Mitsubishi Magna, Ralliart Magna, Verada, Verada Diamante, Sigma, V3000 Repair Service Manual 1998-2002
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi Magna, Ralliart Magna, Verada, Verada Diamante, Sigma, V3000, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Mitsubishi Magna, Ralliart Magna, Verada, Verada Diamante, Sigma, V3000 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Mitsubishi
YEAR: 1991 1992 1993 1994 1995
MODEL: Magna (TR-TS Series), Verada (KR-KS Series), Sigma, V3000
MAKE: Mitsubishi
YEAR: 1998 1999 2000 2001 2002
MODEL: Magna (’98-’01 TH, ’03 TL, ’98-’02 TJ), Verada Diamante (’98-’01 KH, ’03 KL, ’98-’02 KJ), Ralliart Magna (’00-’02 TJ)
MAKE: Mitsubishi
YEAR: 1998 1999 2000 2001 2002
MODEL:
’98-’01 Magna TH [incl. AWD models], ’98-02 Magna TJ [incl. AWD models]
’98-’01 Verada Diamante KH [incl. AWD models], ’98-’02 Verada Diamante KJ [incl. AWD models]
’00-’02 Ralliart Magna TJ [incl. AWD models]
PRODUCT DETAILS:
Total Pages: 3,832 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
INDEX...4
INTRODUCTION...5
CONVERSION CHART...6
VIN NUMBERS ID...12
LUBRICANTS...25
SECTION 11 ENGINE...33
SECTION 12 LUBRICATION...97
SECTION 13 FUEL SYSTEM...111
SECTION 14 COOLING SYSTEM...211
SECTION 15 EXHAUST SYSTEM AND INTAKE MANIFOLD...221
SECTION 16 ENGINE ELECTRICAL...235
SECTION 17 EMISSION CONTROL SYSTEMS...303
SECTION 21 CLUTCH...327
SECTION 22 MANUAL TRANSMISSION...337
SECTION 23 AUTOMATIC TRANSMISSION...375
SECTION 26 DRIVE SHAFTS AND TRANSFER SHAFT...563
SECTION 27 REAR AXLE...577
SECTION 31 WHEELS AND TYRES...585
SECTION 32 POWER PLANT MOUNTINGS...595
SECTION 33A FRONT SUSPENSION...603
SECTION 33B ACTIVE SUSPENSION...615
SECTION 34 REAR SUSPENSION...665
SECTION 35 BREAKS...679
SECTION 36 PARKING BREAKS...786
SECTION 37 STEERING...798
SECTION 42A BODY...826
SECTION 42B BODY REPAIR...870
SECTION 51 EXTERIOR...878
SECTION 52 INTERIOR...905
SECTION 52B SRS...929
SECTION 54 ELECTRICAL...973
SECTION 54 HOW TO READ DIAGRAMS...982
SECTION 55 HEATER AND A/C...1313
...
!!! # Generated bmk file
MagnaVerada_home...1
TJRALLIA...2
02RTITLE...2
thkhman...3
9900...3
9900p12c...3
MAIN INDEX...0
GENERAL...3
9900p335...5
MAIN INDEX...0
GENERAL - Table of Contents...0
How To Use This Manual...5
Maintenance, Repair and Servicing Explanations...5
On Vehicle Service...5
Inspection...5
Definition of Terms...5
Indication of Tightening Torque...5
Abbreviations...5
Explanation of Manual Contents...6
How to Use Troubleshooting/Inspection Service Points...8
Troubleshooting Contents...8
Diagnosis Function...10
How To Use The Inspection Procedures...11
Connector Measurement Service Points...12
Connector Inspeciton...13
Inspection Service Points for a Blown Fuse...14
Points to Note for Intermittent Malfunctions...14
Vehicle Identification...15
Vehicle Identification Number (VIN)...15
Compliance Plate...16
Data Plate...16
Australian Design Rules...16
Engine Model Number...16
Major Specifications...17
Vehicles for Australia...17
Vehicles for New Zealand...20
Vehicles for Pacific Region & Brunei...22
Vehicles for Brunei...23
How To Diagnose...24
Troubleshooting Steps...24
Information for Diagnosis...24
Inspection...25
Inspection Instruments...25
Checking Switches...26
Checking Relays...27
Checking Fuses...28
Cables and Wires Check...29
Battery Handling...29
General Electrical System Check...29
Service Precautions...32
SRS...32
Servicing The Electrical System...33
Vehicle Washing...33
MUT-II...33
Towing and Hoisting...34
Wrecker Towing Recommendation...34
Lifting, Jacking Support Location...35
Tightening Torque...37
titlep1v...38
9911a...39
11ato...39
MAIN INDEX...0
ENGINE...39
9911ap32...41
MAIN INDEX...0
ENGINE...0
General Information...41
Service Specifications...41
Sealant...42
Special Tools...42
Troubleshooting...44
On Vehicle Service...45
Drive Belt Tension Check and Adjustment...45
Ignition Timing Check...46
Curb Idle Speed Check...47
Idle Mixture Check...48
Compression Pressure Check...49
Manifold Vacuum Check...50
Lash Adjuster Check...51
Bleeding the Lash Adjuster System...52
Engine Assembly...53
Removal and Installation...53
Removal Service Points...54
Installation Service Points...54
Camshaft Oil Seal...55
Removal and Installation...55
Removal Service Points...55
Installation Service Points...56
Crankshaft Oil Seals...57
Front...57
Removal and Installation...57
Removal Service Point...57
Installation Service Point...57
Rear...58
Removal and Installation...58
Removal Service Points...58
Installation Service Points...59
Oil Pan...60
Lower...60
Removal and Installation...60
Removal Service Point...60
Installation Service Point...61
Upper...62
Removal and Installation...62
Removal Service Point...63
Installation Service Point...63
Inspection...64
Cylinder Head Gasket...65
Removal and Installation...65
Removal Service Point...66
Installation Service Points...66
tjkj...67
0100...67
00p336...67
MAIN INDEX...0
GENERAL...0
How To Use This Manual...67
Maintenance, Repair and Servicing Explanations...67
On Vehicle Service...67
Inspection...67
Definition of Terms...67
Indication of Tightening Torque...67
Abbreviations...67
Explanation of Manual Contents...68
How to Use Troubleshooting/Inspection Service Points...70
Troubleshooting Contents...70
Diagnosis Function...72
How To Use The Inspection Procedures...73
Connector Measurement Service Points...74
Connector Inspection...75
Inspection Service Points for a Blown Fuse...76
Points to Note for Intermittent Malfunctions...76
Vehicle Identification...77
Vehicle Identification Number (VIN)...77
Compliance Plate...78
Data Plate...78
Australian Design Rules...78
Engine Model Number...78
Option Codes...79
Data Plate...79
Major Specifications...80
Vehicles for Australia...80
Vehicles for New Zealand...83
Vehicles for Pacific Region & Brunei...85
Vehicles for Brunei...86
How To Diagnose...87
Troubleshooting Steps...87
Information for Diagnosis...87
Inspection...88
Inspection Instruments...88
Checking Switches...89
Checking Relays...90
Checking Fuses...91
Cables and Wires Check...92
Battery Handling...92
General Electrical System Check...92
Service Precautions...95
SRS...95
Engine-A/T ECU and BEM/Immobiliser Service Requirements...95
Servicing The Electrical System...96
Vehicle Washing...96
MUT-II...97
Towing and Hoisting...97
Towing Recommendation...97
Lifting, Jacking Support Location...98
Tightening Torque...100
00toc...101
MAIN INDEX...0
GENERAL...101
0100p1cd...102
010200p1...103
0102p26...104
MAIN INDEX...0
GENERAL...0
Option Codes...104
Data Plate...104
Vehicle Identification...105
Vehicle Identification Number (VIN)...105
Major Specifications...106
01awd00p...109
01awdp21...110
MAIN INDEX...0
GENERAL...0
How To Use This Manual...110
Maintenance, Repair and Servicing Explanations...110
On-Vehicle Service...110
Definition of Terms...110
Indication of Tightening Torque...110
Abbreviations...110
Vehicle Identification...111
Vehicle Identification Number (VIN)...111
Option Codes...112
Data Plate...112
Major Specifications...113
Vehicles for Australia...113
Vehicles for New Zealand...114
Vehicles for Pacific Region & Brunei...115
Towing and Hoisting...116
Towing Recommendation...116
Lifting, Jacking Support Location...118
Tightening Torque...120
01p25...122
MAIN INDEX...0
GENERAL...0
Option Codes...122
Data Plate...122
Major Specifications...123
titlep1v...126
0111a...127
11a328...127
MAIN INDEX...0
ENGINE...0
General Information...127
Service Specifications...127
Sealant...128
Special Tools...128
Troubleshooting...130
On Vehicle Service...131
Drive Belt Tension Check and Adjustment...131
Ignition Timing Check...132
Curb Idle Speed Check...133
Idle Mixture Check...134
Compression Pressure Check...135
Manifold Vacuum Check...136
Lash Adjuster Check...137
Bleeding the Lash Adjuster System...138
Engine Assembly...139
Removal and Installation...139
Removal Service Points...140
Installation Service Points...140
Camshaft Oil Seal...141
Removal and Installation...141
Removal Service Points...141
Installation Service Points...142
Crankshaft Oil Seals...143
Front...143
Removal and Installation...143
Removal Service Point...143
Installation Service Point...143
Rear...144
Removal and Installation...144
Removal Service Points...145
Installation Service Points...145
Oil Pan...146
Lower...146
Removal and Installation...146
Removal Service Point...147
Installation Service Point...147
Upper...148
Removal and Installation...148
Removal Service Point...149
Installation Service Point...149
Inspection...150
Cylinder Head Gasket...151
Removal and Installation...151
Removal Service Point...152
Installation Service Points...152
0111b...153
11bp365...153
MAIN INDEX...0
ENGINE OVERHAUL...0
Specifications...153
General Specifications...153
Service Specifications...154
Rework Dimensions...156
Torque Specifications...157
Sealants...159
Special Tools...160
Alternator and Drive Belt...162
Removal and Installation...162
Removal Service Point...163
Installation Service Point...163
Intake Manifold Plenum and Throttle Body...164
Removal and Installation...164
Ignition System...165
Removal and Installation...165
Installation Service Point...166
Timing Belt...167
Removal and Installation...167
Removal Service Points...168
Installation Service Points...168
Inspection...172
Intake Manifold and Fuel Parts...174
Removal and Installation...174
Installation Service Points...175
Exhaust Manifold and Water Pump...177
Removal and Installation...177
Installation Service Points...178
Rocker Arms and Camshaft...179
Removal and Installation...179
Removal Service Point...180
Installation Service Points...180
Inspection...182
Cylinder Head and Valve...186
Removal and Installation...186
Removal Service Points...187
Installation Service Points...188
Inspection...190
Valve Seat Reconditioning Procedure...192
Valve Seat Replacement Procedure...192
Valve Guide Replacement Procedure...192
Oil Pan and Oil Pump...193
Removal and Installation...193
Removal Service Point...194
Installation Service Points...195
Inspection...198
Piston and Connecting Rod...199
Removal and Installation 6G72...199
Removal and Installation 6G74...200
Removal Service Points...201
Installation Service Points...202
Inspection...206
Crankshaft, Flywheel and Drive Plate...209
Removal and Installation...209
Installation Service Points...212
Inspection...214
0112...216
12p24...216
MAIN INDEX...0
LUBRICATION...0
General Information...216
Engine Oils...216
Health Warning...216
Recommended Precautions...216
Lubricants...217
Special Tools...217
On-Vehicle Service...217
Engine Oil Inspection...217
Engine Oil Replacement...217
Oil Filter Replacement...218
0113a...219
0113ap25...219
MAIN INDEX...0
MULTIPOINT FUEL INJECTION...0
Troubleshooting...219
Inspection Chart for Diagnosis...219
Inspection Chart for Trouble Symptoms...234
Problem Symptoms Table (FYI)...235
Inspection Procedure for Trouble Symptoms...236
