2009 Mitsubishi Galant Service Repair Manual

Page 1

*5283 ,1'(;

*$/$17

*HQHUDO

(QJLQH

(QJLQH /XEULFDWLRQ

)XHO

(QJLQH &RROLQJ

,QWDNH DQG ([KDXVW

7KLV :RUNVKRS PDQXDO FRQWDLQV SURFHGXUHV IRU VHU (QJLQH (OHFWULFDO YLFH PHFKDQLFV LQFOXGLQJ UHPRYDO GLVDVVHPEO\ LQ VSHFWLRQ DGMXVWPHQW UHDVVHPEO\ DQG LQVWDOODWLRQ (QJLQH DQG (PLVVLRQ &RQWURO 8VH WKH IROORZLQJ PDQXDOV LQ FRPELQDWLRQ ZLWK WKLV $XWRPDWLF 7UDQVD[OH 7UDQVPLVVLRQ

PDQXDO DV UHTXLUHG

)URQW $[OH

5HDU $[OH

:KHHO DQG 7\UH

3RZHU 3ODQW 0RXQW

)URQW 6XVSHQVLRQ

5HDU 6XVSHQVLRQ

:25.6+23 0$18$/

)25(:25'

7(&+1,&$/ ,1)250$7,21 0$18$/ %2'< 5(3$,5 0$18$/ 3$576 &$7$/2*8(

$OO LQIRUPDWLRQ LOOXVWUDWLRQV DQG SURGXFW GHVFULSWLRQV FRQWDLQHG LQ WKLV PDQXDO DUH FXUUHQW DV DW WKH WLPH RI 6HUYLFH %UDNHV SXEOLFDWLRQ :H KRZHYHU UHVHUYH WKH ULJKW WR PDNH FKDQJHV DW DQ\ WLPH ZLWKRXW SULRU QRWLFH RU REOLJDWLRQ 3DUNLQJ %UDNHV

©0LWVXELVKL 0RWRUV &RUSRUDWLRQ

-XQH

6WHHULQJ

%RG\

([WHULRU ,QWHULRU DQG 6XSSOHPHQWDO 5HVWUDLQW 6\VWHP 656

&KDVVLV (OHFWULFDO +HDWHU $LU &RQGLWLRQHU DQG 9HQWLODWLRQ

&RPSRQHQW /RFDWLRQV

&RQILJXUDWLRQ 'LDJUDPV

&LUFXLW 'LDJUDPV


*5283

*(1(5$/ &217(176

*(1(5$/

*(1(5$/ (/(&75,&$/! (


*5283

*(1(5$/ &217(176 +2: 72 86( 7+,6 0$18$/

7528%/(6+227,1* *8,'(/,1(6

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

7528%/(6+227,1* &217(176

9(+,&/( :$6+,1*

$33/,&$7,21 2) $17, &25526,21 $*(176 $1' 81'(5&2$76 6&$1 722/ 0 8 7 ,,, 68% $66(0%/<

72:,1* $1' +2,67,1*

+2: 72 86( 7+( ,163(&7,21 352&('85(6

*(1(5$/ '$7$ $1' 63(&,),&$7,216

&211(&725 0($685(0(17 6(59,&( 32,176

7,*+7(1,1* 72548(

&211(&725 ,163(&7,21 6(59,&( 32,176

/8%5,&$7,21 $1' 0$,17(1$1&(

+2: 72 &23( :,7+ ,17(50,77(17 0$/)81&7,216

,163(&7,21 6(59,&( 32,176 )25 $ %/2:1 )86( +2: 72 75($7 &855(17 7528%/(

+2: 72 75($7 3$67 7528%/(

,17(56<67(0 $)),/,$7(' '7& 5()(5(1&( 7$%/(

9(+,&/( ,'(17,),&$7,21

9(+,&/( ,'(17,),&$7,21 180%(5 /2&$7,21 9(+,&/( ,1)250$7,21 &2'( 3/$7(

35(&$87,216 %()25( 6(59,&(

6833/(0(17$/ 5(675$,17 6<67(0 656

+2: 72 3(5)250 9(+,&/( ,'(17,),&$7,21 180%(5 9,1 :5,7,1* ,1,7,$/,=$7,21 352&('85( )25 /($51,1* 9$/8( ,1 0), (1*,1(

5(&200(1'(' /8%5,&$176 $1' /8%5,&$17 &$3$&,7,(6 7$%/( 6&+('8/(' 0$,17(1$1&( 7$%/( 0$,17(1$1&( 6(59,&(

)8(/ 6<67(0 7$1. 3,3( /,1( $1' &211(&7,21 $1' )8(/ 7$1. ),//(5 78%( &$3 &+(&. )25 /($.6 )8(/ +26(6 &+(&. &21',7,21

$,5 &/($1(5 (/(0(17 5(3/$&(

(9$325$7,9( (0,66,21 &21752/ 6<67(0 (;&(37 (9$325$7,9( (0,66,21 &$1,67(5 &+(&. )25 &/2**,1* 63$5. 3/8*6 5(3/$&(

,17$.( $1' (;+$867 9$/9( &/($5$1&( > * 0,9(& (1*,1( $1' * 0,9(& (1*,1( ,17$.( 6,'( 21/<@ ,163(&7 $1' $'-867

7,0,1* %(/7 5(3/$&(

/($51,1* 352&('85( )25 ,'/,1* ,1 0), (1*,1(

'5,9( %(/76 )25 7+( *(1(5$725 $1' 32:(5 67((5,1* 3803 &+(&.

