0 n Mqnuol Worl<shop

MITSUBISHI MOTORS

chossis
SUPPLEMENT

3000GiT'96

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MITSUBISHI

(-, i.

3000GiT
WORKSHOP MANUAL
SUPPLEMENT FOREWORD

General Fuel Engine Electrical Body

G IE IE
JE -E

procedures This Workshop Manualcontains for removal, disassembly, inspection, adjustment, reas- Chassis Electrical sembly and installation, etc.for service mechanics. Usethefollowing manuals in combination withthis manual as required. T E C H N I C AIN L F OR MA T ION MA N U AL PYUE92O1 WORKSHOP MANUAL C H A S S I GR S OU P P WU E g 119 (Loose-leaf edition) (Basic) PWUE9203 PWUE92O3-1 (Supplement) PWUE92O3-2 (Supplement) PWUE92O3-3 (Supplement) ENGINE GROUP P WE E D N!N
(Loose-leaf edition) ELECTRICAL WIRING PHUE92O1 (Loose-leaf edition) (Basic) PHUE9406 PHUE94O6-1 (Supplement) PARTSCATALOGUE 8608K40!A! B608K454An B608K406A! 8808K404A! 8808K454A! BFASK4O4AD BFA8K454A! 8808K405A! 8808K406A! BFASK4O6AN

GI -l

All information, illustrations and product descriptionscontained in thismanual arecurrent asat the timeof publication. We,however, reserye the right to makechanges priornotice at any timewithout or obligation.

A[!,LT-,'.H-BJ-iJJI
@ Milsubishi Molors Corporation July 1995

ll WARNINGS REGARDING RESTRAINT OF SUPPLEMENTAL SYSTEM (sRs)EQUTPPED VEHTCLES

WARNING! (1) lmproperservice or maintenance of any component of the SRS,or any SRS-related component, can (from inadvertent lead to personalinjury or deathto servicepersonnel firing of the air bag) or to the driver(from rendering the SRSinoperative). (2) lf it is possible that the SRScomponents to heatover93oC(200'F)in bakingor in drying aresubjected (air bag module, afterpainting, remove the SRScomponents SRSdiagnosis unit,front impactsensors) beforehand. (3) Service or maintenance of any SRScomponent or SRS-related component mustbe performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealerpersonnel mustthoroughly review this manual, and especially its GROUP 528(SRS), Supplemental Restraint beforebeginning any service or maintenance System of anycomponent of the SRSor any SRS-related component. NOTE (.) in the table of contents Section titleswith asterisks in each group indicate operations requiring warnings.

ri

r)

GENERAL- Vehicle ldentification

00-1

GROUP OO

GENERAL
VEHICLE IDENTIFICATION
MODELS
VEHICLES FOREUROPE
Model code Zl6AMNGFL6 Zl6AMNGFR6 Zl6AMJGFL6 Zl6AMJGFR6 W6MG1 Enginemodel Transmission model

Fuelsupply system
MPI

6G72(2,972 mt )

WsMG1

VEHICLES FORGENERAL EXPORT

Model code Zl64MNGFL Zl6AMNGFR Enginemodel 6G72 (2,972m( ) Transmission model

Fuelsupply system
MPI

WsMG1

VEHICLES FORGCC
Model code Zl6AMNGFLW Enginemodel 6G72 (2,972m( ) Transmission model

Fuelsupply system
MPI

WsMG1

VEHICLESFOR AUSTRALIA
Model code Zl64MNGFR8 Enginemodel Transmission model

Fuelsupply system
MPI

6G72(2,972 me )

WsG1

CHASSIS NUMBER The chassis numberis stamped on the toeboard inside the engine compartment.

<VEHICLES FOREUROPE AND AUSTRALIA>

AJMBMN216
123456

T_ITTTIttttll

TTT ttl
ltl
789

APY

000001 A ---l--10

00-2

ldentification GENERAL- Vehicle

7. Sort A - Passenger car 8. Modelyear P - 1993 R - 1994 s - 1995 T - 1996 9. Plant Y - OheMotorVehicle Works 10.Serial number

1. A s i a 2. Japan 3 . M I T SU B I S H I A - ForEurope, righthanddrive B - For Europe, left handdrive F - ForAustralia, righthanddrive 4. Bodystyle M - 2-doorhatchback 5. Transmission type N - S-speed manual transmission J - 6-speed manual transmission 6. Development order 216- 2,972 me (Full time4WD)

ll

FORGENERAL <VEHICLES EXPORT AND GCC>

TTT_T-]_TT tttlttl
1234567

00001 C M N 216 A P Y --T--

tttrrtl

B 5 . Sort A - Passenger car 6. Model year P - 1993 R - 1994 s - 1995 T - 1996 7 . Plant Y - Ohe MotorVehicle Works Serialnumber

Export, righthanddrive C - For General D - For General Export or GCC,left hand drive Bodystyle M - 2-doorhatchback Transmission type N - S-speed manual transmission 4. Development order 216 - 2,972 me (Fulltime4WD)

1 . M I T SU B I S H I

GENERAL- MajorSpecifications I V

00-3

MAJORSPECIFICATIONS

Items

Zl6AMNGFL6 Zl6AMNGFR6

Zl6AMJGFL6 Zl6AMJGFR6

Zl6AMNGFL Zl6AMNGFR Zl6AMNGFLW 4,570(179.9) 1,840(72.4) 1,285(50.6) 2,470(97.2) 1,560(61.4) 1,580(62.2) 145 (5.7) 1,030(40.6) 1,070(42.1) 12.0" 17.4"

