manual galant.pdf

8/10/2019 Manual Galant.pdf

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54-1

CHASSISELECTRICAL

CONTENTS 54109000211

BATTERY 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE SPECIFICATION 4. . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 4. . . . . . . . . . . . . . . . . .Fluid Level and Specific Gravity Check 4. . . . .

Charging 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Testing Procedure 6. . . . . . . . . . . . . . . . . .

IGNITION SWITCH, ETACS-ECU ANDIMMOBILIZER SYSTEM* 7. . . . . . . . . . . . .

SPECIAL TOOL 7. . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . .

IGNITION SWITCH, ETACS-ECU ANDIMMOBILIZER SYSTEM 17. . . . . . . . . . . . . . . .

COMBINATION METERS 20. . . . . . . . . . . .

SERVICE SPECIFICATIONS 20. . . . . . . . . . . .

SEALANT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 21. . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . .

CONTINUED ON NEXT PAGE

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

WARNING!

(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personalinjuryor deathto service personnel (frominadvertentfiringof theairbag) orto thedriverand passenger(fromrenderingthe SRS inoperative).

(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorizedMITSUBISHI dealer.

(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - SupplementalRestraintSystem(SRS) beforebeginninganyservice or maintenance of any component of theSRS or anySRS-relatedcomponent.

NOTE

The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors andinterconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service ormaintenance) are indicated in the table of contents by an asterisk (*).
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54-2

ON-VEHICLE SERVICE 24. . . . . . . . . . . . . . . .Speedometer Check 24. . . . . . . . . . . . . . . . . . . . . .

Tachometer Check 24. . . . . . . . . . . . . . . . . . . . . . .

Fuel Gauge Simple Check 25. . . . . . . . . . . . . . . .

Fuel Gauge Unit Check 25. . . . . . . . . . . . . . . . . . .

Engine Coolant Temperature Gauge SimpleCheck 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Coolant Temperature Gauge UnitCheck 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMBINATION METERS 28. . . . . . . . . . . . . . .

HEADLAMP AND FRONTTURN-SIGNAL LAMP* 30. . . . . . . . . . . . . .


SPECIAL TOOLS 30. . . . . . . . . . . . . . . . . . . . . .


ON-VEHICLE SERVICE 37. . . . . . . . . . . . . . . .Headlamp Aiming 37. . . . . . . . . . . . . . . . . . . . . . . .

Intensity Measurement 38. . . . . . . . . . . . . . . . . . . .

Bulb Replacement 39. . . . . . . . . . . . . . . . . . . . . . . .

HEADLAMP AND FRONT TURN-SIGNALLAMP 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE TURN-SIGNAL LAMP 44. . . . . . . . .

SPECIAL TOOL 44. . . . . . . . . . . . . . . . . . . . . . .

FRONT FOG LAMP 45. . . . . . . . . . . . . . . .


SPECIAL TOOL 45. . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 45. . . . . . . . . . . . . . . .Front Fog Lamp Aiming 45. . . . . . . . . . . . . . . . . .

Bulb Replacement 46. . . . . . . . . . . . . . . . . . . . . . . .

FRONT FOG LAMP 47. . . . . . . . . . . . . . . . . . . .

REAR COMBINATION LAMP 48. . . . . . . .

SPECIAL TOOL 48. . . . . . . . . . . . . . . . . . . . . . .

REAR COMBINATION LAMP 49. . . . . . . . . . .

HIGH MOUNTED STOP LAMP 51. . . . . .

RHEOSTAT 52. . . . . . . . . . . . . . . . . . . . . . . .

HAZARD WARNING LAMPSWITCH 53. . . . . . . . . . . . . . . . . . . . . . . . . . .

HORN 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIGARETTE LIGHTER 54. . . . . . . . . . . . . .

CLOCK 55. . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIAL TOOL 55. . . . . . . . . . . . . . . . . . . . . . .

CLOCK 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTINUED ON NEXT PAGE


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54-3

RADIO AND TAPE PLAYER 56. . . . . . . .


RADIO AND TAPE PLAYER 72. . . . . . . . . . . .

SPEAKER 73. . . . . . . . . . . . . . . . . . . . . . . . .ANTENNA 74. . . . . . . . . . . . . . . . . . . . . . . . .

REAR WINDOW DEFOGGER 77. . . . . . .


ON-VEHICLE SERVICE 77. . . . . . . . . . . . . . . .Printed-heater Line Check 77. . . . . . . . . . . . . . . . .

Rear Window Defogger Relay Continuity Check77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WINDOW DEFOGGER SWITCH 78. . . . . .

THEFT-ALARM SYSTEM 79. . . . . . . . . . . .

SPECIAL TOOLS 79. . . . . . . . . . . . . . . . . . . . . .


TRACTION CONTROL (TCL)Refer to GROUP 13. . . . . . . . . . . . . . . . . . .

RADIATOR FAN MOTORRefer to GROUP 14. . . . . . . . . . . . . . . . . . .

AUTOMATIC TRANSMISSIONRefer to GROUP 23. . . . . . . . . . . . . . . . . . .

SERVICE BRAKES (ABS)Refer to GROUP 35B. . . . . . . . . . . . . . . . .

DOOR GLASS AND REGULATOR(POWER WINDOWS)

Refer to GROUP 42. . . . . . . . . . . . . . . . . . .

DOOR HANDLE AND LATCH(DOOR LOCKING)

Refer to GROUP 42. . . . . . . . . . . . . . . . . . .

KEYLESS ENTRY SYSTEMRefer to GROUP 42. . . . . . . . . . . . . . . . . . .

SUNROOF Refer to GROUP 42. . . . . . . .

WINDSHIELD WIPER AND WASHER

Refer to GROUP 51. . . . . . . . . . . . . . . . . . .REAR WIPER AND WASHER

Refer to GROUP 51. . . . . . . . . . . . . . . . . . .

DOOR MIRROR (ELECTRONICCONTROLLED DOOR MIRROR)

Refer to GROUP 51. . . . . . . . . . . . . . . . . . .

SUPPLEMENTAL RESTRAINT SYSTEM(SRS) Refer to GROUP 52B. . . . . . . . . . .

HEATER Refer to GROUP 55. . . . . . . . . .

AIR CONDITIONERRefer to GROUP 55. . . . . . . . . . . . . . . . . . .
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CHASSIS ELECTRICAL - Battery54-4

BATTERY 54100030028SERVICE SPECIFICATION

Item Specification

Specific gravity of the battery fluid 1.220 -1.290 [20 _C]

ON-VEHICLE SERVICE 54100090026FLUID LEVEL AND SPECIFIC GRAVITY CHECK1. Inspect whether or not the battery fluid is between the

UPPER LEVEL and LOWER LEVEL marks.2. Use a hydrometer and thermometer to check the specific

gravity of the battery fluid.Standard value: 1.220-1.290 [20 _C]

The specific gravity of the battery fluid varies with thetemperature, so use the following formula to calculatethe specific gravity for 20 _C. Use the calculated valueto determine whether or not the specific gravity issatisfactory.

D20=Dt+0.0007 (t- 20)D20: Specific gravity of the battery fluid calculated

for 20 _C.Dt: Actually measured specific gravityt: Actually measured temperature

Thermometer

Hydrometer

Good


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CHASSIS ELECTRICAL - Battery 54-5

CHARGING 541001100291. When charging a battery while still installed in the vehicle,

disconnect the battery cables to prevent damage toelectrical parts.

2. The current normally used for charging a battery shouldbe approximately 1/10th of the battery capacity.

3. When performing a quick-charging due to lack of time,etc., the charging current should never exceed the batterycapacity as indicated in amperes.

4. Determining if charging is completed.(1) If the specific gravity of the battery fluid reaches

1.250-1.290 and remains constant for at least onehour.

(2) If the voltage of each cell reaches 2.5 - 2.8 V andremains constant for at least one hour.

Caution1. Be careful since the battery fluid level may rise

during charging.2. Keep all sources of fire away while charging

because there is a danger of explosion.

3. Be careful not to do anything that could generatesparks while charging.4. When charging is completed, replace the battery

caps, pour clean water over the battery to removeany sulfuric acid and dry.


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CHASSIS ELECTRICAL - Battery54-6

BATTERY TESTING PROCEDURE 54100120176TEST STEP

(1) Turn headlamps on for 15 seconds.(2) Turn headlamps off for 2 minutes to allow battery voltage to

stabilize.(3) Disconnect cables.

OK

Read open circuit voltage.