6(59,&,1* (/(&75,&$/ 6<67(0

(;+$867 6<67(0 &211(&7,21 3257,21 2) 08))/(5 08))/(5 3,3(6 $1' &219(57(5


+($7 6+,(/'6 &+(&. $1' 6(59,&(

(1*,1( 2,/ &+$1*(

(1*,1( 2,/ ),/7(5 5(3/$&(

$8720$7,& 75$16$;/( )/8,' &+(&. )/8,' /(9(/ $1' &21',7,21 (1*,1( &22/$17 &+$1*(

&22/$17 +26(6 5$',$725 +26( +($7(5 +26( ,163(&7 ',6& %5$.( 3$'6 527256 ,163(&7 )25 :($5 %5$.( +26(6 &+(&. )25 '(7(5,25$7,21 25 /($.6

%$// -2,17 $1' 67((5,1* /,1.$*( 6($/6 ,163(&7 )25 *5($6( /($.6 $1' '$0$*(

'5,9( 6+$)7 %2276 ,163(&7 )25 *5($6( /($.6 $1' '$0$*( 6863(16,21 6<67(0 ,163(&7 )25 /226(1(66 $1' '$0$*(

7,5(6 527$7(

0$,1 6($/$17 $1' $'+(6,9( 7$%/(


*(1(5$/

+2: 72 86( 7+,6 0$18$/

+2: 72 86( 7+,6 0$18$/ 0$,17(1$1&( 5(3$,5 $1' 6(59,&,1* (;3/$1$7,216

7KLV PDQXDO SURYLGHV H[SODQDWLRQV HWF FRQFHUQLQJ SURFHGXUHV IRU WKH LQVSHFWLRQ PDLQWHQDQFH UHSDLU DQG VHUYLFLQJ RI WKH VXEMHFW PRGHO 8QOHVV RWKHUZLVH VSHFLILHG HDFK VHUYLFH SURFHGXUH FRYHUV DOO PRGHOV 3URFHGXUHV FRYHULQJ VSHFLILF PRGHOV DUH LGHQWLILHG E\ WKH PRGHO FRGHV RU VLPLODU GHVLJQDWLRQ HQJLQH W\SH WUDQVD[OH W\SH HWF $ GHVFULSWLRQ RI WKHVH GHV LJQDWLRQV LV FRYHUHG LQ WKLV PDQXDO XQGHU 9(+,&/( ,'(17,),&$7,21

21 9(+,&/( 6(59,&( 7KH 21 9(+,&/( 6(59,&( VHFWLRQ KDV SURFH GXUHV IRU SHUIRUPLQJ LQVSHFWLRQV DQG DGMXVWPHQWV RI SDUWLFXODUO\ LPSRUWDQW FRPSRQHQWV 7KHVH SURFH GXUHV DUH GRQH ZLWK UHJDUG WR PDLQWHQDQFH DQG VHU YLFLQJ EXW RWKHU LQVSHFWLRQV ORRVHQHVV SOD\ FUDFNLQJ GDPDJH HWF PXVW DOVR EH SHUIRUPHG

6(59,&( 352&('85(6 7KH VHUYLFH VWHSV DUH DUUDQJHG LQ QXPHULFDO RUGHU $WWHQWLRQ WR EH SDLG LQ SHUIRUPLQJ YHKLFOH VHUYLFH DUH GHVFULEHG LQ GHWDLO LQ 6(59,&( 32,176

'(),1,7,21 2) 7(506

67$1'$5' 9$/8( ,QGLFDWHV WKH YDOXH XVHG DV WKH VWDQGDUG IRU MXGJLQJ ZKHWKHU RU QRW D SDUW RU DGMXVWPHQW LV FRUUHFW

/,0,7 6KRZV WKH PD[LPXP RU PLQLPXP YDOXH IRU MXGJLQJ ZKHWKHU RU QRW D SDUW RU DGMXVWPHQW LV DFFHSWDEOH

5()(5(1&( 9$/8( ,QGLFDWHV WKH DGMXVWPHQW YDOXH SULRU WR VWDUWLQJ WKH ZRUN SUHVHQWHG LQ RUGHU WR IDFLOLWDWH DVVHPEO\ DQG DGMXVWPHQW SURFHGXUHV DQG VR WKH\ FDQ EH FRP SOHWHG LQ D VKRUWHU WLPH

76% 5HYLVLRQ

0

'$1*(5 :$51,1* $1' &$87,21 '$1*(5 :$51,1* DQG &$87,21 FDOO VSHFLDO DWWHQWLRQ WR D QHFHVVDU\ DFWLRQ RU WR DQ DFWLRQ WKDW PXVW EH DYRLGHG 7KH GLIIHUHQFHV DPRQJ '$1*(5 :$51,1* DQG &$87,21 DUH DV IROORZV • ,I D '$1*(5 LV QRW IROORZHG WKH UHVXOW LV VHYHUH ERGLO\ KDUP RU HYHQ GHDWK • ,I D :$51,1* LV QRW IROORZHG WKH UHVXOW FRXOG EH ERGLO\ LQMXU\ • ,I D &$87,21 LV QRW IROORZHG WKH UHVXOW FRXOG EH GDPDJH WR WKH YHKLFOH YHKLFOH FRPSRQHQWV RU VHUYLFH HTXLSPHQW

