2006-2013 Mitsubishi Triton L200 Workshop Manual – PDF DOWNLOAD
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2006-2013 Mitsubishi Triton L200 Workshop Manual – PDF DOWNLOAD
- SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components.
- For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission.
- ON-VEHICLE SERVICE “On-vehicle Service” is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed.
- INSPECTION Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well. DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance.
- LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time).
- DANGER, WARNING, AND CAUTION DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows: •If a DANGER is not followed, the result is severe bodily harm or even death. •
- If a WARNING is not followed, the result could be bodily injury. •If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment. INDICATION OF TIGHTENING TORQUE Tightening torques (units: N⋅m) are set to take into account the central value and the allowable tolerance.
- The central value is the target value, and the allowable tolerance provides the checking range for tightening torques. If bolts and nuts are not provided with tightening torques, refer to P.00-37. MODEL INDICATIONS The following abbreviations are used in this manual for identification of model types. 2500: Indicates an engine with the 2,477mL <4D56> diesel engine.
- 3200: Indicates an engine with the 3,200mL <4M41> diesel engine. DOHC: Indicates an engine with the double overhead camshaft. M/T: Indicates the manual transmission. A/T: Indicates the automatic transmission. A/C: Indicates the air conditioner.
TABLE OF CONTENTS:
2006-2013 Mitsubishi Triton L200 Workshop Manual – PDF DOWNLOAD
00.pdf................................................................................................................................................................................................................................. 1 GENERAL............................................................................................................................................................................................................................ 1 01.pdf................................................................................................................................................................................................................................. 3 GENERAL............................................................................................................................................................................................................................ 3 HOW TO USE THIS MANUAL......................................................................................................................................................................................................... 4 SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS.................................................................................................................................................................... 4 DEFINITION OF TERMS........................................................................................................................................................................................................ 4 INDICATION OF TIGHTENING TORQUE............................................................................................................................................................................................ 4 MODEL INDICATIONS.......................................................................................................................................................................................................... 4 EXPLANATION OF MANUAL CONTENTS............................................................................................................................................................................................. 5 HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS........................................................................................................................................................................... 7 CONTENTS OF TROUBLESHOOTING................................................................................................................................................................................................ 7 Diagnosis method....................................................................................................................................................................................................... 8 2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS..................................................................................................................................................................... 8 3. DIAGNOSIS FUNCTION.................................................................................................................................................................................................. 8 4. DIAGNOSIS CODE CHART................................................................................................................................................................................................ 8 5. DIAGNOSIS CODE PROCEDURES........................................................................................................................................................................................... 8 6. TROUBLE SYMPTOM CHART............................................................................................................................................................................................... 8 7. SYMPTOM PROCEDURES.................................................................................................................................................................................................. 9 8. SERVICE DATA REFERENCE TABLE........................................................................................................................................................................................ 9 9. ACTUATOR TEST TABLE................................................................................................................................................................................................. 9 10. CHECK AT ECU TERMINALS............................................................................................................................................................................................. 9 11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE...................................................................................................................................................................... 9 DIAGNOSIS FUNCTION......................................................................................................................................................................................................... 9 HOW TO READ DIAGNOSIS CODE............................................................................................................................................................................................. 9 ERASING DIAGNOSIS CODE................................................................................................................................................................................................. 9 HOW TO USE THE INSPECTION PROCEDURES....................................................................................................................................................................................... 10 CURRENT TROUBLE........................................................................................................................................................................................................ 11 PAST TROUBLE........................................................................................................................................................................................................... 11 HARNESS CHECK.......................................................................................................................................................................................................... 11 MEASURES TO TAKE AFTER REPLACING THE ECU............................................................................................................................................................................... 11 CONNECTOR MEASUREMENT SERVICE POINTS....................................................................................................................................................................................... 12 CONNECTOR INSPECTION SERVICE POINTS........................................................................................................................................................................................ 13 INSPECTION SERVICE POINTS FOR A BLOWN FUSE................................................................................................................................................................................. 14 HOW TO COPE WITH INTERMITTENT MALFUNCTIONS................................................................................................................................................................................. 14 HOW TO TREAT PAST TROUBLE.................................................................................................................................................................................................. 15 VEHICLE IDENTIFICATION......................................................................................................................................................................................................... 15 VEHICLE NAME PLATE......................................................................................................................................................................................................... 15 MODEL CODE................................................................................................................................................................................................................. 17 CHASSIS NUMBER............................................................................................................................................................................................................. 18 ENGINE MODEL STAMPING...................................................................................................................................................................................................... 19 GENERAL DATA AND SPECIFICATIONS................................................................................................................................................................................................ 19 CLUB CAB................................................................................................................................................................................................................... 19 <2WD>...................................................................................................................................................................................................................... 19 <4WD>...................................................................................................................................................................................................................... 21 DOUBLE CAB................................................................................................................................................................................................................. 22 <2WD>...................................................................................................................................................................................................................... 22 <4WD>...................................................................................................................................................................................................................... 24 PRECAUTIONS BEFORE SERVICE..................................................................................................................................................................................................... 25 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER....................................................................................................................................................... 25 WHAT THE COMMON RAIL ENGINE LEARNS......................................................................................................................................................................................... 26 REGISTRATION AND LEARNING PROCEDURE.................................................................................................................................................................................... 26 INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE........................................................................................................................................................................ 26 PURPOSE................................................................................................................................................................................................................ 26 REGISTRATION PROCEDURE................................................................................................................................................................................................. 27 SMALL INJECTION QUANTITY LEARNING PROCEDURE................................................................................................................................................................................ 27 PURPOSE................................................................................................................................................................................................................ 27 LEARNING PROCEDURE..................................................................................................................................................................................................... 28 SUPPLY PUMP CORRECTION LEARNING PROCEDURE.................................................................................................................................................................................. 28 PURPOSE................................................................................................................................................................................................................ 28 LEARNING PROCEDURE FOR IDLING.............................................................................................................................................................................................. 29 SERVICING ELECTRICAL SYSTEM................................................................................................................................................................................................ 29 VEHICLES WITH SEMI AUTOMATIC AIR CONDITIONER............................................................................................................................................................................... 29 APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS........................................................................................................................................................................ 29 VEHICLE WASHING............................................................................................................................................................................................................ 29 PRE-INSPECTION CONDITION................................................................................................................................................................................................... 29 MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY................................................................................................................................................................................. 30 HOW TO USE THE THROTTLE CONTROLLER......................................................................................................................................................................................... 30 IN ORDER TO PREVENT VEHICLES FROM FIRE..................................................................................................................................................................................... 31 ENGINE OILS................................................................................................................................................................................................................ 31 HEALTH WARNING......................................................................................................................................................................................................... 