Data List Reference Table...270
Actuator Test Reference Table...274
0113atoc...275
13ap3110...276
MAIN INDEX...0
MULTIPOINT FUEL INJECTION...0
General Information...276
General Specifications...277
MPI System Diagram...278
MPI System Diagram with TCL...279
Service Specifications...280
Sealant...280
Special Tools...281
Troubleshooting...283
Diagnosis Troubleshooting Flow...283
Diagnosis Function...283
Fail-Safe Function Reference Table...285
Inspection Chart for Diagnosis...286
Inspection Chart for Trouble Symptoms...298
Problem Symptoms Table (FYI)...300
Inspection Procedure for Trouble Symptoms...301
Data List Reference Table...335
Actuator Test Reference Table...339
Check at the Engine A/T-ECU Terminals...340
Inspection Procedure Using an Analyser...345
On-Vehicle Service...354
Throttle Body (Throttle Valve Area) Cleaning...354
Closed Throttle Position Switch and Throttle Position Sensor Adjustment Vehicles without TCL...354
Throttle Position Sensor Adjustment Vehicles with TCL...356
Closed Throttle Position Switch and Accelerator Pedal Position Sensor Adjustment Vehicles with TCL...356
Fixed SAS Adjustment...358
Basic Idle Speed Adjustment...358
Fuel Pressure Test...359
Fuel Pump Connector Disconnection (How to Reduce Pressurised Fuel Lines)...361
Fuel Pump Operation Check...362
Inspection of MPI Components...363
Component Location...363
MPI Control Relay and Fuel Pump Relay Continuity Check...367
Intake Air Temperature Sensor Check...367
Engine Coolant Temperature Sensor Check...367
Throttle Position Sensor Check...368
Accelerator Pedal Position Sensor Check Vehicles with TCL...368
Closed Throttle Position Switch Check Vehicles without TCL...369
Closed Throttle Position Switch Check Vehicles with TCL...369
Oxygen Sensor Check...370
Injector Check...371
Idle Speed Control (ISC) Servo (Stepper Motor) Check...371
Checking the Coil Resistance...384
Operational Check...384
Purge Control Solenoid Valve Check...371
EGR Control Solenoid Valve Check...371
Ventilation Control Solenoid Valve Check Vehicles with TCL...372
Vacuum Control Solenoid Valve Check Vehicles with TCL...372
Vacuum Tank Check Vehicles with TCL...373
Vacuum Actuator Check Vehicles with TCL...373
Throttle Valve Operation Check Vehicles with TCL...373
Negative Pressure Check During Traction Control Operation Vehicles with TCL...373
Injector...375
Removal and Installation...375
Removal Service Point...376
Installation Service Points...376
Throttle Body...378
Removal and Installation...378
Vehicles without traction control, with cruise control...378
Vehicles with traction control and cruise control...379
Installation Service Point...379
Disassembly and Reassembly...380
Vehicles without traction control, with cruise control...380
Vehicles with traction control, and cruise control...381
Cleaning Throttle Body Parts...382
Reassembly Service Point...382
0113f...385
01awd...385
MAIN INDEX...0
FUEL SUPPLY...0
Fuel Tank...385
General Information...385
Fuel Tank AWD...386
Removal and Installation...386
Removal Service Points...387
Inspection...387
Fuel Cut Off Valve Check...387
Fuel Gauge Unit and Pump Assembly Replacement...387
Fuel Gauge Unit Check...388
Installation Service Point...388
Fuel Filter...389
Removal and Installation...389
Removal Service Points...390
Installation Service Points...390
01awd13f...391
13fp27...392
MAIN INDEX...0
FUEL SUPPLY...0
Fuel Tank...392
General Information...392
Fuel Tank Sedan...393
Removal and Installation...393
Fuel Tank Wagon...394
Fuel Filter...396
Removal and Installation...396
Installation Service Points...397
13fto...398
0113h...399
0113h...399
0113hp21...400
MAIN INDEX...0
TRACTION CONTROL SYSTEM...0
General Description...400
Diagnosis...401
Inspection Chart for Diagnosis Trouble Codes...401
Inspection Procedures for Diagnosis Codes...402
Inspection Chart for Trouble Symptoms...412
Inspection Procedures for Each Trouble Symptom...413
13hp231...418
MAIN INDEX...0
TRACTION CONTROL SYSTEM...0
Special Tools...419
Service Specifications...419
Diagnosis...420
Diagnostic Troubleshooting Flow...420
Diagnosis Function...420
Inspection Chart for Diagnosis Trouble Codes...421
Inspection Procedures for Diagnosis Codes...422
Inspection Chart for Trouble Symptoms...432
Inspection Procedures for Each Trouble Symptom...433
Data List Reference Table...438
On-Vehicle Service...442
Indicator Lamp Check...442
TCL System Operation Check...442
Stop Lamp Switch Check...444
Wheel Speed Sensor Check...444
Vacuum Solenoid Valve Check...444
Ventilation Solenoid Valve Check...444
Vacuum Tank Check...444
Vacuum Actuator Check...444
Accelerator Pedal Position Sensor (APS) Check...444
TCL Switch...445
Removal and Installation...445
Steering Wheel Sensor...446
Removal and Installation...446
Removal Service Point...446
Inspection...446
TCL-ECU...447
Removal and Installation...447
Inspection...447
0114...448
14p214...448
MAIN INDEX...0
ENGINE COOLING...0
General Information...448
Construction Diagram...448
Service Specifications...448
Lubricant...448
Sealant...448
On-Vehicle Service...449
Engine Coolant Leak Check...449
Radiator Cap Valve Opening Pressure Check...449
Engine Coolant Replacement...449
Concentration Measurement...450
Thermostat...452
Removal and Installation...452
Removal Service Point...453
Installation Service Points...453
Inspection...454
Water Pump...455
Removal and Installation...455
Installation Service Point...455
Water Hose and Water Pipe...456
Removal and Installation...456
Removal Service Point...457
Installation Service Points...457
Inspection...457
Radiator...458
Removal and Installation...458
Removal Service Pointa...459
Installation Service Point...459
Inspection...460
0115...461
0015awdp...461
0115awdp...462
MAIN INDEX...0
INTAKE AND EXHAUST...0
Exhaust Pipe and Main Muffler...462
Removal and Installation...462
0115p23...463
MAIN INDEX...0
INTAKE AND EXHAUST...0
Air Cleaner...463
Removal and Installation...463
Exhaust Pipe and Main Muffler...464
Removal and Installation...464
0115t...465
15p29...466
MAIN INDEX...0
INTAKE AND EXHAUST...0
General Information...466
Service Specifications...466
Special Tool...466
On-Vehicle Service...466
Air Cleaner...467
Removal and Installation...467
Intake Manifold Plenum...468
Removal and Installation...468
Inspection...469
Installation Service Point...469
Intake Manifold...470
Removal and Installation...470
Removal Service Point...470
Inspection...471
Installation Service Point...471
Exhaust Manifold...472
Removal and Installation...472
Exhaust Pipe and Main Muffler...473
Removal and Installation...473
15toc0...474
MAIN INDEX...0
INTAKE AND EXHAUST...474
0116...475
16p241...475
MAIN INDEX...0
ENGINE ELECTRICAL...0
Charging System...475
General Information...475
Service Specifications...476
Special Tool...476
On-Vehicle Service...477
Alternator Output Line Voltage Drop Test...477
Output Current Test...478
Regulated Voltage Test...480
Wave Pattern Check using an Analysre...482
Alternator Relay Continuity Check...484
Alternator...485
Removal and Installation...485
Disassembly and Reassembly...486
Disassembly Service Points...486
Inspection...487
Starting System...489
General Information...489
Service Specifications...490
Starter Motor...491
Removal and Installation...491
Disassembly and Reassembly...493
Disassembly Service Points...494
Starter Motor Part Cleaning...494
Reassembly Service Point...495
Inspection...495
Brush and Spring Replacement...496
Armature Test...497
Ignition System...498
General Information...498
Service Specifications...499
On-Vehicle Service...500
Spark Plug Cable Test...500
Spark Plug Test...500
Ignition Coil Check...500
Power Transistor Check...501
Spark Plug Cable Resistance Check...501
Spark Plug Check and Cleaning...502
Camshaft Position Sensor Check...502
Ignition Secondary Voltage Wave Pattern Check...503
Ignition Primary Voltage Wave Pattern Check...506
Removal and Installation...510
Installation Service Points...511
Distributor...512
Disassembly and Reassembly...512
Inspection...512
Crank Angle Sensor...513
Removal and Installation...513
Inspection...513
0117...514
17p348...514
MAIN INDEX...0
ENGINE AND EMISSION CONTROL...0
Engine Control System...514
General Information...514
Service Specifications...514
On-Vehicle Service...514
Accelerator Cable and Pedal...515
Removal and Installation...515
Installation Service Point...516
Cruise Control System...517
General Information...517
Construction Diagram...517
Service Specifications...518
Special Tools...518
Troubleshooting...519
Standard Flow of Diagnosis Troubleshooting...519
Diagnosis Function...519
Inspection Chart for Diagnosis Codes...520
Inspection Procedure for Diagnosis Codes...521
Inspection Chart for Trouble Symptoms...524
Inspection Procedure for Trouble Symptoms...524
Data List Reference Table...533
Check AT ECU Terminals...534
On-Vehicle Service...536
Cruise Control System Operation Check...536
Cruise Control Component Check...537
Cruise Control...540
Removal and Installation...540
Inspection...542
Emission Control System...543
General Information...543
Emission Control Device Reference Table...543
Service Specifications...543
Special Tool...544
Vacuum Hose...544
Vacuum Hose Piping Diagram...544
Vacuum Circuit Diagram...545
Vacuum Hose Installation...546
Vacuum Hose Inspection...546
Crankcase Emission Control System...547
General Information...547
System Diagram...547
Component Location...547
Positive Crankcase Ventilation System Check...548
Positive Crankcase Ventilation (PCV) Valve Check...548
Evaporative Emission Control System...549
General Information...549
System Diagram...549
Component Location...549
Purge Control System Check...550
Purge Port Vacuum Check...551
Evaporative Emission Purge Solenoid Check...551
Volume Air Flow Sensor, Engine Coolant Temperature Sensor and Intake Air Temperature Sensor Check...552
Air Conditioning Switch Check...552
Canister and Two Way Valve...553
Removal and Installation...553
Inspection...553
Exhaust Gas Recirculation (EGR) System...554
General Information...554
Operation...554
System Diagram...554
Component Location...555
EGR System Check...555
Vacuum Control Valve Check...556
EGR Valve Check...556
EGR Port Vacuum Check...557
EGR Solenoid Check...557
Catalytic Converter...558
General Information...558
Removal and Installation...558
Removal Service Point...559
Inspection...559
0121...560
21p213...560
MAIN INDEX...0
CLUTCH...0
General Information...560
Service Specifications...560
Lubricants...560
On-Vehicle Service...561
Clutch Pedal Check and Adjustment...561
Bleeding...562
Clutch Pedal...563
Removal and Installation...563
Inspection...563
Clutch Disc...564
Removal and Installation...564
Service Points of Removal...565
Service Point of Installation...565
Inspection...566
Clutch Control...567
Removal and Installation...567
Removal Service Point...568
Installation Service Point...568
Inspection...568
