system rpm lower than expected at low
temperature................................................................ 13A-604
DTC P1507: idle control system rpm higher than expected at low
temperature................................................................ 13A-607
DTC P1590: tcm to ECM communication error in torque reduction
request ....................................................................... 13A-610
DTC P1603: battery backup circuit malfunction......... 13A-613
DTC P1676: variant coding........................................ 13A-617
DTC P2066: fuel level sensor (sub)
ormance............................................................... 13A-619
perf
DTC P2096: post catalyst fuel trim system too lean .. 13A-622
DTC P2097: post catalyst fuel trim system too rich ... 13A-625
DTC P2100: throttle actuator control motor circuit (open) 13A-629
DTC P2101: throttle actuator control motor magneto
malfunction................................................................. 13A-634
DTC P2122: accelerator pedal position sensor
input ........................................................................... 13A-638
DTC P2123: accelerator pedal position sensor (main) circuit high
input ........................................................................... 13A-643
DTC P2127: accelerator pedal positio
input ........................................................................... 13A-648
DTC P2128: accelerator pedal position sensor (sub)
input ........................................................................... 13A-653
DTC P2135: throttle position senso
mance problem .......................................................... 13A-657
DTC P2138: accelerator pedal position sensor (main and sub)
range/performance problem....................................... 13A-663
n number (vin)
range/perfor-
usibility .......... 13A-570
ntrol pla
lausibility 13A-573
plausibility 13A-577
circuit range/
main) circuit low
(
n sensor
r
(main and sub) range/perfor-
(sub) circuit low
circuit high
TSB Revision
Page 22
20
ALPHABETICAL INDEX
DTC P2195: heated oxygen sensor (front) inactive... 13A-670
DTC P2228: barometric pressure circuit low input .... 13A-673
DTC P2229: barometric pressure circuit high input ... 13A-675
DTC P2252: heated oxygen sensor offset circuit low
voltage ....................................................................... 13A-677
DTC P2253: heated oxygen sensor offset circuit high
voltage ....................................................................... 13A-679
DTC P2263: intake charge system malfunction......... 13A-681
DTC U0001: bus off ................................................... 13A-684
DTC U0101: TC-SST-ECU time-out <TC-SST>........ 13A-685
DTC U0121: ASC-ECU time-out................................ 13A-689
DTC U0141: ETACS-ECU time-out ........................... 13A-694
DTC U0167: immobilizer communication error.......... 13A-698
DTC U1180: combination meter time-out .................. 13A-700
Fail-safe function reference table.................................. 13A-44
General scan tool (gst) mode
Inspection procedure using an os
Symptom chart .............................................................. 13A-53
Symptom procedures
Inspection procedure 1: communicatio
ble.............................................................................. 13A-704
Inspection procedure 10: when the engine is cold, it stalls at idle (die
out)............................................................................. 13A-733
Inspection procedure 11: when the engine is hot, it stalls
out)............................................................................. 13A-735
Inspection procedure 12: the engine stalls accelerat
(pass out)................................................................... 13A-738
Inspection procedure 13: the engine st
Inspection procedure 14: hesitation, sag, stumble, poor
or surge...................................................................... 13A-742
Inspection procedure 15: acceleration shock ............ 13A-745
Inspection procedure 16: knocking ............................ 13A-747
Inspection procedure 17: too high co and hc concentration when
idling .......................................................................... 13A-749
Inspection procedure 18: transient, m
ure.............................................................................. 13A-751
Inspection procedure 19: purge flow test of the evaporative emis-
sion canister failure.................................................... 13A-755
Inspection procedure 2: the malfunction indicator lamp (service
engine soon or
the ignition switch is turned to the "ON" position ....... 13A-708
Inspection procedure 20: pressure test of the evaporative system
failure ......................................................................... 13A-756
Inspection procedure 21: generator output voltage is low (approxi-
mately 12.3 volts)....................................................... 13A-757
Inspection procedure 22: power supply system and ignition switch-
IG system................................................................... 13A-760
Inspection procedure 23: fuel pump system .............. 13A-771
Inspection procedure 24: ignition switch-st
system <M/T> ............................................................ 13A-784
Inspection procedure 25: ignition switch-st system
system <TC-SST> ..................................................... 13A-796
Inspection procedure 26: ign
Inspection procedure 27: A/C system........................ 13A-813
Inspection procedure 28: engine oil pressure switch
system ....................................................................... 13A-816
Inspection procedure 3: the malfunction indicator lamp (service
engine
goes out ..................................................................... 13A-709
Inspection procedure 4: cranks, won’t start ............... 13A-711
Inspection procedure 5: starts up and dies................ 13A-718
Inspection procedure 6: hard starting ........................ 13A-722
Inspection procedure 7: unstable idle (rough idle,
hunting)...................................................................... 13A-727
Inspection procedure 8: idle speed is high (improper idle
speed)........................................................................ 13A-730
check engine lamp) does not illuminate right after
soon
or check engine lamp) remains illuminated and never
01 reference t
cilloscope.................. 13A-850
i
tion circuit system ........ 13A-808
able .......... 13A-834
n with ECM
alls deceler
ass
emission tailpipe test fail-
only is not possi-
ing
ating 13A-740
acceleration
system
and starter relay
and starter relay
at idle (die
Inspection procedure 9: idle speed is low (improper idle
speed) ........................................................................ 13A-732
Troubleshooting strategy ............................................... 13A-9
O
Oil cooler
Removal and installation................................................ 22C-429
Oil filter
Removal and installation................................................ 22C-431
Oil pan
Inspection ...................................................................... 11A-50
Removal and installation
Engine mechanical..................................................... 11A-48
Twin c lut ch-sportron ic shif t t ransmission (TC-SST) ... 22C-418
Oil pan and timing chain case
Removal and installation................................................ 11B-27
Oil pump
Removal and installation................................................ 12-12
Oil pump chain
Inspection ...................................................................... 11B-63
Removal and installation
Engine overhaul ......................................................... 11B-58
Engine lubrication ...................................................... 12-10
On-vehicle service
A/C compressor clutch test............................................ 55-164
Accuracy check of occupant classification
Supplement
Circuit diagrams ......................................................... 52B-405
ACD operation check
Manual transaxle........................................................ 22A-120
Twin c lut ch-sportron ic shif t t ransmission (TC-SST) ... 22C-402
Antenna communication test ......................................... 42B-236
Auto-tensioner check ..................................................... 11A-8
Ayc bleeding .................................................................. 27-29
Ayc differential carrier oil seal replacement
Ayc operation check ...................................................... 27-30
Ball joint dust cover check
Front suspension ....................................................... 33-9
Power steering ........................................................... 37-22
Ball joint dust cover inspection ...................................... 34-10
Bleeding
Manual transaxle........................................................ 22A-119
Twin c lut ch-sportron ic shif t t ransmission (TC-SST) ... 22C-402
Basic brake system.................................................... 35A-16
Brake booster operation check ...................................... 35A-15
Brake drag force check.................................................. 35A-23
Brake fluid level switch check ........................................ 35A-17
Brake pad check ............................................................ 35A-18
Brake pad replacement.................................................. 35A-18
Brake pedal check and adjustment................................ 35A-12
Calibration of cut valve and inlet valve .......................... 35C-295
Charging <vehicles using r-134a refrigerant>................ 55-165
Check valve operation check......................................... 35A-16
Clean air filter replacement procedure........................... 55-170
Clutch bleeding .............................................................. 21A-3
Clutch pedal check ........................................................ 21A-2
Component location....................................................... 13A-859
Compression pressure check ........................................ 11A-15
al restraint system (SRS)........................ 52B-405
sensor
............
....... 27-33
TSB Revision
Page 23
ALPHABETICAL INDEX
21
Compressor drive belt adjustment................................. 55-165
Compressor noise check ............................................... 55-168
Cooling fan motor check................................................ 14-21
Cooling fan relay continuity check ................................. 14-20
Curb idle speed check ................................................... 11A-12
Customization function
Keyless operation system (KOS)............................... 42B-238
Wireless control module (WCM) ................................ 42C-129
Disk brake rotor check................................................... 35A-21
Drive belt tension check
Engine mechanical .................................................... 11A-7
Power steering........................................................... 37-24
Engine coolant change .................................................. 14-17
Engine coolant concentration test ................................. 14-19
Engine coolant leak check............................................. 14-17
..........
Engine coolant temperature sensor check
Engine oil check ............................................................ 12-4
Engine oil control valve check ....................................... 13A-880
Engine oil filter replacement .......................................... 12-5
Engine oil replacement .................................................. 12-4
Evaporative emission purge solenoid check ................. 13A-881
Evaporative emission ventilatio
Fluid check
Manual transaxle ....................................................... 22A-119
Twin c lut ch-sportron ic shift transmission (T
Fluid level check
Rear axle ................................................................... 27-28
Power steering........................................................... 37-24
Fluid replacement.......................................................... 37-24
Front wheel alignment check and adjustment ............... 33-8
Fuel level sensor (sub) check........................................ 13B-6
Fuel level sensor (sub) replacement ............................. 13B-9
Fuel pressure test.......................................................... 13A-865
Fuel pump circuit resistor check.................................... 13A-874
Fuel pump module replacement.................................... 13B-6
Fuel pump operation check
Multiport fuel injection (MFI) ...................................... 13A-869
Fuel supply ................................................................ 13B-6
Fuel pump relay continuity check .................................. 13A-871
G and yaw rate sensor calibration ................................. 35C-287
Gear oil level check ....................................................... 27-26
Gear oil replacement ..................................................... 27-27
Heated oxygen sensor check ........................................ 13A-876
How to reduce pressurized fuel pressure ...................... 13A-868
Hub bolt replacement
Front axle................................................................... 26-8
Rear axle ................................................................... 27-33
Hydraulic pressure check
Manual transaxle ....................................................... 22A-121
Twin c lut ch-sportron ic shift transmission (T
Hydraulic unit check ...................................................... 35C-284
Id codes registration procedure ..................................... 42C-116
Id codes registration procedures ................................... 42B-227
Idle mixture check.......................................................... 11A-13
Idle-up operation check ................................................. 55-169
Ignition timing check ...................................................... 11A-10
In the event of a discharged battery .............................. 35C-287
Injector check ................................................................ 13A-878
Injector relay continuity check ....................................... 13A-873
n solenoid check
.......... 13A-875
.......... 13A-881
C-SST
)... 22C-402
)... 22C-403
C-SST
Inspection of keyless entry timer lock function
Keyless operation system (KOS) ............................... 42B-237
Wireless control module (WCM) ................................ 42C-128
Intake air temperature sensor check ............................. 13A-874
Intake charge pressure check........................................ 15-5
Intake charge pressure control system check ............... 15-7
Key interlock mechanism check .................................... 22C-401
Keyless entry system check
Keyless operation system (KOS) ............................... 42B-237
Wireless control module (WCM) ................................ 42C-128
Lower arm ball joint end play check............................... 33-9
Manifold vacuum check ................................................. 11A-16
Master cylinder brake fluid pressur
Multiport fuel injection (MFI) relay continuity check
Oil pressure check
Engine lubrication ...................................................... 12-6
Rear axle.................................................................... 27-31
Oil pump pressure test................................................... 37-26
Parking brake lever stroke check and adjustment ......... 36-8
Parking brake lining seating procedure ......................... 36-9
Parking brake switch check ........................................... 36-9
Performance test <vehicles using r-134a refrigerant> ... 55-166
Power door locks with selective unlocking inspection
Keyless operation system (KOS) ............................... 42B-237
Wireless control module (WCM) ................................ 42C-128
Power relay check ......................................................... 55-168
Power steering pressure switch check .......................... 37-27
Power steering system air bleeding............................... 37-25
Propeller shaft universal joint check .............................. 25-5
Radiator cap opening pressure check ........................... 14-17
Rear axle total backlash check ...................................... 27-25
Rear wheel alignment check and adjustment ................ 34-9
Refrigerant leak repair procedure .................................. 55-167
Shift lever operation check ............................................ 22C-400
Shift lock mechanism check .......................................... 22C-402
Sight glass refrigerant level test..................................... 55-164
Simple inspection of the A/C pressure sensor............... 55-164
Stationary steering effort ch eck ... .................................. 37-23
Steering an gle check .. ....... ....... ......................... ....... ..... 37-16
Steering column shaft assembly shock absorbing mechanism
check ............................................................................. 37-28
Steering wh eel fre e play check ... ....... .................. ....... ... 37-16
Steering wh eel ret urn to center check .. .................. ....... 37-23
Steering wh eel sen sor calibration ....... ........................... 35C-289
Throttle actuator control motor check............................ 13A-879
Throttle actuator control motor r
Throttle body (throttle valve area
Tie rod end ball joint rotation torque check.................... 37-22
Tie-rod looseness check ....................
Timing chain elongation visu
Tire inflation pressure check.......................................... 31-7
Tire wear check.............................................................. 31-7
TPMS transmitter check
Keyless operation system (KOS) ............................... 42B-236
Wireless control module (WCM) ................................ 42C-128
TPMS transmitter id check
Keyless operation system (KOS) ............................... 42B-236
Wireless control module (WCM) ................................ 42C-128
e sensor
elay contin
) cleaning ................... 13A-865
al check ............................ 11A-17
calibration. 35C-294
....... 13A-870
uity check ... 13A-873
............................ 37-17
TSB Revision
Page 24
22
ALPHABETICAL INDEX
Transfer oil change
Manual transaxle ....................................................... 22A-119
Twin c lut ch-sportron ic shift transmission (TC-SST
Transfer oil check
Manual transaxle ....................................................... 22A-118
Twin c lut ch-sportron ic shift transmission (T
Transmission fluid change............................................. 22C-399
Transmission fluid leakage check .................................. 22C-398
Transmission fluid level check ....................................... 22C-398
Transmission oil change ................................................ 22A-117
Transmission oil level check .......................................... 22A-117
Turbocharger bypass valve check ................................. 15-10
Turbocharger waste gate solenoid check
Turbocharger wastegate actuator check ....................... 15-7
Val ve clea rance check and adju stment ........ ....... .......... 11A-10
Water pump coolant lea k check .................................... 14-19
Wheel bearing end play check
Front axle................................................................... 26-7
Rear axle ................................................................... 27-32
Wheel runout check....................................................... 31-7
Other devices .................................................................... 70-3
Output shaft
Disassembly and assembly ........................................... 22B-29
Inspection ...................................................................... 22B-35
Overall configuration diagram ........................................... 80A-2
............
)... 22C-400
C-SST
)... 22C-400
.......... 15-8
P
Paddle shift assembly
Inspection
Paddle shift switch check........................................... 22C-433
Removal and installation ............................................... 22C-433
Panic alarm
Diagnosis
Diagnostic function .................................................... 54A-776
Standard flow of diagnostic troubleshooting .............. 54A-776
General information ....................................................... 54A-774
On-vehicle service
Customization function .............................................. 54A-779
Removal and installation ............................................... 54A-779
Special too ls ......... ....... ....... ......................... .................. 54A-775
Symptom procedures
Panic alarm does not work normally.......................... 54A-777
Trouble symptom chart .................................................. 54A-777
Parking brake cable
Removal and installation ............................................... 36-12
Parking brake diagnosis
Introduction.................................................................... 36-2
Symptom chart .............................................................. 36-3
Symptom procedures
king brake function 36-3
Inspection procedure 1: insufficient p
Inspection procedure 2: when the parking brake lever
brake warning light does not illuminate...................... 36-4
Troubleshooting strategy ............................................... 36-2
Parking brake lever
Removal and installation ............................................... 36-10
Parking brake lining and drum........................................... 36-14
Parking brake lining and drum
Inspection ...................................................................... 36-17
ar
is pulled, the
Removal and installation................................................ 36-14
Parking brake reminder tone alarm
Supplemental restraint system (SRS)............................ 90-370
Circuit diagrams............................................................. 90-370
Passenger's (front) air bag module
Inspection
Supplemental restraint system (SRS)........................ 52B-424
Circuit diagrams ......................................................... 52B-424
Removal and installation
Supplemental restraint system (SRS)........................ 52B-420
Circuit diagrams ......................................................... 52B-420
Piston and connecting rod
Inspection ...................................................................... 11B-72
Removal and installation................................................ 11B-64
Post-collision diagnosis
Supplemental restraint system (SRS)............................ 52B-398
Circuit diagrams............................................................. 52B-398
Power distribution system
Supplemental restraint system (SRS)............................ 90-28
Circuit diagrams............................................................. 90-28
Power steering diagnosis
Introduction to power steering diagnosis ....................... 37-5
Power steering diagnosis troubleshooting strategy .......
Symptom chart............................................................... 37-5
Symptom procedures
ing w
Inspection procedure 1: excessive play of steer
Inspection procedure 10: oil leakage from ho
Inspection procedure 11: oil leakage from ho
Inspection procedure 12: oil leakage from oil reservoir 37-13
Inspection pr
Inspection procedure 14: oil leakage from steer
Inspection procedure 2: difficult steering
cient power assist) ..................................................... 37-7
Inspection procedure 3: rattling noise ........................ 37-8
Inspection procedure 4: shrill noise
Inspection procedure 5: squealing noise
Inspection procedure 6: hissing noise........................ 37-9
Inspection procedure 7: droning noise
Inspection procedure 8: squeaking noise
Inspection procedure 9: vibration............................... 37-12
Power steering gear box and linkage
Disassembly and assembly ........................................... 37-42
Inspection ...................................................................... 37-41
Removal and installation................................................ 37-38
Power steering hoses ........................................................ 37-47
Power steering hoses
Removal and installation................................................ 37-47
Power steering oil pump assembly
Inspection ...................................................................... 37-46
Removal and installation................................................ 37-45
Power windows
Supplemental restraint system (SRS)............................ 90-160
Circuit diagrams............................................................. 90-160
Precautions before service
Application of anti-corrosion agents and undercoats..... 00-43
Bolts and nuts with stabilizer for coef
Cautions for working in engine compartment ................ 00-20
Coding list ...................................................................... 00-26
Engine idling learning procedure ................................... 00-36
ocedure 13: oil leakage from oil pump
wheel operation (insuffi-
........................... 37-9
................... 37-9
....................... 37-10
.................. 37-11
ficient of friction
heel 37-6
se connection 37-12
se assembly 37-12
.. 37-13
ing gear 37-13
.... 00-43
37-5
TSB Revision
Page 25
ALPHABETICAL INDEX
23
Form− in− place gasket (fipg) ............................................ 00-43
How to perform vehicle identification number (vin) writing 00-22
How to shif
Initialization procedure for learning value in MFI engine 00-35
Scan tool (multi use tester { M.U
Servicing electrical system ..................................