7,*+7(1,1* 72548( ,1',&$7,21

7KH WLJKWHQLQJ WRUTXH LQGLFDWHV D PHGLDQ DQG LWV WRO HUDQFH E\ D XQLW RI 1â‹…P LQ OE RU 1â‹…P IW OE )RU IDV WHQHUV ZLWK QR DVVLJQHG WRUTXH YDOXH UHIHU WR 3

63(&,$/ 722/ 127(

2QO\ 00& VSHFLDO WRRO SDUW QXPEHUV DUH FDOOHG RXW LQ WKH UHSDLU VHFWLRQV RI WKLV PDQXDO 3OHDVH UHIHU WR WKH VSHFLDO WRRO FURVV UHIHUHQFH FKDUW ORFDWHG DW WKH EHJLQQLQJ RI HDFK JURXS IRU WKH VSHFLDO WRRO QXPEHU WKDW LV DYDLODEOH LQ \RXU PDUNHW

$%%5(9,$7,216

7KH IROORZLQJ DEEUHYLDWLRQV DUH XVHG LQ WKLV PDQXDO IRU FODVVLILFDWLRQ RI PRGHO W\SHV $ 7 $XWRPDWLF WUDQVD[OH RU PRGHOV HTXLSSHG ZLWK DXWRPDWLF WUDQVD[OH 0), 0XOWLSRUW IXHO LQMHFWLRQ RU HQJLQHV HTXLSSHG ZLWK PXOWLSRUW IXHO LQMHFWLRQ / HQJLQH OLWHU * ! HQJLQH RU D PRGHO HTXLSSHG ZLWK VXFK DQ HQJLQH / HQJLQH OLWHU * ! HQJLQH RU D PRGHO HTXLSSHG ZLWK VXFK DQ HQJLQH


Denotes tightening torque. If there is no indication of tightening torque, refer to tightening torque.

*(1(5$/

+2: 72 86( 7+,6 0$18$/

Indicates the section title.

Indicates the group title.

Indicates the group number.

Indicates the page number.

Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Mark N denotes non-reusable part. Component diagram A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts.

Repair kit or parts sets are shown. (Only very frequently used parts are shown.)

Maintenance and servicing procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. Removal steps : The part designation number corresponds to the number in the illustration to indicate removal steps. Disassembly steps : The part designation number corresponds to the number in the illustration to indicate disassembly steps.

Installation steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. Assembly steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if assembly is possible in reverse order of disassembly steps.

AC400266 AB

76% 5HYLVLRQ


*(1(5$/

+2: 72 86( 7+,6 0$18$/

Classifications of major maintenance / service points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.). These are arranged together as major maintenance and service points and explained in detail. <<A>> : Indicates that there are essential points for removal or disassembly. >>A<< : Indicates that there are essential points for installation or assembly.

Operating procedures, cautions, etc. on removal, installation, disassembly and assembly are described

The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.

Indicates (by symbols) where lubrication is necessary.

Symbols for lubrication, sealants and adhesives Symbols are used to show the locations for lubrication and for application of sealants and adhesives. These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol.

Grease (Multi-purpose grease unless there is a brand or type specified) Sealant or adhesive Brake fluid or automatic transmission fluid Engine oil, gear oil or air conditioning compressor oil Adhesive tape or butyl rubber tape

AC400267AB

76% 5HYLVLRQ


*(1(5$/

7528%/(6+227,1* *8,'(/,1(6

7528%/(6+227,1* *8,'(/,1(6 9(5,)< 7+( &203/$,17

• 0DNH VXUH WKH FXVWRPHU V FRPSODLQW DQG WKH VHU YLFH ZULWHU V ZRUN RUGHU GHVFULSWLRQ DUH XQGHU VWRRG EHIRUH VWDUWLQJ ZRUN • 0DNH VXUH \RX XQGHUVWDQG WKH FRUUHFW RSHUDWLRQ RI WKH V\VWHP 5HDG WKH VHUYLFH PDQXDO GHVFULS WLRQ WR YHULI\ QRUPDO V\VWHP RSHUDWLRQ • 2SHUDWH WKH V\VWHP WR VHH WKH V\PSWRPV /RRN IRU RWKHU V\PSWRPV WKDW ZHUH QRW UHSRUWHG E\ WKH FXVWRPHU RU RQ WKH ZRUN RUGHU WKDW PD\ EH UHODWHG WR WKH SUREOHP