Clutch Master Cylinder...569
Disassembly and Reassembly...569
Inspection...569
Clutch Release Cylinder...570
Disassembly and Reassembly...570
Removal Service Point...571
Installation Service Point...571
Inspection...571
0122...572
22p211...572
MAIN INDEX...0
MANUAL TRANSMISSION...0
MANUAL TRANSMISSION...0
Lubricant...572
Special Tools...572
On-Vehicle Service...573
Transmission Oil Level Check...573
Transmission Oil Replacement...573
Transmission Control...574
Removal and Installation...574
Installation Service Point...575
Shift Lever Assembly...576
Disassembly and Reassembly...576
Transmission Assembly...577
Removal and Installation...577
Removal Service Points...579
Installation Service Point...581
0122a...582
22ap249...582
MAIN INDEX...0
MANUAL TRANSMISSION...0
MANUAL TRANSMISSION OVERHAUL...0
Sectional View...582
General Specifications...583
Service Specifications...583
Lubricants...583
Sealants...584
Torque Specifications...584
Form-In-Place Gasket...585
Disassembly...585
Surface Preparation...585
Form-In-Place Gasket Application (FIPG)...585
Snap Rings, Spacers and Thrust Plate Adjustment...586
Special Tools...589
Transmission...593
Removal Service Points...596
Inspection...596
Pre-Assembly Adjustments...597
Installation Service Points...598
Input Shaft...601
Removal Service Points...602
Inspection...603
Installation Service Points...604
Output Shaft...608
Disassembly and Reassembly...608
Removal Service Points...609
Inspection...610
Installation Service Points...612
Reverse Idler Gear...616
Disassembly and Reassembly...616
Inspection...616
Speedometer Gear...617
Disassembly and Reassembly...617
Selector Lever...618
Disassembly and Reassembly...618
Installation Service Points...618
Control Housing...619
Disassembly and Reassembly...619
Removal Service Points...620
Installation Service Points...622
Clutch Housing...621
Disassembly and Reassembly...621
Removal Service Points...621
Installation Service Points...622
Transmission Case...625
Installation Service Points...625
Differential...627
Removal Service Points...627
Pre-Assembly Adjustments...628
Installation Service Points...628
0123a...630
0123a...630
0123ap22...631
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
Lubricant...631
Troubleshooting...631
Inspection Chart for Diagnosis Codes...631
Inspection Procedures for Diagnosis Codes...633
Inspection Chart for Trouble Symptoms...644
Inspection Procedure for Trouble Symptoms...645
0123atoc...655
23ap368...656
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
Service Specifications...656
Lubricant...656
Special Tools...656
Troubleshooting...658
Standard Flow of Diagnosis Troubleshooting...658
Diagnosis Function...659
Road Test...660
Shift Pattern...668
Inspection Chart for Diagnosis Codes...669
Inspection Procedures for Diagnosis Codes...670
Inspection Chart for Trouble Symptoms...681
Inspection Procedure for Trouble Symptoms...682
Service Data Reference Table...692
Actuator Test Judgement Value...695
INVECS-II Cancel Command...695
Check AT Engine A/T-ECU Terminals...696
Oscilloscope Inspection Procedure...698
On-Vehicle Service...699
Automatic Transmission Fluid Check...699
Automatic Transmission Fluid Replacement...700
Throttle Position Sensor Adjustment...701
Inhibitor Switch Continuity Check...701
Inhibitor Switch and Control Cable Adjustment...702
A/T Control Component Location...703
A/T Control Component Check...704
Torque Converter Stall Test...706
Hydraulic Pressure Test...707
Hydraulic Circuit...712
Line Pressure Adjustment...713
Selector Lever Operation Check...713
Transmission Control...714
Removal and Installation...714
Installation Service Point...715
Selector Lever Assembly Magna...716
Selector Lever Assembly Verada...717
Checking...718
Transmission Assembly...719
Removal and Installation...719
Removal Service Points...721
Installation Service Points...722
23toc...723
MAIN INDEX...0
AUTOMATIC TRANSMISSION...723
0123b...724
23bp374...724
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
General Information...724
Sectional View...725
Hydraulic Circuit...726
Specifications...727
General Specifications...727
Service Specifications...727
Valve Body Spring Identification Table...728
Snap Ring, Spacer, Thrust Washer, Thrust Race and Pressure Plate for Adjustment...729
Torque Specifications...732
Sealants...732
Special Tools...733
Form-In-Place Gasket...736
Disassembly...736
Surface Preparation...736
Form-In-Place Gasket Application (FIPG)...736
Transmission...737
Disassembly...742
Reassembly...753
Oil Pump...771
Disassembly and Reassembly...771
Disassembly Service Points...771
Underdrive Clutch and Input Shaft...773
Disassembly and Reassembly...773
Disassembly Service Point...774
Reassembly Service Points...774
Reverse and Overdrive Clutch...776
Disassembly and Reassembly...776
Disassembly Service Point...777
Reassembly Service Points...777
Planetary Carrier Assembly...780
Disassembly and Reassembly...780
Reassembly Service Points...781
Low-Reverse Brake...782
Disassembly and Reassembly...782
Reassembly Service Point...782
Second Brake...783
Disassembly and Reassembly...783
Reassembly Service Point...783
Output Shaft...784
Disassembly and Reassembly...784
Disassembly Service Points...784
Reassembly Service Points...785
Differential...786
Disassembly and Reassembly...786
Disassembly Service Points...786
Reassembly Service Points...787
Valve Body...789
Disassembly and Reassembly...789
Disassembly Service Point...792
Reassembly Service Points...792
Speedometer Gear...793
Disassembly and Reassembly...793
Reassembly Service Point...793
Drive Shaft Oil Seal...794
Disassembly and Reassembly...794
Reassembly Service Point...794
0123c...796
0123cp22...796
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
Lubricant...796
Troubleshooting...796
Inspection Chart for Diagnosis Codes...796
Inspection Procedures for Diagnosis Codes...798
Inspection Chart for Trouble Symptoms...811
Inspection Procedure for Trouble Symptoms...812
0123ctoc...823
23cp369...824
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
Service Specifications...824
Lubricant...824
Special Tools...824
Troubleshooting...826
Standard Flow of Diagnosis Troubleshooting...826
Diagnosis Function...827
Road Test...828
Shift Pattern...834
Inspection Chart for Diagnosis Codes...835
Inspection Procedures for Diagnosis Codes...836
Inspection Chart for Trouble Symptoms...849
Inspection Procedure for Trouble Symptoms...850
Service Data Reference Table...861
Actuator Test Judgement Value...864
INVECS-II Cancel Command...864
Check AT Engine A/T-ECU Terminals...865
Oscilloscope Inspection Procedure...867
On-Vehicle Service...868
Automatic Transmission Fluid Check...868
Automatic Transmission Fluid Replacement...869
Throttle Position Sensor Adjustment / Accelerator Pedal Position Sensor...870
Inhibitor Switch Continuity Check...870
Inhibitor Switch and Control Cable Adjustment...871
A/T Control Component Location...872
A/T Control Component Check...873
Torque Converter Stall Test...875
Hydraulic Pressure Test...876
Hydraulic Circuit...881
Line Pressure Adjustment...882
Selector Lever Operation Check...882
Transmission Control...883
Removal and Installation...883
Installation Service Point...884
Selector Lever Assembly...885
Checking Manual Control Switch Assembly Circuit...886
Transmission Assembly...887
Removal and Installation...887
Removal Service Points...889
Installation Service Points...890
0123d...891
23dp378...891
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
General Information...891
Sectional View...892
Hydraulic Circuit...893
Specifications...894
General Specifications...894
Service Specifications...894
Valve Body Spring Identification Table...895
Snap Ring, Spacer, Thrust Washer, Thrust Race and Pressure Plate for Adjustment...896
Torque Specifications...899
Sealants...899
Special Tools...900
Form-In-Place Gasket...903
Disassembly...903
Surface Preparation...903
Form-In-Place Gasket Application (FIPG)...903
Transmission...904
Disassembly and Reassembly...904
Disassembly...908
Reassembly...919
Oil Pump...940
Disassembly and Reassembly...940
Reassembly Service Points...940
Underdrive Clutch and Input Shaft...941
Disassembly and Reassembly...941
Disassembly Service Point...942
Reassembly Service Points...942
Reverse and Overdrive Clutch...944
Disassembly and Reassembly...944
Disassembly Service Point...945
Reassembly Service Points...945
Direct Clutch...948
Disassembly and Reassembly...948
Disassembly Service Point...949
Reassembly Service Points...949
Planetary Carrier Assembly...950
Disassembly and Reassembly...950
Reassembly Service Points...951
Low-Reverse Brake...952
Disassembly and Reassembly...952
Reassembly Service Point...952
Second Brake...953
Disassembly and Reassembly...953
Reassembly Service Point...953
Direct Planetary Carrier...954
Disassembly and Reassembly...954
Disassembly Service Points...954
Assembly Service Points...955
Differential...957
Disassembly and Reassembly...957
Disassembly Service Points...957
Reassembly Service Points...958
Valve Body...960
Disassembly and Reassembly...960
Disassembly Service Point...962
Reassembly Service Points...962
Reduction Brake Piston...963
Disassembly and Reassembly...963
Speedometer Gear...964
Disassembly and Reassembly...964
Drive Shaft Oil Seal...965
Disassembly and Reassembly...965
Reassembly Service Point...965
tlkl...967
0100...967
00p336...967
MAIN INDEX...0
GENERAL...0
How To Use This Manual...967
Maintenance, Repair and Servicing Explanations...967
On-Vehicle Service...967
Inspection...967
Definition of Terms...967
Indication of Tightening Torque...967
Abbreviations...967
Explanation of Manual Contents...968
How To Use Troubleshooting / Inspection Service Points...970
Troubleshooting Contents...970
Diagnosis Function...972
How To Use The Inspection Procedures...973
Connector Measurement Service Points...974
Connector Inspection...975
Inspection Service Points for a Blown Fuse...976
Points to Note for Intermittent Malfunctions...976
Vehicle Identification...977
Vehicle Identification Number (VIN)...977
Compliance Plate...978
Data Plate...978
Australian Design Rules...978
Engine Model Number...978
Option Codes...979
Data Plate...979
Major Specifications...980
Vehicles for Australia...980
Vehicles for New Zealand...984
Vehicles for Pacific Region & Brunei...988
How To Diagnose...991
Troubleshooting Steps...991
Inspection...992
Inspection Instruments...992
Checking Switches...993
Checking Relays...994
Checking Fuses...995
Cables and Wires Check...996
Battery Handling...996
General Electrical System Check...996
Service Precautions...999
Supplemental Restraint System (SRS)...999
Engine-A/T ECU and BEM / Immobiliser Service Requirements...999
Servicing the Electrical System...1000
Vehicle Washing...1000
MUT-II...1000
Towing and Hoisting (2WD)...1001
Towing Recommendation...1001
Towing and Hoising (AWD)...1002