Zl64MNGFRB

Dimensions mm (in.) Overalllength 1 Overallwidth 2 height(unladen) Overall 3 Wheelbase 4 Track-front 5 Track- rear 6 (unladen) 7 Ground clearance Overhang-front 8 - rear Overhang 9 Angle of approachdegrees 10 '11 Angle of departure degrees

4,570(179.9) 1,840(72.4) 1,285(50.6) 2,470(97.2) 1,560(61.4) 1,580(62.2) 140 (5.5) 1,030(40.6) (42.1) 1,070 1'1.00 17.60 1,720(3,792) 2,120(4,674) (2,535) 1,150 1,020(2,249) 4 6G72 2,972

4,570(179.9) 1,840(72.4) 1,285(50.6) 2,470(97.2) '1,560 (61.4) 1,580(62.2) 140 (5.5) 1,030(40.6) (42.1) 1,070 '1 1.00 17.60 1,730(3,858) 2,120(4,674) 1,150(2,535) 1,020(2,249) 4

4,570(179.9) 1,840(72.4) 1,285(50.6) 2,470(97.2) 1560(61.4) (62.2) 1,580 145 (5.7) 1,030(40.6) (42.1) 1,070 12.00 17.40

Weight k9 (lbs.) Kerb weight Grossvehicleweight Max. axle weight front rear Seatingcapacity Engine Model Total displacement

(3,737) 1,695 (4,57s) 2,075 (2,535) 1,150 (2,249) 1,020

4

(3,748) 1,700 (4,575) 2,075 (2,535) 1,150 (2,249) 1,020

4

m(

6G72 2,972

6G72 2,972

6G72 2,972

Transmission Model Type

WsMG1 W6MG1 S-speed manual 6-speedmanual

WsMG1 WsMG1 5-speed manual S-speed manual

13-1
\/

FUEL
CONTENTS
GENERAL o f C h a n g e s. . . . . . . . . . . . . . Outline SPECIFICATIONS .. G e n e r aS l pecification s. . . . . . . . . . . TROUBLESHOOTING Warning Lamp Engine ( C h e c kE n g i n eL a m p ) ......... S e l f - d i a g n o s.i.s ProblemDiagnosis ContentChart by Check Chart Classified Problem Symptoms

, t,

2 2 2 2 2 2 2 2

OF MPI INSPECTION ON.VEHICLE

.. ...... coMPoNENT S Fuel Pump

4 4 A i r C o n d i t i o n eS r w i t c ha n d P o w e rR e l a y. . . . . . .8 Engine C o n t r o lU n i t T e r m i n a l VoltageCheck

13-2 GENERAL

FUEL - General/Specifications/Troubleshooting

OUTLINE OF CHANGES
The followingmaintenance servicepointshavebeenestablished to correspond to the additionof vehicles with immobilizer system. o An engine-ECU has beenadded. . Enginewarninglamp illumination and self-diagnosis itemshavebeenadded. details . Inspection procedures havebeenaddedfor the fuel pump,air conditioner switchand powerrelayand for terminal voltages.

SPECIFICATIONS
GENERAL SPECIFICATIONS
Items Engine controlunit ldentification modelNo. EuropeLHD 6 M/T - Vehicles with immobilizer system EuropeLHD 5 MlT - Vehicles with immobilizer system EuropeRHD 6 M/T - Vehicles with immobilizer system EuropeRHD 5 Mft - Vehicles with immobilizer system - Vehicles Australia with immobilizer system Specifications E2T61481 E2T61483

E2T61482
E2T61484 E2T61486

TROUBLESHOOTING
ENGINE LAMP) ENGTNE WARNTNG LAMP(CHECK
ITEMSINDICATED BY THE ENGINEWARNINGLAMP
lmmobilizer system

SELF.DIAGNOSIS Diagnosis Chart

Malfunction code Diagnosis item No. lmmobilizer system 54 Check item (Remedy) procedures given (lnspectaccordingto the troubleshooting System.) in GROUP54 - lgnitionSwitchand lmmobilizer

Memory
Retained

PROBLEMDIAGNOSIS CONTENTCHART
Malfunction code No. 54 Diagnosis item lmmobilizer system

Diagnosis contents
Communication problembetweenthe and the engine-ECU immobilizer-ECU

Probablecause (1) Malfunction of communication wire betweenthe engine-ECU and immobilizer-ECU (2) Malfunction of immobilizer-ECU (3) Malfunction of engine-ECU

Remark (Troublesymptom,etc.) Startingis impossible

FUEL - Troubleshooting

13-3

CHECK CHARTCLASSIFIED BY PROBLEM SYMPTOMS

(Vehicleswith immobilizer system)
Problemsymptoms Starting l d l i n gs t a b i l i t y Driving
O 6 E f F 6 F 6 O 6 o

r 6
c

o o

-=^
3C E-o o o@

o o .g E a

o .g p
!> Y'= *7

:9'