Supplemental restraint system (SRS) ........................... 00-20
Timing chain maintenance............................................. 00-37
Vehicle washing ............................................................. 00-43
Precautions on how to repair the CAN bus lines............... 54C-8
Propeller shaft
Disassembly and assembly ........................................... 25-10
Inspection ...................................................................... 25-9
Removal and installation ............................................... 25-7
Propeller shaft diagnosis
Introduction to propeller shaf
Propeller shaft diagnostic troubleshooting strategy....... 25-4
Symptom chart .............................................................. 25-4
Symptom procedures
Inspection procedure 1: noise at start........................ 25-4
Inspection procedure 2: noise and
t lock forced release..................................... 00-42
.T.-III }
sub assembly). 00-21
.......... 00-41
t diagnosis..............
vibration at high speed 25-5
.......... 25-4
R
Radiator
Removal and installation ............................................... 14-32
Radio and CD player
Diagnosis
Diagnosis function ..................................................... 54A-319
Introduction to audio system diagnosis...................... 54A-317
Standard flow of diagnostic troubleshooting .............. 54A-319
Diagnostic trouble code chart ........................................ 54A-322
Diagnostic trouble code procedures
DTC B2420: power integrated circuit......................... 54A-342
DTC B2421: radio tuner............................................. 54A-343
DTC B2423: 6 CD player error .................................. 54A-345
DTC B2424: CD player error ..................................... 54A-347
DTC B2450: switch panel communication ................. 54A-350
DTC B2451: audio panel type error ........................... 54A-354
DTC U0019: bus off (CAN-B) .................................... 54A-322
DTC U0141: ETACS CAN timeout............................. 54A-324
DTC U0151: SRS-ECU CAN timeout ........................ 54A-326
DTC U0154: ocm (occupant classification-ECU) CAN
timeout ....................................................................... 54A-328
DTC U0155: meter CAN timeout ............................... 54A-330
DTC U0164: A/C CAN timeout .................................. 54A-332
DTC U0168: WCM CAN timeout ............................... 54A-334
DTC U0195: satellite radio CAN timeout ................... 54A-336
DTC U0197: hands free module CAN timeout........... 54A-338
DTC U1415: coding not completed/data fail .............. 54A-340
General information ....................................................... 54A-315
Inspection
Audio adapter inspection ........................................... 54A-409
On-vehicle service
Adjustment of volume and sound quality automatic correction func-
tion............................................................................. 54A-407
Removal and installation ............................................... 54A-408
Service data................................................................... 54A-407
Special too ls ......... ....... ....... ......................... .................. 54A-316
Symptom procedures
Inspection procedure 1: power is not turned on when the power
switch is turned on. .................................................... 54A-357
Inspection procedure 10: broadcasts can be heard but both AM and
FM have a lot of noise................................................ 54A-395
Inspection procedure 11: there is more n
AM or FM. .................................................................. 54A-396
Inspection procedure 12: noise is
(FM). .......................................................................... 54A-397
Inspection procedure 13: noise appears during vibration or
shocks........................................................................ 54A-398
Inspection procedure 14: noise is detected with engine
running. ...................................................................... 54A-400
Inspection procedure 15: constant noise. .................. 54A-401
Inspection procedure 16: noise comes out, but neither AM nor FM
sounds. ...................................................................... 54A-401
Inspection procedure 17: poor reception. .................. 54A-402
Inspection procedure 18: distortion on AM or on both AM
and FM....................................................................... 54A-403
Inspection procedure 19: distortion on
Inspection procedure 2: No sound is heard. <vehicles with
amplifier> ................................................................... 54A-362
Inspection procedure 20: using the auto select function, too few
automatic stations are selected. ................................ 54A-403
Inspection procedure 21: preset station are erased... 54A-404
Inspection procedure 22: CD can not be inserted...... 54A-404
Inspection procedure 23: No sound. (CD only)
Inspection procedure 2
Inspection procedure 25: sound quality is poor.......... 54A-406
Inspection procedure 26: CD can not be
Inspection
ers. <vehicles with audio amplifier> ........................... 54A-375
Inspection procedure 3: No sound is heard from one of the speak-
ers. <vehicles without audio amplifier> ...................... 54A-369
Inspection procedure 4: the audio does not operate normally by
operating the radio and C
unit. ............................................................................ 54A-382
Inspection procedure 5: audio illuminations does not work
norm
Inspection procedure 6: the sound of external input are not
played. ....................................................................... 54A-391
Inspection procedure 7: noise is p
(AM). .......................................................................... 54A-393
Inspection procedure 8: noise is present while
(FM). .......................................................................... 54A-394
Inspection procedure 9: sound mixed with noise, only at night
(AM). .......................................................................... 54A-395
Trouble symptom chart .................................................. 54A-356
Rear axle diagnosis <AYC>
Actuator test reference table.......................................... 27-20
Check at AWC-ECU....................................................... 27-20
Data list reference table................................................. 27-20
Diagnostic function ........................................................ 27-6
Diagnostic trouble code chart ........................................ 27-8
Inspection procedure for diagnosis code
Code No. C1619 AYC current value abnormality....... 27-9
Code No. C161A AYC direction valve (RH) output error 27-12
Code No. C161B AYC direction valve (LH) output error 27-15
Code No. C1620 AYC control abnormality................. 27-18
Standard flow of diagn ostic troubleshooting .................. 27-6
Symptom procedures
Inspection procedure 1: abnormal noise from ayc differential (torque
transfer mechanism) during cornering ....................... 27-19
Trouble symptom chart .................................................. 27-19
Rear axle diagnosis <except AYC>
Introduction .................................................................... 27-4
procedure 3: No sound is heard from one of the speak-
ally...................................................................... 54A-386
4: CD sound skips. ................ 54A-405
D player of the center panel
oise on either
present while moving
FM only.
resent while
........ 54A-403
.......... 54A-405
ejected....... 54A-406
moving
moving
audio
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Page 26
24
ALPHABETICAL INDEX
Symptom chart .............................................................. 27-4
Symptom procedures
Inspection procedure 1: noise during wheel rotation
<driveshaft> ............................................................... 27-5
Inspection procedure 8: oil leakage <differential> ..... 27-5
Troubleshooting strategy ............................................... 27-4
Rear axle hub assembly
Inspection ...................................................................... 27-38
Removal and installation ............................................... 27-35
Rear bumper assembly
Removal and installation ............................................... 51-6
Rear combination light
Diagnosis
Diagnostic function .................................................... 54A-215
Standard flow of diagnostic troubleshooting .............. 54A-215
Diagnostic trouble code chart ........................................ 54A-217
Diagnostic trouble code procedures
circuit
DTC B16A0: taillight (RH) circuit open (open
marker light (RH), taillight (RH) or position light (RH))DTC B16A7:
taillight (RH) circuit short (short circuit in rear side marker light (RH),
taillight (RH) or position light ... ................................. 54A-218
DTC B16A1: taillight (LH) circuit open (open
marker light (LH), taillight (LH), position light (LH), or license plate
light)DTC B16A8: taillight (LH) circuit short (short circuit in rear side
marker light (LH), taillight ( ........................................ 54A-224
General information ....................................................... 54A-213
Rear combination light removal and installation ............ 54A-237
Special too ls ......... ....... ....... ......................... .................. 54A-214
Symptom procedures
Inspection procedure 1: none of taillights illuminates. 54A-230
Inspection procedure 2: one of the taillights does not
illuminate.................................................................... 54A-233
Taillight removal and installation.................................... 54A-237
Trouble symptom chart .................................................. 54A-230
Rear disc brake assembly
Disassembly and assembly ........................................... 35A-37
Inspection
Basic brake system.................................................... 35A-36
Basic brake system.................................................... 35A-39
Removal and installation ............................................... 35A-35
Rear roll stopper and crossmember
Removal and installation ............................................... 32-10
Rear spoiler
Removal and installation ............................................... 51-16
Rear suspension crossmember
Removal and installation ............................................... 34-30
Rear suspension diagnosis............................................... 34-6
Rear suspension diagnosis
...........
Introduction to rear suspension diagnosis
Rear suspension diagnostic troubleshooting strategy ... 34-6
Symptom chart .............................................................. 34-6
Symptom procedures
Inspection procedure 1: squeaks or o
Inspection procedure 2: poor ride .............................. 34-7
Inspection procedure 3: body tilting ........................... 34-7
Rear window defogger
Supplemental restraint system (SRS) ........................... 90-222
Circuit diagrams............................................................. 90-222
Receiver antenna assembly
Removal and installation ............................................... 42C-140
Recommended lubricants and lubricant capacities table .. 00-54
ther abn
.......... 34-6
ormal noise 34-6
in rear side
circuit
in rear side
Refrigerant line
Refrigerant line removal and installation........................ 55-187
Relay ................................................................................. 70-2
Remote controlled mirror
Supplemental restraint system (SRS)............................ 90-220
Circuit diagrams............................................................. 90-220
Reverse idler gear
Disassembly and assembly ........................................... 22B-37
Inspection ...................................................................... 22B-39
S
Satellite radio tuner
Diagnosis
Diagnosis function...................................................... 54A-595
diagn
Introduction to satellite radio
Standard flow of diagnostic troubleshooting .............. 54A-595
Diagnostic trouble code chart ........................................ 54A-598
Diagnostic trouble code procedures
DTC B2222: radio receiver internal fail ...................... 54A-598
DTC U0019: bus off (CAN-B)..................................... 54A-600
DTC U0141: ETACS CAN timeout............................. 54A-601
DTC U0151: SRS-ECU CAN timeout ........................ 54A-603
DTC U0154: ocm (occupant classification-ECU) CAN
timeout .......................................................................
DTC U0155: meter CAN timeout ............................... 54A-607
DTC U0164: A/C CAN timeout................................... 54A-609
DTC U0168: WCM CAN timeout................................ 54A-611
DTC U0184: audio CAN timeout................................ 54A-613
DTC U0197: hands free module CAN timeout........... 54A-615
General information ....................................................... 54A-594
On-vehicle service
How to read sirius id .................................................. 54A-628
Removal and installation................................................ 54A-628
Special too ls..... ....... ....... .................. ....... ....................... 54A-594
Symptom procedures
Inspection procedure 1: a satellite radio cannot be
received. .................................................................... 54A-618
Inspection procedure 2: check the satellite radio tuner pow
circuit.......................................................................... 54A-623
Inspection procedure 3: the error code "antenna
on the display............................................................. 54A-626
Trouble symptom chart .................................................. 54A-617
Scheduled maintenance table ........................................... 00-57
Sealant
Engine lubrication .......................................................... 12-3
Engine cooling ............................................................... 14-3
Rear axle ....................................................................... 27-4
Power steering............................................................... 37-5
Sealant and adhesive ........................................................ 13A-6
Sealants............................................................................. 11A-3
Sealants and adhesives
Engine overhaul............................................................. 11B-7
Manual transaxle overhaul............................................. 22B-4
Twin c lutch sst o verhaul. ........... ... ........ ... ........... ... ........ . 22D-3
Seat assembly
Front seat assembly ...................................................... 52A-21
Front seat assembly
Disassembly and assembly ....................................... 52A-25
Inspection................................................................... 52A-23
osis...................... 54A-595
54A-605
er supply
er
ror" is displayed
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Page 27
ALPHABETICAL INDEX
25
Removal and installation............................................ 52A-21
Rear seat assembly
Disassembly and assembly ....................................... 52A-29
Removal and installation............................................ 52A-27
Seat belt
Front seat belt
Inspection .................................................................. 52A-31
Removal and installation............................................ 52A-30
Rear seat belt
Removal and installation............................................ 52A-32
Seat belt warning tone alarm
Supplemental restraint system (SRS) ........................... 90-362
Circuit diagrams............................................................. 90-362
Seat belts with pre-tensioner
Inspection
Supplemental restraint system (SRS)........................ 52B-443
Circuit diagrams......................................................... 52B-443
Removal and installation
Supplemental restraint system (SRS)........................ 52B-440
Circuit diagrams......................................................... 52B-440
Select lever
Disassembly and assembly ........................................... 22B-43
Sensor ............................................................................... 70-8
Sensor, switch and relay
Inspection
AWC switch check ................ ..................................... 22A-134
Electric pump relay check.......................................... 22A-134
Removal and installation
Manual transaxle ....................................................... 22A-133
C-SST
Twin c lut ch-sportron ic shift transmission (T
Service precautions
Supplemental restraint system (SRS) ........................... 52B-24
Controller area network (CAN) ...................................... 54C-7
Circuit diagrams............................................................. 52B-24
Service precautions
Caution labels................................................................ 55-6
Service specification
Intake and exhaust ........................................................ 15-2
Manual transaxle ........................................................... 22A-2
Propeller shaft ............................................................... 25-3
Service specification(s)
Engine lubrication .......................................................... 12-2
Multiport fuel injection (MFI) .......................................... 13A-6
Clutch ............................................................................ 21A-2
Service specifications
Engine mechanical ........................................................ 11A-3
Engine overhaul............................................................. 11B-2
Engine cooling ............................................................... 14-2
Clutch overhaul.............................................................. 21B-2
Manual transaxle overhaul ............................................ 22B-3
Front axle....................................................................... 26-4
Rear axle ....................................................................... 27-3
Wheel and tire ............................................................... 31-2
Front suspension........................................................... 33-3
Rear suspension............................................................ 34-5
Basic brake system ....................................................... 35A-3
Active stability control system (ASC)............................. 35C-6
Parking brakes............................................................... 36-2
Power steering............................................................... 37-4
)... 22C-434
Heater, air conditioning and ventilation.......................... 55-5
Shift lock mechanism
Supplemental restraint system (SRS)............................ 90-80
Circuit diagrams............................................................. 90-80
Shock absorber assembly
Disassembly and assembly ........................................... 34-25
Removal and installation................................................ 34-24
Side air dam
Removal and installation................................................ 51-13
Side impact sensor
Inspection
Supplemental restraint system (SRS)........................ 52B-431
Circuit diagrams ......................................................... 52B-431
Removal and installation
Supplemental restraint system (SRS)........................ 52B-429
Circuit diagrams ......................................................... 52B-429
Side turn-signal light
Removal and installation................................................ 54A-258
Side-airbag module(s)
Inspection
Supplemental restraint system (SRS)........................ 52B-435
Circuit diagrams ......................................................... 52B-435
Removal and installation
Supplemental restraint system (SRS)........................ 52B-432
Circuit diagrams ......................................................... 52B-432
Solenoid and solenoid valve.............................................. 70-14
Spar e connector (for audio)
Supplemental restraint system (SRS)............................ 90-256
Circuit diagrams............................................................. 90-256
Spar e conne ctor (f or navi gation system)
Supplemental restraint system (SRS)............................ 90-262
Circuit diagrams............................................................. 90-262
Speaker
General information ....................................................... 54A-633
On-vehicle service
Speaker test <vehicles with MMCS> ......................... 54A-638
Speaker test <vehicles with radio and CD player> . ... 54A-636
Removal and installation................................................ 54A-638
Special tool
Multiport fuel injection (MFI) .......................................... 13A-7
Propeller shaft................................................................ 25-5
Rear axle ....................................................................... 27-21
Power plant mount......................................................... 32-3
Parking brakes............................................................... 36-7
Interior............................................................................ 52A-2
Special tools
Engine mechanical ........................................................ 11A-4
Engine overhaul............................................................. 11B-8
Engine lubrication .......................................................... 12-4
Fuel supply .................................................................... 13B-5
Engine cooling ............................................................... 14-15
Intake and exhaust ........................................................ 15-4
Clutch overhaul.............................................................. 21B-3
Manual transaxle ........................................................... 22A-3
Manual transaxle overhaul............................................. 22B-8
Twin c lutch-sport ronic sh ift tr ansmission (TC -SS T) ... .... 22C-4
Twin c lutch sst o verhaul. ........... ... ........ ... ........... ... ........ . 22D-4
Front axle....................................................................... 26-6
Front suspension........................................................... 33-7
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Page 28
26
ALPHABETICAL INDEX
Rear suspension............................................................ 34-8
Basic brake system ....................................................... 35A-12
Active stability control system (ASC)............................. 35C-283
Power steering............................................................... 37-14
Keyless operation system (KOS)................................... 42B-8
Wireless control module (WCM).................................... 42C-5
Supplemental restraint system (SRS) ........................... 52B-396
Local interconnect network (LIN)................................... 54B-3
Controller area network (CAN) ...................................... 54C-5
Heater, air conditioning and ventilation.......................... 55-161
Circuit diagrams............................................................. 52B-396
Specification(s)
Adhesive........................................................................ 51-2
Lubricant........................................................................ 51-2
Service specifications .................................................... 51-2
Splash shield
Removal and installation ............................................... 42A-12
SRS air bag diagnosis
Accuracy check of occupant
Supplemental restraint system (SRS)........................ 52B-395
Circuit diagrams......................................................... 52B-395
Actuator test reference table
Supplemental restraint system (SRS)........................ 52B-395
Circuit diagrams......................................................... 52B-395
Data list reference table
Supplemental restraint system (SRS)........................ 52B-393
Circuit diagrams......................................................... 52B-393
Diagnostic function
Supplemental restraint system (SRS)........................ 52B-27
Circuit diagrams......................................................... 52B-27
Diagnostic trouble code chart <occup
Supplemental restraint system (SRS)........................ 52B-316
Circuit diagrams......................................................... 52B-316
Diagnostic trouble code chart <SRS-ECU>
Supplemental restraint system (SRS)........................ 52B-30
Circuit diagrams......................................................... 52B-30
Diagnostic trouble code procedures <occup
DTC B1B78: passenger seat weight sensor (front: LH) performanceDTC B1B7D: passenger seat weight sensor (front: RH) per-
formanceDTC B1B82: passenger seat weight sensor (rear: LH)
performanceDTC B1B87: passenger seat weight sensor ( ...
Supplemental restraint system (SRS)........................ 52B-318
Circuit diagrams......................................................... 52B-318
DTC B1B79: passenger seat weight sensor (gr
cuited (front: LH)DTC B1B7E: passenger seat weight sensor
(ground side) short-circuited (front: RH)DTC B1B83: passenger seat
weight sensor (ground side) short-circuited (rea ...
Supplemental restraint system (SRS)........................ 52B-322
Circuit diagrams......................................................... 52B-322
DTC B1B7A: passenger seat weight sensor
short-circuited or open (front: LH)DTC B1B7F: passenger seat
weight sensor (power supply side) short-circuited or open (front:
RH)DTC B1B84: passenger seat weight sensor (power ...
Supplemental restraint system (SRS)........................ 52B-326
Circuit diagrams......................................................... 52B-326
DTC B1B8C: driver seat slide sensor circuit per
Supplemental restraint system (SRS)........................ 52B-331
Circuit diagrams......................................................... 52B-331
DTC B1B8D: driver seat slide sensor ope
Supplement
Circuit diagrams......................................................... 52B-336
al restraint system (SRS)........................ 52B-336
classification senso
ant classification-
r
ECU>
ssification-ECU>
ant cla
ound side)
ower supply side)
(p
nce
forma
n circuit
short-cir-
DTC B1B8E: seat slide sensor (pow
Supplemental restraint system (SRS)........................ 52B-339
Circuit diagrams ......................................................... 52B-339
DTC B1B91: driver seat slide sensor configuration mismat
Supplement
Circuit diagrams ......................................................... 52B-343
DTC B1BA7: occupant classification system verification r
Supplemental restraint system (SRS)........................ 52B-345
Circuit diagrams ......................................................... 52B-345
DTC B1BA8: occupant classification-ECU out of calibration/not calibrated
Supplemental restraint system (SRS)........................ 52B-346
Circuit diagrams ......................................................... 52B-346
DTC B1BBA: passenger seat weight sensor power supply circuit
Supplemental restraint system (SRS)........................ 52B-348
Circuit diagrams ......................................................... 52B-348
DTC B1BBC: occupant classification syst
weight
Supplemental restraint system (SRS)........................ 52B-350
Circuit diagrams ......................................................... 52B-350
DTC B1BBD: occupant classification-EC
table unprogrammed
Supplemental restraint system (SRS)........................ 52B-352
Circuit diagrams ......................................................... 52B-352
DTC B1C23: passenger seat weight sensor (fr
mismatchDTC B1C24: passenger seat weight sensor (front: RH)
configuration mismatchDTC B1C25: passenger seat weight sensor
(rear: LH) configuration mismatchDTC B1C2 ...