OK: Open circuit voltage is more than 12.4 V(specific gravity: 1.240)

NGCharge battery at 5 amps. (see LOAD TEST RATE CHART)

RetestOK

(1) Connect a load tester to the battery.(2) Load the battery at therecommendeddischargerate (seeLOAD

TEST RATE CHART) for 15 seconds.(3) Read voltage after 15 seconds, then remove load.(4) Compare the measured value with the minimum voltage (see

LOAD TEST CHART).OK: Higher than minimum voltage

NGReplace battery

OK

Normal

LOAD TEST RATE CHART

Battery type 75D26L 95D31L

Charging time when fully dischargedh [5-amp rated current charging]

11 14

Load test (Amps) 260 310

LOAD TEST CHART

Temperature _C 21 andabove

16 10 4 -1 -7 -12 -18

Minimum voltage V 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
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CHASSIS ELECTRICAL -Ignition Switch, ETACS-ECUand Immobilizer System 54-7

IGNITION SWITCH, ETACS-ECU AND IMMOBILIZERSYSTEM 54300060092SPECIAL TOOL

Tool Number Name Use

MB991502 MUT- II subassemblyD

Immobilizer system check(Diagnosis display using the MUT- II )D Registration of the ID codeD ETACS-ECU input signal checking

TROUBLESHOOTING 54300070477IGNITION SWITCHDIAGNOSIS FUNCTIONINPUT SIGNAL INSPECTION POINTS 1. Connect the MUT- II to the diagnosis connector.2. If buzzer of the MUT- II sounds once when a switch is

operated (ON/OFF), the ETACS-ECU input signal for thatswitch circuit system is normal.

INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom Inspectionprocedure No.

Reference page

Communication with MUT-II is notpossible.

Communicationwithallsystemsisnotpossible.

1 54-8

Communication with the one-shotpulse input signal only is not possible.

2 54-8

While key hole illumination lamp is illuminated, ignition key is turned to the ONposition but key hole illumination lamp does not switch off. (However, it switchoff after 10 seconds.)

3 54-8

Key hole illumination lamp remains illuminated. 4 54-9

Even if drivers side door is opened, key hole illumination lamp does notilluminate.

5 54-9

MUT- II
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CHASSIS ELECTRICAL -Ignition Switch, ETACS-ECUand Immobilizer System54-8

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMSINSPECTION PROCEDURE 1

Communication with MUT- II is not possible. (Communica-tion with all systems is not possible.)

Probable cause

The cause is probably a defect in the power supply system (including earth) for thediagnosis line.

D Malfunction of connectorD Malfunction of harness wire

Refer to GROUP 13A - Troubleshooting.

INSPECTION PROCEDURE 2

Communication with MUT- II is not possible. (Communica-tion with the one-shot pulse input signal only is notpossible.)

Probable cause

The cause is probably a defective one-shot pulse input signal circuit system of thediagnosis line.

D Malfunction of connectorD Malfunction of harness wireD Malfunction of ECU

Check the harness between the diagno-

sis connector and junction block.

OK Check the following connectors:

C-20, C-134 and C-144

NGRepair

NG

Repair

OK

Check trouble symptom.NG

Replace the ECU.

INSPECTION PROCEDURE 3

While key hole illumination lamp is illuminated, ignitionkey is turned to the ON position but key hole illuminationlamp does not switch off. (However, it switch off after 10seconds.)

Probable cause

The cause is probably a defective ignition switch input circuit or a defective ECU. D Malfunction of connectorD Malfunction of harness wireD Malfunction of ECU

NG

MUT- II Input Signal InspectionIgnition switch input signalOK: The MUT-II buzzer sounds once

when the ignition key is turnedto the ON or OFF position.

OK Replace the ECU.

NG

Disconnect the junctionblockconnectorC-131, andmeasure atthe harnessside.D Voltage betweenthe terminal (6) and

earthOK: System voltage

OK Check the following connectors:C-144 and C-131

NGRepair

NG

Check the harness wire between theignition switch (IG1) and junction block,and repair if necessary.

OK

Check trouble symptom. Replace the ECU.


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CHASSIS ELECTRICAL -Ignition Switch, ETACS-ECUand Immobilizer System 54-11

INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No. 11 Transponder communication system Probable causeThe ID code of the transponder is not sent to the immobilizer-ECU immediately afterthe ignition switch is turned to the ON position.If the engine is started while several ignition keys are in the vicinity, then interferencebetween the different keys may occur, which will cause this code to be generated.

D Radio interference of ID codesD Malfunction of the transponderD Malfunction of the ignition key ring antennaD Malfunction of harness or connectorD Malfunction of the immobilizer-ECU

NG

OK

Check the following connectors:C-68, C-104

NGRepair

OK

Check trouble symptoms.NG

Check the harness wire between immo-bilizer-ECU and key ring antenna.

NGRepair

OK

Replace the immobilizer-ECU.

Does the engine start using the spareignition key which has had the ID coderegistered?

OK Replace the ignition key that does notwork.

Re-register the ID code.(Refer to P.54-19.)

NG

Diagnosis codes checkCode No. 12 occurs

To INSPECTION PROCEDURE FORDIAGNOSIS CODE No. 12(Refer to P.54-11.)

Code No. 11 occurs

Check the continuity of the ignition keyring antenna. (Refer to P.54-18.)

NGReplace

Are there any other ignition keys in thevicinity of the ignition key being usedfor starting?

Yes Move other keys well away from thekey being used.

Check the trouble symptoms.No

Code No. 12 ID code are not the same or are not registered Probable causeThe ID code which is sent from the transponder is not the same as the ID codewhich is registered in the immobilizer-ECU.

D The ID code in the ignition key being used has notbeen properly registered.

D Malfunction of the immobilizer-ECU

Re-register the ID code.(Refer to P.54-19.)




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Code No.21 Communication system between immobiliz-er-ECU and engine-ECU

Probable cause

After the ignition switch is turned to the ON position, the confirmation code is notreceivedfromtheengine-ECU within theallowabletime, or anabnormal codeis received.

D Malfunction of harness or connectorD Malfunction of the engine-ECUD Malfunction of the immobilizer-ECU

Is diagnosis code No. 54 being gener-ated by the engine-ECU?

NOCheck the engine-ECU power sourceand the earth circuit.(Refer to GROUP 13A - Troubleshoot-ing.)

YES

Check the following connectors:C-68, C-81, C-38 C-37, , C-54

NGRepair

OK


Check the harness wire between en-gine-ECU and immobilizer-ECU.

NGRepair

OK

Check trouble symptoms.

NG

Replace the immobilizer-ECU.OK


Replace the engine-ECU.

Code No. 31 EEPROM abnormality inside immobilizer-ECU

Probable cause

No data has been written to the EEPROM inside the immobilizer-ECU. D Malfunction of the immobilizer-ECU



Code No.32 Ignition switch IG signal circuit system Probable causeThe ignition switch signsl is not being input to the immobilizer-ECU. D Malfunction of harness or connector

D Malfunction of the ignition switchD Malfunction of the immobilizer-ECU

Check the input of the ignition switchIG signal.Measure at the immobilizer-ECU con-nector C-68.D Disconnect the connector, and

measure at the harness side.D Voltage between 2 and body earth

(Ignition switch: ON position)OK System voltage

NGCheck the following connectors:C-68, C-134, C-131

NGRepair

OK


NGNG

Check the fuse and the harness wirebetween ignition switch (IG) and immo-bilizer-ECU.

Repair

OK

Check trouble symptomsNG

Check the ignition switch.(Refer to 54-18.)

OK



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INSPECTION PROCEDURE FOR TROUBLE SYMPTOMSInspection Procedure 1

Communication with MUT- II is impossible. Probable causeThe cause is probably that a malfunction of the diagnosis line or the immobilizer-ECUis not functioning.

D Malfunction of the diagnosis lineD Malfunction of harness or connectorD Malfunction of the immobilizer

Can the MUT- II communicate with theengine-ECU?

NO Check the following connectors:C-68, C-104

NG Repair

YES

Disconnect the immobilizer-ECU con-nector C-68 and check at the harnessside.(Short-circuited harness wire betweenterminal No. 13 and No. 14)

NGRepair

OK


NG

Check the harness wire between immo-bilizer-ECU and diagnosis connector.

NGRepair

OK

Check the immobilizer-ECU power sup-ply and earth circuit. (Refer to INSPEC-TION PROCEDURE 5.)

OK



OK


NG


Inspection Procedure 2

Diagnosis code No. 54 has been generated by theengine-ECU.

Probable cause

There is a problem with communication between the engine-ECU and theimmobilizer-ECU.

D Malfunction of harness or connectorD Malfunction of the immobilizer-ECUD Malfunction of the engine-ECU

Check the following connectors:C-68, C-81, C-38 ,C-37 , C-54

NGRepair

OK


NG

Check the harness wire between en-gine-ECU and immobilizer-ECU.

NGRepair

OK

Is diagnosis code No. 21 being gener-ated by the immobilizer-ECU?

YES

NO

Check the immobilizer-ECU power sup-ply and earth circuit. (Refer to INSPEC-TION PROCEDURE 5.)

OK Check trouble symptoms.

NGReplace the immobilizer-ECU.

NG


Replace the engine-ECU.


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Malfunction of the immobilizer-ECU power supply and earth circuit

Measure at the immobilizer-ECU con-nector.D Disconnect the connector and

measure at the harness side.1. Voltage between 1 and earth and

between 9 and earth OK: System voltage

2 Continuity between 8 and earthOK: Continuity

3 Continuity between 16 and bodyearthOK: Continuity

1. NGCheck the following connectors:C-81, C-47

NGRepair

OK


Check the harness wire between immo-bilizer-ECU andenginecontrolrelayandrepair if necessary.