=
r
o
L6

o c E
l

-E o U)
E

g
a
l

Check items P o w e rs u p p l ya n d i g n i t i o n switch-lG Enginecontrol unit power earth F u e lp u m p Air flow sensor Intakeair temperature sensor pressure Barometric sensor Enginecoolanttemperature sensor Throttlepositionsensor ldle positionswitch Cam positionsensor C r a n ka n g l es e n s o r lgnition switch-ST Vehiclespeedsensor Powersteeringfluid pressure switch Air conditionerswitch and power relay Detonation sensor Electrical load switch Fan motor relay (radiator fan, condenser fan) Oxygen sensor Mixtureadjustingscrew (variable resistor) Injectors ldle speedcontrol servo (steppermotor type) lgnitioncoil and power transistor Purgecontrol solenoidvalve EGR control solenoidvalve Fuel pressure control valve Wastegate control solenoidvalve Anti-lock braking signat Fuel pressure

o c :<

co cc3

PE

e o

o I c

otr
@a @tr otr

-1P.1 3-54 .3P.1 3-52 -1P.1 3-57 -3P.1 3-55

otr

OE

otr
@ E @E @E

r
'T

3-00 3-58 3-56 3-64

J-OZ

@m@E

-3P

@tr @B @E @E otr @E OE @a @ E @E @tr @tr @ts otr @a @E

@E @e @E

o o

@ E @tr

@e

.1P.1 - 3 P .3-69 13-62 -1P.13-72 .3P.1 3-70 .1P.13-74 -3P.13-72 '1P.13-77 -3P.1 3-75 -1 P.13-80 .3P.13-78 3-82 3-80
,1P

@a

@tr @E @ts
G'LqI
r2)

otr
@

otr
\9

3-86 3-84 - r P 3-89 *3P 3-87

*3P

13-90 13-88

-r P.1 3-92 -3P.13-90 P.13-00 -1 P.1 3,94 .3P.'13-92

on
@ @ @ @ @@

.rP.13-96 -3P.13-94 .1P.1 3-98 -3P.1 3-96

.2P .3P
J-J

3-100-1 3-100 3-98

@E @a OE

@tr @a @a on @tr otr OE @a

@E
@

otr
@@

e
@E

3-106 -1 P.1 3 109 .3P.1 - 1 3- 01 . r P . 1 3 -1 16 .3P.13-108 -1P.1 21 . 3 P . 3-1 1 - 113 3 -1P.13-127 .3P.1311 9 . 1P . 1 3 -2 19 .3P.1 1 3- 21 .1P.1 3-1 31 .3P.1 3-123 -1P.13-'134 -3P.13-126
'3P

OE

os
@E
@@

otr
@E

@ts
@E

o
@tr @E o@ OE @tr @a
@E
Referto 3000GT'93WorkshopManual (Pub.No. PWUE9203) Referto 3000GT'95WorkshopManual(Pub. No. PWUE920S-3) Referto 3000GTWorkshopManual (Pub.No. PWUE9119-D)

3-138 3-130 3-139

J-IJI

-3P

: Warm engine (numberinsideindicates check order) : Cold engine (numberinsrdeindicates check order)

13-4

FUEL - On-vehicle Inspection of MPI Gomponents

v

ON-VEHICLE INSPECTION OF MPICOMPONENTS

FUELPUMP(Vehicleswith immobilizer system)
-1 ,r'n

,l ,

w ,/o u>Z/
pump Fuel check terminal
\:::-=-====<=

(:

----r-

\_----'==

;;G,

Fuel pump connector

lJ

tL

tg

FUEL - On-vehicle Inspection of MPI Components

lgnition switch flGl

13-5

side @ Equipment connector

) Equipment side side connector @ Harness L4f5 (61

CIrrrcl
Fuel pump

connector

Control @ reray (for fuel pump)

@ r..;.---r ll rl-1 l2l3l #l

| 4

| 5 ll

Equipment side connector

\9

[ffi,]:ipump)lrcra-sl
Equipment side connector Enginecontrol unit 1a

Fuelpump check termina

EF

7FU1352 Enginecontrol unit connector

"t"l "t"l

;F[ 'l'l'

"t. ,l 't-

+:t:

9FU0lol

13-6

FUEL - On-vehicle Inspection of MPI Gomponents

HARNESSINSPECTION
Check the fuel pump. o Apply battery voltage to the checkingterminaland operate the pump.

l4

@
OK

the earthcircuitof the fuel Check pump. o Fuelpumpconnector: Disconnected

@
0(
Z \_-/ \

Repair the harness.

(@trEarth)

F I
side @ Harness conneclor
7FUOg5

Check for continuitybetweenthe fuel pump and the checking terminal.

o connector: Disconnected

OK)
Repair the harness.

(@tr-oa)

r
7FU0960

Check for continuitybetweenthe checkingterminaland the control relay (for fuel pump),and between the resistor(for fuel pump). r Control relay (for fuel pump) connector:Disconnected o Resistor (for fuel pump) connector:Discon nected r Fuelpump connector: Disconnected

tu

@
OK

Repairthe narness.

(otr-@) (@tr-@)

Engine control Check for an open-circuit, a or unitharness to earth,betweenthe sideconnector short-circuit control relay (for fuel pump) and the enginecontrolunit. o Control relay (for fuel pump) connector:Disconnected . Enginecontrol unit connector: Disconnected

Repairthe harness.

(@tr-E)

v)

FUEL - On-vehicle Inspection of Mpl Components

6
@ Harnessside connector

13-7

Check for continuitybetweenthe control relay (for fuel pump) and the resistor(for fuel pump).

Control relay(forfuelpump) connector: Disconnected Resistor (forfuelpump) connector: Disconnected

@
0(
'9K)
Repair the harness.

o= Harness side
connector

(@E-@tr)

Measure the power supply voltageof the control relay. r Control relayconnector: Disconnected lgnitionswitch OFF ON Voltage(V)

0-1
SV

OK

Repairthe harness. (lgnition switch-@fl) or check the ignition switch.

Check for an open-circuit, or a short-circuitto earth betweenthe control relayand the enginecontrol unit. o Control relayconnector: Disconnected o Enginecontrolunit connector: Disconnected

@
Repair the harness.