31 RECOMMENDED PRECAUTIONS................................................................................................................................................................................................ 31 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)............................................................................................................................................................................................ 32 SRS SERVICE PRECAUTIONS........................................................................................................................................................................................................ 33 SUPPORT LOCATIONS FOR LIFTING AND JACKING...................................................................................................................................................................................... 35 <2WD>...................................................................................................................................................................................................................... 35 <4WD>...................................................................................................................................................................................................................... 36 <2WD>...................................................................................................................................................................................................................... 37 <4WD>...................................................................................................................................................................................................................... 38 STANDARD PART/TIGHTENING-TORQUE TABLE.......................................................................................................................................................................................... 39 11.pdf................................................................................................................................................................................................................................. 41 ENGINE............................................................................................................................................................................................................................. 41 11A.pdf................................................................................................................................................................................................................................ 43 ENGINE MECHANICAL <4D5-SOHC>....................................................................................................................................................................................................... 43 GENERAL INFORMATION............................................................................................................................................................................................................ 44 SERVICE SPECIFICATIONS......................................................................................................................................................................................................... 44 SEALANTS....................................................................................................................................................................................................................... 45 SPECIAL TOOLS.................................................................................................................................................................................................................. 46 ON-VEHICLE SERVICE............................................................................................................................................................................................................. 48 DRIVE BELT TENSION CHECK AND ADJUSTMENT.................................................................................................................................................................................... 48 ALTERNATOR DRIVE BELT TENSION CHECK AND ADJUSTMENT..................................................................................................................................................................... 48 POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK....................................................................................................................................................................... 49 A/C COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT................................................................................................................................................................. 50 VALVE CLEARANCE CHECK AND ADJUSTMENT....................................................................................................................................................................................... 50 INJECTION TIMING CHECK AND ADJUSTMENT...................................................................................................................................................................................... 52 IDLE SPEED CHECK........................................................................................................................................................................................................... 54 COMPRESSION PRESSURE CHECK................................................................................................................................................................................................. 54 TIMING BELT TENSION ADJUSTMENT............................................................................................................................................................................................. 55 TIMING BELT B TENSION ADJUSTMENT........................................................................................................................................................................................... 56 CRANKSHAFT PULLEY.............................................................................................................................................................................................................. 57 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 57 REMOVAL SERVICE POINTS................................................................................................................................................................................................. 58 INSTALLATION SERVICE POINT............................................................................................................................................................................................. 59 CAMSHAFT AND VALVE STEM SEAL................................................................................................................................................................................................... 60 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 60 REMOVAL SERVICE POINTS................................................................................................................................................................................................. 61 INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 62 OIL PAN AND OIL SCREEN......................................................................................................................................................................................................... 64 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 64 REMOVAL SERVICE POINTS................................................................................................................................................................................................. 65 INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 65 CRANKSHAFT OIL SEAL............................................................................................................................................................................................................ 67 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 67 REMOVAL SERVICE POINT.................................................................................................................................................................................................. 68 INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 68 CYLINDER HEAD GASKET........................................................................................................................................................................................................... 69 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 69 REMOVAL SERVICE POINTS................................................................................................................................................................................................. 70 INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 71 TIMING BELT.................................................................................................................................................................................................................... 73 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 73 REMOVAL SERVICE POINT.................................................................................................................................................................................................. 74 INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 74 TIMING BELT B.................................................................................................................................................................................................................. 76 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 76 REMOVAL SERVICE POINT.................................................................................................................................................................................................. 76 INSTALLATION SERVICE POINT............................................................................................................................................................................................. 77 ENGINE ASSEMBLY................................................................................................................................................................................................................ 78 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 78 REMOVAL SERVICE POINTS................................................................................................................................................................................................. 80 INSTALLATION SERVICE POINT............................................................................................................................................................................................. 80 12.pdf................................................................................................................................................................................................................................. 81 ENGINE LUBRICATION................................................................................................................................................................................................................. 81 GENERAL INFORMATION............................................................................................................................................................................................................ 82 ENGINE OILS................................................................................................................................................................................................................ 82 SERVICE SPECIFICATION.......................................................................................................................................................................................................... 82 SEALANTS....................................................................................................................................................................................................................... 82 LUBRICANTS..................................................................................................................................................................................................................... 83 SPECIAL TOOLS.................................................................................................................................................................................................................. 83 ON-VEHICLE SERVICE............................................................................................................................................................................................................. 83 ENGINE OIL CHECK........................................................................................................................................................................................................... 83 ENGINE OIL REPLACEMENT..................................................................................................................................................................................................... 83 ENGINE OIL FILTER REPLACEMENT.............................................................................................................................................................................................. 84 OIL PRESSURE CHECK......................................................................................................................................................................................................... 86 ENGINE OIL COOLER.............................................................................................................................................................................................................. 87 REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................ 87 REMOVAL AND INSTALLATION <4D5-DOHC>........................................................................................................................................................................................ 88 INSTALLATION SERVICE POINT............................................................................................................................................................................................. 88 REMOVAL AND INSTALLATION <4M4>............................................................................................................................................................................................. 89 INSTALLATION SERVICE POINTS............................................................................................................................................................................................ 90 15.pdf................................................................................................................................................................................................................................. 91 INTAKE AND EXHAUST................................................................................................................................................................................................................. 91 SERVICE SPECIFICATIONS......................................................................................................................................................................................................... 92 SPECIAL TOOL................................................................................................................................................................................................................... 93 ON-VEHICLE SERVICE............................................................................................................................................................................................................. 94 TURBOCHARGER SUPERCHARGING PRESSURE CHECK.................................................................................................................................................................................. 94 WASTE GATE ACTUATOR CHECK.................................................................................................................................................................................................. 95 AIR CLEANER.................................................................................................................................................................................................................... 96 REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................ 