2, 3. NGCheck the following connectors:L.H. drive vehicles: C-62.R.H. drive vehicles: C-63, C-64.

NGRepair

OK


NG

Check the harness wire betweenimmo-bilizer-ECU and body earth and repairif necessary.

CHECK AT IMMOBILIZER-ECUTERMINAL VOLTAGE CHECK CHART

Terminal No. Signal Checking requirements Terminal voltage

1 Immobilizer-ECU power supply Ignition switch: ON System voltage

2 Ignition switch-IG Ignition switch: OFF 0V

Ignition switch: ON System voltage

8 Immobilizer-ECU earth Always 0V

9 Immobilizer-ECU power supply Ignition switch: ON System voltage

16 Immobilizer-ECU earth Always 0V


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CHASSIS ELECTICAL -Ignition Switch, ETACS-ECUand Immobolizer System 54-17

IGNITION SWITCH, ETACS-ECU AND IMMOBILIZER SYSTEM 54300210220REMOVAL AND INSTALLATION

Caution: SRSBefore removal of air bag module and clockspring, refer to GROUP 52B - ServicePrecautions and Air Bag Module and ClockSpring.

5

69

7

12

11

10

8

2

1

3 4

: metal clip position

ETACS-ECU removal steps

1. J unction block2. ETACS-ECUImmobilizer-ECU removal steps3. Hood lock release handle4. Instrument under cover

(Refer to GROUP 52A - Instru-ment Panel.)

5. Immobilizer-ECU

Ignition switch and ignition keyring antenna removal steps3. Hood lock release handle4. Instrument under cover

(Refer to GROUP 52A - Instru-ment Panel.)

6. Steering wheel(Refer to GROUP 37A.)

7. Column cover, upper8. Column cover, lower9. Column switch (Refer to GROUP

37A - Steering Wheel and Shaft.)10. Ignition key ring antenna

A A" 11. Steering lock cylinder12. Ignition switch
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CHASSIS ELECTICAL -Ignition Switch, ETACS-ECUand Immobolizer System54-18

REMOVAL SERVICE POINTSA A" STEERING LOCK CYLINDER REMOVAL1. Insert the key in the steering lock cylinder and turn it

to the ACC position.2. Using a cross-tip (+) screwdriver (small) or a similar tool,

push the lock pin of the steering lock cylinder inwardand then pull the steering lock cylinder toward you.

INSPECTION 54300220032IGNITION SWITCH CONTINUITY CHECK1. Remove the column cover lower and upper.2. Disconnect the wiring connector from the ignition switch.3. Operate the switch, and check the continuity between

the terminals.

Ignition key posi- Terminal No.Ignition key posi-

tion 1 2 3 4 5 6LOCK

ACC

ON

START

IGNITION KEY RING ANTENNA CONTINUITY CHECKUse a circuit tester to check the continuity between theterminals.

Cross-tip (+)screwdriver


19/84

CHASSIS ELECTICAL -Ignition Switch, ETACS-ECUand Immobolizer System 54-19

ID CODE REGISTRATION METHOD 54300810062If using an ignition key that has just been newly purchased,or if the immobilizer-ECU has been replaced, you will needto register the ID codes for each ignition key being usedinto the immobilizer-ECU. (A maximum of eight different IDcodes can be registered.)Moreover, when the immobilizer-ECU has been replaced, youwill need to use the MUT- II to register the ID number thatthe user specifies into the immobilizer-ECU. (Refer to theMUT- II instructionmanual forinstructionsonusingtheMUT- II .)

CautionIf registering of the ID codes is carried out allpreviously-registered codes will be erased. Accordingly,you should have ready all of the ignition keys that havealready been registered.

1. Connect the MUT- II to the diagnosis connector.

CautionConnection and disconnection of the MUT- II shouldalways be carried out with the ignition switch in theOFF position.

2. Use the ignition key that is to be registered to turn theignition switch to the ON position.

3. Use the MUT- II to register the ID code. If you areregistering two or more codes, use the next key to be

registered to turn the ignition switch to the ON positionwithout disconnecting the MUT- II .4. Disconnect the MUT- II . This completes the registration

operation.

MUT- II


20/84

CHASSIS ELECTRICAL - Combination Meters54-20

COMBINATION METERS 54300030215SERVICE SPECIFICATIONS

Items Standard value

Speedometer indication error km/h(mph) 40 (20) 40 - 48 (20 - 25)

80 (40) 80- 92 (40- 47)

120 (60) 120- 136 (60- 69)

160 (80) 160- 180 (80- 91)

- (100) - (100- 114)

Tachometer indication error r/min 700 100

3,000 150

5,000 250

6,000 300Fuel gauge unit resistance W Float point F 4 2

Float point E 112 7

Fuel gauge unit float height mm A (Float point F) 28.6

B (Float point E) 159.9

Fuel gauge resistance W Power supply and earth 111.5

Power supply and fuel gauge 98.2

Fuel gauge and earth 101.0

Engine coolant temperature gauge Power supply and earth 111.5resistance W

Power supply and engine coolanttemperature gauge

53.6

Engine coolant temperature gaugeand earth

165.0

Engine coolant temperature gauge unit resistance (at 70 _C) W 104 13.5

SEALANT 54300050037

Items Specified sealant Remark

Engine coolant temperature gaugeunit threaded portion

3M Adhesive nut locking No. 4171 orequivalent

Drying sealant


21/84

CHASSIS ELECTRICAL - Combination Meters 54-21

SPECIAL TOOLS 54300060429


A

B

C

D

MB991223 A: MB991219B: MB991220C: MB991221

D: MB991222

Harness set A: Test harnessB: LED harnessC: LED harness

adapterD: Probe

Making voltage and resistance measurementsduring troubleshooting A: Connector pin contact pressure checkB: Power circuit check

C: Power circuit checkD: Commercial tester connection


22/84


TROUBLESHOOTING 5430070471INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom Inspectionprocedure

Referencepage

Speedometer does not work. 1 54-22

Tachometer does not work. 2 54-23


Speedometer does not work. Probable causeThe cause may be a defective vehicle speed sensor circuit system or a defectivespeedometer. Vehicle speed sensor is also used by the engine-ECU and A/T-ECU.

D Malfunction of vehicle speed sensorD Malfunction of speedometerD Malfunction of harness or connector

Disconnect the combination meter con-nectors D-01, D-02 and D-03 and mea-

sure at the harness sides.1. Measure the voltage betweenterminalNo.25andbody earth whenthe vehicle is moved forwards andbackwards.OK: 4.7 V or more

2. Voltage between the terminal No.4and body earthOK: System voltage (Ignition

switch: ON)3. Continuity between the terminal

No.46 and body earthOK: Continuity

1. NGVehicle speed sensor circuit systeminspection (Refer to Inspection

Procedure 3 on P.54-23.)

2. NGCheck the following connectors:D-03, C-135, C-131

NGRepair

OK


Check the harness wire between thepower supply and combination meter,and repair if necessary.

3. NG

Check the following connectors:C-25, D-01

NGRepair

OK

Replace the speedometer.

OK


Check the harness wire between thebody earth and combination meter, andrepair if necessary.


23/84



Tachometer does not work. Probable causeThe ignition signal may not be input from the engine, or there may be a malfunctionin the power supply or ground circuit.

D Malfunction of tachometerD Malfunction of harness or connector

Disconnect the combination meter con-nector D-03and measureat theharnesssides.1. Measure the voltage between

terminal No.8 and body earth.OK: 5 V

2. Continuity between the terminalNo.7 and body earthOK: Continuity

3. Voltage between the terminal No.4and body earthOK: System voltage

1. NGCheck the following connectors:C-90, D-03

NGRepair

OK


Check the harness wire between thedistributor assembly or engine-ECU and combination me-ter, and repair if necessary.

2. NGCheck the following connectors:C-45, C-90, D-03

NGRepair

OK


Check the harness wire between thecombination meter and the body earth,and repair if necessary.

OK

Replace the tachometer.

3. NG

Check the following connectors:C-131, C-135, D-03

NGRepair

OK


Check the harness wire between thepower supply and combination meter,and repair if necessary.


Vehicle speed sensor circuit system inspection

Vehicle speed sensor inspection (Refer to P.54-29.)NG

Replace

OK

Disconnect the vehicle speed sensor connector B-67 orB-66 and measure at the harness side.1. Voltage between the terminal No.3 and body earth

OK: 4.5 V or more2. Continuity between terminal No.2 and body earth

OK: Continuity3. Voltage between the terminal No.1 and body earth

OK: System voltage (Ignition switch: ON)

1. NGCheck the followingconnectors:D-02, C-25, C-66, C-83,B-67 , B-66 ,B-65

NGRepair

NG

Check trouble symptom.

NG

Check the harness wire between the vehicle speed sensor andcombination meter, and repair if necessary.