'(7(50,1( 3266,%/( &$86(6

&RPSDUH WKH FRQILUPHG V\PSWRPV WR WKH GLDJQRVWLF V\PSWRP LQGH[HV WR ILQG WKH ULJKW GLDJQRVLV SURFH GXUH ,I WKH FRQILUPHG V\PSWRPV FDQQRW EH IRXQG RQ DQ\ V\PSWRP LQGH[ GHWHUPLQH RWKHU SRVVLEOH FDXVHV • $QDO\]H WKH V\VWHP GLDJUDPV DQG OLVW DOO SRVVLEOH FDXVHV IRU WKH SUREOHP V\PSWRPV • 5DQN DOO WKHVH SRVVLEOH FDXVHV LQ RUGHU RI SURED ELOLW\ EDVHG RQ KRZ PXFK RI WKH V\VWHP WKH\ FRYHU KRZ OLNHO\ WKH\ DUH WR EH WKH FDXVH DQG KRZ HDV\ WKH\ ZLOO EH WR FKHFN %H VXUH WR WDNH H[SHULHQFH LQWR DFFRXQW &RQVLGHU WKH FDXVHV RI VLPLODU SUREOHPV VHHQ LQ WKH SDVW 7KH OLVW RI FDXVHV VKRXOG EH UDQNHG LQ RUGHU IURP JHQHUDO WR VSHFLILF IURP PRVW OLNHO\ WR OHDVW OLNHO\ DQG IURP HDV\ WR FKHFN WR KDUG WR FKHFN

76% 5HYLVLRQ

),1' 7+( 352%/(0

0

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• JHQHUDO WR VSHFLILF • PRVW OLNHO\ WR OHDVW OLNHO\ • HDV\ WR FKHFN WR KDUG WR FKHFN

5(3$,5 7+( 352%/(0

:KHQ WKH VWHS E\ VWHS WURXEOHVKRRWLQJ FKHFNV ILQG D IDXOW SHUIRUP WKH SURSHU UHSDLUV 0DNH VXUH WR IL[ WKH URRW FDXVH RI WKH SUREOHP QRW MXVW WKH V\PSWRP -XVW IL[LQJ WKH V\PSWRP ZLWKRXW IL[LQJ WKH URRW FDXVH ZLOO FDXVH WKH V\PSWRP WR HYHQWXDOO\ UHWXUQ

9(5,)< 7+( 5(3$,5

$IWHU UHSDLUV DUH PDGH UHFKHFN WKH RSHUDWLRQ RI WKH V\VWHP WR FRQILUP WKDW WKH SUREOHP LV HOLPLQDWHG %H VXUH WR FKHFN WKH V\VWHP WKRURXJKO\ 6RPHWLPHV QHZ SUREOHPV DUH UHYHDOHG DIWHU UHSDLUV KDYH EHHQ PDGH


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176 7528%/(6+227,1* &217(176 CAUTION • 'XULQJ GLDJQRVLV D '7& FRGH DVVRFLDWHG ZLWK RWKHU V\VWHP PD\ EH VHW ZKHQ WKH LJQLWLRQ VZLWFK LV WXUQHG RQ ZLWK FRQQHFWRU V GLVFRQ QHFWHG 2Q FRPSOHWLRQ FRQILUP DOO V\VWHPV IRU '7& FRGH V ,I '7& FRGH V DUH VHW HUDVH WKHP DOO • :KHQ WKH 0 8 7 ,,, GHWHFWV D GLDJQRVWLF WURX EOH FRGH LWV GLVSOD\ LQIRUPV XVHUV ZKHWKHU D PHFKDQLFDO SUREOHP FXUUHQWO\ H[LVWV FXUUHQW WURXEOH RU ZKHWKHU LW H[LVWHG EHIRUH EXW QRU PDO RSHUDWLRQ KDV EHHQ UHVWRUHG SDVW WURX EOH +RZHYHU LI DQ 0), 7306 RU 656 DLUEDJ UHODWHG '7& LV VHW $FWLYH '7& 6WRUHG '7& LV QRW GLVSOD\HG ,Q WKLV FDVH IROORZ WKH GLDJQRVLV SURFHGXUH IRU FXUUHQW WURXEOH • ,I D WURXEOH GHWHFWHG LQ D &$1 FRPPXQLFD WLRQ FDSDEOH V\VWHP FDQ EH UHSURGXFHG GLDJQRVH WKH &$1 EXV OLQHV 5HIHU WR *5283 & &DQ %XV /LQH 'LDJQRVWLFV &KDUW 3 & 7URXEOHVKRRWLQJ RI HOHFWURQLF FRQWURO V\VWHPV IRU ZKLFK WKH VFDQ WRRO FDQ EH XVHG IROORZV WKH EDVLF RXWOLQH GHVFULEHG EHORZ (YHQ LQ V\VWHPV IRU ZKLFK WKH VFDQ WRRO FDQQRW EH XVHG SDUW RI WKHVH V\VWHPV VWLOO IROORZ WKLV RXWOLQH

67$1'$5' )/2: 2) ',$*1267,& 7528%/(6+227,1*

7URXEOHVKRRWLQJ VWUDWHJ\ LV VKRZQ LQ HDFK JURXS

6<67(0 23(5$7,21 $1' 6<03720 9(5,),&$7,21 7(676

,I YHULILFDWLRQ RI WKH V\PSWRP V LV GLIILFXOW SURFH GXUHV IRU FKHFNLQJ RSHUDWLRQ DQG YHULI\LQJ V\PSWRPV DUH VKRZQ

',$*1267,& )81&7,21

7KH IROORZLQJ WURXEOH FRGH GLDJQRVHV DUH VKRZQ • +RZ WR UHDG GLDJQRVWLF WURXEOH FRGHV • +RZ WR HUDVH GLDJQRVWLF WURXEOH FRGHV • ,QSXW LQVSHFWLRQ VHUYLFH SRLQWV