(@tr-tr )
Checkfor continuity betweenthe controlrelayand the controlrelay(for fuel pump). . Control relayconnector: Disconnected o Control relay (for fuel pump) connector:Disconnected

r ^'-l t-\
l/\---\

t n l ./ t ___,

Repair the harness.

(@n-@tr) (@tr-@tr)
f-\---l
Check for an open-circuit, or a short-circuit to earth,betweenthe control relay (for fuel pump) and the fuel pump. o Control relay (for fuel pump) connector:Disconnected o Fuel pump connector: Disconnected

l-)i-l t _,:z__J

Repair the narness.

(@tr-oE)

13-8

Inspection of MPI Components FUEL - On-vehicle

AND POWER RELAY AIR CONDITIONER SWITCH (Vehicleswith immobilizer system)

Battery

'uu

Air conditioner control unit

^l

1i-#\

Air conditioner compressorrelay -//

)

l\

/ \

A - , \- \ l

Engine c o n t r o lu n i t

tq
-t"t'

Enoinecontrol unit connector

4
OK

"t" " t ' ,l:

INSPECTION HARNESS
the power supply voltageof Measure circuit. the air conditioner e Air conditioner switch:ON o Enginecontrolunit connector: Disconnected o lgnitionswitch:ON o Dual air conditioner switch:ON Voltage(V) SV

o(

Checkthe air conditioner circuit.

l,)

Inspection of MPI Components FUEL - On-vehicle

13-9

VOLTAGE CHECK UNITTERMINAL ENGINE CONTROL

CHART VOLTAGE CHECK TERMINAL (Vehicleswith immobilizer system)
No. Terminal Checkpoint relay Air conditioner (Engine conditions) Standardvalue Checkconditions . E n g i n eR at idle : unning o Air conditioner switch:OFF -* ON (Air compressor in drivenstate) lgnitionswitch:ON at idle E n g i n eR : unning Remarks

SV or 6V or morefor a moment * 0-3v

SV

22

relay Control (fuelpump)

0- 3v

16-1
{"

ENGINE ELECTRICAL
CONTENTS
GENERAL Outline of Change SPECIFICATIONS Service Specification s. . . . . . . . . . . ..

2 2 2 2

SERVICE ADJUSTMENT PROCEDURES ....... 2

Output Current Test

Procedures Adiustment 16-2 ENGINE ELECTRICAL- General/Specifications/Service

GENERAL
OF CHANGE OUTLINE
and for Australia to 95Ain vehicles from11OA hasbeenchanged o The nominal outputof the alternator to this. to correspond hasbeenchanged valuies specification Export. bne of the service General

SPECIFICATIONS
SPECIFICATIONS SERVICE
(Vehicles for Australiaand GeneralExport) ALTERNATOR
Item Limit Outputcurrent A Specifications 66.5

PROCEDURES ADJUSTMENT SERVICE

Export) and General TEST(Vehiclesfor Australia CURRENT OUTPUT
as before' points arethe same service Inspection Outputcurrent Limit:66.5A

BODY - General/Specifications/Troubleshooting

42-1

GROUP 42

BODY
GENERAL
OUTLINE OF CHANGE
o A powertilt and outer slidingsunroofhas beenprovided as an option in vehicles for Europe.

SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Roof lid sliding resistance N Sunroofmotor clutch slippageforce N Standardvalue 147 or more 39- 49

TROUBLESHOOTING
INSPECTION CHART FOR TROUBLESYMPTOMS
Trouble symptom
sunroof does not operatewithin 30 secondsafter driver'sdoor is openeo. Sunroofdoes not operateat all. procedure Inspection 1 2

INSPECTION PROCEDURE FORTROUBLE SYMPTOMS

Inspection Procedure 1 Frontsunroofdoesnot operate within30 seconds after drive/s door is opened.
After the driver'sdoor is openedwithin 30 secondsafter the ignition switch is turned off, the sunroof can still be operatedfor a further 30 seconds.lf it is impossible, the driver'sdoor switch or the sunroof control unit mav be defective.

Probablecause
. Malfunctionof door switch (driver'sside) o Malfunction of sunroofcontrolunit . Malfunction of wiring harness or connector

Check the following connectors. c-63, E-16,E-39,E-40,F-35

Repair

Check the harnessbetweenthe sunroof controlunit and the driver's door switch.

Repair

Replace the sunroofcontrolunit.

Inspection Procedure 2 Sunroofdoesnot operate at all.

One of the following items may be defective Sunroofswitch Sunroofmotor Sunroofcontrolunit Powersupplycircuit(including theYuse)

Probablecause
. . r . Malfunction of sunroofswitch Malfunction of sunroofmotor Malfunction of sunroofcontrolunit Malfunction of wiring harness or connector

42-2
Checkthe fuse No. 18 ( 1 )N G

BODY - Troubleshooting
Replace

t'l)
Repair

Measure at sunroofcontrolunit terminal E-39. . D i s c o n n e c tt h e c o n n e c t o r a n d measureat the harnessside. o lgnitionswitchon (1) Voltagebetween terminal(3)-eadh OK: Systemvoltage (2) Voltagebetween terminal(4)-eadh OK: Systemvoltage (3) Continuity between terminal(18)earth OK: Continuity

Check the following connectors. c-63, C-74,C-78, E-39,E-40,F-35

Check the harness between the ignition switch (lG1) and the sunrooi controlunit. Repair, if necessary.

( 2 )N G

Check the following connectors. c-03, E-39, E-40, F-35

Repair

Checktroublesymptoms.