96 REMOVAL AND INSTALLATION <4D5-DOHC, 4M4>................................................................................................................................................................................... 97 INTERCOOLER <4D5-DOHC,4M4>..................................................................................................................................................................................................... 98 REMOVAL AND INSTALLATION................................................................................................................................................................................................... 98 INSTALLATION SERVICE POINT............................................................................................................................................................................................. 98 INLET AND EXHAUST MANIFOLDS <4D5-SOHC>......................................................................................................................................................................................... 99 REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................ 99 INLET MANIFOLD.................................................................................................................................................................................................................101 REMOVAL AND INSTALLATION <4D5-DOHC>........................................................................................................................................................................................101 REMOVAL SERVICE POINT..................................................................................................................................................................................................102 INSTALLATION SERVICE POINT.............................................................................................................................................................................................102 REMOVAL AND INSTALLATION <4M4>.............................................................................................................................................................................................103 EXHAUST MANIFOLD AND TURBOCHARGER..............................................................................................................................................................................................104 REMOVAL AND INSTALLATION <4D5-DOHC>........................................................................................................................................................................................104 INSTALLATION SERVICE POINTS............................................................................................................................................................................................105 REMOVAL AND INSTALLATION <4M4>.............................................................................................................................................................................................106 INSTALLATION SERVICE POINTS............................................................................................................................................................................................107 TURBOCHARGER ASSEMBLY <4D5-SOHC>...............................................................................................................................................................................................108 REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................108 INSTALLATION SERVICE POINT.............................................................................................................................................................................................109 EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER <4D5-SOHC>..................................................................................................................................................................109 REMOVAL AND INSTALLATION <4D5-SOHC>........................................................................................................................................................................................109 EXHAUST PIPE AND MAIN MUFFLER <4D5-DOHC, 4M4>..................................................................................................................................................................................110 REMOVAL AND INSTALLATION...................................................................................................................................................................................................110 31.pdf.................................................................................................................................................................................................................................111 WHEEL AND TYRE.....................................................................................................................................................................................................................111 GENERAL INFORMATION............................................................................................................................................................................................................112 SERVICE SPECIFICATIONS.........................................................................................................................................................................................................112 TROUBLESHOOTING................................................................................................................................................................................................................113 DIAGNOSIS..................................................................................................................................................................................................................113 WHEEL BALANCE ACCURACY.....................................................................................................................................................................................................114 PURPOSE................................................................................................................................................................................................................114 PROCEDURE <BALANCING TIPS>.............................................................................................................................................................................................115 <CONFIRMING PROPER BALANCE>............................................................................................................................................................................................115 <WHEEL BALANCER CALIBRATION CHECKS>....................................................................................................................................................................................116 WHEEL BALANCER CALIBRATION CHECKING FLOW CHART.........................................................................................................................................................................117 ON-VEHICLE SERVICE.............................................................................................................................................................................................................118 TYRE INFLATION PRESSURE CHECK..............................................................................................................................................................................................118 TYRE WEAR CHECK............................................................................................................................................................................................................118 WHEEL RUNOUT CHECK.........................................................................................................................................................................................................118 WHEEL AND TYRE.................................................................................................................................................................................................................118 INSTALLATION SERVICE POINT.................................................................................................................................................................................................118 SPARE TYRE CARRIER.............................................................................................................................................................................................................119 REMOVAL AND INSTALLATION...................................................................................................................................................................................................119 33.pdf.................................................................................................................................................................................................................................121 FRONT SUSPENSION...................................................................................................................................................................................................................121 GENERAL INFORMATION............................................................................................................................................................................................................122 SPECIFICATIONS.............................................................................................................................................................................................................123 SERVICE SPECIFICATIONS.........................................................................................................................................................................................................123 SPECIAL TOOLS..................................................................................................................................................................................................................124 ON-VEHICLE SERVICE.............................................................................................................................................................................................................125 FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT <2WD>...........................................................................................................................................................................125 FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT <4WD>...........................................................................................................................................................................126 CAMBER AND CASTER REFERENCE TABLE......................................................................................................................................................................................127 LOWER ARM BALL JOINT AXIAL PLAY CHECK......................................................................................................................................................................................128 LOWER ARM BALL JOINT COVER CHECK...........................................................................................................................................................................................128 UPPER ARM ASSEMBLY.............................................................................................................................................................................................................129 REMOVAL AND INSTALLATION <2WD>.............................................................................................................................................................................................129 REMOVAL SERVICE POINT..................................................................................................................................................................................................130 REMOVAL AND INSTALLATION <4WD>.............................................................................................................................................................................................131 REMOVAL SERVICE POINT..................................................................................................................................................................................................132 INSTALLATION SERVICE POINT.............................................................................................................................................................................................132 INSPECTION.................................................................................................................................................................................................................132 SHOCK ABSORBER AND COIL SPRING.................................................................................................................................................................................................133 REMOVAL AND INSTALLATION...................................................................................................................................................................................................133 REMOVAL SERVICE POINT..................................................................................................................................................................................................134 INSTALLATION SERVICE POINT.............................................................................................................................................................................................134 INSPECTION.................................................................................................................................................................................................................134 SHOCK ABSORBER ASSEMBLY........................................................................................................................................................................................................135 REMOVAL AND INSTALLATION <4WD>.............................................................................................................................................................................................135 INSPECTION.................................................................................................................................................................................................................135 DISASSEMBLY AND REASSEMBLY <4WD>...........................................................................................................................................................................................136 DISASSEMBLY SERVICE POINTS.............................................................................................................................................................................................136 REASSEMBLY SERVICE POINTS..............................................................................................................................................................................................137 INSPECTION.................................................................................................................................................................................................................138 LOWER ARM......................................................................................................................................................................................................................139 REMOVAL AND INSTALLATION <2WD>.............................................................................................................................................................................................139 REMOVAL SERVICE POINT..................................................................................................................................................................................................139 REMOVAL AND INSTALLATION <4WD>.............................................................................................................................................................................................140 REMOVAL SERVICE POINT..................................................................................................................................................................................................141 