Supplemental restraint system (SRS)........................ 52B-353
Circuit diagrams ......................................................... 52B-353
DTC B1CB2: occupant classification-ECU p
patibleDTC B2212: occupant classification-ECU internal failureDTC
B2250: occupant classification-ECU not parameter flash required-
DTC B2262: occupant classification-ECU e ...
Supplemental restraint system (SRS)........................ 52B-355
Circuit diagrams ......................................................... 52B-355
DTC B210D: battery voltage lowDTC B210E: battery voltage high
Supplemental restraint system (SRS)........................ 52B-357
Circuit diagrams ......................................................... 52B-357
DTC B2206: chassis number does not match
Supplemental restraint system (SRS)........................ 52B-361
Circuit diagrams ......................................................... 52B-361
DTC U0020: CAN-B bus off performanceDTC U0021: CAN-B bus
I) cir
(H
groundDTC U0023: CAN-B bus (HI) shorted to circuit power supplyDTC U0024: CAN-B bus (LO) circuit open ...
Supplemental restraint system (SRS)........................ 52B-363
Circuit diagrams ......................................................... 52B-363
DTC U0141: ETACS CAN timeout
Supplemental restraint system (SRS)........................ 52B-364
Circuit diagrams ......................................................... 52B-364
DTC U0151: SRS-ECU CAN timeout
Supplemental restraint system (SRS)........................ 52B-366
Circuit diagrams ......................................................... 52B-366
DTC U0155: combination meter CAN timeout
Supplemental restraint system (SRS)........................ 52B-368
Circuit diagrams ......................................................... 52B-368
DTC U0164: A/C-ECU CAN timeout
Supplemental restraint system (SRS)........................ 52B-370
Circuit diagrams ......................................................... 52B-370
DTC U0168: KOS-ECU or WCM CAN timeout
Supplemental restraint system (SRS)........................ 52B-372
Circuit diagrams ......................................................... 52B-372
al restraint system (SRS)........................ 52B-343
cuit openDTC U0022: CAN-B bus (HI) shorted to circuit
er supply sid
e) short circuit
ch
equir
ed
negative system
em
U
current configuration
LH) configuration
ont:
rameter table incom-
a
TSB Revision
Page 29
ALPHABETICAL INDEX
27
DTC U0184: audio CAN timeout
Supplemental restraint system (SRS)........................ 52B-374
Circuit diagrams......................................................... 52B-374
DTC U0195: satellite radio tuner CAN timeout
Supplemental restraint system (SRS)........................ 52B-376
Circuit diagrams......................................................... 52B-376
DTC U0197: hands free module CAN timeout
Supplemental restraint system (SRS)........................ 52B-378
Circuit diagrams......................................................... 52B-378
DTC U0245: audio visual navigatio
Supplement
Circuit diagrams......................................................... 52B-380
DTC U1419: the signal from a weight sensor (
alDTC U141A: the signal from a weight sensor (front: RH) is unusu-
alDTC U141B: the signal from a weight sensor (rear: LH) is
unusualDTC U141C: the signal from a weight ...
Supplemental restraint system (SRS)........................ 52B-382
Circuit diagrams......................................................... 52B-382
Diagnostic trouble code procedur
DTC B1206: passenger’s air bag off indicator light (open
Supplemental restraint system (SRS)........................ 52B-34
Circuit diagrams......................................................... 52B-34
DTC B1207: passenger’s air bag off indicator light (short circuit
betwe
Supplement
Circuit diagrams......................................................... 52B-38
DTC B1B00: driver's air bag module (1st squib) system (shorted to
squib circuit ground)
squib) system (shorted to squib circuit ground)
Supplemental restraint system (SRS)........................ 52B-42
Circuit diagrams......................................................... 52B-42
DTC B1B01: driver's air bag module (1st squib) system (shorted to
squib circuit pow
squib) system (shorted to squib circuit power supply
Supplemental restraint system (SRS)........................ 52B-49
Circuit diagrams......................................................... 52B-49
DTC B1B02: driver's air bag module (1st squib)
cuit open)DTC B1B06: driver's air bag module (2nd squib) system
(squib circuit open)
Supplemental restraint system (SRS)........................ 52B-56
Circuit diagrams......................................................... 52B-56
DTC B1B03: driver's air bag module (1st squib) system (short circuit
betwe
(2nd squib) system (short circuit between squib circuit terminals)
Supplemental restraint system (SRS)........................ 52B-63
Circuit diagrams......................................................... 52B-63
DTC B1B08: passenger's (front) air bag module (1st squib) system
(shor
bag module (2nd squib) system (shorted to squib circuit ground)
Supplemental restraint system (SRS)........................ 52B-71
Circuit diagrams......................................................... 52B-71
DTC B1B09: passenger's (front) air bag module (1st squib) system
(shor
(front) air bag module (2nd squib) system (shorted to squib circuit
power supply
Supplemental restraint system (SRS)........................ 52B-76
Circuit diagrams......................................................... 52B-76
DTC B1B0A: passenger's (front) air bag module (1st squib) system
(squib
(2nd squib) system (squib circuit open)
Supplemental restraint system (SRS)........................ 52B-81
Circuit diagrams......................................................... 52B-81
DTC B1B0B: passenger's (front) air bag module (1st squib) system
(shor
ger's (front) air bag module (2nd squib) system (short circuit
between squib circuit terminals)
al restraint system (SRS)........................ 52B-380
en circuit terminal)
al restraint system (SRS)........................ 52B-38
DTC
er supply)
en squib
ted t
ted t
t circuit betwee
circuit terminals)DTC B1B07: driver's air bag module
o squib circuit ground)DTC B1B0C: passenger's (front) air
o squib circuit power supply)DTC B1B0D: passenger's
circuit open)D
TC B1B0E: passenger's (front) air bag module
n squib circuit terminals)DTC B1B0F: passen-
n unit CAN timeout
front:
LH) is unusu-
es <SRS-
B1B04: driver's air bag module (2nd
DTC B1B05: driver's air bag module (2nd
ECU>
circuit)
syst
em (squib cir-
Supplemental restraint system (SRS)........................ 52B-86
Circuit diagrams ......................................................... 52B-86
DTC B1B10: driver's knee air bag (squib) system (shorted to squib
c
uit ground)
cir
Supplemental restraint system (SRS)........................ 52B-92
Circuit diagrams ......................................................... 52B-92
(shor
DTC B1B11: driver's knee air bag (squib) system
circuit power supply)
Supplemental restraint system (SRS)........................ 52B-97
Circuit diagrams ......................................................... 52B-97
DTC B1B12: driver's knee air bag (squib) system (squib circuit
open)
Supplemental restraint system (SRS)........................ 52B-102
Circuit diagrams ......................................................... 52B-102
DTC B1B13: driver's knee air bag (squib)
between squib circuit terminals)
Supplemental restraint system (SRS)........................ 52B-107
Circuit diagrams ......................................................... 52B-107
DTC B1B18: curtain air bag module (LH) (squib) system (shorted to
squib circuit g
Supplemental restraint system (SRS)........................ 52B-113
Circuit diagrams ......................................................... 52B-113
DTC B1B19: curtain air bag module (LH) (squib) system (shorted to
squib circuit p
Supplemental restraint system (SRS)........................ 52B-119
Circuit diagrams ......................................................... 52B-119
DTC B1B1A: curtain air bag module (LH) (squib) system (squib circuit open)
Supplemental restraint system (SRS)........................ 52B-125
Circuit diagrams ......................................................... 52B-125
DTC B1B1B: curtain air bag module (LH) (squib) system (short circuit between squib circuit terminals)
Supplemental restraint system (SRS)........................ 52B-133
Circuit diagrams ......................................................... 52B-133
DTC B1B20: curtain air bag module (RH) (squib) system (shorted to
squib circuit g
Supplemental restraint system (SRS)........................ 52B-141
Circuit diagrams ......................................................... 52B-141
DTC B1B21: curtain air bag module (RH) (squib) system (shorted to
squib circuit p
Supplemental restraint system (SRS)........................ 52B-148
Circuit diagrams ......................................................... 52B-148
DTC B1B22: curtain air bag module (RH) (squib) system (squib circuit open)
Supplemental restraint system (SRS)........................ 52B-155
Circuit diagrams ......................................................... 52B-155
DTC B1B23: curtain air bag module (
cuit between squib circuit terminals)
Supplemental restraint system (SRS)........................ 52B-163
Circuit diagrams ......................................................... 52B-163
DTC B1B54: seat belt buckle switch (RH)
shorted DTC B1B55: seat belt buckle switch (RH) circuit (power
supply side) shortedDTC B1B56: seat belt buckle switch (RH) circuit
open
Supplemental restraint system (SRS)........................ 52B-170
Circuit diagrams ......................................................... 52B-170
DTC B1B70: malfunction of G-sensor inside
(LH)DTC B1B71: malfunction of G-sensor inside front impact sensor
(RH)
Supplemental restraint system (SRS)........................ 52B-175
Circuit diagrams ......................................................... 52B-175
DTC B1B72: malfunction of G-sensor inside
(LH)DTC B1B75: malfunction of G-sensor inside side impact sensor
(RH)
Supplemental restraint system (SRS)........................ 52B-176
r
ound)
o
wer supply)
r
ound)
wer supply)
o
RH) (
system
squib) system (short cir-
circuit
ted to squib
(short circuit
(ground side)
ont impact sensor
fr
impact sensor
side
TSB Revision
Page 30
28
ALPHABETICAL INDEX
Circuit diagrams......................................................... 52B-176
DTC B1BA3: driver’s seat slide sensor malfunction (
sification-ECU)
Supplemental restraint system (SRS)........................ 52B-178
Circuit diagrams......................................................... 52B-178
DTC B1BA5: SRS-ECU squib count mismatch
Supplemental restraint system (SRS)........................ 52B-180
Circuit diagrams......................................................... 52B-180
DTC B1BAA: occupant classification-ECU configuration mismatch
Supplemental restraint system (SRS)........................ 52B-181
Circuit diagrams......................................................... 52B-181
DTC B1BC7: SRS-ECU (record data full) system
Supplemental restraint system (SRS)........................ 52B-183
Circuit diagrams......................................................... 52B-183
DTC B1C27: side-air bag module (LH) (squib) system (shorted to
squib circuit ground)
Supplemental restraint system (SRS)........................ 52B-185
Circuit diagrams......................................................... 52B-185
DTC B1C28: side-air bag module (LH) (squib) system (shorted to
squib circuit power
Supplement
Circuit diagrams......................................................... 52B-189
DTC B1C29: side-air bag module (LH) (squib) system (squib circuit
open)
Supplemental restraint system (SRS)........................ 52B-194
Circuit diagrams......................................................... 52B-194
DTC B1C2A: side-air bag module (LH) (squib) system (short circuit
en squ
betwe
Supplemental restraint system (SRS)........................ 52B-200
Circuit diagrams......................................................... 52B-200
DTC B1C2B: side-air bag module (RH) (squib) system (shorted to
squib circuit ground)
Supplemental restraint system (SRS)........................ 52B-206
Circuit diagrams......................................................... 52B-206
DTC B1C2C: side-air bag module (RH) (squib) system (shorted to
squib circuit power
Supplement
Circuit diagrams......................................................... 52B-210
DTC B1C2D: side-air bag module (RH) (squib) system (squib circuit
open)
Supplemental restraint system (SRS)........................ 52B-216
Circuit diagrams......................................................... 52B-216
DTC B1C2E: side-air bag module (RH) (squib) system (short circuit
en squ
betwe
Supplemental restraint system (SRS)........................ 52B-221
Circuit diagrams......................................................... 52B-221
DTC B1C38: driver's seat belt pre-tensioner
to squib circuit ground)
Supplemental restraint system (SRS)........................ 52B-227
Circuit diagrams......................................................... 52B-227
DTC B1C39: driver's seat belt pre-tensioner
to squib circuit power supply)
Supplemental restraint system (SRS)........................ 52B-232
Circuit diagrams......................................................... 52B-232
DTC B1C3A: driver's seat belt pre-tensioner
circuit open)
Supplemental restraint system (SRS)........................ 52B-236
Circuit diagrams......................................................... 52B-236
DTC B1C3B: driver's seat belt pre-tensioner
circuit between squib circuit terminals)
Supplemental restraint system (SRS)........................ 52B-242
Circuit diagrams......................................................... 52B-242
supply)
al restraint system (SRS)........................ 52B-189
ib circuit terminals)
supply)
al restraint system (SRS)........................ 52B-210
ib circuit terminals)
(
(
occupant clas-
squib) system (shorted
squib) system (shorted
(squib) system (squib
(squib) system (short
DTC B1C47: front passenger's seat belt pre-tensioner (squib) sys-
tem (shorted to squib circuit ground)
Supplemental restraint system (SRS)........................ 52B-248
Circuit diagrams ......................................................... 52B-248
DTC B1C48: front passenger's seat belt pretem (shorted to squib circuit power supply)
Supplemental restraint system (SRS)........................ 52B-253
Circuit diagrams ......................................................... 52B-253
DTC B1C49: front passenger's seat belt pretem (squib circuit open)
Supplemental restraint system (SRS)........................ 52B-258
Circuit diagrams ......................................................... 52B-258
DTC B1C4A: front passenger's seat belt pre-tensioner (squib) system (short circuit between squib circuit terminals)
Supplemental restraint system (SRS)........................ 52B-263
Circuit diagrams ......................................................... 52B-263
DTC B210D: battery abnormal low voltage
Supplemental restraint system (SRS)........................ 52B-269
Circuit diagrams ......................................................... 52B-269
DTC B212C: open circuit to ig1 power supply (fuse No.12 circuit)DTC B212D: open circuit to ig1 power supply (fuse No.18 cir-
cuit)
Supplemental restraint system (SRS)........................ 52B-275
Circuit diagrams ......................................................... 52B-275
DTC B2207: occupant restraint controller internal 1DTC B2208:
ant restraint controller internal 2DT
occup
restraint controller internal 3DTC B220A: occupant restraint control-
ler internal 4DTC B220B: occupan ...
Supplemental restraint system (SRS)........................ 52B-280
Circuit diagrams ......................................................... 52B-280
DTC B223D: ocm (occupant classification-ECU
Supplemental restraint system (SRS)........................ 52B-282
Circuit diagrams ......................................................... 52B-282
DTC U0019: bus off (CAN-B)
Supplemental restraint system (SRS)........................ 52B-283
Circuit diagrams ......................................................... 52B-283
DTC U0141: ETACS CAN timeout
Supplemental restraint system (SRS)........................ 52B-284
Circuit diagrams ......................................................... 52B-284
DTC U0154: occupant classification-ECU CAN timeout
Supplemental restraint system (SRS)........................ 52B-286
Circuit diagrams ......................................................... 52B-286
DTC U0155: combination meter CAN timeout
Supplemental restraint system (SRS)........................ 52B-288
Circuit diagrams ......................................................... 52B-288
DTC U0164: A/C-ECU CAN timeout
Supplemental restraint system (SRS)........................ 52B-290
Circuit diagrams ......................................................... 52B-290
DTC U0168: KOS-ECU or WCM CAN timeout
Supplemental restraint system (SRS)........................ 52B-292
Circuit diagrams ......................................................... 52B-292
DTC U0170: front impact sensor (LH) communication error
Supplemental restraint system (SRS)........................ 52B-294
Circuit diagrams ......................................................... 52B-294
DTC U0171: front impact sensor (RH) communication error
Supplemental restraint system (SRS)........................ 52B-298
Circuit diagrams ......................................................... 52B-298
DTC U0172: side impact sensor (LH) communication error
Supplemental restraint system (SRS)........................ 52B-301
Circuit diagrams ......................................................... 52B-301
DTC U0175: side impact sensor (RH) communication error
Supplemental restraint system (SRS)........................ 52B-304
tensioner
tensioner
C B2209: occupant
(squib) sys-
(squib) sys-
)
DTC present
TSB Revision
Page 31
ALPHABETICAL INDEX
29
Circuit diagrams......................................................... 52B-304
DTC U0184: audio CAN timeout
Supplemental restraint system (SRS)........................ 52B-307
Circuit diagrams......................................................... 52B-307
DTC U0195: satellite radio tuner CAN timeout
Supplemental restraint system (SRS)........................ 52B-308
Circuit diagrams......................................................... 52B-308
DTC U0197: hands free module CAN timeout
Supplemental restraint system (SRS)........................ 52B-310
Circuit diagrams......................................................... 52B-310
DTC U1414: defective coding data
Supplemental restraint system (SRS)........................ 52B-312
Circuit diagrams......................................................... 52B-312
DTC U1415: coding not completed/data fail
Supplemental restraint system (SRS)........................ 52B-314
Circuit diagrams......................................................... 52B-314
Fail-safe function reference table
Supplemental restraint system (SRS)........................ 52B-395
Circuit diagrams......................................................... 52B-395
Introduction to diagnosis
Supplemental restraint system (SRS)........................ 52B-26
Circuit diagrams......................................................... 52B-26
Passenger's air bag off indicator light check
Supplemental restraint system (SRS)........................ 52B-29
Circuit diagrams......................................................... 52B-29
Passenger's seat belt warning light check
Supplemental restraint system (SRS)........................ 52B-29
Circuit diagrams......................................................... 52B-29
SRS warning light check
Supplemental restraint system (SRS)........................ 52B-28
Circuit diagrams......................................................... 52B-28
Symptom procedures
Inspection procedure 1: communication between the scan tool and
the SRS-
Supplemental restraint system (SRS)........................ 52B-384
Circuit diagrams......................................................... 52B-384
Inspection procedure 2: power
Supplement
Circuit diagrams......................................................... 52B-385
Inspection procedure 3:the SRS warning light does not illuminate.
Supplemental restraint system (SRS)........................ 52B-389
Circuit diagrams......................................................... 52B-389
Inspection procedure 4: the SRS warning light does not go out.