Check the harnessbetweenfusible link No. 4 and the sunroof control unit. Repair,if necessary.

,ll
Check the following connectors. E-39,E-40 Checksunroofswitchcontinuitv Replace Check the harnessbetweenthe sunroof control unit and the body earth. Repair,if necessary. Repair

Measureat sunroof switch terminal

tr-4t.

o lgnitionswitchON . D i s c o n n e c tt h e c o n n e c t o r a n d measureat the harnessside. Voltage between terminal(3)-earth OK: Systemvoltage . Voltagebetween terminal(1)-earth OK: Systemvoltage o Continuitybetweenterminal(2) earth OK: Continuity

Ctect fre tottowingcon'1ectqrs.

tr-:lq tr-41

l-\q

Repair

OK Check the harnessbetween the sunroof control unit and the sunroof switch. Repair,if necessary.

Checkthe sunroofmotor. C h e c k t h e c o n t i n u i t yi n t h e l i m i t switch. Checkthe rotation sensor.

,,J

Reolace the sunroofmotor

Measure at sunroofmotor connector terminalE-42. . D i s c o n n e c tt h e c o n n e c t o r a n d measureat the harnessside. . Continuitybetween terminal(8) earth OK: Continuity

Check the harnessbetween the sunroof motor and the body earth.Repair, if necessarv.

Check the harness between the sunroof control unit and the sunroof molor.

Reolace the sunroofcontrolunit.

Repair

,c

procedures BODY - Service Adjustment

42-3

SERVICE ADJUSTMENT PROCEDURES

SUNROOF LEAKAGE INSPECTION
check if there are any leaksin the sunroofby the following procedure. (1) Fullyclosethe roof lid glass. (2) Adjust the water pressureso that water comes out of the hoseto a heightof approximately 50 cm when the hoseis held vertically facingupwards.
18XO545

Approx. 30 cm

(3) Holdthe end of the hoseabout30 cm above the roofand let the waterrun onto the weatherstrip for 5 minutes or more. (4) While doingthis,checkif anywater leaks through intothe passenger compartment from aroundthe roof lid glass.

a\\\
r8AO216

-<=

SUNROOF WORKING CHECK

=s

z-:-[=

im
\ lL----Jl l-

1. Longitudinal and lateraldirectionadjustment (1) Remove the roof lid trim. (2) Fullyclosethe roof tid. (3) Loosenthe four roof lid mountingnuts and adjustthe positionof the roof lid so that the clearances at the front and rear and at the left and right are the same.

2. Step adjustment (1) Remove the headlining. (2) Fullyclosethe roof lid. (3) Loosen the four adjustingnuts and then adjust the heightof the roof lid so that it is flush with the roof.

42-4

BODY - Sunroof(Power SlidingType)

SUNROOF <POWER SLIDING TYPE>

REMOVAL AND INSTALLATION
Post-installation Operation o SunroofLeakage Inspection o SunroofFit Adjustment

N
<A> <A>
Roof lid removalsteps 1. Roof lid trim 2. Roof lid 3. Roof lid weatherstrip Sunroof switch removalsteps 4. Cover 5. Sunroofswitch panelassembly 6. Sunroofswitch Deflectorassemblyremovalsteps o While roof lid is openedfully 7. Link assembly B. Deflector assembly

11

18F0407

Sunroof control unit removalsteps . Room lamp assembly 4. Cover 5. Sunroofswitch panelassembly 9. Headlining 10. Sunroofc-ontrol unit Sunroof motor removalsteps o Room lamp assembly 4. Cover 5. Sunroofswitch panelassembly 9. Headlininq '11.

>B<

Sunroof riotor

BODY - Sunroof(Power SlidingType)

42-5

v,.,
N--20

R
\

o#

,n 21
/

ip

Lilter assembly. slider assembly/drive unit assemblyremovalsteps '1. Roof lid trim 2. Roof lid 12. Front corner panel 13. Frontholder 14. Rearholder 15. Slid rail 16. Lifterassembly 17. Sliderassembly 18. Reartiming 19. Tube cover 20. Driveunit assembly

<A> <A>

Frame assembly removal steps

Roof lid trim Roof lid Link assembly Deflector assembly Room lamp assembly Cover Sunroofswitch panelassembly 9. Headlining 2 1 . Drain hose connection 22. Frameassembly
1 I.

2. 7. 8. a 4.

hose <B> >A< 21. Drain

Drain hose removal steps o Front splashshield . Rearsidetrim

(Power SlidingType) BODY - Sunroof

POINTS SERVICE REMOVAL

LID REMOVAL LID TRIM/ROOF <A> ROOF ( 1 )Fullyopen the roof lid. the roof lid trim. (2',) Remove (3) Removethe roof lid mountingnuts, and then lift up
the roof lid to removeit.

4,

<B> DRAIN HOSEREMOVAL Tieacordtotheendofthedrainhose,windtapearound itsothatthereisnounevenness,andthenpullthedrain compartment' hoseout from the passenger

Main gear

INSTALLATION SERVICE POINTS HOSEINSTALLATION >A< DRAIN ( thecordwhichw ' 1)Tietheendofthedrainhosewith the hose,and then wind tape usedwhen removing it so thatthereis no unevenness' around the drainhose' (2) Pullthe cordto re-route

gear Transmission

INSTALLATION MOTOR > B < SUNROOF the cover. (1) Remove teethof the maingearwiththe notchof the the nf ign iZi ' ' gearas shownin the illustration' traismission in step(2)'turn gears as.explained (g) Aiier aligningithe by the arrow indicated the drivJgeir in the direction gear180o' thetransmission to rotate Checkthatthematingmarkonthetransmissiong isvertical|ybe|owthecentreofthetransmission

Drivegear

Mating marK

w
,4.
18F0388

(Power SlidingType) BODY - Sunroof

Roof lid

42-7

(4) Tilt up the roof lid and move it so that it is againstthe front holder. (5) lnstallthe sunroofmotor.