INSPECTION.................................................................................................................................................................................................................141 LOWER ARM BUSHING REPLACEMENT <2WD>........................................................................................................................................................................................142 LOWER ARM BUSHING REPLACEMENT <4WD>........................................................................................................................................................................................142 STRUT BAR <2WD>................................................................................................................................................................................................................144 REMOVAL AND INSTALLATION...................................................................................................................................................................................................144 INSTALLATION SERVICE POINT.............................................................................................................................................................................................144 STABILIZER BAR <4WD>...........................................................................................................................................................................................................145 REMOVAL AND INSTALLATION...................................................................................................................................................................................................145 INSTALLATION SERVICE POINTS............................................................................................................................................................................................145 INSPECTION.................................................................................................................................................................................................................145 34.pdf.................................................................................................................................................................................................................................147 REAR SUSPENSION....................................................................................................................................................................................................................147 GENERAL INFORMATION............................................................................................................................................................................................................148 SPECIFICATIONS.............................................................................................................................................................................................................149 SHOCK ABSORBER ASSEMBLY........................................................................................................................................................................................................150 REMOVAL AND INSTALLATION...................................................................................................................................................................................................150 <2WD>..................................................................................................................................................................................................................150 <4WD>..................................................................................................................................................................................................................151 INSTALLATION SERVICE POINT.............................................................................................................................................................................................151 INSPECTION.................................................................................................................................................................................................................152 42.pdf.................................................................................................................................................................................................................................153 BODY...............................................................................................................................................................................................................................153 HOOD...........................................................................................................................................................................................................................155 ON-VEHICLE SERVICE.........................................................................................................................................................................................................155 ADJUSTMENT OF CLEARANCE AROUND HOOD........................................................................................................................................................................................155 ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER...........................................................................................................................................................155 ADJUSTMENT OF HOOD HEIGHT..................................................................................................................................................................................................155 HOOD.......................................................................................................................................................................................................................156 REMOVAL AND INSTALLATION...................................................................................................................................................................................................156 FENDER.........................................................................................................................................................................................................................157 SPECIAL TOOL...............................................................................................................................................................................................................157 FENDER.....................................................................................................................................................................................................................158 REMOVAL AND INSTALLATION...................................................................................................................................................................................................158 REMOVAL SERVICE POINT..................................................................................................................................................................................................159 INSTALLATION SERVICE POINT.............................................................................................................................................................................................159 FUEL FILLER LID................................................................................................................................................................................................................160 REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................160 REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................161 SPLASH SHIELD..................................................................................................................................................................................................................162 REMOVAL AND INSTALLATION...................................................................................................................................................................................................162 WINDOW GLASS...................................................................................................................................................................................................................163 ADHESIVE...................................................................................................................................................................................................................163 SPECIAL TOOL...............................................................................................................................................................................................................163 GENERAL....................................................................................................................................................................................................................163 WINDOW GLASS INSTALLATION..............................................................................................................................................................................................164 WINDSHIELD.................................................................................................................................................................................................................165 REMOVAL AND INSTALLATION...................................................................................................................................................................................................165 REMOVAL SERVICE POINT..................................................................................................................................................................................................166 NSTALLATION SERVICE POINTS.............................................................................................................................................................................................167 SIDE WINDOW GLASS <CLUB CAB>...............................................................................................................................................................................................169 REMOVAL AND INSTALLATION...................................................................................................................................................................................................169 REMOVAL SERVICE POINT..................................................................................................................................................................................................170 INSTALLATION SERVICE POINT.............................................................................................................................................................................................170 REAR WINDOW GLASS <Vehicles without rear panel power window>...............................................................................................................................................................171 REMOVAL AND INSTALLATION...................................................................................................................................................................................................171 REMOVAL SERVICE POINT..................................................................................................................................................................................................172 INSTALLATION SERVICE POINTS............................................................................................................................................................................................172 REAR PANEL POWER WINDOW <Vehicles with rear panel power window>................................................................................................................................................................173 SEALANT....................................................................................................................................................................................................................173 SPECIAL TOOLS..............................................................................................................................................................................................................173 TROUBLESHOOTING............................................................................................................................................................................................................174 DIAGNOSIS TROUBLESHOOTING FLOW.............................................................................................................................................................................................174 DIAGNOSIS CODE CHART.......................................................................................................................................................................................................174 TROUBLE SYMPTOM CHART......................................................................................................................................................................................................175 DIAGNOSTIC TROUBLE CODE PROCEDURES.........................................................................................................................................................................................176 Code No.5001: P/W (RP) SW pulse1 fail, Code No.5002: P/W (RP) SW pulse2 fail...............................................................................................................................................176 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................177 STEP 1. Connector check: D-11 rear panel power window-ECU connector and D-09 rear panel power window motor connector...............................................................................................177 STEP 2. Check the wiring harness between D-11 rear panel power window-ECU connector terminal Nos.7, 8, 11 and 16 to D-09 rear panel power window motor connector terminal 2, 4, 5 and 6............................177 STEP 3. Check whether the diagnosis code is reset..................................................................................................................................................................177 Code No.5003: P/W (RP) SW position error...................................................................................................................................................................................177 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................177 STEP 1. Confirm the rear panel power window learning function......................................................................................................................................................177 STEP 2. Check whether the diagnosis code is reset..................................................................................................................................................................177 Code No.5004: P/W (RP) sensor fail.........................................................................................................................................................................................178 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................179 STEP 1. Connector check: D-11 rear panel power window-ECU connector and D-09 rear panel power window motor connector...............................................................................................179 STEP 2. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No. 8 to D-09 rear panel power window motor connector terminal 5......................................................179 STEP 3. Check whether the diagnosis code is reset..................................................................................................................................................................179 Code No.5005: P/W (RP) 3 times jumm-protection.............................................................................................................................................................................179 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................179 STEP 1. Confirm the rear panel power window learning function......................................................................................................................................................179 STEP 2. Check whether the diagnosis code is reset..................................................................................................................................................................179 Code No.5006: P/W (RP) communication error (LIN)...........................................................................................................................................................................180 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................181 STEP 1. Connector check: C-219 ETACS-ECU connector and D-11 rear panel power window-ECU connector..................................................................................................................181 STEP 2. Check the wiring harness between C-219 ETACS-ECU connector terminal No.54 to D-11 rear panel power window-ECU connector terminal No.14.....................................................................181 STEP 3. Check whether the diagnosis code is reset..................................................................................................................................................................181 Code No.5008: P/W (RP) parameter read fail, Code No.5009: P/W (RP) position read fail......................................................................................................................................182 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................182 Check whether the diagnosis code is reset..........................................................................................................................................................................182 SYMPTOM PROCEDURES.........................................................................................................................................................................................................183 Inspection Procedure 1: Rear Panel Power Window do not Work at All.........................................................................................................................................................183 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................184 STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................184 STEP 2. Check the power window sub switch..........................................................................................................................................................................184 STEP 3. Connector check: D-11 rear panel power window-ECU connector and D-09 rear panel power window motor connector...............................................................................................184 STEP 4. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.1, 2, 8 and 11 to D-09 rear panel power window motor connector terminal No.3, 1, 5 and 6...........................184 STEP 5. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.18 to fusible link (23)............................................................................................184 STEP 6. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.9 to ignition switch (IG1).........................................................................................186 STEP 7. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.10 to body earth...................................................................................................186 STEP 8. Connector check: E-03 power window main switch connector...................................................................................................................................................186 STEP 9. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.12 to E-03 power window main switch connector terminal No.11.......................................................187 STEP 10. Check the wiring harness between E-03 power window main switch connector terminal No.2 and body earth.....................................................................................................187 STEP 11. Connector check: D-22 rear panel power window switch connector............................................................................................................................................187 STEP 12. Check the rear panel power window switch..................................................................................................................................................................187 STEP 13. Check the wiring harness between D-22 rear panel power window switch connector terminal No.2 and body earth...............................................................................................188 STEP 14. Retest the system.........................................................................................................................................................................................188 Inspection Procedure 2: Any of The Rear Panel Power Window Switch Position is defective....................................................................................................................................189 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................189 STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................189 STEP 2. Connector check: D-11 rear panel power window-ECU connector and D-22 rear panel power window switch connector..............................................................................................190 STEP 3. Check the rear panel power window switch...................................................................................................................................................................190 STEP 4. Check the wiring harness between D-11 rear panel power window-ECU connector terminal Nos.4, 5 and 6 to D-22 rear panel power window switch connector terminal Nos.5, 4 and 1...............................190 STEP 5. Retest the system..........................................................................................................................................................................................190 Inspection Procedure 3: Rear Panel Power Window Anti-trap Function does not Work Normally..................................................................................................................................190 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................190 STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................190 STEP 2. Confirm the rear panel power window learning function......................................................................................................................................................191 STEP 3. Retest the system..........................................................................................................................................................................................191 Inspection Procedure 4: Rear Panel Power Window-ECU cannot Communicate with ETACS-ECU......................................................................................................................................191 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................192 STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................192 STEP 2. Connector check: C-219 ETACS-ECU connector and D-11 rear panel power window-ECU connector..................................................................................................................192 STEP 3. Check the wiring harness between C-219 ETACS-ECU connector terminal No.54 to D-11 rear panel power window-ECU connector terminal No.14.....................................................................192 STEP 4. Check the wiring harness between D-11 rear panel power window-ECU connector terminal No.18 to fusible link (23)............................................................................................193 STEP 5. Retest the system..........................................................................................................................................................................................193 Inspection Procedure 5: Rear Pnael Power Window Timer Function does not Work Normally......................................................................................................................................194 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................194 STEP 1. M.U.T.-III diagnosis code..................................................................................................................................................................................194 STEP 2. Check the rear panel power window..........................................................................................................................................................................194 STEP 3. Check the power window timer function......................................................................................................................................................................194 STEP 4. Retest the system..........................................................................................................................................................................................194 ON-VEHICLE SERVICE.........................................................................................................................................................................................................194 REAR SLIDE WINDOW GLASS ADJUSTMENT.........................................................................................................................................................................................194 GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT...............................................................................................................................................................................195 REAR PANEL POWER WINDOW ANTI-TRAP FUNCTION INSPECTION......................................................................................................................................................................195 REAR PANEL POWER WINDOW INITIAL SET........................................................................................................................................................................................195 HOW TO MAKE THE REAR PANEL POWER WINDOW-ECU LEARN THE FULLY CLOSED POSITION OF THE REAR PANEL POWER WINDOW.............................................................................................................195 REAR PANEL WINDOW REGULATOR................................................................................................................................................................................................197 REMOVAL AND INSTALLATION...................................................................................................................................................................................................197 REMOVAL SERVICE POINT..................................................................................................................................................................................................199 INSTALLATION SERVICE POINT.............................................................................................................................................................................................200 INSPECTION.................................................................................................................................................................................................................200 REAR PANEL POWER WINDOW SWITCH CONTINUITY CHECK........................................................................................................................................................................200 REAR PANEL POWER WINDOW-ECU TERMINAL INSPECTION........................................................................................................................................................................201 DOOR...........................................................................................................................................................................................................................202 SERVICE SPECIFICATIONS.....................................................................................................................................................................................................202 SEALANT....................................................................................................................................................................................................................202 SPECIAL TOOLS..............................................................................................................................................................................................................202 TROUBLESHOOTING............................................................................................................................................................................................................204 DIAGNOSIS TROUBLESHOOTING FLOW.............................................................................................................................................................................................204 TROUBLE SYMPTOM CHART <CENTRAL DOOR LOCKING SYSTEM>........................................................................................................................................................................204 TROUBLE SYMPTOM CHART <POWER WINDOWS>......................................................................................................................................................................................204 SYMPTOM PROCEDURES <CENTRAL DOOR LOCKING SYSTEM>...........................................................................................................................................................................205 Inspection Procedure A-1: Central Door Locking System does not Work........................................................................................................................................................205 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................205 STEP 1. Check the power supply circuit.............................................................................................................................................................................205 STEP 2. Connector check: C-218 ETACS-ECU connector.................................................................................................................................................................206 STEP 3. Check the wiring harness between C-218 ETACS-ECU connector terminal No.1 and fusible link (20).............................................................................................................206 STEP 4. Retest the system..........................................................................................................................................................................................207 Inspection Procedure A-2: A Door cannot be Locked or Unlocked by the Central Door Locking System...........................................................................................................................208 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................209 STEP 1. Confirm which door lock actuator is defective..............................................................................................................................................................209 STEP 2. Connector check: E-04 front door lock actuator (RH) connector..............................................................................................................................................209 STEP 3. Check the front door lock actuator (RH)....................................................................................................................................................................209 STEP 4. Connector check: C-220 ETACS-ECU connector.................................................................................................................................................................209 STEP 5. Check the wiring harness from C-220 ETACS-ECU connector terminal Nos. 21 and 23 to E-04 front door lock actuator (RH) connector terminal Nos. 6 and 4......................................................210 STEP 6. Connector check: E-15 front door lock actuator (LH) connector..............................................................................................................................................210 STEP 7. Check the front door lock actuator (LH)....................................................................................................................................................................210 STEP 8. Connector check: C-220 ETACS-ECU connector.................................................................................................................................................................210 STEP 9. Check the wiring harness from C-220 ETACS-ECU connector terminal Nos. 22 and 23 to E-15 front door lock actuator (LH) connector terminal Nos. 6 and 4......................................................211 STEP 10. Connector check: E-07 rear door lock actuator (RH) connector..............................................................................................................................................211 STEP 11. Check the rear door lock actuator (RH)....................................................................................................................................................................211 STEP 12. Connector check: C-220 ETACS-ECU connector................................................................................................................................................................211 STEP 13. Check the wiring harness from C-220 ETACS-ECU connector terminal Nos. 22 and 23 to E-07 rear door lock actuator (RH) connector terminal Nos. 6 and 4......................................................212 STEP 14. Connector check: E-12 rear door lock actuator (LH) connector..............................................................................................................................................213 STEP 15. Check the rear door lock actuator (LH)....................................................................................................................................................................213 STEP 16. Connector check: C-220 ETACS-ECU connector................................................................................................................................................................213 STEP 17. Check the wiring harness from C-220 ETACS-ECU connector terminal Nos. 22 and 23 to E-12 rea door lock actuator (LH) connector terminal Nos. 6 and 4.......................................................213 Inspection Procedure A-3: Selector "P" position-linked door unlock function does not operate normally. <Vehicles with automatic transmission with keyless entry system>....................................................215 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................215 STEP 1. Checking central door unlocking operation..................................................................................................................................................................215 STEP 2. Customize function by using the M.U.T.