',$*1267,& 7528%/( &2'( &+$57

,I WKH VFDQ WRRO GLVSOD\V D GLDJQRVWLF WURXEOH FRGH ILQG WKH DSSOLFDEOH LQVSHFWLRQ SURFHGXUH DFFRUGLQJ WR WKLV FKDUW

76% 5HYLVLRQ

6<03720 &+$57

0

,I WKHUH DUH V\PSWRPV HYHQ WKRXJK WKH VFDQ WRROV VKRZ WKDW QR '7&V DUH VHW LQVSHFWLRQ SURFHGXUHV IRU HDFK V\PSWRP ZLOO EH IRXQG E\ XVLQJ WKLV FKDUW

',$*1267,& 7528%/( &2'( 352&('85(6

,QGLFDWHV WKH LQVSHFWLRQ SURFHGXUHV FRUUHVSRQGLQJ WR HDFK GLDJQRVWLF WURXEOH FRGH 5HIHU WR 3

6<03720 352&('85(6

,QGLFDWHV WKH LQVSHFWLRQ SURFHGXUHV FRUUHVSRQGLQJ WR HDFK V\PSWRP OLVWHG LQ WKH 6\PSWRP &KDUW 5HIHU WR 3

6(59,&( '$7$ 5()(5(1&( 7$%/(

,QVSHFWLRQ LWHPV DQG QRUPDO MXGJPHQW YDOXHV KDYH EHHQ SURYLGHG LQ WKLV FKDUW DV UHIHUHQFH LQIRUPDWLRQ

&+(&. $7 (&8 7(50,1$/6

7HUPLQDO QXPEHUV IRU WKH (&8 FRQQHFWRUV LQVSHF WLRQ LWHPV DQG VWDQGDUG YDOXHV KDYH EHHQ SURYLGHG LQ WKLV FKDUW DV UHIHUHQFH LQIRUPDWLRQ

7(50,1$/ 92/7$*( &+(&.6 &RQQHFW D QHHGOH QRVHG ZLUH SUREH WR D YROWPHWHU SUREH

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


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

$IWHU UHSDLU RU UHSODFHPHQW UHFKHFN ZLWK WKH YROWPHWHU WR FRQILUP WKDW WKH UHSDLU KDV FRUUHFWHG WKH SUREOHP

7(50,1$/ 5(6,67$1&( $1' &217,18,7< &+(&.6 7XUQ WKH LJQLWLRQ VZLWFK WR WKH /2&. 2)) SRVLWLRQ 'LVFRQQHFW WKH (&8 FRQQHFWRU

CAUTION ,I UHVLVWDQFH DQG FRQWLQXLW\ FKHFNV DUH SHU IRUPHG RQ WKH ZURQJ WHUPLQDOV GDPDJH WR WKH YHKLFOH ZLULQJ VHQVRUV (&8 DQG RU RKPPHWHU PD\ RFFXU 8VH FDUH WR SUHYHQW WKLV 0HDVXUH WKH UHVLVWDQFH DQG FKHFN IRU FRQWLQXLW\ EHWZHHQ WKH WHUPLQDOV RI WKH (&8 KDUQHVV VLGH FRQQHFWRU ZKLOH UHIHUULQJ WR WKH FKHFN FKDUW

127( &KHFNV GRQ W KDYH WR EH FDUULHG RXW LQ WKH RUGHU JLYHQ LQ WKH FKDUW ,I WKH RKPPHWHU VKRZV DQ\ GHYLDWLRQ IURP WKH 1RUPDO &RQGLWLRQ YDOXH FKHFN WKH FRUUHVSRQGLQJ VHQVRU DFWXDWRU DQG UHODWHG HOHFWULFDO ZLULQJ WKHQ UHSDLU RU UHSODFH $IWHU UHSDLU RU UHSODFHPHQW UHFKHFN ZLWK WKH RKPPHWHU WR FRQILUP WKDW WKH UHSDLU KDV FRUUHFWHG WKH SUREOHP

,163(&7,21 352&('85(6 86,1* $1 26&,//26&23( :KHQ WKHUH DUH LQVSHFWLRQ SURFHGXUHV XVLQJ DQ RVFLOORVFRSH WKHVH DUH OLVWHG

+2: 72 86( 7+( ,163(&7,21 352&('85(6

0 7KH FDXVHV RI PDQ\ RI WKH SUREOHPV RFFXUULQJ LQ HOHFWULF FLUFXLWU\ DUH JHQHUDOO\ WKH FRQQHFWRUV FRPSRQHQWV WKH (&8 DQG WKH KDUQHVVHV EHWZHHQ FRQQHFWRUV LQ WKDW RUGHU 7KHVH LQVSHFWLRQ SURFHGXUHV IROORZ WKLV RUGHU 7KH\ ILUVW WU\ WR GLVFRYHU D SUREOHP ZLWK D FRQQHFWRU RU D GHIHFWLYH FRPSRQHQW

76% 5HYLVLRQ


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

(1) Relevant circuit(s) of the component which the DTC indicates are described.

(2) For connector color, refer to GROUP 80A, How to read configuration diagrams.