Supplemental restraint system (SRS)........................ 52B-391
Circuit diagrams......................................................... 52B-391
Trouble symptom chart
Supplemental restraint system (SRS)........................ 52B-383
Circuit diagrams......................................................... 52B-383
Troubleshooting strategy
Supplemental restraint system (SRS)........................ 52B-27
Circuit diagrams......................................................... 52B-27
SRS control unit (SRS-ECU)
Inspection
Supplemental restraint system (SRS)........................ 52B-412
Circuit diagrams......................................................... 52B-412
Removal and installation
Supplemental restraint system (SRS)........................ 52B-410
Circuit diagrams......................................................... 52B-410
ECU is not
al restraint system (SRS)........................ 52B-385
possible.
supply circuit system
Stabilizer bar
Inspection ...................................................................... 33-18
Removal and installation
Front suspension ....................................................... 33-17
Rear suspension ........................................................ 34-28
Stabilizer link check ..... ....... ....... ......................... ....... .... 34-29
Star ting system
General information ....................................................... 16-22
General specifications ................................................... 16-23
On-vehicle service
Starter relay check ..................................................... 16-26
Service specifications .................................................... 16-24
Star ter mot or assembly
Disassembly and assembly ....................................... 16-30
Inspection
Engine electrical......................................................... 16-28
Engine electrical......................................................... 16-32
Removal and installation............................................ 16-27
Starting system diagnosis ............................................ .. 16-24
Starting system <M /T>
Supplemental restraint system (SRS)............................ 90-36
Circuit diagrams............................................................. 90-36
Star ting system <TC-SST>
Supplemental restraint system (SRS)............................ 90-38
Circuit diagrams............................................................. 90-38
Steering co lumn..... ......................... ....... ......................... ... 80B-5
Steering shaft
Disassembly and assembly ........................................... 37-36
Removal and installation................................................ 37-33
Steering wheel
Removal and installation................................................ 37-29
Steering wheel audio remote control switch
Diagnosis
Standard flow of diagnostic troubleshooting .............. 54A-579
Trouble symptom chart .................. ............................ 54A-579
General information ....................................................... 54A-577
Removal and installation................................................ 54A-592
Special too ls..... ....... ....... .................. ....... ....................... 54A-578
Steering wh eel aud io remote cont rol switch inspection . 54A-593
Symptom procedures
Inspection procedure 1: steering wheel audio remote control switch
does not function. <vehicles with r
Inspection procedure 2: steering wheel audio remote control switch
does not function. <vehicles with MMCS> ................. 54A-585
Inspection procedure 3: steering wheel audio remote control switch
illumination does not come on. .................................. 54A-589
Steering wheel sensor
Removal and installation................................................ 35C-305
Stoplight
Supplemental restraint system (SRS)............................ 90-142
Circuit diagrams............................................................. 90-142
Strut assembly
Disassembly and assembly ........................................... 33-11
Inspection
Front suspension ....................................................... 33-11
Front suspension ....................................................... 33-14
Removal and installation................................................ 33-10
Strut tower bar
Removal and installation................................................ 42A-14
adio a
nd CD player> 54A-580
TSB Revision
Page 32
30
ALPHABETICAL INDEX
Sunroof
Supplemental restraint system (SRS) ........................... 90-334
Circuit diagrams............................................................. 90-334
Sunroof
Check at ECU terminal .................................................. 42A-185
Diagnostic trouble code procedures
Code no. L0630: s/r power supply ............................. 42A-159
Code no. L0632: s/r switch fail................................... 42A-161
Code no. L0634: s/r sensor signal ............................. 42A-163
Code no. L0637: s/r position...................................... 42A-163
Code no. L0640: s/r over load ................................... 42A-164
General information ....................................................... 42A-157
On-vehicle service
Learning procedures of the sunr
Sunroof check............................................................ 42A-188
Sunroof fit adjustment................................................ 42A-188
Sunroof lid glass operation current check.................. 42A-189
Sunroof operation check............................................ 42A-190
Sunroof safety function check.................................... 42A-188
Sunroof timer function check ..................................... 42A-188
Water test .................................................................. 42A-187
Special too ls ......... ....... ....... ......................... .................. 42A-186
Specificati on(s)
Sealant....................................................................... 42A-157
Service specification .................................................. 42A-157
Sunroof
Disassembly and assembly ....................................... 42A-196
Inspection .................................................................. 42A-195
Sunroof assembly removal and installation ............... 42A-193
Sunroof diagnosis
Diagnostic trouble code chart .................................... 42A-158
Trouble symptom chart ........ ....................... ............... 42A-158
Troubleshooting str ategy ........... ................... ............. 42A-158
Symptom procedures
Inspection procedure 1: sunroof does not w
Inspection pr
down, open, and close normally). .............................. 42A-170
Inspection procedure 3: the sunroof
tilt-down, and close normally). ................................... 42A-173
Inspection procedure 4: the sunroof lid glass does
close (tilt-up and open normally)................................ 42A-176
Inspection procedure 5: sunroof safety function does not
work. .......................................................................... 42A-179
Inspection procedure 6: the sunroof timer function do
work. .......................................................................... 42A-181
Supplemental restraint system (SRS)
Supplemental restraint system (SRS) ........................... 90-288
Circuit diagrams............................................................. 90-288
ocedure 2: the sunroof lid glass does
oof fully closed po
lid glass does not open (tilt-up,
sition 42A-189
ork at all. 42A-165
not tilt-up (tilt-
not tilt-down or
es not
T
Ta il lig ht , p o si ti o n l ig h t, l i ce n se p l at e light and lighting monitor tone alarm
Supplemental restraint system (SRS) ........................... 90-120
Circuit diagrams............................................................. 90-120
Te st eq ui p me n t
Supplemental restraint system (SRS) ........................... 52B-397
Controller area network (CAN) ...................................... 54C-6
Circuit diagrams............................................................. 52B-397
Theft alarm
Diagnosis
Diagnostic function .................................................... 54A-752
Standard flow of diagnostic troubleshooting .............. 54A-752
General information ....................................................... 54A-750
Inspection
Theft-alarm indicator check........................................ 54A-773
Removal and installation................................................ 54A-773
Special too ls..... ....... ....... .................. ....... ....................... 54A-751
Symptom procedures
Inspection procedure 1: the theft-alarm is not armed (the theft-alarm
indicator does not illuminate). .................................... 54A-755
does
Inspection procedure 2: the interior alarm
while the theft-alarm is triggered................................ 54A-762
Inspection procedure 3: theft-alarm horn does not sound while the
theft-alarm system is triggered................................... 54A-764
Inspection procedure 4: horn (high or low) does not sound while the
theft-alarm system is triggered................................... 54A-768
Trouble symptom chart .................................................. 54A-754
Theft-alarm system
Supplemental restraint system (SRS)............................ 90-374
Circuit diagrams............................................................. 90-374
Thermostat
Inspection ......................................................................
Removal and installation................................................ 14-23
Throttle body
Removal and installation................................................ 11B-14
Throttle body assembly
Removal and installation................................................ 13A-886
Tightening torque ............................................................... 00-51
Timing chain
Inspection ...................................................................... 11B-39
Removal and installation
Engine mechanical..................................................... 11A-66
Engine overhaul ......................................................... 11B-34
Tire pressure monitoring system (TPMS)
Removal and installation................................................ 31-8
Tire pressure monitoring system (TPMS) <M/T>
Supplemental restraint system (SRS)............................ 90-312
Circuit diagrams............................................................. 90-312
Tire pressure monitoring system (TPMS) <TC-SST>
Supplemental restraint system (SRS)............................ 90-318
Circuit diagrams............................................................. 90-318
To rq u e sp e ci f ic ati ons . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. ... ... ... ... . .. .. . 21B-2
To wi n g an d h o is t in g . ... ... ... . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. ... ... ... . .. .. . . 00-45
TPMS transmitter
Removal and installation
Keyless operation system (KOS) ............................... 42B-247
Wireless control module (WCM) ................................ 42C-134
Trailing arm
Removal and installation................................................ 34-17
Trailing arm ball joint dust cover inspection ................... 34-19
Trailing arm ball joint dust cover replacement ............... 34-20
ing torque check ...... 34-19
Trailing arm ball joint rotation st
Trailing arm pillow ball bushing rot
Transaxle
Disassembly and assembly
Manual transaxle overhaul......................................... 22B-12
Twin c lut ch sst over hau l...... ... ........ ... ........... ... ........... 22D-6
Inspection ...................................................................... 22B-19
Transaxle adjustment..................................................... 22B-19
Transaxle (transmission) mounting
Removal and installation................................................ 32-6
art
ation torque check ... 34-19
not work normally
14-25
TSB Revision
Page 33
ALPHABETICAL INDEX
31
Transaxle assembly
Removal and installation
Manual transaxle ....................................................... 22A-128
C-SST
Twin c lut ch-sportron ic shift transmission (T
Transaxle case
Disassembly and assembly ........................................... 22B-48
Transaxle case oil seal
Removal and installation ............................................... 22C-425
Transaxle cont rol
Removal and installation ............................................... 22A-122
Transfer
Disassembly and assembly
Manual transaxle overhaul......................................... 22B-55
Twin c lut ch sst over hau l....... ... ........ ... ........... ... .......... 22B-55
Transfer assembly
Removal and installation
Manual transaxle ....................................................... 22A-126
Twin c lut ch-sportron ic shift transmission (T
Transmission control
Removal and installation ............................................... 22C-404
Transmitter
Disassembly and assembly ........................................... 42C-132
Trims
Removal and installation ............................................... 52A-12
Troubleshooting
Diagnosis function ......................................................... 54B-4
Diagnostic trouble code chart ........................................ 54B-6
Diagnostic trouble code procedures
DTC U0169: sunroof LIN timeout <vehicles with sunroof> 54B-7
DTC U0215: P/W sw (dr) LIN timeout........................ 54B-11
DTC U0231: lighting control sensor LIN timeout <vehicles with auto
light function> ............................................................ 54B-16
DTC U1109: column sw LIN timeout.......................... 54B-21
DTC U150B: column sw checksum error................... 54B-25
DTC U150C: P/W sw (dr) checksum error................. 54B-26
DTC U1511: sunroof checksum er
sunroof>..................................................................... 54B-27
DTC U1512: lighting control sensor checksum e
auto light function> .................................................... 54B-28
DTC U1514: bit error (LIN) ........................................ 54B-29
DTC U1515: No-bus activity error (LIN)..................... 54B-31
Troubleshooting guidelines................. ............................... 00-6
Trunk lid
On-vehicle service
Adjustment of clearance around trunk lid .................. 42A-152
Trunk lid height adjustment ........................ ................ 42A-152
Trunk lid striker adjustmen t............. ................... ........ 42A-152
Special too ls ......... ....... ....... ......................... .................. 42A-151
Specificati on(s)
Sealant....................................................................... 42A-150
Symptom procedures
Inspection procedure 1: difficult locking and unlocking 42A-150
Inspection procedure 2: uneven body clearance
Inspection p
Trouble symptom chart .................................................. 42A-150
Trunk lid
Inspection .................................................................. 42A-156
Removal and installation............................................ 42A-153
Trunk lid diagnosis
Introduction to trunk lid diagnosis
rocedure 3: uneven height...................... 42A-151
ror <vehicles wit
....................
)... 22C-412
)... 22C-410
C-SST
h
rror <vehicles with
....... 42A-151
.......... 42A-150
Trunk lid diagnostic troubleshooting strategy ............. 42A-150
Trunk lid opener
Supplemental restraint system (SRS)............................ 90-188
Circuit diagrams............................................................. 90-188
Turn-signal light and hazard warning light
Supplemental restraint system (SRS)............................ 90-134
Circuit diagrams............................................................. 90-134
Twin cl utch sst cont rol mode swit ch
Inspection
Twin c lut ch sst cont rol mode sw itc h check . ... ........ ... . 22C-403
Removal and installation................................................ 22C-403
Twin cl utch-sportronic shif
Supplemental restraint system (SRS)............................ 90-82
Circuit diagrams............................................................. 90-82
t transmission
(TC-SST)
U
Under cover
Removal and installation................................................ 51-15
Upper arm assembly
Removal and installation................................................ 34-21
Upper arm ball joint dust cover inspection..................... 34-22
Upper arm ball joint dust cover replacement ................. 34-23
Upper arm ball joint rotation st
Upper arm pillow ball bushing rotation torque check ..... 34-22
arting torque check
........ 34-22
V
Val ve stem seal
Removal and installation................................................ 11A-40
Vehicle identification
Chassis number............................................................. 00-19
Engine model stamping ................................................. 00-19
Models ........................................................................... 00-18
Tire and loading information placard.. ............................ 00-20
Vehicle identification code plate ......... ..................... ....... 00-19
Vehicle identification number plate .. ... ... ... ... ... ... ... ... ... ... 00-17
Ventilators
Ventilator (instrument pa nel an d f loo r) rem oval and
installation...................................................................... 55-190
W
Water hose and pipe
Removal and installation................................................ 11B-24
Water hose and water pipe ................................................ 14-27
Water hose and water pipe
Inspection ...................................................................... 14-31
Removal and installation................................................ 14-27
Water pump
Removal and installation................................................ 14-26
WCM
Removal and installation................................................ 42C-131
Wheel and tire
Installation service point ................................................ 31-7
Wheel and tire diagnosis
Diagnosis ....................................................................... 31-3
Wheel balance accuracy................................................ 31-4
Wheel speed sensor
Inspection ...................................................................... 35C-303
TSB Revision
Page 34
32
ALPHABETICAL INDEX
Removal and installation ............................................... 35C-300
Window glass
General.......................................................................... 42A-15
Rear window glass
Removal and installation............................................ 42A-23
Special too l .... ......................... ....... ....... ......................... 42A-17
Specificati on(s)
Adhesives .................................................................. 42A-15
Symptom procedures
indshield/rear window
Inspection procedure 1: water leak through
glass .......................................................................... 42A-17
Window glass diagnosis
Introduction to window glass diagnosis ..................... 42A-17
Window glass diagnostic tro
Window glass diagnostic trouble symptom chart.
Windshield
Removal and installation............................................ 42A-18
Windshield wiper and washer
Supplemental restraint system (SRS) ........................... 90-216
Circuit diagrams............................................................. 90-216
Windshield wiper and washer
Data list reference table................................................. 51-71
General information ....................................................... 51-18
Lighting control sensor
Adaptation.................................................................. 51-84
Removal and installation............................................ 51-84
On-vehicle service
Customization function .............................................. 51-73
Delayed finishing wipe function inspection ................ 51-72
Intelligent washing function inspection ...................... 51-72
Lighting control sensor (rain sensor) inspection
Wind
shield intermittent wiper interval check.............. 51-72
Special too ls ......... ....... ....... ......................... .................. 51-24
Symptom procedures
Inspection procedure 1: the windshield wipers do no
work at all................................................................... 51-27
Inspection procedure 10: the windshield washer do
mally........................................................................... 51-63
Inspection procedure 11: the intelligent washing fu
work normally............................................................. 51-68
Inspection procedure 12: delayed finishing w
work normally............................................................. 51-69
Inspection procedure 2: the windshield
wiper switch is at the "INT", "washer" or "mist" position. however, the
wipers work at low speed when the switch is at the "lo" or "hi" posi-
tion............................................................................. 51-35
Inspection procedure 3: windshield wipers do
fied park position........................................................ 51-38
Inspection procedure 4: windshield wipers do not work
normally. .................................................................... 51-41
Inspection procedure 5: the windshield intermittent wiper
cannot be adjusted by operating the windshield intermittent wiper
interval control switch. ............................................... 51-47
Inspection procedure 6: the windshield intermittent
not changed according to the vehicle speed. ............ 51-50
Inspection procedure 7: the rain sensitive auto
not work at all <vehicles with lighting contr
Inspection procedure 8: the rain sensitive au
even though there is no rainfall <vehicles with lighting control sen-
sor>............................................................................ 51-57
Inspection procedure 9: sometimes the rain sensitive
function works even though there is no rainfall < vehicles with light-
ing control sensor>. ................................................... 51-60
Windshield washer
Inspection .................................................................. 51-81
ubleshooting strateg
w
y.... 42A-17
.......... 42A-17
........ 51-72
t
es not work nor-
nction does not
ipe function does not
wiper
s do not work when the
not stop at the speci-
w
iper interval is
wiper function does
ol sensor>. 51-52
to wiper function works
auto wiper
interval
Removal and installation............................................ 51-80
Windshield wiper
Inspection................................................................... 51-78
Removal and installation............................................ 51-74
Windshield wiper and washer diagnosis
Standard flow of diagnostic troubleshooting .............. 51-26
Trouble symptom chart .................. ............................ 51-26
TSB Revision
Page 35
NOTE:
For the information on all service manual
groups not listed above, please refer to
Volume 1 and 2.
2010
GROUP INDEX
MITSUBISHI
LANCER EVOLUTION
SERVICE MANUAL
Volume 3
FOREWORD
This service manual is subdivided into various group
categories. Each section contains diagnostic,
disassembly, repair, and installation procedures,
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any service necessary to maintain or
restore the high levels of performance and reliability
designed into this Mitsubishi vehicle.
This manual is designed for use with the 2010 Service
Manual Volume 1, 2 and the 2008 LANCER EVOLU-
TION Body Repair Manual to provide complete service
information for the LANCER EVOLUTION.
When reference is made in this manual to a brand
name, number, or specific tool, an equivalent product
may be used in place of the recommended item. All
information, illustrations and specifications contained
in this manual are based on the latest product
information available at the time of publication
approval. The right is reserved to make changes at
any time without notice.
Chassis Electrical . . . . . . . . . . . . . . .
Heater, Air Conditioning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Ventilation . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . .
Configuration Diagrams
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Splice Locations . . . . . . . . . . . .
Circuit Diagrams . . . . . . . . . . . . . . . .
Alphabetical Index . . . . . . . . . . . . . .
54
55
70
80
90
No part of this publication may be reproduced, stored in any
retrieval system of transmitted, in any form or by any means,
including but not limited to electronic, mechanical photocopying,
recording or otherwise, without the prior written permission of
Mitsubishi Motors Corporation.
©2009 Mitsubishi Motors Corporation
All Rights, Reserved
Printed in USA
MSCD-206B-2010 (3/3)
Page 36
Proper service methods and repair procedures are necessary for the safe,
WARNING
reliable operation of all motor vehicles as well as the personal safety of the
person doing the repair. There are many types of procedures, techniques,
tools, and parts for servicing vehicles, as well as differences in the skills of
the people doing the work. This manual cannot give advice or precautions for
every possible situation. Because of this, anyone who does not follow the
instructions in this manual must first make sure that the choice of methods,
tools, or parts will not cause damage to the vehicle or injury to the person
doing the work. The following list contains general precautions that should
always be followed while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires work under the
vehicle.
• Be sure the ignition switch is always "off" unless otherwise specified by
a procedure.
• Set the parking brake when working on a vehicle.
• Operate the engine only in a well-ventilated area.
• Keep clear of moving parts when the engine is running.
• To p revent s erious bur ns, avoid contact with h ot meta l pa rts such as t he
radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
• Do not smoke while working on or near a vehicle.
Page 37
CALIFORNIA PROPOSITION 65 WARNING
WARNING
WARNING
WARNING
•
This product contains or emits chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
CALIFORNIA PERCHLORATE MATERIALS REQUIREMENTS
•
Certain components of this vehicle, such as air bag modules and seat belt pre-tensioners, may
contain perchlorate materials. Special handling may apply. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) EQUIPPED VEHICLES
•
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).
•
If it is possible that the SRS components are subjected to heat over 93° C (200° F) in baking or in
drying after painting, remove the SRS components [air bag module (driver's side and front
passenger's side), SRS-ECU, clock spring, side impact sensor, front seat assembly (side air bag
module)] beforehand.
•
Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
•
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B, Supplemental Restraint System (SRS), before beginning any service or maintenance of any
component of the SRS or any SRS-related component.
NOTE
Section titles with the asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
Page 38
MITSUBISHI PUBLICATION COMMENT FORM
Use this form to advise us of any errors you might find in this publication. We also welcome your
suggestions that might help us improve Mitsubishi publications.