F r o n th o l d e r

INSPECTION
SLIDINGRESISTANCE OF ROOF LID CHECK 1. Remove the roof lid trim. 2. Loosenthe roof lid front mountingnuts and tie a ropeio them. 3. Fully close the roof lid and then remove the sunroof motor. 4. Use a spring balance to measure the slidingresistance of the roof lid glass. Standardvalue: 147 N or less lf the sliding resistance of the roof lid is higherthan the standard value,checkthe following. . slider assemblyinstallation, Lifter assembly warpingor jammingby foreignmaterials Drivecableconnection Tilt of roof lid

SLIDINGFORCEOF SUNROOF MOTOR'S CLUTCHCHECK 1. Insertthe sunroofwrench of the on-boardtools into the hexagonal hole in the motordriveshaft,and hook a spring balance as shown in the illustration. 2. Apply batteryvoltagebetween (1) and (2) of the terminals sunroof motor connectorto operatethe motor. 3. Measure the loadon the springbalance at the pointwhere the rotationtorque of the motor matchesthe spring force of the springbalance. Standardvalue: 39-49 N Gaution 1. The spring balanceshould be kept a right angle to the sunroof wrench. 2. lf a wrench other than that in the on-board tools is used, the value for the clutch sliding force will be different,so only the on-board tool should be used. 4. lf the clutch sliding force is outsidethe standardvalue, replacethe sunroof motor.

42-8
Drivegear

BODY - Sunroof(Power SlidingType)

-ffi
CLOSE

CHECK MOTOR SUNROOF

Batteryconnectionterminal

rotation Right

Drivegearrotation direction

CHECK CONTINUITY LIMITSWITCH l.Removethelimitswitchesfromthesunroofmotor'and of the limitswitches' the operation thencheck

TerminalNo.

,d
LimitswitchA
L i m i ts w i t c hB

oN-^ OrF-[+__1 t@ @l
(Black) (Black)

2'ChecktheidentificationcoIors.Theninsta||theIimit as shown in the illustration' switches

(White/Green)

18 F O 3 9 6

Rotationsensor

CHECK SENSOR ROTATION l.Whenconnectinganohmmeternegativeprobetoterm be (8),thereshould probe to terminal (3)andthe posiiive be should there reversed, probes are whenthe iontinuity. no cclntinuitY.

the cover,and then check that there is no 2. Remove probe to terminal the ne.gative whenconnecting continuity (7)andthepositiveprobe-totermina|(8).A|socheck to the areconnected whenthe probes inbreis coniinuity and light is shined onto the sensor same terminals receiver.

BODY - Sunroof(Power SlidingType)

'(,

42-9
Terminal No. 1 2 --{

SUNROOF SWITCH CONTINUITY CHECK

Switch position Open OFF Close

o_

G-

----c

54-1

- General/speciat cHASSls ELECTRIGAL root/Troubleshooting

,4g,

GROUP 54

CHASSIS ELECTRICAL
GENERAL
OUTLINE OF CHANGE
o An immobilizer system has been providedas an option in vehiclesfor Europe,and as standard equipment in vehicles for Australia.

IGNITION SWITCH AND IMMOBILIZER SYSTEM SPECIAL TOOL

Tool Number M8991502 Name

Use
Checking the immobilizer system (diagnosis display usingthe MUT-II) Registering lD codesfor the immobilizer sysrem

MUT-II sub assembly

lra

TROUBLESHOOTING
STANDARD FLOWOF DIAGNOSTIC TROUBLESHOOTING
Gathering information from customer Verifycomplaint Does not reoccur Checkdiagnosis code (Referto P.54-2.) Diagnosis code displayed Recheck diagnosis code(s)then erase (Relerto P.54-2.) No diagnosis code

Checkdiagnosis code (Referto P.54-2.1 No diagnosis code or can'tcommunicate

,rl)

Checktroublecodes (Referto P.54-2.) Diaonosis code Inspection chart for troublesymptoms (Referto P.54-2.) Inspection chartfor diagnosis codes (Referto P.54-2.)

t/l

- Troubteshooring CHASSIS ELECTRICAL DIAGNOSIS FUNCTION

54-2

DIAGNOSIS CODES CHECK Connect the MUT-IIto the diagnosis connector (16-pin) at the lower of theinstrument under cover, thencheck diagnosis codes. ERASING DIAGNOSIS CODES Connect the MUT-IIto thediagnosis connector (16-pin) then erase the diagnosis codes. Caution The diagnosis troublecodeswhich resultfrom disconnecting the batterycablescannotbe erased. INSPECTION CHART FORDIAGNOSIS TROUBLE CODES
Diagnosis code No. '11

Inspection items Transponder communication system

lD codes are not the sameor are not registered

Referencepage 54-3 54-3 54-4 54-4 54-5

12* 21 31 32

Communication system between MUT-IIand engine-ECU EEPROM abnormality inside immobilizer-ECU

lgnitionswitch lG signalcircuit system

NOTE * : Diagnosis code No. 12 is not recorded.