(3) Shows the location of the connector(s) from the circuit(s) above. (4) Explains about the operation principle of the component or its relevant parts in that circuit.

B-48(B)

ACX00861AE

76% 5HYLVLRQ


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

(5) Explains about technical details.

(6) Describes the conditions for that DTC being set (stored). (7) Describes possible cause(s)for that DTC.

(8) Start of the diagnosis procedure for that DTC.

(M.U.T.-III Sub Assembly)

(9) Identifies the special tool(s) necessary for diagnosing that DTC.

(10) Provides the inspection procedure for that DTC step by step.

AC210616 AB

&855(17 7528%/(

,QGLFDWHV WKDW WKH WURXEOH LV FXUUHQWO\ SUHVHQW &DUU\ RXW WURXEOHVKRRWLQJ DV GHVFULEHG LQ WKH DSSOLFDEOH LQVSHFWLRQ SURFHGXUH

76% 5HYLVLRQ

3$67 7528%/(

,QGLFDWHV WKDW WKH VWDWXV LV 6WRUHG DQG WKH WURXEOH LV KLVWRULF 6LQFH WKH WURXEOH PD\ VWLOO EH SUHVHQW VHW WKH YHKLFOH WR WKH GLDJQRVLV FRGH GHWHFWLRQ FRQGLWLRQ DQG FKHFN WKDW WKH VWDWXV FKDQJHV WR $FWLYH ,I WKH VWDWXV GRHV QRW FKDQJH IURP 6WRUHG REVHUYH WKH DSSOLFDEOH LQVSHFWLRQ SURFHGXUH ZLWK SDUWLFXODU HPSKDVLV RQ FRQQHFWRU V DQG ZLULQJ KDUQHVV


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

+$51(66 ,163(&7,21

&KHFN IRU DQ RSHQ RU VKRUW FLUFXLW LQ WKH KDUQHVV EHWZHHQ WKH WHUPLQDOV ZKLFK ZHUH IDXOW\ DFFRUGLQJ WR WKH FRQQHFWRU PHDVXUHPHQWV &DUU\ RXW WKLV LQVSHF WLRQ ZKLOH UHIHUULQJ WR *5283 ( +DUQHVV &RQ QHFWRU ,QVSHFWLRQ 3 ( +HUH &KHFN KDUQHVV EHWZHHQ SRZHU VXSSO\ DQG WHUPLQDO [[ DOVR LQFOXGHV FKHFNLQJ IRU EORZQ IXVH )RU LQVSHFWLRQ VHUYLFH SRLQWV ZKHQ WKHUH LV D EORZQ IXVH UHIHU WR ,QVSHF WLRQ 6HUYLFH 3RLQWV IRU D %ORZQ )XVH 3

0($685(6 72 7$.( $)7(5 5(3/$&,1* 7+( 3&0 25 (&8

,I WKH WURXEOH V\PSWRPV KDYH QRW GLVDSSHDUHG HYHQ DIWHU UHSODFLQJ WKH 3&0 RU (&8 UHSHDW WKH LQVSHF WLRQ SURFHGXUH IURP WKH EHJLQQLQJ

&211(&725 0($685(0(17 6(59,&( 32,176

0 7XUQ WKH LJQLWLRQ VZLWFK WR WKH /2&. 2)) SRVLWLRQ ZKHQ FRQQHFWLQJ DQG GLVFRQQHFWLQJ WKH FRQQHFWRUV 7XUQ WKH LJQLWLRQ VZLWFK WR 21 ZKHQ PHDVXULQJ XQOHVV WKHUH DUH LQVWUXFWLRQV WR WKH FRQWUDU\

,) ,163(&7,1* :,7+ 7+( &211(&725 &211(&7(' :$7(53522) &211(&7256! SPECIAL TOOL

%H VXUH WR XVH VSHFLDO WRRO 1HYHU LQVHUW D WHVW SUREH IURP WKH KDUQHVV VLGH DV WKLV ZLOO UHGXFH WKH ZDWHUSURRI SHUIRUPDQFH DQG UHVXOW LQ FRUURVLRQ

ACX00863AE

,) ,163(&7,1* :,7+ 7+( &211(&725 &211(&7(' 25',1$5< 121 :$7(53522) &211(&7256! 5HTXLUHG 6SHFLDO 7RRO • 0% ([WUD )LQH 3UREH ,QVSHFW E\ LQVHUWLQJ D WHVW SUREH IURP WKH KDUQHVV VLGH ,I WKH FRQQHFWRU LV WRR VPDOO WR LQVHUW D WHVW SUREH H J FRQWURO XQLW FRQQHFWRU GR QRW LQVHUW LW IRUFLEO\ 8VH VSHFLDO WRRO H[WUD ILQH SUREH 0%

MB992006

AC105598AG

76% 5HYLVLRQ


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

,) ,163(&7,1* :,7+ 7+( &211(&725 ',6&211(&7(' :+(1 ,163(&7,1* $ )(0$/( 3,1! 5HTXLUHG 6SHFLDO 7RRO • 0% ,QVSHFWLRQ +DUQHVV ,QFOXGHG LQ 0% +DUQHVV 6HW