3. NG

Check the followingconnectors:B-65, C-90, C-135,C-131

NGRepair

2. NG

Check the followingconnector:B-65 , B-67 ,B-66

NG RepairOK


NG

Checkthe harnesswirebetweenthe vehicle speed sensorand power supply, and repair if necessary.

OK


NG

Check the harness wire between the vehicle speed sensor andbody earth, and repair if necessary.

OK

Replace the speedometer.


24/84


ON-VEHICLE SERVICE 54300090176SPEEDOMETER CHECK1. Adjust tire pressure to the specified level.

(Refer to GROUP 31 Service Specifications.)2. Set the vehicle onto a speedometer tester and use wheel

chocks to hold the rear wheels.

3. To prevent the front wheel from moving from side to side,attach tension bars to the tie-down hook, and secureboth ends to anchor plates.

4. To prevent the vehicle from launching, attach a chainor wire to the rear retraction hook, and make sure theend of the chain or wire is secured firmly.

5. Check if the speedometer indicator range is within thestandard values.CautionDo not operate the clutch suddenly. Do notincrease/decrease speed rapidly while testing.Standard values:

Standard indication km/h(mph)

Allowable range km/h (mph)

40 (20) 40 - 48 (20 -25)

80 (40) 80 -92 (40 - 47)

120 (60) 120 -136 (60 -69)

160 (80) 160 - 180 (80 -91)

- (100) - (100 - 114)

TACHOMETER CHECK 543001001761. Insert a paper clip in the engine speed detection connector

from the harness side, and attach an external high qualitytachometer.

NOTEFor tachometer check, use an external high qualityinductive tachometer.

2. Compare the readings of the vehicle tachometer and theexternal tachometer at every engine speed, and check

if the variations are within the standard values.Standard values:

700 r/min : 100 r/min3,000 r/min : 150 r/min5,000 r/min : 250 r/min6,000 r/min : 300 r/min

Wheel chocks

Tension bar

Front

Anchor plate

Engine speeddetection connector

Tachometer

Paper clip


25/84


FUEL GAUGE SIMPLE CHECK 54300110179

NG

Replace the fuel gauge.NG

Repair the harness.

When the ignition switch is turned toON, the test lamp illuminates.

OK The needle of the fuel gauge moves.

OK Replace the fuel gauge unit.

Use the special tool to connect a testlamp (12 V - 3.4 W) to the harnessconnector.

Remove the fuel gauge unit connector.

MB991219EarthTest lamp

(12 V - 3.4 W)

Fuel gauge

FUEL GAUGE UNIT CHECK 54300120240Remove the fuel gauge unit from the fuel tank.(Refer to GROUP 13F.)FUEL GAUGE UNIT RESISTANCE1. Check that resistance value between the fuel gauge

terminal and ground terminal is at standard value whenfuel gauge unit float is at point F (highest) and pointE (lowest).Standard value:

Point F: 4 2 WPoint E: 112 7 W

2. Check that resistance value changes smoothly when floatmoves slowly between point F (highest) and point E(lowest).

Fuel gauge unit

Earth


26/84


FUEL GAUGE UNIT FLOAT HEIGHTMove float and measure the height A at point F (highest)and B at point E (lowest) with float arm touching stopper.

Standard value:A: 28.6 mmB: 159.9 mm

THERMISTOR1. Connect fuel gauge unit (thermistor) to battery via test

lamp (12 V - 3.4 W). Immerse in water.2. Condition is good if lamp goes off when the thermistor

is immersed in water and comes on when it is takenout of water.CautionAfter finishing this test, wipe the unit dry and install

it in the fuel tank.

Point F(highest)

Point E(lowest)B

A

Thermistor EarthThermistor

Illuminated

Notilluminated


27/84


ENGINE COOLANT TEMPERATURE GAUGE SIMPLE CHECK 54300140215

When the ignition switch is turned toON, the test lamp illuminates.

OK The needle of the engine coolant tem-perature gauge moves.

NGReplace the engine coolanttemperature gauge.

OK

Replace theengine coolant temperaturegauge unit.

NG

Repair the harness.

Connect a test lamp (12 V - 3.4 W)between the harness side connectorand the earth.

Remove the engine coolant gauge unitconnector.

Earth

Test lamp(12 V - 3.4 W)

Connector



Connector

Earth

MB991219

Earth


28/84


ENGINE COOLANT TEMPERATURE GAUGE UNITCHECK 543001500411. Bleed the engine coolant.

(Refer to GROUP 00 Maintenance Service.)2. Remove the engine coolant temperature gauge unit.3. Immerse the unit in 70 _C water to measure the resistance.

Standard value: 104 13.5 W

4. After checking, apply the specified adhesive around thethread of engine coolant temperature gauge unit.Specified sealant:

3M Adhesive Nut Locking No. 4171 or equivalent5. Add engine coolant.

(Refer to GROUP 14 On-vehicle Service.)

COMBINATION METERS 54300290200REMOVAL AND INSTALLATION

3 2

1

Vehicle speed sensor removalstepsD Air cleaner assembly1. Vehicle speed sensor

Combination meter removal steps2. Meter bezel3. Combination meter

11 Nm


29/84

CHASSIS ELECTRICAL - Combination MetersCHASSIS ELECTRICAL - Combination Meters 54-29

INSPECTION 5430060135VEHICLE SPEED SENSOR CHECK1. Remove the vehicle speed sensor and connect a 3 -

10 k W resistance as shown in the illustration.2. Turn the shaft of the vehicle speed sensor and check

that there is voltage between terminals 2 - 3. (1 turn= 4 pulses)

FUEL GAUGE RESISTANCE CHECK 543003001321. Remove the power supply tightening screw.2. Use an ohmmeter to measure the resistance value

between the terminals.

Standard value:Power supply - Earth: 111.5 WPower supply - Fuel gauge: 98.2 WFuel gauge - Ground: 101.0 W

CautionWhen inserting the testing probe into thepower supplyterminal, be careful not to touch the printed board.

ENGINE COOLANT TEMPERATURE GAUGERESISTANCE CHECK1. Remove the power supply tightening screw.2. Use an ohmmeter to measure the resistance value

between the terminals.Standard value:

Power supply - Earth: 111.5 WPower supply - Engine coolant temperaturegauge: 53.6 WEngine coolant temperature gauge - Earth:165.0 W

CautionWhen inserting the testing probe into thepower supplyterminal, be careful not to touch the printed board.

Turn Shaft

Ohmmeter

Resistance3 - 10 k W

Power supply

Fuel gauge

Earth

Engine coolanttemperaturegauge

Earth Power supply


30/84

CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp54-30

HEADLAMP AND FRONT TURN-SIGNAL LAMP 54200300199SERVICE SPECIFICATIONS

Items Standard value Limit

Headlight airming for low Vertical direction 60 mm below horizontal (H) -beam

Horizontal direction Position where the 15 sloping sectionintersects the vertical line (V)

-

Headlamp aiming for high Vertical direction 22 mm below horizontal (H) -beam

Horizontal direction Parallel to direction of vehicle travel -

Headlamp intensity cd - 30,000 or more

SPECIAL TOOLS 54200060457


MB991502 MUT- II sub assen-bly ETACS-ECU input signal checking

A

B

C

D

MB991223 A: MB991219B: MB991220C: MB991221D: MB991222

Harness set A: Test harnessB: LED harnessC: LED harness

adapterD: Probe

Making voltage and resistancemeasurements during troubleshooting A: Connector pin contact pressure checkB: Power circuit checkC: Power circuit checkD: Commercial tester connection


31/84

CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp 54-31

TROUBLESHOOTING 54200900063The special tool (MB991223) should always be used to measure voltages and resistance when carryingout troubleshooting.

DIAGNOSTIC FUNCTIONINPUT SIGNAL INSPECTION POINTS1. Connect the MUT- II to the diagnosis connector.2. If a buzzer of the MUT- II sounds once when a switch

is operated (ON/OFF), the ETACS-ECU input signal forthat switch circuit system is normal.

INSPECTION CHART FOR TROUBLE SYMPTOMS 54200910103

Trouble symptoms Trouble symptoms Inspectionprocedure

Referencepage

Communication with MUT -II is impossi-ble.

Communication with all systems isimpossible.

1 54-32

Communication with one-shot pulse inputsignal only is impossible.

2 54-32

The lighting monitor buzzer doesnt sound under the following conditions while taillamps or headlamps illuminate.D When the ignition switch is turned to OFF and the drivers side door is open.

3 54-32

Headlamp leveling does not occur when the headlamp leveling switch is operated. 5 54-34

The headlamps do not illuminate when the vehicle is in the following condition and theignition switch is at the ON position. However, the headlamps illuminate when thelighting switch is moved to the HEAD position.D Lighting switch: OFFD Passing switch: OFF

6 54-35

The headlamps do not switch off when the vehicle is in the following condition and thelighting switch is moved to the TAIL position.D Ignition switch: OFFD Passing switch: OFF

7 54-36

MUT-II


32/84



Communication with MUT- II is impossible. (Communica-tion with all systems is impossible.)