-III.................................................................................................................................................................215 STEP 3. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................215 STEP 4. M.U.T.-III other system diagnosis code.....................................................................................................................................................................215 STEP 5. Retest the system..........................................................................................................................................................................................215 SYMPTOM PROCEDURES <POWER WINDOWS>.........................................................................................................................................................................................216 Inspection Procedure B-1: Power Windows do not Work at All.................................................................................................................................................................216 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................217 STEP 1. M.U.T.-III data list.......................................................................................................................................................................................217 STEP 2. Connector check: A-24X power window relay connector........................................................................................................................................................217 STEP 3. Check the power window relay...............................................................................................................................................................................217 STEP 4. Voltage measurement at the A-24X power window relay connector..............................................................................................................................................217 STEP 5. Check the wiring harness between A-24X power window relay connector terminal No.4 and fusible link (23)....................................................................................................218 STEP 6. Voltage measurement at the A-24X power window relay connector..............................................................................................................................................218 STEP 7. Connector check: C-219 ETACS-ECU connector.................................................................................................................................................................218 STEP 8. Check the wiring harness between C-219 ETACS-ECU connector terminal No.59 and A-24X power window relay connector terminal No.2.............................................................................219 STEP 9. Resistance measurement at the A-24X power window relay connector...........................................................................................................................................219 STEP 10. Check the wiring harness between A-24X power window relay connector terminal No.1 and body earth..........................................................................................................219 STEP 11. Connector check: E-03 power window main switch connector..................................................................................................................................................220 STEP 12. Voltage measurement at the E-03 power window main switch connector........................................................................................................................................220 STEP 13. Check the wiring harness between A-24X power window relay connector terminal No.3 and E-03 power window main switch connector terminal No.10..............................................................221 STEP 14. Resistance measurement at the E-03 power window main switch connector.....................................................................................................................................221 STEP 15. Check the wiring harness between E-03 power window main switch connector terminal No.2 and body earth.....................................................................................................222 STEP 16. Retest the system.........................................................................................................................................................................................222 Inspection Procedure B-2: Driver's Power Window does not Work by means of the Power Window Main Switch.....................................................................................................................223 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................224 STEP 1. Check the power window main switch.........................................................................................................................................................................224 STEP 2. Connector check: Connector check: E-03 power window main switch connector and E-01 power window motor (front: RH) connector................................................................................224 STEP 3. Check the wiring harness from E-03 power window main switch connector terminal Nos. 12 and 14 to E-01 power window motor (front: RH) connector terminal Nos. 2 and 1.......................................224 STEP 4. Retest the system..........................................................................................................................................................................................224 Inspection Procedure B-3: Relevant Power Window(s) do not Work by means of the Front Passenger's Power Window Sub Switch and Rear Power Window Sub Switches................................................................225 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................227 STEP 1. Check the power window main switch.........................................................................................................................................................................227 STEP 2. Determine a trouble spot...................................................................................................................................................................................227 STEP 3. Connector check: E-16 power window sub switch (front: LH) connector........................................................................................................................................227 STEP 4. Check the power window sub switch (front: LH)..............................................................................................................................................................227 STEP 5. Voltage measurement at the E-16 power window sub switch (front: LH) connector..............................................................................................................................227 STEP 6. Connector check: A-24X power window relay connector........................................................................................................................................................228 STEP 7. Check the wiring harness from E-16 power window sub switch (front: LH) connector terminal No.6 to A-24X power window relay connector terminal No.3.........................................................228 STEP 8. Connector check: E-18 power window motor (front: LH) connector.............................................................................................................................................229 STEP 9. Check the power window motor (front: LH)...................................................................................................................................................................229 STEP 10. Check the wiring harness from E-18 power window motor (front: LH) connector terminal Nos. 1 and 2 to E-16 power window sub switch (front: LH) connector terminal Nos. 4 and 7.............................229 STEP 11. Retest the system.........................................................................................................................................................................................229 STEP 12. Connector check: E-06 power window sub switch (rear: RH) connector........................................................................................................................................229 STEP 13. Check the power window sub switch (rear: RH)..............................................................................................................................................................229 STEP 14. Voltage measurement at the E-06 power window sub switch (rear: RH) connector..............................................................................................................................230 STEP 15. Connector check: A-24X power window relay connector.......................................................................................................................................................230 STEP 16. Check the wiring harness from E-06 power window sub switch (rear: RH) connector terminal No.6 to A-24X power window relay connector terminal No.3.........................................................230 STEP 17. Connector check: E-05 power window motor (rear: RH) connector.............................................................................................................................................231 STEP 18. Check the power window motor (rear: RH)...................................................................................................................................................................231 STEP 19. Check the wiring harness from E-05 power window motor (rear: RH) connector terminal Nos. 1 and 2 to E-06 power window sub switch (rear: RH) connector terminal Nos. 7 and 4...............................231 STEP 20. Retest the system.........................................................................................................................................................................................232 STEP 21. Connector check: E-13 power window sub switch (rear: LH) connector........................................................................................................................................232 STEP 22. Check the power window sub switch (rear: LH)..............................................................................................................................................................232 STEP 23. Voltage measurement at the E-13 power window sub switch (rear: LH) connector..............................................................................................................................232 STEP 24. Connector check: A-24X power window relay connector.......................................................................................................................................................232 STEP 25. Check the wiring harness from E-13 power window sub switch (rear: LH) connector terminal No.6 to A-24X power window relay connector terminal No.3.........................................................233 STEP 26. Connector check: E-14 power window motor (rear: LH) connector.............................................................................................................................................234 STEP 27. Check the power window motor (rear: LH)...................................................................................................................................................................234 STEP 28. Check the wiring harness from E-14 power window motor (rear: RH) connector terminal Nos. 1 and 2 to E-13 power window sub switch (rear: LH) connector terminal Nos. 7 and 4...............................234 STEP 29. Retest the system.........................................................................................................................................................................................234 Inspection Procedure B-4: Front Passenger's Power Window do not Work by means of the Power Window Main Switch..............................................................................................................235 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................237 STEP 1. Check the power window main switch.........................................................................................................................................................................237 STEP 2. Check the power window sub switch..........................................................................................................................................................................237 STEP 3. Determine a trouble spot...................................................................................................................................................................................237 STEP 4. Connector check: E-03 power window main switch connector and E-16 power window sub switch (front: LH) connector............................................................................................237 STEP 5. Check the wiring harness between E-03 power window main switch connector terminal Nos.7 and 9 to E-16 power window sub switch (front: LH) connector terminal Nos.8 and 5...................................237 STEP 6. Retest the system..........................................................................................................................................................................................238 STEP 7. Connector check: E-03 power window main switch connector and E-06 power window sub switch (rear: RH) connector.............................................................................................238 STEP 8. Check the wiring harness between E-03 power window main switch connector terminal Nos.4 and 6 to E-06 power window sub switch (rear: RH) connector terminal Nos.8 and 5....................................238 STEP 9. Retest the system..........................................................................................................................................................................................239 STEP 10. Connector check: E-03 power window main switch connector and E-13 power window sub switch (rear: LH) connector............................................................................................239 STEP 11. Check the wiring harness between E-03 power window main switch connector terminal Nos.1 and 3 to E-13 power window sub switch (rear: LH) connector terminal Nos.8 and 5...................................239 STEP 12. Retest the system.........................................................................................................................................................................................240 Inspection procedure B-5: Power Window Timer Function does not Work Normally...............................................................................................................................................240 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................240 STEP 1. Check the power window main switch.........................................................................................................................................................................240 STEP 2. Check the power supply circuit.............................................................................................................................................................................240 STEP 3. M.U.T.