• 7KH VSHFLDO WRRO 0% IRU FRQQHFWRU SLQ FRQWDFW SUHV VXUH VKRXOG EH XVHG 7KH WHVW SUREH VKRXOG QHYHU EH IRUF LEO\ LQVHUWHG DV LW PD\ FDXVH D GHIHFWLYH FRQWDFW

MB991219

ACX00865 AB

• )URP EDFN VLGH RI WKH FRQQHFWRU 656 (&8 KDUQHVV VLGH FRQQHFWRU

• 6LQFH WKH 656 (&8 KDUQHVV FRQQHFWRU LV SODWHG WR LPSURYH FRQGXFWLYLW\ REVHUYH WKH ZDUQLQJ EHORZ ZKHQ FKHFNLQJ WKLV FRQQHFWRU

SRS-ECU HARNESS CONNECTOR

WARNING

AC001607AB

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

,) ,163(&7,1* :,7+ 7+( &211(&725 ',6&211(&7(' :+(1 ,163(&7,1* $ 0$/( 3,1! CAUTION $W WKLV WLPH EH FDUHIXO QRW WR VKRUW WKH FRQQHFWRU SLQV ZLWK WKH WHVW SUREHV 'RLQJ VR PD\ GDPDJH WKH FLUFXLWV LQVLGH WKH (&8 7RXFK WKH SLQ GLUHFWO\ ZLWK WKH WHVW SUREH

ACX00867 AB

76% 5HYLVLRQ


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

&211(&725 ,163(&7,21 6(59,&( 32,176 9,68$/ ,163(&7,21 • • • • •

CONNECTOR DISCONNECTED OR IMPROPERLY CONNECTED

0

&RQQHFWRU LV GLVFRQQHFWHG RU LPSURSHUO\ FRQQHFWHG &RQQHFWRU SLQV DUH SXOOHG RXW 6WUHWFKHG DQ EURNHQ ZLUHV DW WHUPLQDO VHFWLRQ /RZ FRQWDFW SUHVVXUH EHWZHHQ PDOH DQG IHPDOH WHUPLQDOV /RZ FRQQHFWLRQ SUHVVXUH GXH WR UXVWHG WHUPLQDOV RU IRUHLJQ PDWWHU ORGJHG LQ WHUPLQDOV

STRETCHED OR BROKEN WIRES

HARNESS WIRE BREAKAGE AT TERMINAL SECTION LOW CONTACT PRESSURE GOOD BAD

ACX00868AC

&211(&725 3,1 ,163(&7,21 ,I WKH FRQQHFWRU SLQ VWRSSHU LV GDPDJHG WKH WHUPLQDO FRQQHF WLRQV PDOH DQG IHPDOH SLQV ZLOO QRW EH SHUIHFW HYHQ ZKHQ WKH FRQQHFWRU ERG\ LV FRQQHFWHG EHFDXVH WKH SLQV PD\ SXOO RXW RI WKH EDFN VLGH RI WKH FRQQHFWRU 7KHUHIRUH JHQWO\ SXOO WKH ZLUHV RQH E\ RQH WR PDNH VXUH WKDW QR SLQV SXOO RXW RI WKH FRQQHFWRU

ACX00869AB

&211(&725 (1*$*(0(17 ,163(&7,21 5HTXLUHG 6SHFLDO 7RRO • 0% ,QVSHFWLRQ +DUQHVV FRQWDLQHG LQ 0% 7HVW +DUQHVV

76% 5HYLVLRQ


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

MB991219

8VH VSHFLDO WRRO 0% WR LQVSHFW WKH HQJDJHPHQW RI WKH PDOH SLQV DQG IHPDOH SLQV >3LQ GUDZLQJ IRUFH 1 SRXQG RU PRUH@

ACX00870 AB

+2: 72 &23( :,7+ ,17(50,77(17 0$/)81&7,216

0 0RVW LQWHUPLWWHQW PDOIXQFWLRQV RFFXU XQGHU FHUWDLQ FRQGLWLRQV ,I WKRVH FRQGLWLRQV FDQ EH LGHQWLILHG WKH FDXVH ZLOO EH HDVLHU WR ILQG

72 &23( :,7+ ,17(50,77(17 0$/)81&7,21 $6. 7+( &86720(5 $%287 7+( 0$/)81&7,21 $VN ZKDW LW IHHOV OLNH ZKDW LW VRXQGV OLNH HWF 7KHQ DVN DERXW GULYLQJ FRQGLWLRQV ZHDWKHU IUHTXHQF\ RI RFFXUUHQFH DQG VR RQ

'(7(50,1( 7+( &21',7,216 )520 7+( &86720(5 6 5(63216(6 7\SLFDOO\ DOPRVW DOO LQWHUPLWWHQW PDOIXQFWLRQV RFFXU IURP FRQGL WLRQV OLNH YLEUDWLRQ WHPSHUDWXUH DQG RU PRLVWXUH FKDQJH SRRU FRQQHFWLRQV )URP WKH FXVWRPHU V UHVSRQVHV LW VKRXOG EH UHD VRQHG ZKLFK FRQGLWLRQ LV PRVW OLNHO\