Towing Recommendation...1002
Lifting, Jacking Support Location...1004
Tightening Torque...1006
00toc...1008
MAIN INDEX...0
GENERAL...1008
0111a...1010
11a328...1010
MAIN INDEX...0
ENGINE...0
Engine 6G74 3.5L-SOHC-24 Valve...1010
General Information...1010
Service Specifications...1010
Sealant...1011
Special Tools...1011
Troubleshooting...1013
On-Vehicle Service...1014
Ignition Timing Check...1015
Curb Idle Speed Check...1016
Idle Mixture Check...1017
Compression Pressure Check...1018
Manifold Vacuum Check...1019
Lash Adjuster Check...1020
Bleeding the Lash Adjuster System...1021
Engine Assembly...1022
Removal and Installation...1022
Removal Service Points...1023
Installation Service Points...1023
Camshaft Oil Seal...1024
Removal and Installation...1024
Removal Service Points...1024
Installation Service Points...1025
Crankshaft Oil Seals...1026
Front Oil Seal...1026
Removal and Installation...1026
Removal Service Point...1026
Installation Service Point...1026
Rear Oil Seal...1027
Removal and Installation...1027
Removal Service Points...1027
Installation Service Points...1028
Oil Pan, Lower...1029
Removal and Installation...1029
Removal Service Point...1029
Installation Service Point...1030
Oil Pan, Upper...1031
Removal and Installation...1031
Removal Service Point...1032
Installation Service Point...1032
Inspection...1033
Cylinder Head Gasket...1034
Removal and Installation...1034
Removal Service Point...1035
Installation Service Points...1035
11atoc...1036
MAIN INDEX...0
ENGINE...1036
0111b...1037
11bp365...1037
MAIN INDEX...0
ENGINE OVERHAUL...0
Specifications...1037
General Specifications...1037
Service Specifications...1038
Rework Dimensions...1040
Torque Specifications...1041
Sealants...1043
Special Tools...1044
Alternator and Drive Belt...1046
Removal and Installation...1046
Removal Service Point...1046
Installation Service Point...1047
Intake Manifold Plenum and Throttle Body...1048
Removal and Installation...1048
Ignition System...1049
Removal and Installation...1049
Installation Service Point...1050
Timing Belt...1051
Removal and Installation...1051
Removal Service Points...1052
Installation Service Points...1052
Inspection...1056
Intake Manifold and Fuel Parts...1058
Removal and Installation...1058
Installation Service Points...1059
Exhaust Manifold and Water Pump...1061
Removal and Installation...1061
Installation Service Points...1062
Rocker Arms and Camshaft...1063
Removal and Installation...1063
Removal Service Points...1064
Installation Service Points...1064
Inspection...1066
Cylinder Head and Valve...1070
Removal and Installation...1070
Removal Service Points...1071
Installation Service Points...1072
Inspection...1074
Valve Seat Reconditioning Procedure...1075
Valve Seat Replacement Procedure...1076
Valve Guide Replacement Procedure...1076
Oil Pan and Oil Pump...1077
Removal and Installation...1077
Removal Service Points...1078
Installation Service Points...1079
Inspection...1082
Piston and Connecting Rod...1083
Removal and Installation...1083
Removal Service Points...1084
Installation Service Points...1084
Inspection...1086
Crankshaft, Flywheel and Drive Plate...1090
Removal and Installation...1090
Installation Service Points...1092
Inspection...1094
11btoc...1096
MAIN INDEX...0
ENGINE OVERHAUL...1096
0112...1098
12p24...1098
MAIN INDEX...0
LUBRICATION...0
General Information...1098
Engine Oils...1098
Health Warning...1098
Recommended Precautions...1098
Lubricants...1099
Special Tools...1099
On-Vehicle Service...1099
Engine Oil Inspection...1099
Engine Oil Replacement...1099
Oil Filter Replacement...1100
12toc0...1101
MAIN INDEX...0
LUBRICATION...1101
0113a...1102
13ap3110...1102
MAIN INDEX...0
MULTIPOINT FUEL INJECTION...0
General...1102
General Information...1102
General Specifications...1103
MPI System Diagram...1104
MPI System Diagram with TCL...1105
Service Specifications...1106
Sealant...1106
Special Tools...1107
Troubleshooting...1109
Diagnosis Troubleshooting Flow...1109
Diagnosis Function...1109
Fail-Safe Function Reference Table...1111
Inspection Chart for Diagnosis...1112
Inspection Chart for Trouble Symptoms...1127
Problem Symptoms Table...1128
Inspection Procedure for Trouble Symptoms...1129
Data List Reference Table...1163
Actuator Test Reference Table...1167
Check At The Engine A/T-ECU Terminals...1168
Inspection Procedure Using An Analyser...1173
On-Vehicle Service...1182
Throttle Body (Throttle Valve Area) Cleaning...1182
Closed Throttle Position Switch and Throttle Position Sensor Adjustment Vehicles without TCL...1182
Throttle Position Sensor Adjustment Vehicles with TCL...1184
Closed Throttle Position Switch and Accelerator Pedal Position Sensor Adjustment Vehicles with TCL...1184
Fixed SAS Adjustment...1186
Basic Idle Speed Adjustment...1186
Fuel Pressure Test...1187
Fuel Pump Connector Disconnection (How To Reduce Pressurised Fuel Lines)...1189
Fuel Pump Operation Check...1190
Inspection of MPI Components...1191
Component Location...1191
MPI Control Relay and Fuel Pump Relay Continuity Check...1195
Intake Air Temperature Sensor Check...1195
Engine Coolant Temperature Sensor Check...1195
Throttle Position Sensor Check...1196
Accelerator Pedal Position Sensor Check Vehicles with TCL...1196
Closed Throttle Position Switch Check Vehicles without TCL...1197
Closed Throttle Position Switch Check Vehicles with TCL...1197
Oxygen Sensor Check...1198
Injector Check...1199
Idle Speed Control (ISC) Servo (Stepper Motor) Check...1199
Checking Coil Resistance and Operation...1199
Purge Control Solenoid Valve Check...1199
EGR Control Solenoid Valve Check...1199
Ventilation Control Solenoid Valve Check Vehicles with TCL...1200
Vacuum Control Solenoid Valve Check Vehicles with TCL...1200
Vacuum Tank Check Vehicles with TCL...1201
Vacuum Actuator Check Vehicles with TCL...1201
Throttle Valve Operation Check Vehicles with TCL...1201
Negative Pressure Check During Traction Control Operation Vehicles with TCL...1201
Injector...1203
Removal and Installation...1203
Removal Service Point...1204
Installation Service Points...1204
Throttle Body...1206
Removal and Installation...1206
Vehicles without traction control, with cruise control...1206
Vehicles with traction control and cruise control...1207
Installation Service Point...1207
Disassembly and Reassembly...1208
Vehicles without traction control, with cruise control...1208
Vehicles with traction control, and cruise control...1209
Cleaning Throttle Body Parts...1210
Reassembly Service Point...1210
Idle Speed Control (ISC) Servo (Stepper Motor) Checking the Coil Resistance...1212
Operational Check...1212
13atoc...1213
MAIN INDEX...0
MULTIPOINT FUEL INJECTION...1213
13toc...1215
0113f...1216
13fp27...1216
MAIN INDEX...0
FUEL SUPPLY...0
Fuel Tank...1216
General Information...1216
Sedan & Wagon...1216
AWD...1216
Fuel Tank Sedan...1217
Removal and Installation...1217
Fuel Tank Wagon...1218
Removal and Installation...1218
Fuel Tank AWD...1219
Removal and Installation...1219
Removal Service Points...1220
Inspection...1220
Installation Service Point...1221
Fuel Filter...1222
Removal and Installation...1222
Removal Service Points...1223
Installation Service Points...1223
13ftoc...1224
MAIN INDEX...0
FUEL SUPPLY...1224
0154a...1225
54ap217...1225
MAIN INDEX...0
CHASSIS ELECTRICAL...0
Relay Location...1225
Control Unit Location...1227
Sensor Location...1229
Solenoid and Solenoid Valve Location...1232
Diode Location...1233
Inspection Terminal Location...1234
Fusible Link and Fuse Location...1235
Ground Cable Location...1236
Ground Locations...1237
Other Devices...1240
54atoc...1241
0154b...1242
54bp215...1242
MAIN INDEX...0
CHASSIS ELECTRICAL...0
Overall Wiring Diagram...1242
Sedan...1242
Wagon...1243
Engine Compartment...1244
Dash Panel...1246
Instrument Panel...1248
Roof & Floor...1249
Seat...1250
Door...1251
Trunk Room...1252
Rear Floor Lower Section...1253
Cargo Area Wagon...1254
Tailgate Wagon...1255
54btoc...1256
0154c...1257
54cp3...1257
MAIN INDEX...0
CHASSIS ELECTRICAL...0
Junction Block (J/B)...1257
Centralised Junction...1259
Dedicated Fuse (Relay box and fuse box)...1260
Relay Box (in engine compartment)...1261
Fuse Box (next to junction box)...1261
Multi-Purpose Fuse (in junction block)...1262
Centralised Relay (Relay box in engine compartment)...1264
Power Distribution System...1265
Starting System...1269
Ignition System...1270
Charging System...1271
MPI System...1272
Manual Transmission Vehicles...1272
Automatic Transmission Vehicles...1275
Cooling System...1278
All Models except Verada...1278
Verada...1279
ELC 4-Speed / 5-Speed Automatic Transmission...1280
Headlamp...1284
Tail Lamp, Position Lamp and Licence Plate Lamp...1285
Sedan...1285
Wagon...1287
Fog Lamp Verada, VR-X and VR...1288
Room Lamp, Personal Lamp and Foot Lamp...1289
Sedan...1289
Wagon...1290
Interior Lamps - Door / Gate Switches Sedan / Wagon...1291
Vanity Mirror Lamps...1292
Glove Compartment Lamp and Trunk Lamp...1293
EC Mirror...1294
Ignition Key Cylinder Lamp...1295
Stop Lamp...1296
Sedan...1296
Wagon...1297
Turn Signal and Hazard Lamp...1298
Sedan...1298
Wagon...1300
Backup Lamp...1302
Sedan...1302
Wagon...1303
Horn...1304
Meter...1305
Centre Message Display...1307
Oil Pressure Warning Lamp...1308
Brake Warning Lamp...1309
Seat Belt Warning Lamp...1310
Door Ajar Warning Lamp...1311
Power Windows...1312
All Models...1312
Verada...1313
All Models Except Verada...1314
Central Door Locking and Keyless Entry All...1315
Trunk Lid Opener...1317
All Models except Verada Xi...1317
Verada Xi only...1318
Full Automatic Air Conditioning...1319
Windshield Wiper/Washer...1323
Front...1323
Rear...1324
Defogger...1325
Remote Control Mirror...1326
Clock...1327
Phone Connection...1328
Audio System...1329
Anti-Skid Braking System (ABS)...1331
Without Traction Control...1331
With Traction Control...1333
Traction Control System...1335
Cruise Control...1338
Supplemental Restraint System (SRS)...1341
Theft Alarm...1343
Immobilisation...1345
Sunroof...1346
Power Seat...1347
Driver...1347
Passenger...1348
Light Monitor/Alarm Buzzer...1349
Rheostat...1350
54ctoc...1351
0155...1353
55p364...1353
MAIN INDEX...0
HEATER, AIR CONDITIONING AND VENTILATION...0
General Information...1353
Safety Precautions...1353
Service Specificaitons...1354
Lubricants...1355
Special Tools...1355
Automatic Air Conditioning...1356
Troubleshooting...1356
Diagnosis Function...1356
Inspection Chart for Diagnosis Codes...1357
Inspection Procedure for Diagnosis Codes...1357
Inspection Chart by Trouble Symptom...1363
Inspection Procedure for Trouble Symptoms...1364
Service Data Reference Table...1374
Actuator Test Reference Table...1374
Check At The A/C-ECU Terminals...1375
On-Vehicle Service...1377
Sight Glass Refrigerant Level Test...1377
Magnetic Clutch Test...1377
Receiver Drier Test...1377
Dual Pressure Switch Check...1378
Compressor Drive Belt Adjustment...1378
Charging...1379