Publication that contains error: __________________________________________________________
Page number where the error appears:____________________________________________________
Figure number where the error appears:___________________________________________________
Vehicle application and system identification: _______________________________________________
Describe, in detail, the error found or your suggestion. Please attach additional pages as necessary.
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Dealer ___________________________________ Dealer Code________________________________
From: Name_________________________________________________________________________
City/Town____________________________ State ________________ Zip Code______________
Signature ____________________________ Date ________________ Phone________________
Mail To: Mitsubishi Motors North America, Inc.
6400 Katella Avenue
P.O. Box 6400
Cypress, California 90630-0064
Fax to: Mitsubishi Motors North America, Inc.
Technical Inform ation Dept.
(714) 373-1021
Attn: Technical Information Dept.
Page 39
NOTE:
For the information on all service manual
groups not listed above, please refer to
Volume 1 and 3.
2010
GROUP INDEX
MITSUBISHI
LANCER EVOLUTION
SERVICE MANUAL
Volume 2
FOREWORD
This service manual is subdivided into various group
categories. Each section contains diagnostic,
disassembly, repair, and installation procedures,
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any service necessary to maintain or
restore the high levels of performance and reliability
designed into this Mitsubishi vehicle.
This manual is designed for use with the 2010 Service
Manual Volume 1, 3 and the 2008 LANCER EVOLU-
TION Body Repair Manual to provide complete service
information for the LANCER EVOLUTION.
When reference is made in this manual to a brand
name, number, or specific tool, an equivalent product
may be used in place of the recommended item. All
information, illustrations and specifications contained
in this manual are based on the latest product
information available at the time of publication
approval. The right is reserved to make changes at
any time without notice.
Propeller Shaft . . . . . . . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tire . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . .
Body. . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . .
Interior and Supplemental
Exterior . . . . . . . . . . . . . . . . . . . . . . .
Restraint System (SRS). . . . . . . . . .
Alphabetical Index . . . . . . . . . . . . . .
25
26
27
31
32
33
34
35
36
37
42
51
52
No part of this publication may be reproduced, stored in any
retrieval system of transmitted, in any form or by any means,
including but not limited to electronic, mechanical photocopying,
recording or otherwise, without the prior written permission of
Mitsubishi Motors Corporation.
©2009 Mitsubishi Motors Corporation
All Rights, Reserved
Printed in USA
MSCD-206B-2010 (2/3)
Page 40
Proper service methods and repair procedures are necessary for the safe,
WARNING
reliable operation of all motor vehicles as well as the personal safety of the
person doing the repair. There are many types of procedures, techniques,
tools, and parts for servicing vehicles, as well as differences in the skills of
the people doing the work. This manual cannot give advice or precautions for
every possible situation. Because of this, anyone who does not follow the
instructions in this manual must first make sure that the choice of methods,
tools, or parts will not cause damage to the vehicle or injury to the person
doing the work. The following list contains general precautions that should
always be followed while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires work under the
vehicle.
• Be sure the ignition switch is always "off" unless otherwise specified by
a procedure.
• Set the parking brake when working on a vehicle.
• Operate the engine only in a well-ventilated area.
• Keep clear of moving parts when the engine is running.
• To p revent s erious bur ns, avoid contact with h ot meta l pa rts such as t he
radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
• Do not smoke while working on or near a vehicle.
Page 41
CALIFORNIA PROPOSITION 65 WARNING
WARNING
WARNING
WARNING
•
This product contains or emits chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
CALIFORNIA PERCHLORATE MATERIALS REQUIREMENTS
•
Certain components of this vehicle, such as air bag modules and seat belt pre-tensioners, may
contain perchlorate materials. Special handling may apply. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) EQUIPPED VEHICLES
•
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).
•
If it is possible that the SRS components are subjected to heat over 93° C (200° F) in baking or in
drying after painting, remove the SRS components [air bag module (driver's side and front
passenger's side), SRS-ECU, clock spring, side impact sensor, front seat assembly (side air bag
module)] beforehand.
•
Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
•
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B, Supplemental Restraint System (SRS), before beginning any service or maintenance of any
component of the SRS or any SRS-related component.
NOTE
Section titles with the asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
Page 42
MITSUBISHI PUBLICATION COMMENT FORM
Use this form to advise us of any errors you might find in this publication. We also welcome your
suggestions that might help us improve Mitsubishi publications.
Publication that contains error: __________________________________________________________
Page number where the error appears:____________________________________________________
Figure number where the error appears:___________________________________________________
Vehicle application and system identification: _______________________________________________
Describe, in detail, the error found or your suggestion. Please attach additional pages as necessary.
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Dealer ___________________________________ Dealer Code________________________________
From: Name_________________________________________________________________________
City/Town____________________________ State ________________ Zip Code______________
Signature ____________________________ Date ________________ Phone________________
Mail To: Mitsubishi Motors North America, Inc.
6400 Katella Avenue
P.O. Box 6400
Cypress, California 90630-0064
Fax to: Mitsubishi Motors North America, Inc.
Technical Inform ation Dept.
(714) 373-1021
Attn: Technical Information Dept.
Page 43
NOTE:
For the information on all service manual
groups not listed above, please refer to
Volume 2 and 3.
2010
GROUP INDEX
MITSUBISHI
LANCER EVOLUTION
SERVICE MANUAL
Volume 1
FOREWORD
This service manual is subdivided into various group
categories. Each section contains diagnostic,
disassembly, repair, and installation procedures,
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any service necessary to maintain or
restore the high levels of performance and reliability
designed into this Mitsubishi vehicle.
This manual is designed for use with the 2010 Service
Manual Volume 2, 3 and the 2008 LANCER EVOLU-
TION Body Repair Manual to provide complete service
information for the LANCER EVOLUTION.
When reference is made in this manual to a brand
name, number, or specific tool, an equivalent product
may be used in place of the recommended item. All
information, illustrations and specifications contained
in this manual are based on the latest product
information available at the time of publication
approval. The right is reserved to make changes at
any time without notice.
General . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . . . .
Engine Electrical. . . . . . . . . . . . . . . .
Engine and Emission Control . . . . .
Clutch. . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transaxle . . . . . . . . . . . . . . .
Alphabetical Index . . . . . . . . . . . . . .
00
11
12
13
14
15
16
17
21
22
No part of this publication may be reproduced, stored in any
retrieval system of transmitted, in any form or by any means,
including but not limited to electronic, mechanical photocopying,
recording or otherwise, without the prior written permission of
Mitsubishi Motors Corporation.
©2009 Mitsubishi Motors Corporation
All Rights, Reserved
Printed in USA
MSCD-206B-2010 (1/3)
Page 44
Proper service methods and repair procedures are necessary for the safe,
WARNING
reliable operation of all motor vehicles as well as the personal safety of the
person doing the repair. There are many types of procedures, techniques,
tools, and parts for servicing vehicles, as well as differences in the skills of
the people doing the work. This manual cannot give advice or precautions for
every possible situation. Because of this, anyone who does not follow the
instructions in this manual must first make sure that the choice of methods,
tools, or parts will not cause damage to the vehicle or injury to the person
doing the work. The following list contains general precautions that should
always be followed while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires work under the
vehicle.
• Be sure the ignition switch is always "off" unless otherwise specified by
a procedure.
• Set the parking brake when working on a vehicle.
• Operate the engine only in a well-ventilated area.
• Keep clear of moving parts when the engine is running.
• To p revent s erious bur ns, avoid contact with h ot meta l pa rts such as t he
radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
• Do not smoke while working on or near a vehicle.
Page 45
CALIFORNIA PROPOSITION 65 WARNING
WARNING
WARNING
WARNING
•
This product contains or emits chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
CALIFORNIA PERCHLORATE MATERIALS REQUIREMENTS
•
Certain components of this vehicle, such as air bag modules and seat belt pre-tensioners, may
contain perchlorate materials. Special handling may apply. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) EQUIPPED VEHICLES
•
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).
•
If it is possible that the SRS components are subjected to heat over 93° C (200° F) in baking or in
drying after painting, remove the SRS components [air bag module (driver's side and front
passenger's side), SRS-ECU, clock spring, side impact sensor, front seat assembly (side air bag
module)] beforehand.
•
Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
•
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B, Supplemental Restraint System (SRS), before beginning any service or maintenance of any
component of the SRS or any SRS-related component.
NOTE
Section titles with the asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
Page 46
MITSUBISHI PUBLICATION COMMENT FORM
Use this form to advise us of any errors you might find in this publication. We also welcome your
suggestions that might help us improve Mitsubishi publications.
Publication that contains error: __________________________________________________________
Page number where the error appears:____________________________________________________
Figure number where the error appears:___________________________________________________
Vehicle application and system identification: _______________________________________________
Describe, in detail, the error found or your suggestion. Please attach additional pages as necessary.
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Dealer ___________________________________ Dealer Code________________________________
From: Name_________________________________________________________________________
City/Town____________________________ State ________________ Zip Code______________
Signature ____________________________ Date ________________ Phone________________
Mail To: Mitsubishi Motors North America, Inc.
6400 Katella Avenue
P.O. Box 6400
Cypress, California 90630-0064
Fax to: Mitsubishi Motors North America, Inc.
Technical Inform ation Dept.
(714) 373-1021
Attn: Technical Information Dept.
Page 47
GROUP 22D
TWIN CLUTCH SST
OVERHAUL
CONTENTS
22D-1
GENERAL DESCRIPTION. . . . . . . . . 22D-2
GENERAL SPECIFICATION . . . . . . . 22D-2
FASTENER TIGHTENING
SPECIFICATION . . . . . . . . . . . . . . . . 22D-2
SEALANTS AND ADHESIVES . . . . . 22D-3
LUBRICANT . . . . . . . . . . . . . . . . . . . . 22D-3
SPECIAL TOOLS . . . . . . . . . . . . . . . . 22D-4
TRANSAXLE. . . . . . . . . . . . . . . . . . . . 22D-6
DISASSEMBLY AND ASSEMBLY . . . . . . . 22D-6
TRANSFER . . . . . . . . . . . . . . . . . . . . . 22D-18
DISASSEMBLY AND ASSEMBLY . . . . . . . 22D-18
Page 48
22D-2
TWIN CLUTCH SST OVERHAUL
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1226000100229
TRANSAXLE MODEL
Transaxle model Engine model Vehicle model
W6DGA-3-11AA 4B11 DOHC MIVEC CZ4A
GENERAL SPECIFICATION
M1226000200022
GEAR RATIO TABLE
Item Specification
Transaxle model W6DGA
Transaxle type 6-speed forward, 1-speed reverse constant mesh
Transaxle gear ratio 1st 3.655
2nd 2.368
3rd 1.754
4th 1.322
5th 1.008
6th 0.775
Reverse 4.011
Final gear ratio 4.062
Transfer gear ratio 0.302
FASTENER TIGHTENING SPECIFICATION
M1226000700146
TRANSAXLE
Item Specification
Oil filter bracket 10 ± 1.5 N⋅ m (89 ± 8 in-lb)
Oil filter case assembly 15 ± 2 N⋅ m (11 ± 1 ft-lb)
Manual control shaft mounting screw 10 ± 1.5 N⋅ m (89 ± 8 in-lb)
Plug 32 ± 2 N⋅ m (24 ± 1 ft-lb)
Mechatronic assembly mounting bolt 5.0 ± 1.0 → 10 ± 1.5 N⋅ m
(44 ± 8 → 89 ± 8 in-lb)
Mechatronic assembly (The connector part) mounting screw 6.0 ± 1.0 N⋅ m (53 ± 8 in-lb)
Oil pan mounting screw 10 ± 1 N⋅ m (89 ± 8 in-lb)
Clutch assembly 7.5 ± 1.0 N⋅ m (66 ± 8 in-lb)
Seal cover bracket mounting screw 10 ± 1 N⋅ m (89 ± 8 in-lb)
Control cable bracket 11 ± 3 N⋅ m (97 ± 26 in-lb)
Harness bracket 25 ± 4 N⋅ m (18 ± 2 ft-lb)
TSB Revision
Page 49
TWIN CLUTCH SST OVERHAUL
CAUTION
SEALANTS AND ADHESIVES
22D-3
TRANSFER
Item Specification
Cover 9.0 ± 2.0 N⋅ m (80 ± 18 in-lb)
SEALANTS AND ADHESIVES
TRANSFER
Item Specified sealant
Cover Mitsubishi Part No. MD997740 or equivalent
.
FORM-IN-PLACE GASKET (FIPG)
This transaxle has several areas where the
form-in-place gasket (FIPG) is used for sealing. To
ensure that the FIPG fully serves its purpose, it is
necessary to observe some precautions when apply
ing it. Bead size, continuity and location are of paramount importance.
Too thin a bead cou ld cause l eaks. Too t hick a be ad,
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To
prevent leaks or blocking of passages, therefore, it is
absolutely necessary to apply the FIPG evenly with
out a break, while observing the correct bead size.
FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.
When re-applying liquid gasket (FIPG), be sure
that:
1. Residues of FIPG are cleared from all the ins
and outs of parts;
2. Use Mitsubishi genuine parts cleaner
(MZ100387) or equivalent to well degrease the
FIPG-applied surface.
3. FIPG is correctly applied in accordance with
FIPG Application.
.
Disassembly
Parts sealed with a FIPG can be easily removed
without need for the use of a special method. In
some cases, however, the FIPG in joints may have to
be broken by tapping parts with a mallet or similar
tool.
.
Surface Preparation
Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper.
Make sure that the FIPG application surfaces is flat
-
and smooth. Also make sure that the surface is free
from oils, greases and foreign substances. Do not fail
to remove old FIPG that may remain in the fastener
fitting holes.
.
FIPG Application
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet. Do not
allow FIPG to spread beyond the sealing areas dur
ing installation. Avoid operating the transaxle or letting oils or water come in contact with the sealed
area before a time sufficient for FIPG to harden
(approximately one hour) has passed.
FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.
M1226000500012
-
LUBRICANT
TRANSAXLE
Item Specified lubricant
Transaxle oil Mitsubishi genuine part Diaqueen SSTF-1
TSB Revision
M1226000400082
Page 50
22D-4
TRANSFER
Item Specified lubricant
Transfer oil Hypoid gear oil API classification GL-5, SAE90
O-ring Mitsubishi Genuine DiaQueen ATF SPIII
Oil seal Retinax A
TWIN CLUTCH SST OVERHAUL
SPECIAL TOOLS
SPECIAL TOOLS
TRANSAXLE
Tool Tool numbe r
and name
MB992332
Clutch remover
& installer
MB992324
Seal cover
guide A
MB992325
Seal cover
guide B
Supersession Application
−
−
−
Installation of Clutch assembly
Installation of Seal cover
Installation of Seal cover
M1226000800109
MB992323
Seal cover
installer
MB992311
Oil seal guide
MB992310
Oil seal installer
TSB Revision
−
−
−
Installation of Seal cover
Installation of transaxle case (LH)
oil seal
Installation of transaxle case (LH)
oil seal
Page 51
TWIN CLUTCH SST OVERHAUL
D998382
SPECIAL TOOLS
22D-5
Tool Tool n umber
and name
MB992313
Oil seal guide
MB992312
Oil seal installer
MB992314
V ring guide
TRANSFER
Tool Tool numbe r
and name
MD998382
Crankshaft front
oil seal installer
Supersession Application
−
−
−
Supersession Application
MD998382-01 Installation of oil seal
Installation of transaxle case (RH)
oil seal
Installation of transaxle case (RH)
oil seal
Installation of V ring
MD998550
Input shaft
holder
−
Installation of oil seal
TSB Revision
Page 52
22D-6
AK900603
10 ± 1 N·m
89 ± 8 in-lb
8
3
AC
10 ± 1 N·m
89 ± 8 in-lb
13
1
4
9
21
22
15 ± 2 N·m
11 ± 1 ft-lb
10 ± 1.5 N·m
89 ± 8 in-lb
2
11 ± 3 N·m
97 ± 26 in-lb
6
7
5
20
19
10
11
12
15
16
18
17
14
6.0 ± 1.0 N·m
53 ± 8 in-lb
10 ± 1.5 N·m
89 ± 8 in-lb
32 ± 2 N·m
24 ± 1 ft-lb
7.5 ± 1.0 N·m
66 ± 8 in-lb
5.0 ± 1.0 N·m → 10 ± 1.5 N·m
44 ± 8 in-lb → 89 ± 8 in-lb
25 ± 4 N·m
18 ± 2 ft-lb
TWIN CLUTCH SST OVERHAUL
TRANSAXLE
TRANSAXLE
DISASSEMBLY AND ASSEMBLY
M1226001000184
Removal steps
1. Control cable bracket
2. Harness bracket
>>J<<
<<A>> >>I<<
<<A>> >>H<<
<<B>> >>G<<
<<B>> >>G<<
<<C>> >>F<<
Required Special Tools:
>>E<<
3. V ring
4. Transaxle case oil seal (RH)
5. Transaxle case oil seal (LH)
6. Breather
7. Seal cover bracket
8. Seal cover
9. Clutch assembly
10. Needle roller bearing
11. Seal ring
• MB992332: Clutch remover & installer
• MB992324: Seal cover guide A
• MB992325: Seal cover guide B
• MB992323: Seal cover installer
• MB992311: Oil seal guide
TSB Revision
>>D<<
<<D>> >>C<<
<<E>> >>B<<
>>B<<
>>B<<
<<F>> >>A<<
12. Needle roller bearing
13. Oil pan assembly
14. O-ring
15. Mechatronic assembly
16. Gasket A
17. Gasket B
18. Gasket C
19. Manual control shaft
20. Oil seal
21. Oil filter case assembly
22. Oil filter bracket assembly
• MB992310: Oil seal installer
• MB992313: Oil seal guide
• MB992312: Oil seal installer
• MB992314: V ring guide
Removal steps (Continued)
Page 53
TWIN CLUTCH SST OVERHAUL
CAUTION
AK802283AC
Oil seal Back side
<Reference>
AK802289
TRANSAXLE
• When installing or removing screws, use
magnetic tools to prevent them from falling
out.
• If debris or parts enter into the transaxle case,
pay attention to the following to replace the
transaxle assembly:
• When the mechatronic assembly is replaced,
reprogram the ECU and carry out the follow
ing Teach-In (Refer to GROUP 22C, Troubleshooting <TC-SST> − Learning Procedure for
TC-SST
P.22C-7).
• When the clutch assembly is replaced, the following Teach-In must be carried out (Refer to
GROUP 22C, Troubleshooting <TC-SST> −
Learning Procedure for TC-SST
P.22C-7).
DISASSEMBLY SERVICE POINTS
.
<<A>> TRANSAXLE CASE OIL SEAL (RH) / TRANSAXLE CASE OIL SEAL (LH) REMOVAL
1. Insert the tapping screw (φ 3 mm[0.1 inch]) to one of four
hollows (round shape) on the oil seal by turning it 2 or 3
times.
22D-7
TSB Revision
Page 54
22D-8
CAUTION
AK802290
AK802291
AK802293
TWIN CLUTCH SST OVERHAUL
TRANSAXLE
2. Tap the opposite side of the inserted tapping screw using a
knock pin punch to press in the oil seal approximately 1 mm
(0.04 inch).
3. Hold the inserted tapping screw with pliers or similar tools,
and remove the oil seal.
NOTE: If the transaxle case oil seal (RH) is replaced, the V-ring
must also be replaced.