-III data list.......................................................................................................................................................................................240 STEP 4. Retest the system..........................................................................................................................................................................................240 Inspection Procedure B-6: The Window Glass Lowers Automatically while it is Rising.........................................................................................................................................241 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................241 STEP 1. Check the power window operating current...................................................................................................................................................................241 STEP 2. Check that the door window glasses are installed correctly.................................................................................................................................................241 STEP 3. Retest the system..........................................................................................................................................................................................241 ON-VEHICLE SERVICE.........................................................................................................................................................................................................241 DOOR FIT ADJUSTMENT........................................................................................................................................................................................................241 FRONT DOOR WINDOW GLASS ADJUSTMENT.........................................................................................................................................................................................242 GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT...............................................................................................................................................................................243 POWER WINDOW TIMER FUNCTION CHECK..........................................................................................................................................................................................244 POWER WINDOW OPERATING CURRENT CHECK.......................................................................................................................................................................................244 POWER WINDOW RELAY CHECK...................................................................................................................................................................................................244 POWER WINDOW CHECK.........................................................................................................................................................................................................244 CENTRAL DOOR LOCKING SYSTEM INSPECTION.....................................................................................................................................................................................245 CHECK OF KEY LOCK PREVENTION FUNCTION......................................................................................................................................................................................245 SHIFT "P" INTERLINK DOOR UNLOCK FUNCTION CHECK.............................................................................................................................................................................245 DOOR OUTSIDE HANDLE PLAY CHECK.............................................................................................................................................................................................245 DOOR INSIDE HANDLE PLAY ADJUSTMENT.........................................................................................................................................................................................246 DOOR INSIDE HANDLE KNOB PLAY CHECK.....................................................................................................................................................................................246 DOOR INSIDE HANDLE LOCK KNOB STROKE CHECK..............................................................................................................................................................................246 DOOR ASSEMBLY..............................................................................................................................................................................................................247 REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................247 INSTALLATION SERVICE POINT.............................................................................................................................................................................................247 REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................248 INSTALLATION SERVICE POINT.............................................................................................................................................................................................249 INSPECTION.................................................................................................................................................................................................................249 DOOR SWITCH CHECK......................................................................................................................................................................................................249 DOOR GLASS AND REGULATOR...................................................................................................................................................................................................250 REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................250 REMOVAL SERVICE POINTS.................................................................................................................................................................................................251 INSTALLATION SERVICE POINT.............................................................................................................................................................................................251 REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................252 REMOVAL SERVICE POINTS.................................................................................................................................................................................................254 INSTALLATION SERVICE POINT.............................................................................................................................................................................................254 INSPECTION.................................................................................................................................................................................................................255 POWER WINDOW SWITCH CONTINUITY CHECK...................................................................................................................................................................................255 POWER WINDOW MOTOR CONTINUITY CHECK....................................................................................................................................................................................256 POWER WINDOW MOTOR CHECK...............................................................................................................................................................................................256 DOOR HANDLE AND LATCH......................................................................................................................................................................................................257 REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................257 INSTALLATION SERVICE POINTS............................................................................................................................................................................................258 REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................259 INSTALLATION SERVICE POINT.............................................................................................................................................................................................261 INSPECTION.................................................................................................................................................................................................................261 FRONT DOOR LOCK ACTUATOR CHECK.........................................................................................................................................................................................261 REAR DOOR LOCK ACTUATOR CHECK..........................................................................................................................................................................................262 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP......................................................................................................................................................................263 REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................263 REMOVAL SERVICE POINT..................................................................................................................................................................................................264 INSTALLATION SERVICE POINTS............................................................................................................................................................................................264 REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................265 REMOVAL SERVICE POINTS.................................................................................................................................................................................................267 INSTALLATION SERVICE POINTS............................................................................................................................................................................................267 KEYLESS ENTRY SYSTEM...........................................................................................................................................................................................................268 SERVICE SPECIFICATIONS.....................................................................................................................................................................................................268 SPECIAL TOOL...............................................................................................................................................................................................................268 TROUBLESHOOTING............................................................................................................................................................................................................269 DIAGNOSIS TROUBLESHOOTING FLOW.............................................................................................................................................................................................269 TROUBLE SYMPTOM CHART......................................................................................................................................................................................................269 INPUT SIGNAL CHART.........................................................................................................................................................................................................269 SYMPTOM PROCEDURES.........................................................................................................................................................................................................270 Inspection Procedure 1: Keyless Entry System does not Work.................................................................................................................................................................270 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................270 STEP 1. Check the operation of the central door locking system.....................................................................................................................................................270 STEP 2. Check the power supply circuit.............................................................................................................................................................................270 STEP 3. M.U.T.-III data list.......................................................................................................................................................................................271 STEP 4. Pulse check................................................................................................................................................................................................271 STEP 5. Retest the system..........................................................................................................................................................................................271 Inspection Procedure 2: Keyless Entry Hazard Lamp Answerback Function or the Room Lamp Answerback Function does not Work Normally..........................................................................................271 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................271 STEP 1. Check the operation of the hazard warning lamp.............................................................................................................................................................271 STEP 2. Check the operation of the room lamp.......................................................................................................................................................................271 STEP 3. Check the operation of the keyless entry system............................................................................................................................................................272 STEP 4. Check the customize function...............................................................................................................................................................................272 STEP 5. Check the power supply circuit.............................................................................................................................................................................272 STEP 6. Retest the system..........................................................................................................................................................................................272 Inspection Procedure 3: Encrypted Code cannot be Registered................................................................................................................................................................273 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................273 STEP 1. Check the encrypted code registration mode.................................................................................................................................................................273 STEP 2. M.U.T.