86( 6,08/$7,21 7(67 8VH WKH VLPXODWLRQ WHVWV EHORZ WR DWWHPSW WR GXSOLFDWH WKH FXV WRPHU V FRPSODLQW 'HWHUPLQH WKH PRVW OLNHO\ FLUFXLW V DQG SHU IRUP WKH VLPXODWLRQ WHVWV RQ WKH FRQQHFWRUV DQG SDUWV RI WKDW FLUFXLW V %H VXUH WR XVH WKH LQVSHFWLRQ SURFHGXUHV SURYLGHG IRU GLDJQRVWLF WURXEOH FRGHV DQG WURXEOH V\PSWRPV )RU WHPSHUDWXUH DQG RU PRLVWXUH FRQGLWLRQ UHODWHG LQWHUPLWWHQW PDOIXQFWLRQV WU\ WR FKDQJH WKH FRQGLWLRQV RI WKH VXVSHFWHG FLU FXLW FRPSRQHQWV WKHQ XVH WKH VLPXODWLRQ WHVWV EHORZ

9(5,)< 7+( ,17(50,77(17 0$/)81&7,21 ,6 (/,0,1$7(' 5HSDLU WKH PDOIXQFWLRQLQJ SDUW DQG WU\ WR GXSOLFDWH WKH FRQGL WLRQ V DJDLQ WR YHULI\ WKH LQWHUPLWWHQW PDOIXQFWLRQ KDV EHHQ HOLPLQDWHG

6,08/$7,21 7(676 127( ,Q FDVH RI GLIILFXOW\ LQ ILQGLQJ WKH FDXVH RI WKH LQWHUPLW WHQW PDOIXQFWLRQ WKH GDWD UHFRUGHU IXQFWLRQ LQ WKH VFDQ WRRO LV HIIHFWLYH

76% 5HYLVLRQ


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

)RU WKHVH VLPXODWLRQ WHVWV VKDNH WKHQ JHQWO\ EHQG SXOO DQG WZLVW WKH ZLULQJ RI HDFK RI WKHVH H[DPSOHV WR GXSOLFDWH WKH LQWHU PLWWHQW PDOIXQFWLRQ • 6KDNH WKH FRQQHFWRU XS DQG GRZQ DQG ULJKW DQG OHIW • 6KDNH WKH ZLULQJ KDUQHVV XS DQG GRZQ DQG ULJKW DQG OHIW (VSHFLDOO\ FKHFN WKH VSOLFH SRLQWV RI ZLULQJ KDUQHVVHV FDUH IXOO\ 5HIHU WR *5283 ( +DUQHVV &RQQHFWRU ,QVSHFWLRQ 3 ( • 6KDNH WKH SDUW RU VHQVRU

ACX00871 AB

76% 5HYLVLRQ


*(1(5$/

+2: 72 86( 7528%/(6+227,1* ,163(&7,21 6(59,&( 32,176

,163(&7,21 6(59,&( 32,176 )25 $ %/2:1 )86(

0 5HPRYH WKH EORZQ IXVH DQG PHDVXUH WKH UHVLVWDQFH EHWZHHQ WKH ORDG VLGH RI WKH EORZQ IXVH DQG WKH JURXQG &ORVH WKH VZLWFKHV RI DOO FLUFXLWV ZKLFK DUH FRQQHFWHG WR WKLV IXVH ,I WKH UHVLVWDQFH LV DOPRVW Ω DW WKLV WLPH WKHUH LV D VKRUW VRPH ZKHUH EHWZHHQ WKHVH VZLWFKHV DQG WKH ORDG ,I WKH UHVLVWDQFH LV QRW Ω WKHUH LV QR VKRUW DW WKH SUHVHQW WLPH EXW D PRPHQWDU\ VKRUW KDV SUREDEO\ FDXVHG WKH IXVH WR EORZ 7KH PDLQ FDXVHV RI D VKRUW FLUFXLW DUH WKH IROORZLQJ • +DUQHVV EHLQJ FODPSHG E\ WKH YHKLFOH ERG\ • 'DPDJH WR WKH RXWHU FDVLQJ RI WKH KDUQHVV GXH WR ZHDU RU KHDW • :DWHU JHWWLQJ LQWR WKH FRQQHFWRU RU FLUFXLWU\ • +XPDQ HUURU PLVWDNHQO\ VKRUWLQJ D FLUFXLW HWF

BATTERY

FUSE

LOAD SWITCH

SHORTCIRCUIT OCCURRENCE SECTION

LOAD

ACX00872 AB

+2: 72 75($7 &855(17 7528%/(

0 0DNH D QRWH RI WKH GLDJQRVWLF WURXEOH FRGH DQG HUDVH LW &KHFN WKH WURXEOH V\PSWRP DJDLQ &KHFN IRU GLDJQRVWLF WURXEOH FRGHV DJDLQ ,I D GLDJQRVWLF WURXEOH FRGH LV VHW IROORZ WKH DSSOLFDEOH 'LDJQRVWLF 7URXEOH &RGH &KDUW ,I QR GLDJQRVWLF WURXEOH FRGH LV VHW UHIHU WR +RZ WR &RSH ZLWK ,QWHUPLWWHQW 0DOIXQFWLRQ 3

+2: 72 75($7 3$67 7528%/(

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

76% 5HYLVLRQ


Thank you very much for your reading. Please Click Here Then Get More Information.


Issuu converts static files into: digital portfolios, online yearbooks, online catalogs, digital photo albums and more. Sign up and create your flipbook.