Probable cause

The cause is probably a defective power supply system (including ground) for thediagnosis line.

D Malfunction of connectorD Malfunction of harness wire

Refer to GROUP 13A - Troubleshoot-ing.


Communication with the MUT- II is impossible. (Commu-nication with the one-shot pulse input signal only isimpossible.)

Probable cause

The cause is probably a defective one-shot pulse input circuit system of the diagnosisline.

D Malfunction of connectorD Malfunction of harness wireD Malfunction of ETACS-ECU

Check the harness wire between thediagnosis connector and junction block.

OK Check the following connectors:C-20, C-134

NG

Repair

NG

Repair

OK


Replace the ETACS-ECU.


The ignition switch is turned to the OFF position and thedrivers side door is opened while the tail lamps orheadlamps are operating, but the lighting monitor buzzerdoes not sound.

Probable cause

The cause is probably a defective lighting switch input circuit system or a defectivedrivers side door switch input circuit system.

D Malfunction of drivers side door switchD Malfunction of harness or connectorD Malfunction of BUZZER-ECU or ETACS-ECU

Drivers side door switch input circuitsystem inspection(Refer to Inspection Procedure 4.)

OK

Check the following connectors:C-20, C-134

NGRepair

OK


Check the harness wire between the junction block and column switch.

OK Replace the BUZZER-ECU orETACS-ECU.

NG

Repair


33/84



Drivers side door switch input circuit system inspection

Door switch inspection(Refer to GROUP 42 Door Assembly.)

NGReplace

OK

Door switch earth inspectionNG

RepairOK

Disconnect the door switch connectorE-19 ,E-08 and measure at the harness side.D Voltage between the terminal No.

2 and body earthOK: 5 V

NGCheck the following connectors:L.H. drive vehicles: E-19, C-144, C-145R.H. drive vehicles: E-08, C-144, C-145

NGRepair

OK


Check the harness wire between thedoor switch and junction block, andrepair if necessary.OK


NG

Replace the BUZZER-ECU orETACS-ECU.


34/84


Inspection procedure 5

Headlamp leveling does not occur when the headlampleveling switch is operated.

Probable cause

The cause is probably a malfunction of the headlamp leveling switch circuit systemor a malfunction of the headlamp leveling unit circuit system.If there is a blown fuse, there may also be a short-circuit in a harness.

D Malfunction of fuseD Malfunction of the headlamp leveling switchD Malfunction of connectorD Malfunction of harnessD Malfunction of the headlamp leveling unit

Headlamp leveling switch check(Refer to P.54-42.)

NGReplace

OK

Disconnect the headlamp levelingswitch connector C-94 and measure atthe harness side.D Continuity between terminal No.3

-earthOK: Continuity

NGCheck the following connectors:C-94, A-33

NGRepair

OK


Check the harness between the head-lamp leveling switch and body earth.Repair, if necessary.

1. NGCheck the following connectors: A-12, A-33, C-74, C-115

NGRepair

OK


Check the harness between the head-lamp relay and the headlamp levelingunitRepair, if necessary.

OK

Disconnect the headlamp leveling unit

connectors A-12, A-33 and measure atthe harness side. Both the left and rightconnectors of theheadlamp levelingunitshould be checked.1 Voltage between terminal No.1 -


2 Continuity between terminal No.2 -earthOK: Continuity 2. NG Check the following connectors:

A-12, A-33

NGRepair

OK


Check the harness between the bodyearth and the headlamp leveling unit.Repair, if necessary.

OK

Disconnect the headlamp leveling unit(LH), headlamp leveling unit (RH) andheadlamp leveling switch connectors A-12, A-33, C-94 and measure at theharness side.D Continuity between terminal No. 3

of the headlamp leveling unit (both)and terminal No. 4 of the headlampleveling switch.OK: Continuity

NG Check the following connectors: A-12, A-33, C-115, C-74, C-94

NG Repair

OK


Check the harness between the head-lamp leveling switch and the headlampleveling unit (both).Repair, if necessary.

OK

Malfunction of the headlamp levelingunit.

Replace


35/84



The headlamps do not illuminate when the vehicle is in thefollowingconditionandthe ignition switch is moved to theON position. However, they illuminate when the lightingswitch is moved to the HEAD position.D Lighting switch: OFF

D Passing switch: OFF

Probable cause

Thecause is probablya malfunctionof the daytime running lamp control unit(DRL-ECU)circuit system. If there is a blown fuse, there may also be a short-circuit in a harness.

D Malfunction of fuseD Malfunction of connectorD Malfunction of harnessD Malfunction of the DRL-ECU

OK

Malfunction of the DRL-ECU. Replace

2. NGCheck the following connectors: A-37, C-14, C-116, B-18X

Headlamp relay check (Refer toP.54-42.)

NGReplace

OK

Disconnect the DRL-ECU connector A-37 and measure at the harness side.D Ignition switch: ON1. Voltage betweenterminal (No.1) and


2. Voltage betweenterminal (No.9) andearthOK: System voltage

3. Continuity between terminal (No.2)and earthOK: Continuity

1. NGCheck the following connectors: A-37, C-14, C-63, C-132, C-131

NGRepair

OK


NG

Check the harness between the DRL-ECU and the ignition switch. Repair, if necessary.

OK


Check the harness between the DRL-ECU and the headlamp relay. Repair,if necessary.

3. NG

Check the following connectors: A-37, C-14

OK


Check the harness between the DRL-ECU and the body earth. Repair, if nec-essary.


36/84



The headlamps do not switch off when the vehicle is in thefollowingconditionandthe lighting switch is moved to theTAIL position.D Ignition switch: OFFD Passing switch: OFF

Probable cause

Thecause is probablya malfunctionof the daytime running lamp control unit(DRL-ECU)circuit system. If there is a blown fuse, there may also be a short-circuit in a harness.

D Malfunction of fuseD Malfunction of connectorD Malfunction of harnessD Malfunction of the tail lamp relayD Malfunction of the DRL-ECU

OK


{{36#1}}

Lighting switch check(Refer to P.54-41.)

NGReplace

OK

Disconnect DRL-ECU connector A-37and measure at the harness side.D Continuity between terminal (2) -

earthOK: Continuity

NGCheck the following connectors: A-37, C-14

NGRepair

OK


Check the harness between the DRL-ECU and body earth.Repair, if necessary.

OK

Malfunction of the DRL-ECU Replace

OK

Disconnect the DRL-ECU connector A-37 and measure at the harness side.D Continuity between terminal (5) -


NGCheck the following connectors: A-37, C-14, C-116, B-14X

NGRepair

OK

Tail lamp relay check (Refer to P.54-40.) Replace


37/84


ON-VEHICLE SERVICE 54200090173HEADLAMP AIMING1. The headlamps should be aimed with the proper

beamsetting equipment, and in accordance with theequipment manufactures instructions.

NOTEIf there are any regulations pertinent to the aiming of headlamps in the area where the vehicle is to be used,adjust so as to meet those requirements.

2. Alternately turn the adjusting screw to adjust the headlampaiming. (Refer to P.54-38.)

3. With the engine running at 2,000 r/min. aim the headlamp.

1. Inflate the tyres to the specified pressures and there

should be no other load in the vehicles other than driveror substituted weight of approximately 75 kg placed indrivers position.

2. Set the distance between the screen and the centre marksof the headlamps as shown in the illustration.

3. Check if the beam shining onto the screen is at thestandard value.

Standard value:(Vertical direction)

60 mm below horizontal (H)(Horizontal direction)

Position where the 15 _ sloping sectionintersects the vertical line (V)

Screen

5 m

Distance of vertical direction Lamp centre

15

Highintensity zone

(V)

(H)


38/84


Standard value:(Vertical direction)

22 mm below horizontal (H)(Horizontal direction)

Parallel to direction of vehicle travelCaution

1. When making the aiming adjustment, be sure tomask those lamps which are not being adjusted.2. When it is difficult, because of outside light, to

distinguish the light/dark dividing line, use acurtain, screen or similar material to reduce theeffects of the outside light.

4. Alternately turn the adjusting screw to adjust the headlampaiming.

CautionBe sure to adjust the aiming adjustment screw inthe tightening direction.

INTENSITY MEASUREMENT 54200100135Using a photometer, and following its manufactures instructionmanual, measure the headlamp intensity and check to besure that the limit value is satisfied.

Limit: 30,000 cd or moreNOTE1. When measuring the intensity, maintain an engine speed

of 2,000 r/min, with the battery in the charging condition.2. There may be special local regulations pertaining to

headlamp intensity, be sure to make any adjustmentsnecessary to satisfy such regulations.3. If an illuminometer is used to make the measurements,

convert its values to photometer values by using thefollowing formula.I = Er2 Where:I = intensity (cd)E = illumination (lux)r = distance (m) from headlamps to illuminometer

(V)Lamp centre

(H)

Centre of highintensity zone High intensity

zone

Distanceof verticaldirection

Horizontal direction adjustment (Lower beam)

Horizontal directionadjustment(Upper beam)

Vertical directionadjustment(Upper beam)


39/84


BULB REPLACEMENT 542001301891. Disconnect the connector.2. Remove the socket cover.