Performance Test...1383
Refrigerant Leak Repair...1384
Compressor Noise Check...1384
Power Relay Check...1385
Idle-Up Operation Check...1386
Automatic Air Conditioning, Heater Unit, Heater Core, Blower Assembly and Cooling Unit...1387
Removal and Installation...1387
Removal Service Points...1388
Inspection...1388
Blower Motor Assembly...1389
Removal and Installation...1389
Air Conditioning Control Unit Assembly...1390
Removal and Installation...1390
Inspection...1391
Damper Control Motor Assembly and Power Transistor...1392
Removal and Installation...1392
Inspection...1393
Compressor and Tension Pulley...1395
Removal and Installation...1395
Removal Service Points...1396
Installation Service Points...1396
Inspection...1397
Disassembly and Reassembly...1397
Disassembly Service Points...1397
Reassembly Service Points...1398
Inspection...1399
Refrigerant Line...1400
Removal and Installation...1400
Installation Service Point...1400
Condenser and Condenser Fan Motor...1401
Removal and Installation...1401
Installation Service Point...1402
Inspection...1402
Sensors...1403
Photo Sensors...1403
Removal and Installation...1403
Inspection...1403
Outside Air Temperature Sensor...1404
Removal and Installation...1404
Inspection...1404
Heater Water Temperature Sensor...1404
Removal and Installation...1404
Removal Service Points...1405
Installation Service Points...1405
Inspection...1405
Ventilators...1406
Removal and Installation...1406
Air Outlet...1407
Removal and Installation...1407
55toc...1408
MAIN INDEX...0
HEATER, AIR CONDITIONING AND VENTILATION...1408
13h...1410
13hp231...1410
MAIN INDEX...0
TRACTION CONTROL SYSTEM...0
General Description...1410
Special Tools...1411
Service Specifications...1411
Diagnosis...1412
Diagnostic Troubleshooting Flow...1412
Diagnosis Function...1412
Inspection Chart for Diagnosis Trouble Codes...1413
Inspection Chart for Trouble Symptoms...1424
Data List Reference Table...1430
Check At ECU Terminals...1432
On-Vehicle Service...1434
Indicator Lamp Check...1434
TCL System Operation Check...1434
Stop Lamp Switch Check...1436
Wheel Speed Sensor Check...1436
Vacuum Solenoid Valve Check...1436
Ventilation Solenoid Valve Check...1436
Vacuum Tank Check...1436
Vacuum Actuator Check...1436
Accelerator Pedal Position Sensor (APS) Check...1436
TCL Switch...1437
Removal and Installation...1437
Inspection...1437
Steering Wheel Sensor...1438
Removal and Installation...1438
Removal Service Point...1438
Inspection...1438
TCL-ECU...1439
Removal and Installation...1439
Inspection...1439
13htoc...1440
MAIN INDEX...0
TRACTION CONTROL SYSTEM...1440
14...1442
14p214...1442
MAIN INDEX...0
ENGINE COOLING...0
General Information...1442
Construction Diagram...1442
Service Specifications...1442
Lubricant...1442
Sealant...1442
On-Vehicle Service...1443
Engine Coolant Leak Check...1443
Radiator Cap Valve Opening Pressure Check...1443
Engine Coolant Replacement...1443
Concentration Measurement...1444
Thermostat...1446
Removal and Installation...1446
Removal Service Point...1447
Installation Service Points...1447
Inspection...1448
Water Pump...1449
Removal and Installation...1449
Installation Service Point...1449
Water Hose and Water Pipe...1450
Removal and Installation...1450
Removal Service Point...1451
Installation Service Points...1451
Inspection...1451
Radiator...1452
Removal and Installation...1452
Removal Service Points...1453
Installation Service Point...1453
Inspection...1454
14toc...1455
MAIN INDEX...0
ENGINE COOLING...1455
15...1456
15p29...1456
MAIN INDEX...0
INTAKE AND EXHAUST...0
General Information...1456
Service Specifications...1456
Special Tool...1456
On-Vehicle Service...1456
Intake Manifold Vacuum Check...1456
Air Cleaner...1457
Removal and Installation...1457
Intake Manifold Plenum...1458
Removal and Installation...1458
Inspection...1459
Installation Service Point...1459
Intake Manifold...1460
Removal and Installation...1460
Removal Service Point...1460
Inspection...1461
Installation Service Point...1461
Exhaust Manifold...1462
Removal and and Installation...1462
Exhaust Pipe and Main Muffler 2WD...1463
Removal and Installation...1463
Exhaust Pipe and Main Muffler AWD...1464
Removal and Installation...1464
15toc...1465
MAIN INDEX...0
INTAKE AND EXHAUST...1465
16...1466
16p241...1466
MAIN INDEX...0
ENGINE ELECTRICAL...0
Charging System...1466
General Information...1466
Service Specifications...1467
Special Tool...1467
On-Vehicle Service...1468
Alternator Output Line Voltage Drop Test...1468
Output Current Test...1469
Regulated Voltage Test...1471
Wave Pattern Check Using An Analyser...1473
Alternator Relay Continuity Check...1475
Alternator...1476
Removal and Installation...1476
Disassembly and Reassembly...1477
Disassembly Service Points...1477
Inspection...1478
Starting System...1480
General Information...1480
Service Specifications...1481
Starter Motor...1482
Removal and Installation...1482
Disassembly and Reassembly...1484
Disassembly Service Points...1485
Starter Motor Part Cleaning...1485
Reassembly Service Point...1486
Inspection...1486
Brush and Spring Replacement...1487
Armature Test...1488
Ignition System...1489
General Information...1489
Service Specifications...1490
On-Vehicle Service...1491
Spark Plug Cable Test...1491
Spark Plug Test...1491
Ignition Coil Check...1491
Power Transistor Check...1492
Spark Plug Cable Resistance Check...1492
Spark Plug Check and Cleaning...1493
Camshaft Position Sensor Check...1494
Ignition Secondary Voltage Wave Pattern Check...1494
Ignition Primary Voltage Wave Pattern Check...1497
Removal and Installation...1501
Installation Service Points...1502
Distributor...1503
Disassembly and Reassembly...1503
Inspection...1503
Crank Angle Sensor...1504
Removal and Installation...1504
Inspection...1504
16toc...1505
MAIN INDEX...0
ENGINE ELECTRICAL...1505
17...1506
17p348...1506
MAIN INDEX...0
ENGINE AND EMISSION CONTROL...0
Engine Control System...1506
General Information...1506
Service Specifications...1506
On-Vehicle Service...1506
Accelerator Cable Check and Adjustment...1506
Accelerator Cable and Pedal...1507
Removal and Installation...1507
Installation Service Point...1508
Cruise Control System...1509
General Information...1509
Construction Diagram...1509
Service Specifications...1510
Special Tools...1510
Troubleshooting...1511
Standard Flow of Diagnosis Troubleshooting...1511
Diagnosis Function...1511
Inspection Chart for Diagnosis Codes...1512
Inspection Procedure for Diagnosis Codes...1513
Inspection Chart for Trouble Symptoms...1516
Inspection Procedure for Trouble Symptoms...1516
Data List Reference Table...1525
Check At ECU Terminals...1526
On-Vehicle Service...1528
Cruise Control System Operation Check...1528
Cruise Control Component Check...1529
Removal and Installation...1532
Inspection...1534
Emission Control System...1535
General Information...1535
Emission Control Device Reference Table...1535
Service Specifications...1535
Special Tool...1536
Vacuum Hose...1536
Vacuum Hose Piping Diagram...1536
Vacuum Circuit Diagram...1537
Vacuum Hose Installation...1538
Vacuum Hose Inspection...1538
Crankcase Emission Control System...1539
General Information...1539
System Diagram...1539
Component Location...1539
Positive Crankcase Ventilation System Check...1540
Positive Crankcase Ventilation (PCV) Valve Check...1540
Evaporative Emission Control System...1541
General Information...1541
System Diagram...1541
Component Location...1541
Purge Control System Check...1542
Purge Port Vacuum Check...1543
Evaporative Emission Purge Solenoid Check...1543
Volume Air Flow Sensor, Engine Coolant Temperature Sensor and Intake Air Temperature Sensor Check...1544
Canister and Two Way Valve...1545
Removal and Installation...1545
Inspection...1546
Exhaust Gas Recirculation (EGR) System...1546
General Information...1546
Operation...1546
System Diagram...1546
Component Location...1547
EGR System Check...1547
Vacuum Control Valve Check...1548
EGR Valve Check...1548
EGR Port Vacuum Check...1549
EGR Solenoid Check...1549
Catalytic Converter...1550
General Information...1550
Removal and Installation 2WD...1550
Removal and Installation AWD...1551
Removal Service Point...1552
Inspection...1552
17toc...1553
MAIN INDEX...0
ENGINE AND EMISSION CONTROL...1553
21...1555
21p213...1555
MAIN INDEX...0
CLUTCH...0
General Information...1555
Service Specifications...1555
Lubricants...1555
On-Vehicle Service...1556
Clutch Pedal Check and Adjustment...1556
Bleeding...1557
Clutch Pedal...1558
Removal and Installation...1558
Inspection...1558
Clutch Disc...1559
Removal and Installation...1559
Service Points of Removal...1560
Service Point of Installation...1560
Inspection...1561
Clutch Control...1562
Removal and Installation...1562
Removal Service Point...1563
Installation Service Point...1563
Inspection...1563
Clutch Master Cylinder...1564
Disassembly and Reassembly...1564
Inspection...1564
Clutch Release Cylinder...1565
Disassembly and Reassembly...1565
Removal Service Point...1566
Installation Service Point...1566
Inspection...1566
21toc...1567
MAIN INDEX...0
CLUTCH...1567
22a...1568
22atoc...1568
22p211...1569
MAIN INDEX...0
MANUAL TRANSMISSION...0
Lubricant...1569
Special Tools...1569
On-Vehicle Service...1570
Transmission Oil Level Check...1570
Transmission Oil Replacement...1570
Transmission Control...1571
Removal and Installation...1571
Installation Service Point...1572
Shift Lever Assembly...1573
Disassembly and Reassembly...1573
Transmission Assembly...1574
Removal and Installation...1574
Removal Service Points...1576
Installation Service Point...1578
22toc1...1579
MAIN INDEX...0
MANUAL TRANSMISSION...1579
22b...1580
22ap249...1580
MAIN INDEX...0
MANUAL TRANSMISSION...0
Sectional View...1580
General Specifications...1581
Service Specifications...1581
Lubricants...1581
Sealants...1582
Torque Specifications...1582
Form-In-Place Gasket...1583
Disassembly...1583
Surface Preparation...1583
Form-In-Place Gasket Application (FIPG)...1583
Snap Rings, Spacers and Thrust Plate Adjustment...1584
Special Tools...1587
Transmission...1591
Disassembly and Reassembly...1591
Removal Service Points...1594
Inspection...1594
Pre-Assembly Adjustments...1595
Installation Service Points...1596
Input Shaft...1599
Disassembly and Reassembly...1599
Removal Service Points...1600
Inspection...1601
Installation Service Points...1602
Output Shaft...1606
Disassembly and Reassembly...1606
Removal Service Points...1607
Inspection...1608
Installation Service Points...1610
Reverse Idler Gear...1614
Disassembly and Reassembly...1614
Inspection...1614
Speedometer Gear...1615
Disassembly and Reassembly...1615
Selector Lever...1616
Disassembly and Reassembly...1616
Installation Service Points...1616
Control Housing...1617
Disassembly and Reassembly...1617
Removal Service Points...1618
Installation Service Points...1618
Clutch Housing...1619
Disassembly and Reassembly...1619