.
<<B>> SEAL COVER BRACKET AND SEAL
COVER REMOVAL
1. Remove the seal cover bracket.
• Before removing the seal cover, securely remove iron
powders including dusts by air spray.
• Before removing the seal cover, use the ladder sheet
and so forth for the supporting point not to damage the
clutching housing.
2. Remove the seal cover from the transaxle, using the tool
such as crowbar.
.
TSB Revision
Page 55
TWIN CLUTCH SST OVERHAUL
CAUTION
CAUTION
AK900459AF
MB992332
AK900459AG
MB992332
AK900283AF
TRANSAXLE
<<C>> CLUTCH ASSEMBLY REMOVAL
1. Align the four pins of the special tool, clutch remover &
installer (MB992332), with the four holes of the clutch
assembly to set the special tool, clutch remover & installer
(MB992332), to the clutch assembly.
2. Rotate the clutch assembly in the axial direction to insert the
pins into all four clutch disks in the clutch assembly.
NOTE: When the pins are inserted into all four clutch disks,
the clutch assembly cannot easily be rotated in the axial
direction.
3. Rotate the clutch assembly counterclockwise six to seven
times to loosen the clutch assembly.
22D-9
• When lifting the clutch assembly, the tool must not
hook the clutch disk.
• The clutch assembly might possibly have the needle
bearing. Pay attention to it.
• Carefully handle the clutch assembly to place it on the
clean place.
4. Lift the clutch assembly in the vertical direction to remove
the clutch assembly from the transaxle assembly.
.
<<D>> OIL PAN ASSEMBLY REMOVAL
When removing the oil pan assembly, pay attention to
avoid damage to the connector and the O-ring between the
oil pan assembly and the connector.
.
TSB Revision
Page 56
22D-10
AK900284
AK900330
AK900285
A-AC-CB-B
AK900257AF
11
10
9
8
7
6
5
4
3
2
1
TWIN CLUTCH SST OVERHAUL
TRANSAXLE
<<E>> MECHATRONIC ASSEMBLY REMOVAL
1. Remove the connector carefully.
2. Remove the three bolts.
3. Pull carefully at the connector to loose by approx. 2 - 3
mm(0.08 - 0.12 inch).
4. Remove the eleven bolts as shown and remove the
mechatronic assembly carefully.
.
TSB Revision
Page 57
TWIN CLUTCH SST OVERHAUL
AK900313AF
AK900310
AK900311
AK900311
TRANSAXLE
<<F>> MANUAL CONTROL SHAFT REMOVAL
1. Move the park manual outer lever from D in clock direction
to the service position as shown.
2. Remove the plug.
22D-11
3. When removing the screw located behind the plug, pay
attention to the screw not to fall in the transaxle case.
4. Remove the manual control shaft carefully.
ASSEMBLY SERVICE POINTS
.
>>A<< MANUAL CONTROL SHAFT INSTALLATION
1. Install the manual control shaft carefully and tighten the
screw to the specified torque.
Tightening torque: 10 ± 1.5 N⋅ m (89 ± 8 in-lb)
TSB Revision
Page 58
22D-12
AK900310
AK900286
AK900287
A-AC-CB-B
AK900257AG
1
2
3
4
5
6
7
8
9
10
11
TWIN CLUTCH SST OVERHAUL
TRANSAXLE
2. Tighten the plug to the specified torque.
Tightening torque: 32 ± 2 N⋅ m (24 ± 1 ft-lb)
.
>>B<< GASKET A / GASKET C / MECHATRONIC
ASSEMBLY INSTALLATION
1. As shown in the illustration, fix the gasket to the transaxle
case by pushing the gasket at the area to which the gasket
dowel pin is inserted.
2. Install the mechatronic assembly carefully and tighten the
mechatronic assembly mounting bolts to the specified
torque in the order of number shown in the figure.
Tightening torque: 5.0 ± 1.0 N⋅ m (44 ± 8 in-lb)
3. Tighten again the mechatronic assembly mounting bolts to
the specified torque in the order of number shown in the
figure.
Tightening torque: 10 ± 1.5 N⋅ m (89 ± 8 in-lb)
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Page 59
TWIN CLUTCH SST OVERHAUL
CAUTION
AK900330
AC807528
AC
1
2
3
4
5
6
7
8
9
10
11
AK900349
TRANSAXLE
4. Tighten the bolts to the specified torque.
Tightening torque: 6.0 ± 1.0 N⋅ m (53 ± 8 in-lb)
.
>>C<< OIL PAN ASSEMBLY INSTALLATION
1. Completely degrease the oil pan assembly installation
surface on the transaxle side.
2. Remove the gasket from the oil pan assembly, and
completely degrease the groove of the oil pan assembly
(gasket installation area) and the gasket. Then, install the
gasket to the groove of the oil pan assembly.
22D-13
When installing the oil pan assembly, pay attention to
avoid damage to the connector and the O-ring installed to
the connector.
3. Tighten the screws to the specified torque in the order
shown in the figure.
Tightening torque: 10 ± 1 N⋅ m (89 ± 8 in-lb)
.
>>D<< NEEDLE ROLLER BEARING
INSTALLATION
1. Insert the needle roller bearing and ensure that the lock is
closed completely.
.
TSB Revision
Page 60
22D-14
CAUTION
CAUTION
AK900348
AK900283AG
AK900459AF
MB992332
AK900460
TWIN CLUTCH SST OVERHAUL
TRANSAXLE
>>E<< SEAL RING INSTALLATION
Do not expand the seal ring more than necessary.
1. Insert the seal ring.
2. Ensure that the lock is closed completely and it is seated flat
into its position.
.
>>F<< CLUTCH ASSEMBLY INSTALLATION
Pay attention to the clutch assembly not to touch the seal
ring and needle bearing.
1. Put down the clutch assembly in the vertical direction to
carefully install it.
2. Align the four pins of the special tool, clutch remover &
installer (MB992332), with the four holes of the clutch
assembly to set the special tool, clutch remover & installer
(MB992332), to the clutch assembly.
3. Rotate the clutch assembly in the axial direction to insert the
pins into all four clutch disks in the clutch assembly.
4. Rotate the clutch assembly clockwise to install it.
Tighten it to the specified torque.
Tightening torque: 7.5 ± 1.0 N⋅ m (66 ± 8 in-lb)
.
TSB Revision
Page 61
TWIN CLUTCH SST OVERHAUL
AK802294
MB992324
MB992325
AC
AK802295
MB992325
AC
AK802296
MB992325
AC
AK802297
MB992323
AC
TRANSAXLE
>>G<< SEAL COVER BRACKET AND SEAL
COVER INSTALLATION
1. Install the seal cover to the special tool MB992324 and
MB992325.
2. Remove the special tool MB992324 from MB992325.
22D-15
3. Install the seal cover to the transaxle case. Remove the
special tool MB992325.
4. Use special tool MB992323 to install the seal cover to the
transaxle.
TSB Revision
Page 62
22D-16
AK802298
AK802287AC
MB992311
AK802288
MB992310
AC
AK802299
MB992313
AC
TWIN CLUTCH SST OVERHAUL
TRANSAXLE
5. Install the seal cover bracket.
Confirm that it is not shaky.
6. Tighten the seal cover bracket mounting bolt to the specified
torque.
Tightening torque: 10 ± 1 N⋅ m (89 ± 8 in-lb)
.
>>H<< TRANSAXLE CASE OIL SEAL (LH)
INSTALLATION
1. Apply the transaxle oil to the special tool MB992311.
Insert the oil seal to the special tool MB992311.
2. Use special tool MB992310 to install the oil seal to the
transaxle.
.
>>I<< TRANSAXLE CASE OIL SEAL (RH)
ASSEMBLY INSTALLATION
1. Apply the transaxle oil to the special tool MB992313.
Insert the oil seal to special tool MB992313.
TSB Revision
Page 63
TWIN CLUTCH SST OVERHAUL
AK802300
MB992312
AC
AK802292
AK802441
MB992314
AC
TRANSAXLE
2. Use special tool MB992312 to install the oil seal to the
transaxle.
.
>>J<< V RING INSTALLATION
1. Clean the spline with a brush or the like.
22D-17
2. Apply the transaxle oil to the special tool MB992314.
Insert the V ring to the special tool MB992314, and install
the V ring.
3. Check that the V ring is installed securely.
TSB Revision
Page 64
22D-18
AK800089AF
3
5
2
4
1
6
9.0 ± 2.0 N·m
80 ± 18 in-lb
TWIN CLUTCH SST OVERHAUL
TRANSFER
TRANSFER
DISASSEMBLY AND ASSEMBLY
M1222004000619
Removal steps
1. O-ring
>>C<<
Required special tools:
• MD998382: Crankshaft front oil seal installer
• MD998550: Extension housing seal installer
2. Oil seal
3. Dust seal guard
Removal steps (Continued)
>>B<<
>>A<<
4. Oil seal
5. Cover
6. Transfer
TSB Revision
Page 65
ASSEMBLY SERVICE POINT
AK602385AD
AK800088
MD998382
AD
AK800087
MD998550
AD
TWIN CLUTCH SST OVERHAUL
TRANSFER
.
>>A<< COVER INSTALLATION
1. Completely degrease the FIPG-applied surface so that
water and oil including the old sealant cannot adhere to the
surface coated with the sealant.
Never touch the degreased surface by hand.
2. Apply a 1.5 mm (0.06 in) diameter bead of sealant as
illustrated onto the cover.
Specified sealant: Mitsubishi Part No. MD997740 or
equivalent
3. Attach the cover to the transfer and tighten it to the specified
torque.
.
>>B<< OIL SEAL INSTALLATION
1. Using the special tool MD998382, to install the oil seal.
2. Apply transfer oil to the lip of oil seal.
22D-19
.
>>C<< OIL SEAL INSTALLATION
1. Using the special tool MD998550, to install the oil seal.
2. Apply specified grease to the oil seal lip area.
Specified grease: Retinax A
TSB Revision
Page 66
NOTES
Page 67
GROUP 22B
MANUAL
TRANSAXLE
OVERHAUL
CONTENTS
22B-1
GENERAL INFORMATION . . . . . . . . 22B-2
GENERAL SPECIFICATIONS . . . . . . 22B-3
SERVICE SPECIFICATIONS. . . . . . . 22B-3
FASTENER TIGHTENING
SPECIFICATIONS . . . . . . . . . . . . . . . 22B-4
SEALANTS AND ADHESIVES . . . . . 22B-4
LUBRICANTS . . . . . . . . . . . . . . . . . . 22B-5
ADJUSTMENT SNAP RING AND
SPACERS . . . . . . . . . . . . . . . . . . . . . 22B-6
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22B-8
TRANSAXLE . . . . . . . . . . . . . . . . . . . 22B-12
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-19
TRANSAXLE ADJUSTMENT . . . . . . . . . . . 22B-19
OUTPUT SHAFT. . . . . . . . . . . . . . . . . 22B-29
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-29
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 22B-35
REVERSE IDLER GEAR . . . . . . . . . . 22B-37
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-37
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 22B-39
CONTROL HOUSING. . . . . . . . . . . . . 22B-40
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-40
SELECT LEVER . . . . . . . . . . . . . . . . . 22B-43
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-43
CLUTCH HOUSING . . . . . . . . . . . . . . 22B-44
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-44
TRANSAXLE CASE . . . . . . . . . . . . . . 22B-48
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-48
CENTER DIFFERENTIAL. . . . . . . . . . 22B-52
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-52
INPUT SHAFT . . . . . . . . . . . . . . . . . . 22B-22
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-22
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 22B-27
TRANSFER . . . . . . . . . . . . . . . . . . . . . 22B-55
DISASSEMBLY AND ASSEMBLY . . . . . . . 22B-55
Page 68
22B-2
AK703412
MANUAL TRANSAXLE OVERHAUL
GENERAL INFORMATION
GENERAL INFORMATION
TRANSAXLE MODEL
Transaxle model Engine model Vehicle model
W5M6A-1-A4ZA 4B11 DOHC MIVEC CZ4A
SECTIONAL VIEW
M1222000101082
TSB Revision
Page 69
MANUAL TRANSAXLE OVERHAUL
GENERAL SPECIFICATIONS
22B-3
GENERAL SPECIFICATIONS
M1222000201056
GEAR RATIO TABLE
Item Specification
Transaxle model W5M6A
Transaxle type 5-speed
Transaxle gear ratio 1st 2.857
2nd 1.950
3rd 1.444
4th 1.096
5th 0.761
Reverse 2.892
Final reduction ratio 4.687
SERVICE SPECIFICATIONS
M1222000300782
Item Standard value Limit
Transaxle
Distance between the control shaft (in neural) and shift
cable bracket mm (in)
Distance between the select lever (3rd-4th speed
position) and shift cable bracket mm (in)
Input shaft preload mm (in) 0.10 − 0.17 (0.0039 − 0.0067)
Output shaft preload mm (in) 0.15 − 0.21 (0.0059 − 0.0083)
Center differential preload mm (in) 0.06 − 0.12 (0.0024 − 0.0047)
Input shaft
Input shaft taper roller bearing end play mm (in) 0.01 − 0.09 (0.0004 − 0.0035)
Synchronizer inner ring rear end to outer ring rear end
clearance mm (in)
Output shaft
Output shaft 3rd speed gear end play mm (in) 0.01 − 0.09 (0.0004 − 0.0035)
Output shaft taper roller bearing end play mm (in) 0.01 − 0.09 (0.0004 − 0.0035)
Synchronizer inner ring rear end to outer ring rear end
clearance mm (in)
Reverse idler gear
Reverse idler gear thrust washer end play mm (in) 0 − 0.11 (0 − 0.0043)
154 − 156 (6.063 − 6.141)
139.2 − 140.8 (5.481 − 5.543)
−
−
−
−
−
−
−
−
0.5 (0.02)
−
−
0.5 (0.02)
−
Synchronizer ring back surface to gear clearance mm (in)
TSB Revision
−
0.5 (0.02)
Page 70
22B-4
MANUAL TRANSAXLE OVERHAUL
FASTENER TIGHTE NING SPECIFICAT IONS
FASTENER TIGHTENING SPECIFICATIONS
TRANSAXLE
Item Specification
Reverse shift lever 24 ± 4 N⋅ m (17 ± 2 ft-lb)
Clutch housing-transaxle case mounting bolt 50 ± 5 N⋅ m (37 ± 3 ft-lb)
Reverse idler gear shaft mounting bolt 78 ± 7 N⋅ m (57 ± 4 ft-lb)
Poppet spring 32 ± 2 N⋅ m (24 ± 1 ft-ld)
Control housing mounting bolt 24 ± 4 N⋅ m (17 ± 2 ft-lb)
Select lever 24 ± 4 N⋅ m (17 ± 2 ft-lb)
Harness bracket 24 ± 4 N⋅ m (17 ± 2 ft-lb)
Back-up light switch 32 ± 2 N⋅ m (24 ± 1 ft-ld)
1st-2nd speed rail switch 32 ± 2 N⋅ m (24 ± 1 ft-ld)
Hanger bracket 24 ± 4 N⋅ m (17 ± 2 ft-lb)
Stud adapter 50 ± 5 N⋅ m (37 ± 3 ft-lb)
Shift cable bracket 24 ± 4 N⋅ m (17 ± 2 ft-lb)
Transaxle-transfer mounting bolt 69 ± 9 N⋅ m (51 ± 6 ft-lb)
Stopper bracket mounting bolt 19 ± 3 N⋅ m (14 ± 2 ft-lb)
M1222013900427
Select lever-select lever bracket connecting nut 11 ± 2 N⋅ m (97 ± 17 in-lb)
Clutch release bearing retainer mounting bolt 10 ± 2 N⋅ m (88 ± 17 in-lb)
Oil guide B 10 ± 2 N⋅ m (88 ± 17 in-lb)
Center differential drive gear mounting bolt 133 ± 4 N⋅ m (98 ± 2 ft-lb)
TRANSFER
Item Specification
Cover 9.0 ± 2.0 N⋅ m (80 ± 17 in-lb)
SEALANTS AND ADHESIVES
M1222000501217
TRANSAXLE
Item Specified sealant
Mating face for transaxle case and clutch housing Mitsubishi Part No. MD997740 or equivalent
Mating face for transaxle case and control housing
Steel ball 3M™STUD Locking No.4710 or equivalent
Center differential drive gear bolt
Air breather bracket Three bond 1501 or equivalent
TRANSFER
Item Specified sealant
Cover Mitsubishi Part No. MD997740 or equivalent
.
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Page 71
MANUAL TRANSAXLE OVERHAUL
CAUTION
LUBRICANTS
22B-5
FORM-IN-PLACE GASKET (FIPG)
This transaxle has several areas where the
form-in-place gasket (FIPG) is used for sealing. To
ensure that the FIPG fully serves its purpose, it is
necessary to observe some precautions when apply
ing it. Bead size, continuity and location are of paramount importance.
Too thin a bead cou ld cause l eaks. Too t hick a be ad,
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To
prevent leaks or blocking of passages, therefore, it is
absolutely necessary to apply the FIPG evenly with
out a break, while observing the correct bead size.
FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.
When re-applying liquid gasket (FIPG), be sure
that:
1. Residues of FIPG are cleared from all the ins
and outs of parts;
2. Use Mitsubishi genuine parts cleaner
(MZ100387) or equivalent to well degrease the
FIPG-applied surface.
3. FIPG is correctly applied in accordance with
FIPG Application.
.
-
Disassembly
Parts sealed with a FIPG can be easily removed
without need for the use of a special method. In
some cases, however, the FIPG in joints may have to
be broken by tapping parts with a mallet or similar
tool.
.
Surface Preparation
Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper.
Make sure that the FIPG application surfaces is flat
and smooth. Also make sure that the surface is free
from oils, greases and foreign substances. Do not fail
to remove old FIPG that may remain in the fastener
fitting holes.
.
FIPG Application
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet. Do not
allow FIPG to spread beyond the sealing areas dur
ing installation. Avoid operating the transaxle or letting oils or water come in contact with the sealed
area before a time sufficient for FIPG to harden
(approximately one hour) has passed.
FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.