3. Unhook the spring which secures the bulb, and thenremove the bulb.CautionDo not touch the surface of the bulb with hands ordirty gloves. If the surface does become dirty, cleanit with alcohol or thinner, and let it dry thoroughlybefore installing.

1. Disconnect the connector, and then remove the socket

cover of headlamp lower beam.2. Pinch the spring and pull out the position lamp bulb.

1. Disconnect the connector.2. Turn the bulb socket counterclockwise together with the

bulb, and remove the bulb.CautionIf the bulb socket is not securely installed, the lenswill moisten, or water will get inside the lamp unit,so the bulb socket should be securely installed.

Socket cover

SpringSpring

Spring


40/84


HEADLAMP AND FRONT TURN-SIGNAL LAMP 54200240141REMOVAL AND INSTALLATION

CAUTION: SRSBefore removal of air bag module and clockspring, refer to GROUP 52B - ServicePrecautions and Air Bag Module and ClockSpring.

6

4

1

2

3

5 Nm

5 Nm

5 Nm

5

1. Column switch (Refer to GROUP 37A - SteeringWheel and Shaft.)

Headlamp leveling switch removalsteps2. Switch bezel3. Headlamp leveling switch

Headlamp removal stepsA A" 4. Radiator grille

5. Front turn-signal lamp6. Headlamp


41/84

CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp

*2 *1

54-41

REMOVAL SERVICE POINTA A" RADIATOR GRILLE REMOVALRemove the radiator grille by pushing the tab of the radiatorgrille clips in the direction of the arrows with a flat-tippedscrewdriver, while lightly pulling the radiator grille towardsyou.

INSPECTION 54200250045LIGHTING SWITCH, DIMMER/PASSING SWITCH ANDTURN-SIGNAL LAMP SWITCH CHECK

Switch position Connector A-terminal No.

Connector B-terminal No.

1 2 3 4 6 3 5 6 7 8 9

LIGHTING OFFSWITCH TAIL

HEAD

DIMMER/ LOWERPASSING UPPERSWITCH

PASSING

TURN- RHSIGNAL OFFLAMPSWITCH LH

NOTE1. *1 indicates continuity when the dimmer switch is in the lower

position.2. *2 indicates continuity when the dimmer switch is in the upper

position.

Connector A

Connector B


42/84


HEADLAMP RELAY AND TAIL LAMP RELAY CHECK

Battery voltage Terminal No.

1 3 4 5

Supplied

Not supplied

HEADLAMP LEVELING SWITCH CHECKCheck the resistance between the terminals when theheadlamp leveling switch is operated.Standard value:

Resistance measure- Switch positionment terminal No. 0 1 2 3 4

Between 3 and 4 W 1,235 1,114 977 862 747

Between 4 and 6 W 548 669 806 921 1,036Between 3 and 6 W 1,003

Tail lamp relay

Headlamp relay


43/84


DAYTIME RUNNING LAMP RELAY CHECK

Battery voltage Terminal No.

1 2 3 4

Supplied

Not supplied

Daytimerunninglamp relay


44/84

CHASSIS ELECTRICAL - Side Turn-signal Lamp54-44

SIDE TURN-SIGNAL LAMP 54200060105SPECIAL TOOL


MB990784 Ornament remover Removal of side turn-signal lamp

REMOVAL SERVICE POINT 54200330091A A" SIDE TURN-SIGNAL LAMP REMOVALUse a special tool to remove the lock from the fender panel,and then remove the side turn-signal lamp.

INSTALLATION SERVICE POINT" AA SIDE TURN-SIGNAL LAMP INSTALLATION1. Fit the lock into the fender panel.2. Push the side turn-signal lamp into the fender, and secure

it with the hook.

MB990784

Fender panel

Hook

Fender panel


45/84

CHASSIS ELECTRICAL - Front Fog Lamp 54-45

FRONT FOG LAMP 54200030069SERVICE SPECIFICATIONS

Items Standard value

Front fog lamp aiming Vertical direction 100 mm below horizontal (H)

Horizontal direction Parallel to direction of vehicle travel

SPECIAL TOOL 54200060464


MB990784 Ornament remover Removal of switch garnish

ON-VEHICLE SERVICE 54200110138FRONT FOG LAMP AIMING1. Measure the centre of the fog lamps, as shown in the

illustration.

2. Set the distance between the screen and the centre of the fog lamps as shown in the illustration.

3. Inflate the tyres to the specified pressures and thereshould be no other load in the vehicles other than driveror substituted weight of approximately 75 kg placed inthe drivers position.

4. With the engine running at 2,000 r/min, aim the fog lamp.

Parabola type Unit: mm

Lampcentre

Projector type

Lampcentre

76

28

37

49

Screen

5 m
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CHASSIS ELECTRICAL - Front Fog Lamp54-46

5 Check if the beam shining onto the screen is at thestandard value.Standard value:

(Vertical direction)100 mm below horizontal (H)

(Horizontal direction)Parallel to direction of vehicle travel

NOTEThe horizontal direction is non-adjustable. If the deviationof the light beam axis exceeds the standard value, checkto be sure that the mounting location or some other pointis not defective.

CautionWhen making the aiming adjustment, be sure to maskthose lamps which are not being adjusted.

BULB REPLACEMENT 542001301961. Remove the fog lamp bezel.2. Remove the fog lamp unit.

3. Undo the fog lamp rear cover.4. Unhook the spring which secures the bulb and then

remove the bulb.CautionDo not touch the surface of the bulb with hands ordirty gloves. If the surface does become dirty, cleanit with alcohol or thinner, and let it dry thoroughlybefore installing.

Lamp centre Distance of vertical direction

Centre of highintensity zone

High intensity zone

Parabola type

Adjustingscrew

Projector type

Adjusting screw

Fog lamprear cover

Fog lamprear cover

Spring


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CHASSIS ELECTRICAL - Front Fog Lamp 54-47

FRONT FOG LAMP 54200150161REMOVAL AND INSTALLATION

3

3

4

1

2

4

5

5

Front fog lamp switch removalsteps1. Side air outlet2. Front fog lamp switch

Front fog lamp removal steps3. Fog lamp bezel4. Fog lampD Front bumper (Refer to GROUP 51.)5. Fog lamp bracket


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CHASSIS ELECTRICAL - Rear Combination Lamp54-48

REAR COMBINATION LAMP 54200060471SPECIAL TOOLS


MB991502 MUT- II subassembly

ETACS-ECU input signal checking

MB990784 Ornament remover Removal of side air outlet (L.H.)


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CHASSIS ELECTRICAL - Rear Combination Lamp 54-49

REAR COMBINATION LAMP 54200450094REMOVAL AND INSTALLATION

Caution: SRSBefore removal of air bag module and clockspring, refer to GROUP 52B - SRS ServicePrecautions and Air Bag Module and ClockSpring.

2

3

1

5 Nm

5 Nm

5 6

4

7 8

9

5 Nm

9

1. Column switch (Refer to GROUP 37A - SteeringWheel and Shaft.)

Rear fog lamp switch removalsteps2. Side air outlet3. Rear fog lamp switch

Rear combination lamp removalsteps

D Rear end side trim (L.H.)D Side box (L.H.)

A A" 4. Rear combination lampRear combination lamp removalsteps 5. Maintenance lid6. Tailgate lamp lid7. Rear combination lampD Tail gate waterproof film (Refer to

GROUP 42.)8. Tailgate lamp9. Packing


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CHASSIS ELECTRICAL - Rear Combination Lamp54-50

REMOVAL SERVICE POINTA A" REAR COMBINATION LAMP REMOVAL 1. Turn up the trunk room rear side trim as shown in the

figure, and remove the mounting nut and disconnect theconnector.

2. Remove the rear combination lamp.

INSPECTION 54200460035LIGHTING SWITCH AND TURN-SIGNAL LAMP SWITCHCHECKRefer to P.54-41.

TAIL LAMP RELAY CHECK Refer to P.54-42.

Trunkroom rearside trim


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CHASSIS ELECTRICAL - High Mounted Stop Lamp 54-51

HIGH MOUNTED STOP LAMP 54200510204REMOVAL AND INSTALLATION

3

2

1 1

2

43

Removal steps 1. Socket assembly2. Bulb3. High mounted stop lamp

Removal steps 1. Cover2. Lamp unit3. Bulb4. Socket assembly


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CHASSIS ELECTRICAL - Rheostat54-52

RHEOSTAT 54200600093REMOVAL AND INSTALLATION

1

2

Removal steps1. Meter bezel assembly2. Rheostat

INSPECTION 542006100341. Connect the battery and the test bulb (40W) as shown

in the illustration.2. Operate the rheostat, and if the brightness changes

smoothly without switching off, then the rheostat functionis normal.