Removal Service Points...1619
Installation Service Points...1620
Transmission Case...1623
Disassembly and Reassembly...1623
Installation Service Points...1623
Differential...1625
Disassembly and Reassembly...1625
Removal Service Points...1625
Pre-Assembly Adjustments...1626
Installation Service Points...1626
22btoc...1628
23a...1629
23ap368...1629
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
Service Specifications...1629
Lubricant...1629
Special Tools...1629
Troubleshooting...1631
Standard Flow of Diagnosis Troubleshooting...1631
Diagnosis Function...1632
Road Test...1633
Shift Pattern...1641
Inspection Chart for Diagnosis Codes...1642
Inspection Procedures for Diagnosis Codes...1643
Inspection Chart for Trouble Symptoms...1654
Inspection Procedure for Trouble Symptoms...1655
Service Data Reference Table...1666
Actuator Test Judgement Value...1669
INVECS-II Cancel Command...1669
Check At Engine A/T-ECU Terminals...1670
Oscilloscope Inspection Procedure...1672
On-Vehicle Service...1673
Automatic Transmission Fluid Check...1673
Automatic Transmission Fluid Replacement...1674
Throttle Position Sensor Adjustment...1675
Inhibitor Switch Continuity Check...1675
Inhibitor Switch and Control Cable Adjustment...1676
A/T Control Component Location...1677
A/T Control Component Check...1678
Torque Converter Stall Test...1680
Hydraulic Pressure Test...1681
Hydraulic Circuit...1686
Line Pressure Adjustment...1687
Selector Lever Operation Check...1687
Transmission Control...1688
Removal and Installation...1688
Installation Service Point...1689
Selector Lever Assembly...1690
Checking...1691
Transmission Assembly...1692
Removal and Installation...1692
Removal Service Points...1694
Installation Service Points...1695
23atoc...1696
23toccd1...1698
MAIN INDEX...0
AUTOMATIC TRANSMISSION...1698
23b...1699
23bp374...1699
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
General Information...1699
Sectional View...1700
Hydraulic Circuit...1701
Specifications...1702
General Specifications...1702
Service Specifications...1702
Valve Body Spring Identification Table...1703
Snap Ring, Spacer, Thrust Washer, Thrust Race and Pressure Plate for Adjustment...1704
Torque Specifications...1707
Sealants...1707
Special Tools...1708
Form-In-Place Gasket...1711
Disassembly...1711
Surface Preparation...1711
Form-In-Place Gasket Application (FIPG)...1711
Transmission...1712
Disassembly and Reassembly...1712
Disassembly...1717
Reassembly...1728
Oil Pump...1746
Disassembly and Reassembly...1746
Disassembly Service Points...1746
Underdrive Clutch and Input Shaft...1748
Disassembly and Reassembly...1748
Disassembly Service Point...1749
Reassembly Service Points...1749
Reverse and Overdrive Clutch...1751
Disassembly and Reassembly...1751
Disassembly Service Point...1752
Reassembly Service Points...1752
Planetary Carrier Assembly...1755
Disassembly and Reassembly...1755
Reassembly Service Points...1756
Low-Reverse Brake...1757
Disassembly and Reassembly...1757
Reassembly Service Point...1757
Second Brake...1758
Disassembly and Reassembly...1758
Reassembly Service Point...1758
Output Shaft...1759
Disassembly and Reassembly...1759
Disassembly Service Points...1759
Reassembly Service Points...1760
Differential...1761
Disassembly and Reassembly...1761
Disassembly Service Points...1761
Reassembly Service Points...1762
Valve Body...1764
Disassembly and Reassembly...1764
Disassembly Service Point...1767
Reassembly Service Points...1767
Speedometer Gear...1768
Disassembly and Reassembly...1768
Reassembly Service Point...1768
Drive Shaft Oil Seal...1769
Disassembly and Reassembly...1769
Reassembly Service Point...1769
23btoc...1771
23c...1773
23cp369...1773
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
Service Specifications...1773
Lubricant...1773
Special Tools...1773
Troubleshooting...1775
Standard Flow of Diagnosis Troubleshooting...1775
Diagnosis Function...1776
Road Test...1777
Shift Pattern...1783
Inspection Chart for Diagnosis Codes...1784
Inspection Procedures for Diagnosis Codes...1785
Inspection Chart for Trouble Symptoms...1798
Inspection Procedure for Trouble Symptoms...1799
Service Data Reference Table...1810
Actuator Test Judgement Value...1813
INVECS-II Cancel Command...1813
Check At Engine A/T-ECU Terminals...1814
Oscilloscope Inspection Procedure...1816
On-Vehicle Service...1817
Automatic Transmission Fluid Check...1817
Automatic Transmission Fluid Replacement...1818
Throttle Position Sensor Adjustment / Accelerator Pedal Position Sensor...1819
Inhibitor Switch Continuity Check...1819
Inhibitor Switch and Control Cable Adjustment...1820
A/T Control Component Location...1821
A/T Control Component Check...1822
Torque Converter Stall Test...1824
Hydraulic Pressure Test...1825
Hydraulic Circuit...1829
Line Pressure Adjustment...1830
Selector Lever Operation Check...1830
Transmission Control...1831
Removal and Installation...1831
Installation Service Point...1832
Selector Lever Assembly...1833
Checking Manual Control Switch Assembly Circuit...1834
Transmission Assembly...1835
Removal and Installation...1835
Removal Service Points...1837
Installation Service Points...1838
23ctoc...1839
23d...1841
23dp378...1841
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
General Information...1841
Sectional View...1842
Hydraulic Circuit...1843
Specifications...1844
General Specifications...1844
Service Specifications...1844
Valve Body Spring Identification Table...1845
Snap Ring, Spacer, Thrust Washer, Thrust Race and Pressure Plate for Adjustment...1846
Torque Specifications...1849
Sealants...1849
Special Tools...1850
Form-In-Place Gasket...1853
Disassembly...1853
Surface Preparation...1853
Form-In-Place Gasket Application (FIPG)...1853
Transmission...1854
Disassembly and Reassembly...1854
Disassembly...1858
Reassembly...1869
Oil Pump...1890
Disassembly and Reassembly...1890
Reassembly Service Points...1890
Underdrive Clutch and Input Shaft...1891
Disassembly and Reassembly...1891
Disassembly Service Point...1892
Reassembly Service Points...1892
Reverse and Overdrive Clutch...1894
Disassembly and Reassembly...1894
Disassembly Service Point...1895
Reassembly Service Points...1895
Direct Clutch...1898
Disassembly and Reassembly...1898
Disassembly Service Point...1899
Reassembly Service Points...1899
Planetary Carrier Assembly...1900
Disassembly and Reassembly...1900
Reassembly Service Points...1901
Low-Reverse Brake...1902
Disassembly and Reassembly...1902
Reassembly Service Points...1902
Second Brake...1903
Disassembly and Reassembly...1903
Reassembly Service Point...1903
Direct Planetary Carrier...1904
Disassembly and Reassembly...1904
Disassembly Service Points...1904
Assembly Service Points...1905
Differential...1907
Disassembly and Reassembly...1907
Disassembly Service Points...1907
Reassembly Service Points...1908
Valve Body...1910
Disassembly and Reassembly...1910
Disassembly Service Point...1912
Reassembly Service Points...1912
Reduction Brake Piston...1913
Disassembly and Reassembly...1913
Speedometer Gear...1914
Disassembly and Reassembly...1914
Drive Shaft Oil Seal...1915
Disassembly and Reassembly...1915
Reassembly Service Point...1915
23dtoc...1917
23e...1919
23cp369...1919
MAIN INDEX...0
AUTOMATIC TRANSMISSION...0
General Specifications...1919
Service Specifications...1919
Lubricant...1919
Special Tools...1920
On-Vehicle Service...1921
Automatic Transmission Fluid Check...1921
Automatic Transmission Fluid Replacement...1922
Transfer Case Oil Check...1923
Transfer Case Oil Replacement...1923
Selector Lever Operation Check...1923
Key Interlock Structure Check...1924
Shift Lock Structure Check...1924
Transmission Control...1925
Transmission Shift Lock...1929
Removal and Installation...1929
Transmission Shift Lock...1930
Removal and Installation...1925
Installation Service Point...1926
Selector Lever Assembly...1927
Checking Manual Control Switch Assembly Circuit...1928
Transmission Assembly...1931
Removal and Installation...1931
Removal Service Points...1933
Installation Service Points...1934
Transfer Assembly...1935
Removal and Installation...1935
Removal Service Points...1935
General Information...1936
Construction Diagram...1936
Power Train...1936
23eawdto...1938
25...1940
25awdtoc...1940
MAIN INDEX...0
PROPELLER SHAFT...1940
26p223...1941
MAIN INDEX...0
PROPELLER SHAFT...0
Service Specifications...1941
Item...1941
Lubricants...1941
Adhesives...1941
Special Tools...1941
Propeller Shaft...1942
Removal and Installation...1942
Removal Service Points...1942
Inspection...1943
Installation Service Point...1943
Removal and Installation...1944
Lubrication and Adhesive Points...1945
Disassembly Service Points...1945
Reassembly Service Points...1947
26...1951
26p223...1951
MAIN INDEX...0
FRONT AXLE...0
General Information...1951
Construction Diagram...1951
Service Specifications...1951
Lubricants...1952
Special Tools...1952
On-Vehicle Service...1954
Hub Axial Play Check...1954
Hub Bolt Replacement...1955
Front Hub and Knuckle Assembly...1956
Removal and Installation...1956
Removal Service Points...1956
Installation Service Point...1957
Disassembly and Reassembly...1958
Service Points of Disassembly...1958
Inspection...1959
Service Points of Reassembly...1959
Inspection...1960
Drive Shaft 2WD...1961
Removal and Installation...1961
Drive Shaft AWD...1962
Removal and Installation...1962
Removal Service Points...1963
Installation Service Point...1964
Inspection...1965
Disassembly and Reassembly 2WD...1966
Disassembly and Reassembly AWD...1968
Disassembly Service Points...1969
Reassembly Service Points...1971
Inspection...1973
26toc...1977
MAIN INDEX...0
FRONT AXLE...1977
27...1978
27ap26...1978
MAIN INDEX...0
REAR AXLE...0
General Information...1978
Sectional View...1978
Service Specifications...1978
Special Tools...1978
On-Vehicle Service...1979
Hub Axial Play Check...1979
Rear Hub Rotary-Sliding Resistance Check...1979
Hub Bolt Replacement...1980
Rear Hub Assembly...1981
Removal and Installation...1981
Removal Service Points...1982
Inspection...1982
Installation Service Point...1982
27atoc...1983
27btoc...1984
27cawdto...1985
27p28...1986
MAIN INDEX...0
REAR AXLE...0
General Information...1986
Sectional View...1986
Service Specifications...1986
Special Tools...1986
On-Vehicle Service...1987
Hub Axial Play Check...1987
Rear Hub Rotary-Sliding Resistance Check...1987
Hub Bolt Replacement...1988
Rear Hub Assembly...1989
Removal and Installation...1989
Removal Service Points...1990
Installation Service Point...1990
Inspection...1990
Knuckle...1991
Removal and Installation...1991
Removal Service Point...1992
27p280...1993
MAIN INDEX...0
REAR AXLE...0
Service Specifications...1993
Lubricants...1993
Sealant and Adhesives...1993
Special Tools...1994
On-Vehicle Service...1996
Rear Axial Total Backlash Check...1996
Gear Oil Level Check...1997
Wheel Bearing Check for Free Play in Axial Direction...1997