54-3

- lgnitionSwitchand lmmobilizer System CHASSISELECTRICAL

TROUBLE GODES FORDIAGNOSIS PROCEDURE INSPECTION system communication GodeNo. 11 Transponder

immediately The lD code of the transponderis not sent to the immobilizer-ECU after the ignitionswitch is turned to the ON position.

cause Probable
o . . o Malfunctionof transponder of ignitionkey ring antenna Mallunction Malfunctionof harnessor connector Malfunction of immobilizer-ECU

Does the enginestart using the spare ignition key which has had the lD code registered? NG

the lD code. Re-register (Reler to P.54-11.) code No. 12 generated procedure for diagnosis To inspection code No. 12 (Referto P.54-3.)

Code No. 11 generated lgnition key ring antennacontinuity check (Referto P.54-10.) NG

ud
the immobetween Checkthe harness and the ignitionkey ring bilizer-ECU antenna.

Reolace the immobilizer-ECU.

Code No. 12 lD codes are not the same or are not registered
The lD code which is sent from the transponderis not the same as the lD code in the immobilizer-ECU. which is registered

Probablecause
o The lD code in the ignition key being used has not been properlyregistered" . Malfunction of immobilizer-ECU

the lD code. Re-register (Referto P.54-1 1.)

ui

- tgnition cHAssls ELECTRIGAL switchandrmmobitizer system

CodeNo.21 Communication systembetween MUT-IIand engine-EGU
After the ignitionswitch is turned to the ON position,the confirmationcode is nol received from the engine-ECUwithin the allowabletime, or an abnormalcode is received.

54-4

Probable cause
o a a

Malfunctionof harnessor connector Malfunction of engine-ECL Malf unctionof immobilizer-ECU

ls diagnosis code No. 54 being generatedby the engine-ECUt

Engine-ECUpower circuit and earth circuit check (Referto GROUP 13-

Check the following connectors. c-21. C-44.C-90

Checkthe harnessbetweenthe engine ECU and the immobilizer-ECU.

c
CodeNo.31 EEPROM abnormality inside immobilizer-EGu Probablecause
No data has been written to the EEPROMinsidethe immobilizer-EOU. o Malfunction of immobilizer-EOU

trouble symptoms. l CtrecX

54-5

- lgnitionSwitchand lmmobili4lty$g. GHASSISELECTRICAL

cause Probable
a a a

switchlG signalcircuitsystem CodeNo.32 lgnition

The ignitionswitchsignalis not being inputto the immobilizer-EOU'

Malfunctionof harnessor connector of ignitionswitch Malfunction Malf unctionof immobilizer-ECU

lgnitionswitch lG signalinputcheck connecat immobilizer-ECU Measure tor C-90. o D i s c o n n e c tt h e c o n n e c t o r a n d measureat the harnessside. . Voltage between terminal (2) and body earth (lgnition switch:ON Position) OK: Systemvoltage

Check the following conneclors. c-76. c-78, C-90

Checkthe harnessand fusesbetween the ignitionswitch (lG1) and the immobilizer-ECU.

Irr!

SYMPTOMS CHARTFORTROUBLE INSPECTION

symptom Trouble
with the MUT-II is not possible Communication by the engine-ECU code No. 54 has been generated Diagnosis procedureNo. Inspection
I I

Referencepage

54-6
54-7 54-7 54-8 54-9

2
e

usingthe MUT-II be registered lD codecannot

l

doesnot start(turnsoverbut doesnot ignite) Engine check powercircuitandearthcircuit lmmobilizer-ECU

4 5

,s

- tgnition cHAsSls ELECTRIGAL switchandtmmobitizer system

INSPECTION PROCEDURE FORTROUBLE SYMPTOMS Inspection Procedure 1 Communication with the MUT-II is not possible. Probable cause

54-6

The causeis probably a malfunction of the diagnosis line or the immobilizer-ECU o Malfunctionof diagnosisline is not functioning. . Malfunctionof harnessor connector . Malfunction of immobilizer-ECU

Can the MUT-II communicatewith the engine-ECU?

Check the following connectors.

c-70,c-90

lmmobilizer-ECU connector check C-90 (short-circuitbetweenterminals ( 1 4 )a n d ( 1 5 ) )

Checkthe harness between the immobilizer-ECU and the diagnosisconnector.

Checkthe harness between the immopowercircuitand the earth bilizer-ECU circuit. (Referto inspectionprocedure5.)

Replace the immobilizer-EOU.

54-7

- tgnition cHAssls ELECTRIGAL switchandtmmobitizer system

Inspection Procedure 2 Diagnosis code No. 54 has beengenerated by the engine-ECU.

There is a problem with communicationbetweenthe engine-ECUand the immobilizer-ECU.

Probable cause
a a a

Malfunctionof harnessor connector Malf unctionof immobilizer-ECU Malfunction of engine-ECU

Check the following connectors. c-21. C-44. C-90

Checkthe harnessbetweenthe enoine. ECU and the immobilizer-ECU.

ls diagnosis code No. 21 being generatedby the immobilizer-ECU?

u
Replace the immobilizer-ECU.

Checkthe harness betweenthe immopowercircuitand the earth bilizer-EOU circuit. (Referto inspectionprocedure5.)

Replace the engine-ECU.

Inspection Procedure 3 lD code cannotbe registered usingthe MUT-II

The cause is probablythat the immobilizer-ECucannot read the lD code, or there is a malfunction of the immobilizer-ECU.

Probable cause
. . . . Malfunction of transponder Malfunction of ignitionkey ring antenna Malfunctionof harnessor connector Malfunction of immobilizer-ECU

No ignition keys can be registered.

Replace the ignitionkey that cannot be registered.

Re-register the lD code. (Refer to P.54-11.)