40W


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CHASSIS ELECTRICAL - Hazard Warning Lamp Switch

ILL

ILL

54-53

HAZARD WARNING LAMP SWITCH 54200660121REMOVAL AND INSTALLATION

1

2

Removal stepsD Center console panel (Refer to

GROUP 52A.)D A/C-ECU or heater control panel

(Refer to GROUP 55.)A A" 1. Center outlet assembly

2. Hazard warning lamp switch

REMOVAL SERVICE POINTA A" CENTER OUTLET ASSEMBLY REMOVALPress the tabs indicated in the illustration, and pull the centeroutlet assembly to remove it.

INSPECTION 54200670155

Switch Terminal No.position

1 2 3 4 5 6 7 9 - 10

OFF

ON


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CHASSIS ELECTRICAL - Horn/Cigarette Lighter54-54

HORN 54300800038INSPECTION

Switch position Terminal No.

1 3 4 5

Power is not supplied

Power is supplied

CIGARETTE LIGHTER 54300570083INSPECTIOND Take out the plug, and check for a worn edge on the

element spot connection, and for shreds of tobacco orother material on the element.

D Using a circuit tester, check the continuity of the element.

Horn relayTheft-alarmhorn relay

ElementSpot


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CHASSIS ELECTRICAL - Clock 54-55

CLOCK 54300060436SPECIAL TOOL


MB990784 Ornament remover Removal of center display bezel

CLOCK 54300590072REMOVAL AND INSTALLATION

12

Removal stepsA A" 1. Center display bezelA A" 2. Clock

REMOVAL SERVICE POINTA A" CENTER DISPLAY BEZEL/CLOCK REMOVALUse the special tool (MB990784) to pry up the tabs indicatedin the illustration, and remove the center display bezel andthe clock.


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CHASSIS ELECTRICAL - Radio and Tape Player54-56

RADIO AND TAPE PLAYER 54400070227TROUBLESHOOTINGQUICK-REFERENCE TROUBLESHOOTING CHART

Items Problem symptom Relevant chart

Noise Noise appears at certain places when travelling (AM). A- 1

Noise appears at certain places when travelling (FM). A-2

Mixed with noise, only at night (AM). A-3

Broadcasts can be heard but both AM and FM have a lot of noise. A-4

There is more noise either on AM or on FM. A -5

There is noise when starting the engine. A- 6

Some noise appears when there is vibration or shocks duringtravelling.

A-7

Noise sometimes appears on FM during travelling. A-8

Ever-present noise. A-9

Radio When switch is set to ON, no power is available. B-1

No sound from one speaker. B-2

There is noise but no reception for both AM and FM or no soundfrom AM, or no sound from FM.

B-3

Insufficient sensitivity. B-4

Distortion on AM or on both AM and FM. B-5

Distortion on FM only. B-6

Too few automatic select stations. B-7

Insufficient memory (preset stations are erased). B-8

NOTERefer to problem symptoms of AM radio for MW radio.


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CHASSIS ELECTRICAL - Radio and Tape Player 54-57

Items Problem symptom Relevant chart

Tape player Cassette tape will not be inserted. C-1

No sound. C-2

No sound from one speaker. C-3

Sound quality is poor, or sound is weak. C- 4

Cassette tape will not be ejected. C-5

Uneven revolution. Tape speed is fast or slow. C-6

Faulty auto reverse. C-7

Tape gets caught in mechanism. C-8

Motor antenna Motor antenna wont extend or retract. D-1

Motor antenna extends and retracts but does not receive. D- 2

CHARTA. NOISE

A- 1 Noise appears at certain places when travelling (AM).

Is there a particular structure?No

Do the following measures eliminate thenoise?

1. Change to a different station witha strong signal to boost resistanceto interference.

2. Suppress high tones to reducenoise.

3. Extend antenna completely.

YesOK

Yes

Find out the following information fromthe user:

1. Place2. Locality conditions (valley, moun-

tain, etc.)3. Name and frequency of stations

affected by noise

No

If due to vehicle noise:

It may not be possible to prevent noiseif the signal is weak.

If there is more noise than other radios, find out the noiseconditions and the name and frequency of the receivingstations from the user, and consult with the service centre.

If due to external noise:

In almost all cases, prevention on thereceiver side is impossible. Weak sig-nals especially are susceptible to inter-ference.


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CHASSIS ELECTRICAL - Radio and Tape Player

FM Broadcast Good Reception Areas

10 kWoutput FMbroadcast

For stereo:20- 25 km

For monaural:30- 40 km

For home stereos:80- 90 km

FM Signal Characteristics and Signal Interference

Multipath interference

First fadinginterference

54-58

A- 2 Noise appears at certain places when travelling (FM).

Do the following measures eliminate the noise?

D Change to a different station with a strong signal to boostresistance to interference.

D Suppress high tones to reduce noise.D Extend antenna completely.

YesOK

No

If thereis morenoise thanother radios, find out the noise conditionsand the name and frequency of the receiving stations from theuser, and consult with the service centre.

NOTE About FM waves:FM waves have the same properties as light, andcan be deflected and blocked. Wave reception isnot possible in the shadow of obstructions suchas buildings or mountains.1. The signal becomes weak as the distance from

the stations transmission antenna increases. Although this may vary according to the signalstrength of the transmitting station andintervening geographical formation or buildings,the area of good reception is approx. 20-25km for stereo reception, and 30- 40 km formonaural reception.

2. The signal becomes weak when an area of shadow from the transmitting antenna (placeswhere there are obstructionssuchas mountainsor buildings between the antenna and the car),and noise will appear.

3. If a direct signal hits the antenna at the sametime as a signal reflected by obstructions suchas mountains or buildings, interference of thetwo signals will generate noise. Duringtravelling, noise will appear each time thevehicles antenna passes through this kind of obstructed area. The strength and interval of the noise varies according to the signal strengthand the conditions of deflection.

4. Since FM stereo transmission and receptionhas a weaker field than monaural, it is oftenaccompanied by a hissing noise.


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A- 3 Mixed with noise, only at night (AM).

The following factors can be considered as possiblecauses of noise appearing at night.1. Factors due to signal conditions: Due to the

fact that long-distance signals are more easilyreceived at night, even stations that arereceived without problem during the day mayexperience interference in a general worseningof reception conditions. The weaker a stationis the more susceptible it is to interference,

and a change to a different station or theappearance of a beating sound* may occur.Beat sound*: Two signals close in frequencyinterfere with each other, creating a repetitioushigh-pitched sound. This sound is generatednot only by sound signals but by electricalwaves as well.

2. Factors due to vehicle noise: Alternator noisemay be a cause.

Is the noise still obvious even with thelamps OFF?

No

Yes

Do the following measures eliminate thenoise?

D Tuneto a station witha strong signal.D Tune to a station with a strongsignal

without completely extending theantenna.

YesOK

No

Does the noise fade away when thevehicle harness is moved away fromthe radio chassis? (if the harness is notin the proper position.)

YesOK

No

If there is more noise than other radios, consult a servicecentre.


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A-4 Broadcasts can be heard but both AM and FM have a lot of noise.

(1) (2)

Noise occurs when the engine is stopped.

Yes

Do the following measures eliminate the noise?

D Tune to a station with a strong signal.

D Extend the antenna completely.D Adjust the sound quality to suppress high tones.

Yes

OK

No

Is the radio body earth mounted securely?No

Securely tighten the nuts for the bodyearth. Yes

Is the antenna plug properly connected to the radio?No

Correctly attach the antenna plug.

Yes

Is the antenna itself in good condition or is it properlymounted?

NoClean the antenna plug and earth wiremounting area. Mount the antenna se-curely. Yes

If there is more noise than other radios, consult a servicecentre.

Is the noise eliminated?

No

YesOK

Noise occurs when the engine in running.

Inspect the vehicles noise suppressor. (Refer to A-6.)

NOTE About noise encountered during FM reception only.Due to differences in FM and AM systems, FMis not as susceptible as AM to interference fromengines, power lines, lightning, etc. On the otherhand, there are cases due to the characteristics

of FM waves of noise or distortion generated bytypical noise interference (first fading andmultipath). (Refer to A-2.)


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A- 5 There is more noise either on AM or on FM.

1. There is much noise only on AM.Due to differences in AM and FM systems, AM is more susceptible to noise interference.

Were conditions such as the following present when noise wasreceived?

D Lightning was flashing. A motorcycle was passing.D A vehicle passed close by, but it appeared to be a vehicle

generating a particularly large amount of noise radiation.D Passed beneath a power line. Passed under a bridge.D Passed beneath a telephone line.D Passed close by a signal generator.D Passed close by some other source of electrical noise.

Yes

No

Continue to check for static; when static is detected, check forthe conditions listed above.

YesNoise prevention on the radio side is difficult. If the problem isparticularly worse than other radios, consult a service centre.

No

If the problem is particularly worse than other radios, consult aservice centre.

2. There is much noise only on FM.Due to differences in FM and AM systems,FM is not as susceptible as AM to interferencefrom engines, power lines, lightning, etc. Onthe other hand, there are cases due to thecharacteristics of FM waves of noise or

distortion generated by typical noiseinterference (first fading and multipath). (Referto A - 2)


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A- 6 There is noise when starting the engine.