-
LUBRICANTS
TRANSAXLE
Item Specified sealant
Transaxle oil Mitsubishi Genuine DiaQueen NEW MULTI GEAR
Control shaft oil seal lip gear oil
Oil seal (transaxle case)
Select lever shoe Mitsubishi Part No. 0101011 or equivalent
Input shaft oil seal lip gear oil Retinax A
TRANSFER
Item Specified lubricant
Transfer oil Hypoid gear oil API classification GL-5, SAE90
O-ring Mitsubishi Genuine DiaQueen ATF SPIII
Oil seal Retinax A
TSB Revision
OIL API classification GL-3, SAE 75W-80
M1222000400819
Page 72
22B-6
MANUAL TRANSAXLE OVERHAUL
ADJUSTMENT SNAP RING AND SPACERS
ADJUSTMENT SNAP RING AND SPACERS
Snap ring (For adjustment of input shaft rear bearing end play)
Thickness mm (in) Thickness mm (in)
1.23 (0.0484) 1.55 (0.0610)
1.27 (0.0500) 1.59 (0.0626)
1.31 (0.0516) 1.63 (0.0642)
1.35 (0.0531) 1.67 (0.0657)
1.39 (0.0547) 1.71 (0.0673)
1.43 (0.0563) 1.75 (0.0689)
1.47 (0.0579) 1.79 (0.0705)
1.51 (0.0594)
Spacer (For adjustment of input shaft end play)
Thickness mm (in) Thickness mm (in)
0.80 (0.0315) 1.16 (0.0457)
0.83 (0.0327) 1.19 (0.0469)
0.86 (0.0339) 1.22 (0.0480)
M1222012000799
0.89 (0.0350) 1.25 (0.0492)
0.92 (0.0362) 1.28 (0.0504)
0.95 (0.0374) 1.31 (0.0516)
0.98 (0.0386) 1.34 (0.0528)
1.01 (0.0398) 1.37 (0.0539)
1.04 (0.0409) 1.40 (0.0551)
1.07 (0.0421) 1.43 (0.0563)
1.10 (0.0433) 1.46 (0.0575)
1.13 (0.0445) 1.49 (0.0587)
Snap ring (For adjustment of output shaft 3rd speed gear end play)
Thickness mm (in) Thickness mm (in)
2.23 (0.0878) 2.47 (0.0972)
2.27 (0.0894) 2.51 (0.0988)
2.31 (0.0909) 2.55 (0.1004)
2.35 (0.0925) 2.59 (0.1020)
2.39 (0.0941) 2.63 (0.1035)
2.43 (0.0957) 2.67 (0.1051)
Snap ring (For adjustment of output shaft rear bearing end play)
Thickness mm (in) Thickness mm (in)
1.31 (0.0561) 1.55 (0.0610)
1.35 (0.0531) 1.59 (0.0626)
1.39 (0.0547) 1.63 (0.0642)
TSB Revision
Page 73
MANUAL TRANSAXLE OVERHAUL
ADJUSTMENT SNAP RING AND SPACERS
Thickness mm (in) Thickness mm (in)
1.43 (0.0563) 1.67 (0.0657)
1.47 (0.0579) 1.71 (0.0673)
1.51 (0.0594)
Spacer (For adjustment of output shaft end play)
Thickness mm (in) Thickness mm (in)
0.86 (0.0339) 1.19 (0.0469)
0.89 (0.0350) 1.22 (0.0480)
0.92 (0.0362) 1.25 (0.0492)
0.95 (0.0374) 1.28 (0.0504)
0.98 (0.0386) 1.31 (0.0516)
1.01 (0.0398) 1.34 (0.0528)
1.04 (0.0409) 1.37 (0.0539)
1.07 (0.0421) 1.40 (0.0551)
1.10 (0.0433) 1.43 (0.0563)
1.13 (0.0445) 1.46 (0.0575)
22B-7
1.16 (0.0457) 1.49 (0.0587)
Snap ring (For adjustment of reverse idler gear thrust washer end play)
Thickness mm (in) Thickness mm (in)
1.77 (0.0697) 2.12 (0.0835)
1.82 (0.0717) 2.17 (0.0854)
1.87 (0.0736) 2.22 (0.0874)
1.92 (0.0756) 2.27 (0.0894)
1.97 (0.0776) 2.32 (0.0913)
2.02 (0.0795) 2.37 (0.0933)
2.07 (0.0815) 2.42 (0.0953)
Spacer (For adjustment of center differential case end play)
Thickness mm (in) Thickness mm (in)
1.07 (0.0421) 1.34 (0.0528)
1.10 (0.0433) 1.37 (0.0539)
1.13 (0.0445) 1.40 (0.0551)
1.16 (0.0457) 1.43 (0.0563)
1.19 (0.0469) 1.46 (0.0575)
1.22 (0.0480) 1.49 (0.0587)
1.25 (0.0492) 1.52 (0.0598)
1.28 (0.0504) 1.55 (0.0610)
1.31 (0.0516)
TSB Revision
Page 74
22B-8
MANUAL TRANSAXLE OVERHAUL
SPECIAL TOOLS
SPECIAL TOOLS
TRANSAXLE
Tool Tool numbe r
and name
MD998917
Bearing
remover
MB990842
Drag link
bushing
remover and
installer B
MD998812
Installer cap
M1222000600921
Supersession Application
General service tool Removal of gears and bearings
−
General service tool Use with installer and installer
• Removal of input shaft 5th
speed gear
• Removal of output shaft taper
roller bearing
• Removal of output shaft 5th
and 4th speed gears
adapter
MD998813
Installer-100
MD998819
Installer adapter
(40)
MD998822
Installer adapter
(46)
General service tool Use with installer cap and
installer adapter
General service tool • Installation of taper roller
bearing
• Installation of output shaft 5th
speed gear
−
• Installation of input shaft
3rd-4th speed synchronizer
sleeve and 3rd-4th speed
synchronizer hub
• Installation of input shaft 5th
speed synchronizer sleeve
and 5th speed synchronizer
hub
• Installation of input shaft 4th
speed gear sleeve
• Installation of input shaft 5th
speed gear sleeve
• Installation of input shaft taper
roller bearing
• Installation of output shaft 3rd
speed gear
TSB Revision
Page 75
MANUAL TRANSAXLE OVERHAUL
MB990560
MB990947
SPECIAL TOOLS
22B-9
Tool Tool n umber
and name
MD999601
Valv e stem s eal
installer
MB990560
Rear axle shaft
bearing
remover
MD998814
Installer-200
MD998824
Installer adapter
(50)
Supersession Application
−
Installation of input shaft and
output shaft oil seal
−
Removal of output shaft taper
roller bearing
MIT304180 Use with installer cap and
installer adapter
General service tool • Installation of output shaft 1st
gear sleeve
• Installation of output 1st-2nd
speed synchronizer hub
• Installation of output 2nd
speed gear sleeve
MD998821
Installer adapter
(44)
MD999566
Claw
MB990947
Lower arm push
arbor
MB990984
Mount bushing
remover and
installer arbor
MD998821 Installation of output shaft 4th
speed gear
General service tool Removal of control housing oil
seal
MB990947-01 or
general service tool
−
Removal of control housing slide
ball bearing
Installation of control housing
slide ball bearing
TSB Revision
Page 76
22B-10
MB990883
MANUAL TRANSAXLE OVERHAUL
SPECIAL TOOLS
Tool Tool n umber
and name
MB991246
Lower arm
bushing arbor
MB991946
Pry bar
MB990883
Rear
suspension
bushing arbor
MD999547
Oil seal installer
Supersession Application
−
−
MB990883-01 or
general service tool
−
Installation of control housing oil
seal
Removal of oil guide
• Removal of slide ball bearing
• Installation of slide ball bearing
• Installation of oil guide
• Installation of center
differential taper roller bearing
MB992075
Handle
MB992271
Oil seal installer
MB991115
Oil seal installer
MB990938
Installer bar
−
−
MB991015-01 Installation of center differential
MB990938-01 Installation of center differential
Installation of oil seal
Installation of oil seal
oil seal
oil seal
TSB Revision
Page 77
MANUAL TRANSAXLE OVERHAUL
MB990847
D998382
SPECIAL TOOLS
22B-11
Tool Tool n umber
and name
MD998830
Installer adapter
(66)
MB992272
Bearing installer
MB990847
Rear
suspension
bushing
remover and
installer base
TRANSFER
Tool Tool numbe r
and name
MD998382
Crankshaft front
oil seal installer
Supersession Application
−
Removal of center differential
taper roller bearing
−
Installation of center differential
taper roller bearing
MB990847 Installation of center differential
taper roller bearing
Supersession Application
MD998382-01 Installation of oil seal
MD998550
Input shaft
holder
−
Installation of oil seal
TSB Revision
Page 78
22B-12
AK703151
AC
3
10
4
2
1
9
8
6
7
5
69 ± 9 N·m
51 ± 6 ft-lb
24 ± 4 N·m
17 ± 2 ft-lb
24 ± 4 N·m
17 ± 2 ft-lb
24 ± 4 N·m
17 ± 2 ft-lb
32 ± 2 N·m
24 ± 1 ft-lb
50 ± 5 N·m
37 ± 3 ft-lb
Apply gear oil to
all moving parts
before installation.
MANUAL TRANSAXLE OVERHAUL
TRANSAXLE
TRANSAXLE
DISASSEMBLY AND ASSEMBLY
M1222016500116
>>J<<
>>I<<
Removal steps
1. Transfer assembly
2. Shift cable bracket
3. Stud adapter
4. Hanger bracket
5. 1st-2nd speed rail switch
>>I<<
6. Gasket
7. Back-up light switch
8. Gasket
9. Harness bracket
10. Select lever
Removal steps (Continued)
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Page 79
MANUAL TRANSAXLE OVERHAUL
AK703162
AC
11
13
14
15
16
17
18
19
20
21
22
12
24 ± 4 N·m
17 ± 2 ft-lb
50 ± 5 N·m
37 ± 3 ft-lb
78 ± 7 N·m
57 ± 4 ft-lb
50 ± 5 N·m
37 ± 3 ft-lb
32 ± 2 N·m
24 ± 1 ft-lb
Apply gear oil to
all moving parts
before installation.
TRANSAXLE
22B-13
Removal steps
>>H<<
>>G<<
11. Control housing
12. Poppet spring
13. Gasket
14. Reverse idler gear shaft mounting
bolt
15. Gasket
16. Transaxle case
Removal steps (Continued)
17. Outer race (for center differential)
18. Spacer (for center differential)
19. Outer race (for output shaft)
20. Spacer (for output shaft)
21. Outer race (for input shaft)
22. Spacer (for input shaft)
TSB Revision
Page 80
22B-14
AK703164
42
40
41
2
39
38
29
28
30
26
35
25
31
23
34
46
AC
24
37
32
33
27
36
45
44
43
24 ± 4 N·m
17 ± 2 ft-lb
Apply gear oil to
all moving parts
before installation.
MANUAL TRANSAXLE OVERHAUL
TRANSAXLE
<<A>>
<<A>>
<<B>>
<<C>>
<<D>>
<<D>>
<<D>>
<<D>>
<<D>>
<<D>>
<<D>>
<<D>>
<<E>>
Removal steps
23. Reverse shift lever
24. Reverse shift rail
25. Reverse shift fork
26. 5th-reverse speed shift rail
27. Steel ball
28. Steel ball
29. Spring pin
30. 3rd-4th speed shift rail
31. Reverse idler gear assembly
32. 3rd-4th speed shift fork
33. Snap ring
34. Shift lug
35. 5th speed shift fork
36. 5th speed shift rail assembly
37. Input shaft assembly
38. Output shaft assembly
39. 1st-2nd speed shift fork
40. 1st-2nd speed shift rail assembly
41. Spring pin
TSB Revision
>>A<<
>>A<<
>>A<<
>>A<<
>>A<<
>>A<<
Removal steps (Continued)
42. Center differential assembly
43. Outer race (for center differential)
44. Outer race (for output shaft)
45. Outer race (for input shaft)
46. Clutch housing
Installation steps
46. Clutch housing
45. Outer race (for input shaft)
44. Outer race (for output shaft)
43. Outer race (for center differential)
42. Center differential assembly
38. Output shaft assembly
37. Input shaft assembly
36. 5th speed shift rail assembly
35. 5th speed shift fork
34. Shift lug
33. Snap ring
32. 3rd-4th speed shift fork
39. 1st-2nd speed shift fork
40. 1st-2nd speed shift rail assembly
Page 81
>>B<<
AK703320
AC
AK703321
AK703322
>>C<<
>>D<<
>>E<<
>>F<<
MANUAL TRANSAXLE OVERHAUL
Installation steps (Continued)
41. Spring pin
31. Reverse idler gear assembly
30. 3rd-4th speed shift rail
29. Spring pin
28. Steel ball
27. Steel ball
26. 5th-reverse speed shift rail
25. Reverse shift fork
24. Reverse shift rail
23. Reverse shift lever
TRANSAXLE
22B-15
DISASSEMBLY SERVICE POINTS
.
<<A>> STEEL BALL REMOVAL
Remove the steel balls at the illustrated positions from the shift
lug and 5th speed shift fork.
.
<<B>> SPRING PIN REMOVAL
Knock the spring pin out of the 3rd-4th speed shift fork from the
illustrated direction.
.
<<C>> REVERSE IDLER GEAR ASSEMBLY
REMOVAL
Pull up the input shaft and output shaft together, and remove
the reverse idler gear assembly.
TSB Revision
.
Page 82
22B-16
AK703804
AK703324
AK703323
MANUAL TRANSAXLE OVERHAUL
TRANSAXLE
<<D>> 3RD-4TH SPEED SHIFT FORK / 5TH
SPEED SHIFT FORK / SHIFT LUG / 5TH SPEED
SHIFT RAIL ASSEMBLY / INPUT SHAFT
ASSEMBLY / OUTPUT SHAFT ASSEMBLY /
1ST-2ND SPEED SHIFT FORK / 1ST-2ND SPEED
SHIFT RAIL ASSEMBLY REMOVAL
With the differential assembly raised a little, remove the 3rd-4th
speed shift fork, 5th speed shift fork, shift lug, 5th speed shift
rail assembly, output shaft assembly, 1st-2nd speed shift fork,
1st-2nd speed shift rail assembly and input shaft assembly as a
set.
.
<<E>> SPRING PIN REMOVAL
Knock the spring pin out of the 1st-2nd speed shift fork from the
illustrated direction.
ASSEMBLY SERVICE POINTS
.
>>A<< 3RD-4TH SPEED SHIFT FORK / 5TH
SPEED SHIFT FORK / SHIFT LUG / 5TH SPEED
SHIFT RAIL ASSEMBLY / INPUT SHAFT ASSEM
-
BLY / OUTPUT SHAFT ASSEMBLY REMOVAL
With the differential assembly raised a little, install the 3rd-4th
speed shift fork, 5th speed shift fork, shift lug, 5th speed shift
rail assembly, input shaft assembly and output shaft assembly
as a set.
.
TSB Revision
Page 83
MANUAL TRANSAXLE OVERHAUL
AK703408
2.5 mm
(0.10 inch)
AE
Shift rail
Shift fork
Spring pin
AK703681
Reverse idler
gear assembly
AC
1st-2nd speed
synchronizer sleeve
AK703409
2.5 mm
(0.10 inch)
AE
Shift rail
Shift fork
Spring pin
AK703410
AC
Identification groove
Installation
direction
5th-reverse speed shift rail
TRANSAXLE
>>B<< SPRING PIN INSTALLATION
Install the spring pin to the shift rail so that the slit of the spring
pin aligns with the center axis of the rail as shown.
.
>>C<< REVERSE IDLER GEAR ASSEMBLY
INSTALLATION
Install the reverse idler gear assembly so that the notch of the
reverse idler gear shaft and 1st-2nd speed synchronizer sleeve
meet at the illustrated position.
22B-17
.
>>D<< SPRING PIN INSTALLATION
Install the spring pin to the shift rail so that the slit of the spring
pin aligns with the center axis of the rail as shown.
.
>>E<< 5TH-REVERSE SPEED SHIFT RAIL
INSTALLATION
Install the 5th-reverse speed shift rail, with its identification
groove to the clutch housing side.
TSB Revision
.
Page 84
22B-18
AK703326
AC
Addition mark
AK703818
AD
AK703819
AC
AK703332
AC
Back-up light switch
Control shaft
1st-2nd speed
rail switch
MANUAL TRANSAXLE OVERHAUL
TRANSAXLE
>>F<< REVERSE SHIFT LEVER INSTALLATION
Install the reverse shift lever so that its identification mark is
located at the illustrated position.
.
>>G<< TRANSAXLE CASE INSTALLATION
1. Completely degrease the FIPG-applied surface so that
water and oil including the old sealant cannot adhere to the
surface coated with the sealant.
Never touch the degreased surface by hand.
2. Apply a bead (approximately 2.5 mm (0.10 inch) thick) of
specified sealant to the transaxle case as shown.
Specified sealant: Mitsubishi Part No. MD997740 or
equivalent
.
>>H<< CONTROL HOUSING INSTALLATION
1. Completely degrease the FIPG-applied surface so that
water and oil including the old sealant cannot adhere to the
surface coated with the sealant.
Never touch the degreased surface by hand.
2. Apply a bead (approximately 3.5 mm (0.14 inch) thick) of
specified sealant to the control housing as shown.
Specified sealant: Mitsubishi Part No. MD997740 or
equivalent
.
>>I<< BACK-UP LIGHT SWITCH / 1ST-2ND SPEED
RAIL SWITCH INSTALLATION
Install the back-up light switch and 1st-2nd speed rail switch at
the illustrated positions.
TSB Revision
.
Page 85
MANUAL TRANSAXLE OVERHAUL
AK703153AF
154 - 156 mm
(6.063 - 6.141 inch)
Control
shaft
Shift cable
bracket
AK703154AF
139.2 - 140.8 mm
(5.481 - 5.543 inch)
Select lever bracket
Select lever
Shift cable
bracket
AK201630
TRANSAXLE
>>J<< SHIFT CABLE BRACKET INSTALLATION
1. Install the shift cable bracket loosely.
2. Put the control shaft into neutral.
3. Position the shift cable bracket so that the distance between
the control shaft and shift cable bracket is within the
standard value. Then fix the bracket securely.
Standard value: 154 − 156 mm (6.063 − 6.141 inch)
4. Install the select lever bracket loosely.
5. Put the select lever into the 3rd-4th speed position.
6. Position the select lever bracket so that the distance
between the select lever and shift cable bracket is within the
standard value. Then fix the bracket securely.
Standard value: 139.2 − 140.8 mm (5.481 − 5.543 inch)
22B-19
INSPECTION
.
M1222016600049
BACKUP LIGHT SWITCH / 1-2 speed rall switch
Check for continuity between terminals.
Switch Condition Continuity
Pressed Open
Released Conductive
TRANSAXLE ADJUSTMENT
M1222013800129
ADJUSTMENT BEFORE ASSEMBLY
.
SPACER SELECTION FOR INPUT SHAFT PRELOAD / OUTPUT SHAFT PRELOAD / CENTER DIFFERENTIAL PRELOAD ADJUSTMENT
<Measurement using solder>
• If soft solder is not available, select the spacer in accordance with Plastigage method.
• If the spacer appropriate for the standard value cannot be
selected using soft solder, select the spacer in accordance
with Plastigage method.
TSB Revision
Page 86
22B-20
AK703323
AK703327AC
Solders
AK703329AC
Solders
Solders
MANUAL TRANSAXLE OVERHAUL
TRANSAXLE
1. Install the input shaft, output shaft and center differential as
a set to the clutch housing.
2. Put a piece of solder [1.6 mm (0.06 in) diameter, 10 mm
(0.39 in) long] on the transaxle case at the positions shown
in the illustration.
3. Install the bearing outer races on the pieces of solder.
4. Install the clutch housing to the transaxle case and tighten
the bolts to the specified torque.
5. Remove the clutch housing, then remove the bearing outer
races and take out crushed pieces of solder.
NOTE: If the pieces of solder have not crushed, use thicker
solders and repeat steps 2 to 3.
6. Measure the thickness of crushed solder with a micrometer,
select the spacers that provide the standard preload values
and install them.