't{

ls a normaldiagnosis code output?

To diagnosis code classification table (Referto P.54-2.)

Checkthe harness between the immopowercircuitand the earth bilizer-ECU circuit. (Referto inspectionprocedure5.)

- lgnitionSwitchand lmmobilizer CHASSISELECTRICAL System

4 Procedure Inspection Enginedoesnot start(turnsoverbut doesnot ignite)
lf the fuel injectorsare not operating,there might be a problemwith the MPI systemin additionto a malfunctionof the immobilizersystem. It is normalfor this to occur if an attempt is made to start the engine using a key that has not been properly registered.

54-8

cause Probable
o Malfunctionof MPI system . Malfunctionof immobilizersystem

Check the system voltageduring cranking. OK: 8V or more

ls a normal diagnosis code output f rom the immobilizer-ECU?

table To diagnosiscode classification (Referto P.54-2.) Reter to GROUP 13 - TroubleshootIng.

o,

ls a normal diagnosis code output from the engine-ECU?

To inspection procedure for when there is no ignition(Referto GROUP 13 - Troubleshooting.)

the immobetween Checkthe harness bilizer-ECU oowercircuitand the earth circuit. (Referto inspectionprocedure5.)

54-9

- lgnitionSwitchand lmmobilizer CHASSISELECTRICAL

5 Procedure Inspection powercircuitand earthcircuitcheck lmmobilizer-EGU

connecMeasureat immobilizer-ECU tor C-90. o D i s c o n n e c tt h e c o n n e c t o r a n d measureat the harnessside. (1) Voltagebetween(9) and body earth and between(1) and bodY earth OK: Systemvoltage (2) Continuity between (8) and body earth OK: Continuity (16)and body (3) Continuity between earth OK: Continuity Check the following connectors.

c-90 c-60, c-21.

the immoCheckthe harnessbetween and the engine control bilizer-ECU relay,and repair if necessary.

the immobetween Checkthe harness bilizer-ECUand the body earth, and repairif necessary.

try

'i

AT IMMOBILIZER.ECU CHECK
CHECKCHART VOLTAGE TERMINAL

16WO390

No. Terminal
I

Signal

Check requirements lgnitionswitch:ON lgnitionswitch:OFF lonitionswitch:ON

Terminalvoltage Systemvoltage OV Systemvoltage OV

powersupply lmmobilizer-ECU
lgnitionswitch-lG

B
9 16

earth lmmobilizer-ECU

power supply lmmobilizer-ECU

earth lmmobilizer-ECU

lgnitionswitch:ON

Systemvoltage OV

rc

- lgnitionSwitch CHASSISELECTRICAL

54-10

IGNITION SWITCH
REMOVAL AND INSTALLATION
L.H. drive vehicles

CAUTION:SRS Before removal of air bag module, refer to GROUP 528 - SRS ServicePrecautions and Air Bag Module and Clock Spring.

tf {)

lgnitionswitchsegment removal steps 3. Kneeprotector (Refer to GROUP 52A- lnstrument Panel.) 4. lmmobilizer-ECU 5. Column coverlower 6. Column cover upper 7. Lapcoolerductandfoot shower duct 1]. Keyreminder switch segment 12.Steering column mounting bolt.z 13. lgnition switch segment

{} {f f{ {}

NOTE (1) -t : Removal for LH drivevehicles only (?) lr: Removal for RH drivevehicles only (3) Removal and installation servicepoint5are the same as before.

(Refer to GROUP 52A- Instrument Panel.) 5. Colunin coverlower 6. Column coverupper 7. Lapcooler ductand foot shower duct 8. Column switch andclockspring assembly*1 9. lgnition keyillumination ring 1 0 . Steering lockcylinder

Steeringlock cylinder removalsteps 1. Air bag module*1 (Refer to GROUP528 - Air Bag Moduleand Clock Spring.) 2. Steeringwheel*1 3. Knee protector

INSPECTION
Itemsotherthanthe one belowarethe sameas before. IGNITION KEYRINGANTENNA CONTINUITY CHECK Use a circuittesterto check the continuity between the terminals.

(.'

54-11

- lgnitionSwitch CHASSISELECTRICAL
METHOD ID CODEREGISTRATION purchased, lf using an ignition keythathasjustbeennewly or you will needto if the immobilizer-ECU has beenreplaced, keybeing register for eachignition usedintothe the lD codes (A maximum lD codes immobilizer-ECU. of eight different can be registered.) you hasbeenreplaced, Moreover, whenthe immobilizer-ECU the lD number thatthe will need to usethe MUT-II to register (Refer to the MUT-II intothe immobilizer-ECU. userspecifies for instructions on usingthe MUT-II.) instruction manual Caution Becauseregistering of the lD codes is carried out after all previously-registered codes have been erased,you should have ready all of the ignition keys that have alreadybeen registered.

'!&t

( 1 ) Connect connector. the MUT-IIto thediagnosis

Caution of the MUT-II should Connectionand disconnection alwaysbe carriedout with the ignitionswitchin the OFF position. to turn the (2) Usethe ignition key that is to be registered to the ON position. ignition switch (3) Use the MUT-II to register the lD code. lf you are registering two or more keys,use the next key to be switchto the ON position registered to turn the ignition the MUT-IL without disconnecting (4) Disconnect the registration the MUT-II.This completes operation.

RJ5T507023-38

Pub. No.PWUE9I l9-E ENGLISH EUROPE ANDEXPORT

Pub, No.PWUE9203-4

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A ursuBrsHr MoToRs coRPoRATroN

Printcd in Japan July1995