Noise type Soundsare in parentheses ( ).

Conditions Cause Remedy

AM, FM: Ignitionnoise (Popping,snapping, cracking,

buzzing)

D Increasing theen-gine speed caus-ing the popping

sound to speedup, and volumedecreases.

D Disappears whenthe ignition switchis turned to ACC.

D Mainly due to thespark plugs.

D Due to the engine

noise.

D Check or replace the earth cable.

Earth cable

D Check or replace the noise capacitor.

Other electricalcomponents

- Noise may appear aselectrical compo-nents become older.

Repair or replace electrical components.

Static electricity(Cracking, crinkling)

D Disappears whenthe vehicle iscompletelystopped.

D Severe when theclutchis engaged.

Occurs when partsor wiring move forsome reason andcontact metal partsof the body.

Return parts or wiring to their properposition.

D Various noisesare produced de-pending on thebody part of thevehicle.

Due to detachmentfrom the body of thefront hood, bumpers,exhaust pipe andmuffler, suspension,etc.

Tighten the mounting bolts securely.Cases where the problem is noteliminated by a single response to onearea are common, due to several bodyparts being imperfectly earthed.

Caution1. Connecting a high tension cable to the noise

filter may destroy the noise filter and shouldnever be done.

2. Check that there is no external noise. Sincefailure caused by this may result inmisdiagnosis due to inability to identify thenoise source, this operation must beperformed.

3. Noise prevention should be performed bysuppressing strong sources of noise stepby step.

NOTE1. Capacitor

The capacitor does not pass D.C. current, butas the number of waves increases when it

passes A.C. current, impedance (resistanceagainst A.C.) decreases, and current flow isfacilitated. A noise suppressing condenserwhich takes advantage of this property isinserted between the power line for the noisesource and the earth. This suppresses noiseby earthing the noise component (A.C. or pulsesignal) to the body of the vehicle.

2. CoilThe coil passes D.C. current, but impedancerises as the number of waves increases relativeto the A.C. current. A noise suppressing coilwhich takes advantage of this property isinserted into the power line for the noise source,and works by preventing the noise componentfrom flowing or radiating out of the line.


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A- 7 Some noise appears when there is vibration or shocks during travelling.

Are connectors properly connected?No

Ensure proper connection.

Yes

Does noise appear when the radio switch is turned on while thevehicle is stopped and the radio is struck while tuned away froma station?

NoStatic electricity noise:Body static electric from the shock absorber rubber bushings usedto prevent vibration, tyres, etc. occurs because of separation fromthe earth, causing a buzzing noise. Since no measures can betaken on the radio side, other steps should be taken to dischargethe static electricity of the vehicle body.

Yes

Is the radio correctly earthed? (Is the mounting screw tightenedsecurely?)

NoTighten the screw securely.

Yes

Is theantenna correctlyearthed? (Ifnoise appearswhen theantennais moved, this means the earth is not securely connected.)

NoIf rust is present at the antenna earth screw, clean and tightenthe earth securely.

Yes

Repair or replace radio.

A- 8 Noise sometimes appears on FM during travelling.

Does the problem clear up when returned? Yes

OK

No

Does the problem appear only in certain locations and only withcertain stations?

YesDue to electrical field conditions. (Multipath noise*, fading noise*).

Are connectors properly connected?No

Check connector connections.

Yes

Does noise appear when the radio switch is turned on while thevehicle is stopped and the radio is struck while tuned away from

a station?

NoStatic electricity noise:Body static electric from the shock absorber rubber bushings used

to prevent vibration, tyres, etc. occurs because of separation fromthe earth, causing a buzzing noise. Since no measures can betaken on the radio side, other steps should be taken to dischargethe static electricity of the vehicle body.

Yes

Is theradio bodycorrectly earthed?(Is themountingscrewtightenedsecurely?)

NoTighten the screw securely.

Yes

Is theantenna correctlyearthed? (Ifnoise appearswhen theantennais moved, this means the earth is not securely connected.)

NoIf rust is present at the antenna earth screw, clean and tightenthe earth securely.

Yes


No

* About multipath noise and fading noiseBecause the frequency of FM waves isextremely high, it is highly susceptible to effectsfrom geological formations and buildings.These effects disrupt the broadcast signal andobstruct reception in several ways.D Multipath noise

This describes the echo that occurs whenthe broadcast signal is reflected by a large

obstruction and enters the receiver witha slight time delay relative to the directsignal (repetitious buzzing).

D Fading noiseThis is a buzzing noise that occurs whenthe broadcast beam is disrupted byobstructing objects and the signal strengthfluctuates intricately within a narrow range.


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A- 9 Ever-present noise.

Noise is often created by the following factors, andoften the radio is OK when it is checked individually.D Travelling conditions of the vehicleD Terrain of area travelled throughD Surrounding buildingsD Signal conditionsD Time period

For this reason, if there are still problems with noiseeven after the measures described in steps A-1to A-8 have been taken, get information on thefactors listed above as well as determining whetherthe problem occurs with AM or FM, the stationnames, frequencies, etc., and contact a servicecentre.

B. RADIO

B- 1 No power is supplied when the switch is set to ON.

Is dedicated fuse No. 6 blown or is the circuit open? Yes

Replace fuse or repair harness.

No

Is the connector at the back of the radio connected properly?No

Connect connector securely.

Yes

Disconnect and check the connector at the rear of the radio. Isthe ACC power (12 V) being supplied to the radio?

NoRepair harness.

Yes


B- 2 No sound from one speaker.

Check to see if there is any sound whenattached to another radio.

YesRepair or replace radio.

No

Remove the connector on the back of theradioandcheckthe speakerharnessfor conductance.

YesIt conducts electricity but is shorted out. Repair speaker harness.

No

Check the speaker for conductance. Yes

Repair speaker harness and ensureproper connection of relay connectors.No

Repair or replace speaker.


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B- 3 There is noise but no reception for both AM and FM or no sound from AM, or no sound fromFM.

OK

Is thecheck beingconducted under spe-cial electrical field conditions?

Yes

Example: In an undergroundgarage or inside a building.

No

Does tuning solve the problem?

Is proper performance obtained whenthe vehicle is moved?

Yes

OK Yes

No

No

ReconnectNo

Are the antenna plug and radio unit properly connected?

Yes

Repair or replace radio. Yes

Does theproblemdisappear if connected to anotherradio?

No

Replace the antenna.

B- 4 Insufficient sensitivity.

No


Yes


Does the problem disappear when a different radio is con-nected?

OK


Yes

Example: In an undergroundgarage or inside a building.

No

Does tuning solve the problem?


Yes

OK Yes

No

No

Electrical field condition related*(multipath noise or fading noise)

YesIs the problem limited to the reception of a specific radiostation from a specific position?

No

Ensure proper connection.No

Is the antenna plug properly connected to the unit?

* For multipath noise and fading noise problems, refer to P. 54-63.


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B- 5 Distortion on AM or on both AM and FM.

How much distortion is there?Occasional

Distortion in the vicinity of the radio sta-tion

YesExcessive antenna input

ConstantNo

Are the speaker cords in contact with the cone paper? Yes

Remove cords away from cone paper.

No

Remove the speakers and check for torn cone paper or foreignobjects.

Yes Repair or replace speakers.

No

Check for deformation with speaker installed. Yes

Install speaker securely.

No


B- 6 Distortion on FM only

Doesthe distortion persistwhenthe radio is tuned to anotherstation?No

Due to weak electrical field of radio station

Yes

Does distortion increase or decrease when the vehicle is moved? Yes

Due to multipath noise

No


B- 7 Too few automatic select stations.

OK


Yes

Example: In an undergroundgarage or inside a building

No

Is the antenna plug properly connected to the equipment?


Ensure proper connection.No

No

Yes


Does the equipmentwork properly if the radio is changed?

No


Yes


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B- 8 Insufficient memory (preset stations are erased).



No

Disconnect and check the connector at the rear of the radio.Is the memory backup (battery) power being supplied?

NoRepair harness.

Yes


C. TAPE PLAYER

C- 1 Cassette tape will not be inserted.

Are there any foreign objects in the tape player? Yes

Remove the object(s)* 1

No *1 Attempting to force a foreign object (e.g., a coin or clip, etc.) outof the tape player may damage the mechanism. The player shouldbe taken to a service dealer for repair.

Does the tape player work if another tape is inserted? Yes

Replace tape* 2

No

Repair or replace tape player. *2Ensure that the tape label is not loose, that the tape itself is notdeformed and that the tape is tightly wound. Also, tape of C-120or greater length often get caught in the mechanism and shouldnot be used.

C- 2 No sound (even after a tape has been inserted).



No

Is connector at rear of radio connected tightly? No Connect connector firmly.

Yes

Disconnect connector at rear of radio. Is ACC power beingsuppliedto the radio?

YesRepair or replace tape player.

No

Repair harness.


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CHASSI

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