• Input shaft
Input shaft preload
Spacer thickness: [T + 0.10 mm (0.0039 inch)] − [T +
0.17 mm (0.0067 inch)]
T: Thickness of crushed solder mm (inch)
Standard value: 0.10 − 0.17 mm (0.0039 − 0.0067 inch)
• Output shaft
Output shaft preload
Spacer thickness: [T + 0.15 mm (0.0059 inch)] − [T +
0.21 mm (0.0083 inch)]
T: Thickness of crushed solder mm (inch)
Standard value: 0.15 − 0.21 mm (0.0059 − 0.0083 inch)
• Center differential
Center differential preload
Spacer thickness: [T + 0.06 (0.0024 inch)] − [T + 0.12
mm (0.0047 inch)]
T: Thickness of crushed solder mm (inch)
Standard value: 0.06 − 0.12 mm (0.0024 − 0.0047 inch)
.
TSB Revision
Page 87
AK703323
AK703327AD
Plastigage
AK703329AD
Plastigage
Plastigage
MANUAL TRANSAXLE OVERHAUL
TRANSAXLE
<Measurement using plastigage>
1. Install the input shaft, output shaft and center differential as
a set to the clutch housing.
2. Install the thinnest spacers in position for measurement.
3. Put a piece of Plastigage [about 10 mm (0.39 in) long] on the
transaxle case at the positions shown in the illustration.
4. Install the bearing outer races.
5. Install the clutch housing to the transaxle case and tighten
the bolts to the specified torque.
6. Remove the clutch housing, then remove the bearing outer
races and take out crushed pieces of Plastigage.
7. If the pieces of Plastigage have not crushed and clearance
measurement is impossible, replace them with thicker ones
and repeat steps 3 to 5.
8. Using the scale printed on the Plastigage package, measure
the width of crushed pieces of Plastigage at their widest
part, select the spacers that provide the standard preload
values and install them.
• Input shaft
Input shaft preload
Spacer thickness: [T1 + T2 + 0.10 mm (0.0039 inch)] −
[T1 + T2 + 0.17 mm (0.0067 inch)]
T1: Thickness of crushed Plastigage mm (inch)
T2: Thickness of spacer used for measurement mm
(inch)
Standard value: 0.10 − 0.17 mm (0.0039 − 0.0067 inch)
• Output shaft
Output shaft preload
Spacer thickness: [T1 + T2 + 0.15 mm (0.0059 inch)] −
[T1 + T2 + 0.21 mm (0.0083 inch)]
T1: Thickness of crushed Plastigage mm (inch)
T2: Thickness of spacer used for measurement mm
(inch)
Standard value: 0.15 − 0.21 mm (0.0059 − 0.0083 inch)
• Center differential
Center differential preload
Spacer thickness: [T1 + T2 + 0.06 mm (0.0024 inch)] −
[T1 + T2 + 0.12 mm (0.0047 inch)]
T1: Thickness of crushed Plastigage mm (inch)
T2: Thickness of spacer used for measurement mm
(inch)
Standard value: 0.06 − 0.12 mm (0.0024 − 0.0047 inch)
22B-21
TSB Revision
Page 88
22B-22
AK702340
30
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
1
31
AD
Apply gear oil to
all moving parts
before installation.
MANUAL TRANSAXLE OVERHAUL
INPUT SHAFT
INPUT SHAFT
DISASSEMBLY AND ASSEMBLY
M1222001600764
>>I<<
>>H<<
<<A>> >>G<<
<<A>>
<<A>> >>F<<
<<A>> >>F<<
<<A>>
Removal steps
1. Oil seal
2. Snap ring
3. Taper rol ler bear ing
4. Synchronizer key stopper plate
5. 5th speed synchronizer sleeve
6. 5th speed synchronizer hub
7. Synchronizer key
TSB Revision
<<A>>
<<A>>
<<A>>
<<A>>
<<B>> >>E<<
<<B>>
Removal steps (Continued)
8. Synchronizer outer ring
9. Synchronizer cone
10. Synchronizer inner ring
11. 5th speed gear
12. Needle roller bearing
13. 5th speed gear sleeve
14. 4th speed gear
Page 89
MANUAL TRANSAXLE OVERHAUL
AK703165
MB990842
MD998917
AC
Removal steps (Continued)
<<B>>
<<B>> >>D<<
<<B>>
<<B>>
<<B>>
<<B>> >>C<<
<<B>> >>C<<
<<B>>
<<B>>
<<B>>
<<B>>
<<B>> >>B<<
<<B>>
>>B<<
<<C>> >>A<<
15. Needle roller bearing
16. 4th speed gear sleeve
17. Synchronizer outer ring
18. Synchronizer cone
19. Synchronizer inner ring
20. 3rd-4th speed synchronizer sleeve
21. 3rd-4th speed synchronizer hub
22. Synchronizer key
23. Synchronizer outer ring
24. Synchronizer cone
25. Synchronizer inner ring
26. Thrust bearing
27. 3rd speed gear
28. Needle roller bearing
29. Thrust bearing
30. Ta pe r rol ler bear ing
31. Input shaft
Required Special Tools:
• MD998917: Bearing remover
• MB990842: Drag link bushing remover and
installer B
• MD998812: Installer cap
INPUT SHAFT
• MD998813: Installer-100
• MD998819: Installer adapter (40)
• MD998822: Installer adapter (46)
• MD999601: Valve stem seal installer
22B-23
DISASSEMBLY SERVICE POINTS
.
<<A>> 5TH SPEED GEAR / SYNCHRONIZER
INNER RING / SYNCHRONIZER CONE / SYN
CHRONIZER OUTER RING / 5TH SPEED SYNCHRONIZER HUB / TAPER ROLLER BEARING /
SYNCHRONIZER KEY STOPPER PLATE / 5TH
SPEED SYNCHRONIZER SLEEVE REMOVAL
Using the special tools, MD998917 and MB990842, indicated
below, remove the 5th speed gear, 5th speed synchronizer
sleeve, 5th speed synchronizer hub, synchronizer inner ring,
synchronizer outer ring, synchronizer cone, synchronizer key
stopper plate and taper roller bearing.
.
TSB Revision
Page 90
22B-24
AK703166
MD998917
AC
AK703167
MD998917
AD
AK703168
MD998819
AC
MD998812
MD998813
MANUAL TRANSAXLE OVERHAUL
INPUT SHAFT
<<B>> 3RD SPEED GEAR / 5TH SPEED GEAR
SLEEVE / 4TH SPEED GEAR / NEEDLE ROLLER
BEARING / 4TH SPEED GEAR SLEEVE /
SYNCHRONIZER OUTER RING / SYNCHRONIZER
CONE / SYNCHRONIZER INNER RING / 3RD-4TH
SPEED SYNCHRONIZER SLEEVE / 3RD-4TH
SPEED SYNCHRONIZER HUB / THRUST
BEARING / 3RD SPEED GEAR REMOVAL
Using special tool, MD998917, support the 3rd speed gear, and
then remove the 3rd seed gear, thrust bearings, 3rd-4th speed
synchronizer sleeve, 3rd-4th speed synchronizer hub, synchro
nizer outer ring, synchronizer inner ring, synchronizer cone, 4th
speed gear, needle roller bearing, 4th speed gear sleeve and
5th speed gear sleeve.
-
.
<<C>> TAPER ROLLER BEARING REMOVAL
Using special tool, MD998917, remove the taper roller bearing.
ASSEMBLY SERVICE POINTS
.
>>A<< TAPER ROLLER BEARING INSTALLATION
Using the special tools, MD998812, MD998813 and
MD998819, indicated below, install the taper roller bearing.
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.
Page 91
MANUAL TRANSAXLE OVERHAUL
AK703374
AC
(thick)
3rd speed gear
(thin)
Black
Colorless
(thin)
Colorless
(thick)
Black
AK703159
Identification groove
Installation
direction
AC
AK703169AC
MD998812
MD998813
MD998822
AK703170AC
MD998812
MD998813
MD998822
INPUT SHAFT
>>B<< THRUST BEARING INSTALLATION
Install the thrust bearings as shown.
.
>>C<< 3RD-4TH SPEED SYNCHRONIZER HUB /
3RD-4TH SPEED SYNCHRONIZER SLEEVE
INSTALLATION
1. Install the 3rd-4th speed synchronizer hub and synchronizer
sleeve in the illustrated direction.
22B-25
2. Using the special tools, MD998812, MD998813 and
MD998822, indicated below, install the 3rd-4th speed
synchronizer sleeve, 3rd-4th speed synchronizer hub,
synchronizer outer ring, synchronizer inner ring and
synchronizer cone.
3. After installation, check that the 3rd speed gear rotates
smoothly.
.
>>D<< 4TH SPEED GEAR SLEEVE
INSTALLATION
Using the special tools, MD998812, MD998813 and
MD998822, indicated below, install the 4th speed gear sleeve.
.
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Page 92
22B-26
AK703171AC
MD998812
MD998813
MD998822
AK703158
Identification
groove
Identification
groove
Installation
direction
AC
AK703172AC
MD998812
MD998813
MD998822
AK703173
AC
MD998812
MD998822
MD998813
MANUAL TRANSAXLE OVERHAUL
INPUT SHAFT
>>E<< 5TH SPEED GEAR SLEEVE INSTALLATION
Using the special tools, MD998812, MD998813 and
MD998822, indicated below, install the 5th speed gear sleeve.
.
>>F<< 5TH SPEED SYNCHRONIZER HUB / 5TH
SYNCHRONIZER SLEEVE INSTALLATION
1. Install the 5th speed synchronizer hub and synchronizer
sleeve in the illustrated direction.
2. Using the special tools, MD998812, MD998813 and
MD998822, indicated below, install the 5th speed
synchronizer hub and synchronizer sleeve.
3. After installation, check that the 5th speed gear rotates
smoothly.
.
>>G<< TAPER ROLLER BEARING INSTALLATION
Using the special tools, MD998812, MD998813 and
MD998822, indicated below, press-fit the taper roller bearing.
.
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Page 93
MANUAL TRANSAXLE OVERHAUL
AK703174
AK702519AH
3.5 mm
(0.14 inch)
Oil seal
AK703175AC
MD999601
AK702517
AC
INPUT SHAFT
>>H<< SNAP RING INSTALLATION
Select and install appropriate snap ring onto the input shaft so
that the clearance of the taper roller bearing meets the stan
dard value.
Standard value: 0.01 − 0.09 mm (0.0004 − 0.0035 inch)
.
>>I<< OIL SEAL INSTALLATION
Using special tool, MD999601, drive the oil seal as deep as
shown into place.
22B-27
-
INSPECTION
.
INPUT SHAFT
• Check the needle bearing mounting portion of the shaft for
• Check the splines for damage and wear.
.
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M1222001700330
damage, wear and seizure.
Page 94
22B-28
AK204169
AD
AK703376
AC
AK703161
AC
Gear
Cone
Outer ring
Inner ring
A
AK703375
MANUAL TRANSAXLE OVERHAUL
INPUT SHAFT
NEEDLE BEARING
• Combine the needle bearing with the input shaft and gears
and check that it smoothly rotates without noise or play.
• Check the needle bearing retaining sleeve for deformation.
.
SPEED GEARS
1. Check that the helical and clutch gears of each speed gear
are not damaged or worn in the tooth surface.
2. Check that the synchronizer cone of each speed gear is not
roughened, damaged or worn in the surface.
3. Check that the inner, front and rear surfaces of each speed
gear are not damaged or worn.
.
SYNCHRONIZER RING
1. Check that the outer synchronizer ring clutch gear is free of
damage.
2. Check that the synchronizer rings and synchronizer cones
are free of damage or wear in the contact surface and
broken screw threads.
3. Check that the outer synchronizer ring and synchronizer key
contact surface is free of damage and wear.
4. Join the outer and inner synchronizer rings and synchronizer
cone together and check clearance "A" shown. If "A" is less
than the limit value, replace them.
Limit A (from back of outer ring to clutch gear): 0.5
mm (0.02 inch)
.
SYNCHRONIZER SLEEVE AND HUB
• Combine the synchronizer sleeve and hub, and check that
they slide smoothly.
• Check that the sleeve is free of damage at its inside spline
ends.
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Page 95
MANUAL TRANSAXLE OVERHAUL
AK702341
3
4
5
6
7
8
9
11
16
10
14
13
12
15
18
17
19
20
21
22
24
25
26
1
27
2
AC
23
Apply gear oil to
all moving parts
before installation.
OUTPUT SHAFT
OUTPUT SHAFT
22B-29
DISASSEMBLY AND ASSEMBLY
M1222002200640
<<A>> >>L<<
<<B>> >>J<<
<<C>> >>I<<
<<C>> >>H<<
<<D>> >>F<<
>>M<<
>>K<<
>>G<<
Removal steps
1. Oil seal
2. Ta pe r ro ller bear ing
3. Snap ring
4. Ta pe r ro ller bear ing
5. Collar
6. 5th speed gear
7. 4th speed gear
8. Snap ring
9. 3rd speed gear
10.2nd speed gear
11. Needle roller bearing
12.Synchronizer outer ring
13.Synchronizer cone
14.Synchronizer inner ring
<<E>> >>E<<
<<E>> >>C<<
<<E>>
<<E>>
<<E>>
<<E>>
<<E>> >>B<<
<<E>>
<<E>>
<<E>> >>B<<
<<E>> >>A<<
>>D<<
Removal steps (Continued)
15.1st-2nd speed synchronizer
sleeve
16.2nd speed gear sleeve
17.1st-2nd speed synchronizer
hub
18.Synchronizer key
19.Synchronizer outer ring
20.Synchronizer cone
21.Synchronizer inner ring
22.Thrust bearing
23.1st speed gear
24.Needle roller bearing
25.Thrust bearing
26.1st speed gear sleeve
27.Output shaft
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Page 96
22B-30
AK703313AC
MB990842
MB990560
AK703177AC
MD998917
MB990842
AK703178
MD998917
AC
MB990842
MANUAL TRANSAXLE OVERHAUL
Required Special Tools:
• MB990560: Rear axle shaft bearing remover
• MB990842: Drag link bushing remover and
installer B
• MD998917: Bearing remover
• MD998812: Installer cap
• MD998814: Installer-200
OUTPUT SHAFT
• MD998824: Installer adapter (50)
• MD998822: Installer adapter (46)
• MD998813: Installer-100
• MD998821: Installer adapter (44)
• MD998819: Installer adapter (40)
• MD999601: Valve stem seal installer
DISASSEMBLY SERVICE POINTS
.
<<A>> TAPER ROLLER BEARING REMOVAL
1. Using a chisel or the like, knock off the roller cage of the
taper roller bearing.
2. Using the special tools, MB990842 and MB990560,
indicated below, remove the taper roller bearing.
.
<<B>> TAPER ROLLER BEARING REMOVAL
Using the special tools, MD998917 and MB990842, indicated
below, remove the taper roller bearing.
.
<<C>> 5TH SPEED GEAR / 4TH SPEED GEAR
REMOVAL
Using the special tools, MD998917 and MB990842, indicated
below, remove the 5th speed gear and 4th speed gear.
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Page 97
MANUAL TRANSAXLE OVERHAUL
AK703301AC
MD998917
AK703302AC
MD998917
AK703303AC
MD998814
MD998812
MD998824
OUTPUT SHAFT
<<D>> 3RD SPEED GEAR REMOVAL
Using special tool, MD998917, remove the 3rd speed gear.
.
<<E>> NEEDLE ROLLER BEARING /
SYNCHRONIZER CONE / SYNCHRONIZER
OUTER RING / SYNCHRONIZER INNER RING /
THRUST BEARING / 2ND SPEED GEAR SLEEVE /
1ST-2ND SPEED SYNCHRONIZER HUB / 1ST
SPEED GEAR / 1ST SPEED GEAR SLEEVE
REMOVAL
Using special tool, MD998917, support the 1st speed gear
sleeve, and then remove the 2nd speed gear sleeve, 1st-2nd
speed synchronizer hub, synchronizer cones, synchronizer
outer rings, synchronizer inner rings, thrust bearings, 1st speed
gear, needle roller bearing and 1st speed gear sleeve.
22B-31
ASSEMBLY SERVICE POINTS
.
>>A<< 1ST SPEED GEAR SLEEVE INSTALLATION
Using the special tools, MD998812, MD998814 and
MD998824, indicated below, install the 1st speed gear sleeve.
.
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Page 98
22B-32
AK703377
AC
1st speed
gear sleeve
Needle roller bearing
Thrust bearing
AK703378
AC
Installation
direction
AK703304AC
MD998812
MD998814
MD998824
AK703379
AC
Installation
direction
Identification
groove
MANUAL TRANSAXLE OVERHAUL
OUTPUT SHAFT
>>B<< THRUST BEARING INSTALLATION
Install the thrust bearings as shown.
.
>>C<< 1ST-2ND SPEED SYNCHRONIZER HUB
INSTALLATION
1. Install the 1st-2nd speed synchronizer hub in the illustrated
direction.
2. Using the special tools, MD998812, MD998814 and
MD998824, indicated below, install the 1st-2nd speed
synchronizer hub.
.
>>D<< 1ST-2ND SPEED SYNCHRONIZER SLEEVE
INSTALLATION
1. Install the 1st-2nd speed synchronizer sleeve in the
illustrated direction.
2. Install the synchronizer outer ring, synchronizer cone and
synchronizer inner ring.
3. After installation, check that the 1st-2nd speed gears rotate
smoothly.
.
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Page 99
MANUAL TRANSAXLE OVERHAUL
AK703305AC
MD998812
MD998824
MD998814
AK703306AC
MD998812
MD998822
MD998814
AK703179
AK703307AC
MD998812
MD998821
MD998813
OUTPUT SHAFT
>>E<< 2ND SPEED GEAR SLEEVE
INSTALLATION
Using the special tools, MD998812, MD998814 and
MD998824, indicated below, install the 2nd speed gear sleeve.
.
>>F<< 3RD SPEED GEAR INSTALLATION
Using the special tools, MD998812, MD998814 and
MD998822, indicated below, install the 3rd speed gear.
22B-33
.
>>G<< SNAP RING INSTALLATION
Select and install appropriate snap ring onto the output shaft so
that the clearance of the output shaft-3rd speed gear meets the
standard value.
Standard value: 0.01 − 0.09 mm (0.0004 − 0.0035 inch)
.
>>H<< 4TH SPEED GEAR INSTALLATION
Using the special tools, MD998812, MD998813 and
MD998821, indicated below, install the 4th speed gear.
.
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Page 100
22B-34
AK703308AC
MD998812
MD998819
MD998813
AK703309AC
MD998812
MD998819
MD998813
AK703380AC
Snap ring
AK703414AC
MD998812
MD998819
MANUAL TRANSAXLE OVERHAUL
OUTPUT SHAFT
>>I<< 5TH SPEED GEAR INSTALLATION
Using the special tools, MD998812, MD998813 and
MD998819, indicated below, install the 5th speed gear.
.
>>J<< TAPER ROLLER BEARING INSTALLATION
Using the special tools, MD998812, MD998813 and
MD998819, indicated below, press-fit the taper roller bearing.
.
>>K<< SNAP RING INSTALLATION
Select and install appropriate snap ring onto the output shaft so
that the clearance of the taper roller bearing meets the stan
-
dard value.
Standard value: 0.01 − 0.09 mm (0.0004 − 0.0035 inch)
.
>>L<< TAPER ROLLER BEARING INSTALLATION
Using the special tools, MD998812 and MD998819, indicated
below, install the taper roller bearing.
.
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