VCU LSD Check...1997
Differential Carrier Oil Seal Replacement...1998
Hub Bolt Replacement...1998
Rear Hub Assembly...1998
Removal and Installation...1998
Removal Service Points...1998
Inspection...1999
Installation Service Point...1999
Knuckle...2000
Removal and Installation...2000
Removal Service Point...2000
Drive Shaft...2001
Removal and Installation...2001
Removal Service Points...2002
Installation Service Points...2002
Disassembly and Reassembly...2004
Lubrication Points...2005
Disassembly Service Points...2005
Assembly Service Points...2006
Differential Carrier...2008
Removal and Installation...2008
Removal Service Points...2008
Installation Service Points...2009
Inspection Before Disassembly...2009
Differential...2012
Disassembly...2012
Disassembly Service Points...2013
Reassembly...2015
Lubrication and Adhesive Points...2016
Reassembly Service Points...2016
LSD Case Assembly...2021
Disassembly and Reassembly...2023
Disassembly Service Point...2023
Reassembly Service Points...2023
27toc1...2025
MAIN INDEX...0
REAR AXLE...2025
31...2026
31p24...2026
MAIN INDEX...0
WHEEL AND TYRE...0
General Information...2026
Service Specifications...2027
Troubleshooting...2028
On-Vehicle Service...2029
Tyre Inflation Pressure Check...2029
Tyre Wear Check...2029
Tyre Rotation...2029
Wheel Runout Check...2029
Wheel and Tyre...2029
Removal and Installation...2029
31toc...2030
MAIN INDEX...0
WHEEL AND TYRE...2030
32...2031
32p211...2031
MAIN INDEX...0
POWER PLANT MOUNT...0
Special Tools...2031
Engine Mounting...2032
Removal and Installation...2032
Installation Service Point...2033
Inspection...2033
Transmission Mounting...2034
Removal and Installation...2034
Removal Service Point...2035
Inspection...2035
Installation Service Point...2035
Inspection...2035
Engine Roll Stopper, Centre Member...2036
Removal and Installation...2036
Crossmember...2037
Removal and Installation...2037
Removal Service Points...2039
32toc...2040
MAIN INDEX...0
POWER PLANT MOUNT...2040
33...2041
33p213...2041
MAIN INDEX...0
FRONT SUSPENSION...0
General Information...2041
Coil Springs...2041
Shock Absorber...2041
Construction Diagram...2041
Service Specifications...2042
Special Tools...2042
On-Vehicle Service...2043
Front Wheel Alignment Check and Adjustment...2043
Strut Assembly...2044
Removal and Installation...2044
Removal Service Point...2044
Inspection...2044
Disassembly and Reassembly...2045
Disassembly Service Points...2046
Reassembly Service Points...2046
Lower Arm...2047
Removal and Installation...2047
Removal Service Points...2048
Installation Service Points...2048
Inspection...2048
Ball Joint Dust Cover Replacement...2048
Stabiliser Bar...2050
Removal and Installation...2050
Installation Service Point...2051
Inspection...2051
Ball Joint Dust Cover Replacement...2051
33toc...2053
MAIN INDEX...0
FRONT SUSPENSION...2053
34...2054
34ap29...2054
MAIN INDEX...0
REAR SUSPENSION...0
General Information...2054
Coil Spring...2054
Shock Absorber...2054
Construction Diagram...2054
Service Specifications...2055
Special Tools...2055
On-Vehicle Service...2056
Lower Control Arm Bush Replacement...2056
Lateral Rod Bush Replacement...2057
Upper Control Arm Bush Replacement...2057
Rear Suspension Assembly...2058
Removal and Installation...2058
Removal Service Points...2059
Inspection...2059
Reassembly Service Points...2061
34atoc...2062
34btoc...2063
34ctoc...2064
34p21...2065
MAIN INDEX...0
REAR SUSPENSION...0
General Information...2065
Coil Spring...2065
Shock Absorber...2065
Construction Diagram...2065
Service Specifications...2066
Special Tools...2066
On-Vehicle Service...2067
Rear Wheel Alignment Check and Adjustment...2067
Rear Suspension Assembly...2068
Removal and Installation...2068
Removal Service Point...2069
Inspection...2069
Installation Service Point...2069
Upper Arm Assembly...2070
Removal and Installation...2070
Installation Service Point...2071
Inspection...2071
Trailing Arm Assembly...2072
Removal and Installation...2072
Inspection...2072
Lower Arm and Toe Control Arm Assemblies...2073
Removal and Installation...2073
Removal Service Points...2074
Inspection...2074
Ball Joint Dust Cover Replacement...2074
Shock Absorber Assembly...2075
Removal and Installation...2075
Inspection...2075
Disassembly and Reassembly...2076
Disassembly Service Point...2076
Reassembly Service Points...2077
Stabilizer Bar...2078
Removal and Installation...2078
Installation Service Points...2078
Inspection...2078
Ball Joint Dust Cover Replacement...2079
34p214...2080
MAIN INDEX...0
REAR SUSPENSION...0
General Information...2080
Coil Spring...2080
Shock Absorber...2080
Construction Diagram...2080
Service Specifications...2081
Special Tools...2081
On-Vehicle Service...2082
Rear Wheel Alignment Check and Adjustment...2082
Rear Suspension Assembly...2083
Removal and Installation...2083
Removal Service Point...2084
Inspection...2084
Upper Arm Assembly...2085
Removal and Installation...2085
Installation Service Point...2086
Inspection...2086
Trailing Arm Assembly...2087
Removal and Installation...2087
Inspection...2087
Lower Arm and Toe Control Arm Assemblies...2088
Removal and Installation...2088
Removal Service Points...2089
Inspection...2089
Ball Joint Dust Cover Replacement...2089
Shock Absorber Assembly...2090
Removal and Installation...2090
Inspection...2090
Disassembly Service Point...2091
Reassembly Service Points...2092
Stabilizer Bar...2093
Removal and Installation...2093
Inspection...2093
Ball Joint Dust Cover Replacement...2094
34toc1...2095
MAIN INDEX...0
REAR SUSPENSION...2095
35a...2096
0135ap21...2096
MAIN INDEX...0
SERVICE BRAKES...0
General Specifications...2096
Service Specifications...2096
On-Vehicle Service...2097
Front Disc Brake ...2097
Removal and Installation...2097
Installation Service Points...2097
Inspection...2097
Disassembly and Reassembly...2098
Lubrication Points...2099
Disassembly Service Points...2100
Reassembly Service Point...2100
Inspection...2100
Rear Disc Brake...2100
Rear Disc Brake Pad Check and Replacement...2102
Rear Brake Disc Thickness Check...2103
Rear Brake Disc Run-Out Check...2103
Rear Brake Disc Run-Out Correction...2104
Rear Disc Brake...2105
Removal and Installation...2105
Disassembly and Reassembly...2106
Lubrication Points...2107
35aawdto...2108
35atoc...2109
35p232...2110
MAIN INDEX...0
SERVICE BRAKES...0
General Information...2110
Construction Diagram...2110
Specifications...2111
General Specifications...2111
Service Specifications...2111
Lubricants...2112
Sealant...2112
Special Tools...2112
On-Vehicle Service...2113
Brake Pedal Height Check...2113
Stop Light Switch Adjustment...2113
Stop Light Switch Check...2114
Brake Booster Operating Test...2114
Check Valve Operation Check...2115
Proportioning Valve Function Test...2115
Brake Fluid Level Sensor Check...2116
Bleeding...2116
Front Disc Brake Pad Check and Replacement...2116
Disc Brake Rotor Check...2119
Front Brake Disc Run-Out Check...2119
Front Brake Disc Run-Out Correction...2120
Front Brake Disc Thickness Check...2120
Rear Disc Brake Pad Check and Replacement...2121
Rear Brake Disc Thickness Check...2122
Rear Brake Disc Run-Out Check...2122
Rear Brake Disc Run-Out Correction...2123
Brake Pedal...2124
Removal and Installation...2124
Master Cylinder and Brake Booster...2125
Removal and Installation...2125
Installation Service Points...2126
Master Cylinder...2128
Disassembly and Reassembly...2128
Disassembly Service Point...2129
Inspection...2129
Reassembly Service Point...2129
Front Disc Brake...2130
Removal and Installation...2130
Installation Service Points...2130
Inspection...2130
Disassembly and Reassembly...2131
Lubrication Points...2132
Disassembly Service Points...2133
Inspection...2133
Rear Disc Brake...2135
Removal and Installation...2135
Installation Service Point...2136
Inspection...2136
Disassembly and Reassembly...2137
Lubrication Points...2138
Disassembly Service Points...2138
Inspection...2139
Proportioning Valve Vehicles without ABS...2140
Removal and Installation...2140
Installation Service Point...2140
35toc1...2141
MAIN INDEX...0
SERVICE BRAKES...2141
35b...2142
35bp228...2142
MAIN INDEX...0
SERVICE BRAKES...0
General Information...2142
Construction Diagram...2142
2WD...2142
AWD...2143
Service Specifications...2144
Sealant...2144
Special Tools...2144
Troubleshooting...2145
Standard Flow of Diagnosis Troubleshooting...2145
Diagnosis Function...2145
Erasing Diagnosis Codes...2145
Inspection Chart for Diagnosis Codes...2146
Inspection Procedure for Diagnosis Codes...2147
ABS Warning Light Inspection...2152
Inspection Chart for Trouble Symptoms...2152
Inspection Procedure for Trouble Symptoms...2153
Data List Reference Table...2157
Actuator Test Reference Table...2157
Check At The ABS-ECU...2158
On-Vehicle Service...2160
ABS Operation Check...2160
Master Cylinder and Brake Booster...2165
Removal and Installation...2165
Master Cylinder Disassembly and Reassembly...2165
Disassembly Service Points...2166
Inspection...2166
Hydraulic Unit...2167
Removal and Installation...2167
Removal Service Point...2168
Installation Service Point...2168
Wheel Speed Sensor 2WD...2169
Removal and Installation...2169
Wheel Speed Sensor AWD...2170
Removal and Installation...2170
Inspection...2171
G Sensor AWD...2172
Inspection...2172
35btoc...2173
36...2174
35toc1...2174
MAIN INDEX...0
PARKING BRAKES...2174
36awdtoc...2175
36p21...2176
MAIN INDEX...0
PARKING BRAKES...0
General Information...2176
Construction Diagram...2176
Service Specifications...2177
Lubricants...2177
Special Tools...2177
On-Vehicle Service...2178
Parking Brake Lever Stroke Check...2178
Lining Running-In...2179
Parking Brake Switch Check...2179
Parking Brake Lever...2180
Removal and Installation...2180
Parking Brake Cable...2181
Removal and Installation...2181
Removal Service Points...2182
Installation Service Points...2182
Parking Brake...2184
Removal and Installation...2184
Removal Service Points...2185
Inspection...2185
Installation Service Points...2186
36p213...2187
MAIN INDEX...0
PARKING BRAKES...0
General Information...2187
Construction Diagram...2187
Service Specifications...2188
Lubricants...2188
On-Vehicle Service...2189
Parking Brake Lever Stroke Check...2189
Lining Running-In...2190
Replacing Dust Boot...2191
Parking Brake Switch Check...2191
Parking Brake Lever...2192
Removal and Installation...2192
Parking Brake Cable...2193
Removal and Installation...2193
Removal Service Points...2194
Parking Brake...2195
Removal and Installation...2195
Sedan...2195
Wagon...2196
Removal Service Points...2197
Installation Service Points...2198
Inspection...2198
36toc0...2199
37a...2200
37ap331...2200
MAIN INDEX...0
STEERING...0
General Information...2200
Service Specifications...2200
Lubricants...2201
Sealant...2201
Special Tools...2202
On-Vehicle Service...2204
Steering Wheel Free Play Check...2204
Steering Angle Check...2204
Tie Rod End Ball Joint Starting Torque Check...2204
Stationary Steering Effort Check...2205
Checking Steering Wheel Return To Centre...2205
Fluid Level Check...2205
Fluid Replacement...2206
Bleeding...2206
Oil Pump Pressure Test...2207
Power Steering Pressure Switch Check...2209
Steering Wheel and Shaft...2210
Removal and Installation...2210
Removal Service Point...2211
Disassembly and Reassembly...2211
Disassembly Service Points...2212
Reassembly Service Points...2212
Inspection...2212
Rack and Pinion...2213
Removal and Installation...2213
Removal Service Points...2214
Inspection...2214
Disassembly and Reassembly...2216
Lubrication and Sealing Points...2217
Service Points of Disassembly...2218
Reassembly Service Points...2219
Power Steering Oil Pump...2223
Removal and Installation...2223
Installation Service Point...2224
Inspection...2224
Disassembly and Reassembly...2225
Reassembly Service Points...2226
Inspection...2226
Power Steering Hoses...2227
Removal and Installation...2227
Installation Service Point...2228
37atoc...2229
MAIN INDEX...0
STEERING...2229
42...2231
42p358...2231
MAIN INDEX...0
BODY...0
Special Tools...2231
Hood...2232
Removal and Installation...2232
Installation Service Points...2233
Trunk Lid...2234
Removal and Installation...2234
Removal Service Points...2235
Installation Service Points...2235
Inspection...2236
Tailgate...2237
Removal and Installation...2237
Removal Service Points...2238
Installation Service Points...2238
Fender...2240
Removal and Installation...2240
Fuel Filler Door...2241
Removal and Installation...2241
Inspection...2242
Windshield and Window Glass...2243
Window Glass...2243
General...2243
Windshield...2245
Removal and Installation...2245
Removal Service Points...2246
Installation Service Points...2247
Rear Window Glass...2248
Removal and Installation...2248
Installation Service Points...2249
Tailgate Window Glass...2251
Removal and Installation...2251
Removal Service Points...2252
Installation Service Points...2253
Rear Quarter Window Glass...2255
Removal and Installation...2255
Door Assembly...2256
Removal and Installation...2256
Installation Service Points...2257
Inspection...2258
Door Trim and Waterproof Film...2259
Removal and Installation...2259
Removal Service Points...2260
Door Glass and Regulator...2261
Removal and Installation...2261
Installation Service Points...2262
Inspection...2262
On-Vehicle Service...2265
Door Fit Adjustment...2265
Door Glass Adjustment...2265
Front Door...2267
Rear Door...2268
Circuit Breaker (Incorporated in the Power Window Motor) Inspection...2269
Door Handle and Latch...2270
Removal and Installation...2270
Inspection...2271
Inside Handle Play Adjustment...2272
Outside Handle Play Check...2272
Door Belt Line Moulding and Door Opening Weatherstrip...2273
Removal and Installation...2273
Removal Service Points...2273
Installation Service Points...2274
Sunroof...2275
Service Specifications...2275
Troubleshooting...2275
Inspection Chart for Trouble Symptoms...2275
Inspection Procedure for Trouble Symptoms...2275
Checking the Sunroof ECU Terminals...2278
On-Vehicle Service...2279
Water Test...2279
Sunroof Fit Adjustment...2279
Removal and Installation...2281
Removal Service Points...2282
Installation Service Points...2282
Inspection...2283
Disassembly and Reassembly...2285
42toc...2286
MAIN INDEX...0
BODY...2286
51...2288
51p228...2288
MAIN INDEX...0
EXTERIOR...0
Service Specification...2288
Sealant and Adhesive...2288
Special Tools...2288
Front Bumper...2289
Removal and Installation...2289
Disassembly and Reassembly...2290
Front Bumper VR-X...2291
Removal and Installation...2291
Disassembly and Reassembly...2292
Rear Bumper Sedan...2293
Removal and Installation...2293
Rear Bumper Wagon...2294
Removal and Installation...2294
Grilles and Garnishes...2295
Removal and Installation...2295
Removal Service Point...2296
Mouldings...2297
Removal and Installation...2297
Removal Service Points...2298
Installation Service Points...2299
Moulding Installation...2300
Aero Parts...2301
Removal and Installation...2301
Removal Service Points...2302
Installation Service Points...2302
Rear Spoiler...2303
Removal and Installation...2303
Windshield Wiper and Washer...2304
Removal and Installation...2304
Rear Wiper and Washer...2305
Removal and Installation...2305
Inspection...2305
Installation Service Points...2306
Installation Service Point...2308
Inspection...2308
Door Mirror...2310
Removal and Installation...2310
Removal Service Point...2310
Inspection...2311
Roof Rack...2312
Removal and Installation...2312
Removal Service Point...2312
Installation Service Point...2312
51toc...2313
MAIN INDEX...0
EXTERIOR...2313
52a...2314
52ap328...2314
MAIN INDEX...0
INTERIOR...0
Special Tools...2314
Instrument Panel...2315
Removal and Installation...2315
Disassembly and Reassembly...2317
Floor Console...2318
Removal and Installation...2318
Trims Sedan...2319
Removal and Installation...2319
Trims Wagon...2320
Removal and Installation...2321
Headlining and Inside Rear View Mirror Sedan...2322
Removal and Installation...2322
Headlining and Inside Rear View Mirror Wagon...2323
Removal and Installation...2323
Removal Service Points...2324
Front Seat...2325
Removal and Installation...2325
Disassembly and Reassembly...2327
Manual Seat...2327
Power Seat...2328
Disassembly Service Point...2328
Inspection...2329
Rear Seat Sedan...2331
Removal and Installation...2331
Rear Seat Wagon...2332
Removal and Installation...2332
Front Seat Belt...2333
Removal and Installation...2333
Inspection...2333
Rear Seat Belt Sedan...2334
Removal and Installation...2334
Rear Seat Belt Wagon...2335
Removal and Installation...2335
Rear Centre Seat Belt Wagon...2336
Removal and Installation...2336
Removal Service Points...2337
Installation Service Points...2337
52atoc...2338
MAIN INDEX...0
INTERIOR...2338
52b...2339
52bp238...2339
MAIN INDEX...0
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...0
General Information...2339
Seat Belt with Pre-Tensioner...2339
Construction Diagram...2340
Warning / Caution Labels...2341
SRS Service Precautions...2342
Special Tools...2344
Test Equipment...2345
Troubleshooting...2345
Standard Flow of Diagnosis Troubleshooting...2345
Diagnosis Function...2345
Inspection Chart for Diagnosis Trouble Codes...2346
Inspection Procedure Classified by Diagnosis Code...2347
SRS Warning Light Check...2360
Inspection Chart for Trouble Symptoms...2360
Inspection Procedure for Trouble Symptoms...2360
SRS Maintenance...2361
SRS Component Visual Check...2361
Post-Collision Diagnosis...2365
SRS-ECU Memory Check...2366
Repair Procedure...2366
Individual Component Service...2369
SRS Air Bag Control Unit (SRS-ECU)...2370
Removal and Installation...2370
Removal Service Point...2371
Installation Service Points...2371
Inspection...2371
Air Bag Modules and Clock Spring...2372
Removal and Installation...2373
Air Bag Module (driver's side), Clock Spring...2373
Air Bag Module (front passenger's side)...2374
Side Air Bag Module (front seat)...2375
Removal Service Points...2375
Installation Service Points...2376
Inspection...2378
Front Seat Belts with Pretensioner...2380
Removal and Installation...2380
Removal Service Points...2381
Installation Service Points...2381
Inspection...2382
Air Bag Module Disposal Procedures...2383
Seat Belt with Pretensioner Disposal Procedure...2389
Deployed Pretensioner Fitted Seat Belt Disposal...2391
52btoc...2392
MAIN INDEX...0
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...2392
54...2394
54p3118...2394
MAIN INDEX...0
CHASSIS ELECTRICAL...0
How To Read Configuration Diagrams...2394
How To Read Circuit Diagrams...2395
Markings for Connector Earthing...2397
Wire Colour Codes...2400
Abbreviation Symbols...2401
Special Tools...2403
Battery...2404
On-Vehicle Service...2404
Fluid Level and Specific Gravity Check...2404
Battery Inspection...2404
Battery Charging...2405
Ignition Switch ...2406
Removal and Installation...2406
Removal Service Point...2407
Inspection...2407
Body Electronics Module (BEM)...2408
Special Tools...2408
Troubleshooting...2408
Standard Flow of Diagnosis Troubleshooting...2408
Diagnosis Function...2408
Basic Test Mode (BTM) Procedure...2409
Flash Code Reference Table...2409
Output Test Checklist...2410
Input Test Checklist...2410
Inspection Chart for Trouble Symptoms...2411
Immobiliser...2420
Diagnosis Function...2420
Diagnosis Codes...2420
Inspection Chart for Immobiliser system Diagnosis Codes...2420
Inspection Procedure for Diagnosis Codes...2421
BEM Pinout Reference Table...2422
On-Vehicle Service...2424
Immobiliser Teaching Options...2424
MUT-II Immobiliser Menu...2424
RF Transmitter...2425
Battery Testing...2425
Battery Replacement...2425
Programming RF Transmitters...2426
Combination Meters...2427
Speedometer Check 2WD...2427
Tachometer Check...2427
Fuel Gauge Test 2WD...2428
Fuel Gauge Unit Check...2429
Fuel Gauge Check AWD...2430
Inspection...2430
Engine Coolant Temperature Gauge Unit Check...2432
Removal and Installation...2433
Inspection...2434
Trip Computer...2435
Service Specifications...2435
Special Tools...2435
Preliminary Trouble Symptom Checks...2436
Inspection Chart for Trouble Symptoms...2437
Trip Computer Setting Procedure...2458
Centre Message Display...2459
Removal and Installation...2459
Inspection...2459
Exterior Lamps...2460
Headlamps...2460
On-Vehicle Service...2460
Headlight Aiming...2460
Luminous Intensity Measurement...2462
Headlamp, Position Lamp Assembly and Front Turn Signal Lamp Assembly...2463
Removal and Installation...2463
Removal Service Point...2464
Inspection...2464
Side Turn Signal Lamp...2467
Removal and Installation...2467
Removal Service Point...2467
Fog Lamp...2468
Fog Lamp Aiming...2468
Removal and Installation...2469
Removal Service Point...2469
Inspection...2470
Rear Combination Lamp and Rear Lid Lamp...2471
Removal and Installation...2471
Sedan...2471
Wagon...2472
Tail Lamp Relay Continuity Check...2473
High Mounted Stop Lamp...2474
Removal and Installation...2474
Rheostat...2475
Removal and Installation...2475
Inspection...2475
Hazard Warning Lamp Switch...2476
Removal and Installation...2476
Inspection...2476
Horn...2477
Inspection...2477
Audio Unit...2478
Quick Reference Troubleshooting Chart...2478
Chart...2479
Speakers...2495
Removal and Installation...2495
Door Speaker...2495
Rear Speaker...2495
Instrument Panel Speaker...2496
Tailgate Speakers...2496
Removal Service Points...2496
Antenna...2497
Removal and Installation...2497
Sedan...2497
Wagon...2498
Inspection...2498
Antenna Pole Replacement...2499
Rear Window Defogger...2500
On-Vehicle Service...2500
Printed-Heater Line Check...2500
Steering Remote Control and Slip Ring...2501
Removal and Installation...2501
Inspection...2501
54toc...2502
MAIN INDEX...0
CHASSIS ELECTRICAL...2502
54toc0...2503
titlep1v...2505
Mitsubishi Magna, Ralliart Magna, Verada, Verada Diamante, Sigma, V3000 Repair Service Manual 1998-2002