-III data list.......................................................................................................................................................................................273 STEP 3. Pulse check................................................................................................................................................................................................274 STEP 4. Retest the system..........................................................................................................................................................................................274 Inspection Procedure 4: The Timer Lock Function does not Work after the Doors have been Unlocked by the Keyless Entry System...............................................................................................274 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................274 STEP 1. Check the operation of the keyless entry system............................................................................................................................................................274 STEP 2. Check the customize function...............................................................................................................................................................................274 STEP 3. Retest the system..........................................................................................................................................................................................274 INPUT SIGNAL PROCEDURES....................................................................................................................................................................................................275 Inspection Procedure 5: Each Button Signal of the Keyless Entry Transmitter is not Received................................................................................................................................275 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................275 STEP 1. Pulse check................................................................................................................................................................................................275 STEP 2. Check the transmitter battery..............................................................................................................................................................................275 STEP 3. Register the encrypted code, and then retest the system....................................................................................................................................................275 STEP 4. Retest the system..........................................................................................................................................................................................275 Inspection Procedure 6: The Key Reminder Switch Signal is not Received.....................................................................................................................................................276 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................277 STEP 1. Connector check: C-301 key reminder switch connector.......................................................................................................................................................277 STEP 2. Check the key reminder switch..............................................................................................................................................................................277 STEP 3. Resistance measurement at the C-301 key reminder switch connector..........................................................................................................................................277 STEP 4. Check the wiring harness between C-301 key reminder switch connector terminal No.4 and the body earth......................................................................................................278 STEP 5. Connector check: C-219 ETACS-ECU connector.................................................................................................................................................................278 STEP 6. Check the wiring harness between C-219 ETACS-ECU connector terminal No.53 and C-301 key reminder switch connector terminal No.6............................................................................278 STEP 7. Retest the system..........................................................................................................................................................................................278 ON-VEHICLE SERVICE.........................................................................................................................................................................................................279 KEYLESS ENTRY SYSTEM INSPECTION............................................................................................................................................................................................279 KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION........................................................................................................................................................................279 HOW TO REGISTER SECRET CODE................................................................................................................................................................................................279 WHEN THE SPECIAL TOOL V.C.I. (MB991824) IS USED........................................................................................................................................................................279 TRANSMITTER................................................................................................................................................................................................................281 DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................281 DISASSEMBLY SERVICE POINT..............................................................................................................................................................................................281 REASSEMBLY SERVICE POINT...............................................................................................................................................................................................282 INSPECTION.................................................................................................................................................................................................................282 TRANSMITTER BATTERY CHECK..............................................................................................................................................................................................282 BODY MOUNTING..................................................................................................................................................................................................................283 REMOVAL AND INSTALLATION...................................................................................................................................................................................................283 REMOVAL SERVICE POINTS.................................................................................................................................................................................................285 REAR GATE......................................................................................................................................................................................................................286 SERVICE SPECIFICATIONS.....................................................................................................................................................................................................286 ON-VEHICLE SERVICE.........................................................................................................................................................................................................286 REAR GATE PANEL FIT ADJUSTMENT.............................................................................................................................................................................................286 ALIGNMENT OF REAR GATE LATCH AND STRIKER...............................................................................................................................................................................286 ADJUSTMENT OF CLEARANCE AROUND REAR GATE...............................................................................................................................................................................286 REAR GATE OUTSIDE HANDLE ADJUSTMENT........................................................................................................................................................................................287 REAR GATE..................................................................................................................................................................................................................288 REMOVAL AND INSTALLATION...................................................................................................................................................................................................288 REAR GATE LATCH ASSEMBLY...................................................................................................................................................................................................289 REMOVAL AND INSTALLATION...................................................................................................................................................................................................289 REAR SIDE PANEL................................................................................................................................................................................................................290 REMOVAL AND INSTALLATION...................................................................................................................................................................................................290 52.pdf.................................................................................................................................................................................................................................291 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM(SRS)....................................................................................................................................................................................291 52A.pdf................................................................................................................................................................................................................................293 INTERIOR...........................................................................................................................................................................................................................293 SPECIAL TOOL...................................................................................................................................................................................................................294 INSTRUMENT PANEL ASSEMBLY......................................................................................................................................................................................................294 REMOVAL AND INSTALLATION...................................................................................................................................................................................................294 CLIP AND CRAW POSITIONS................................................................................................................................................................................................297 REMOVAL SERVICE POINTS.................................................................................................................................................................................................298 DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................299 FLOOR CONSOLE ASSEMBLY.........................................................................................................................................................................................................300 FRONT FLOOR CONSOLE ASSEMBLY...............................................................................................................................................................................................300 REMOVAL AND INSTALLATION...................................................................................................................................................................................................300 REAR FLOOR CONSOLE ASSEMBLY................................................................................................................................................................................................301 REMOVAL AND INSTALLATION...................................................................................................................................................................................................301 <Except GL>............................................................................................................................................................................................................301 <GL>...................................................................................................................................................................................................................302 TRIMS..........................................................................................................................................................................................................................302 INTERIOR TRIM..............................................................................................................................................................................................................302 REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................302 CLIP AND CLAW POSITIONS................................................................................................................................................................................................303 REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................304 CLIP AND CLAW POSITIONS................................................................................................................................................................................................305 DOOR TRIM..................................................................................................................................................................................................................306 REMOVAL AND INSTALLATION <CLUB CAB>........................................................................................................................................................................................306 CLIP AND CLAW POSITIONS................................................................................................................................................................................................307 REMOVAL SERVICE POINTS.................................................................................................................................................................................................307 REMOVAL AND INSTALLATION <DOUBLE CAB>......................................................................................................................................................................................308 CLIP AND CLAW POSITIONS................................................................................................................................................................................................309 REMOVAL SERVICE POINTS.................................................................................................................................................................................................309 HEADLINING.....................................................................................................................................................................................................................310 REMOVAL AND INSTALLATION...................................................................................................................................................................................................310 REMOVAL SERVICE POINT..................................................................................................................................................................................................310 INSIDE REAR VIEW MIRROR........................................................................................................................................................................................................311 REMOVAL SERVICE POINT......................................................................................................................................................................................................311 FRONT SEAT ASSEMBLY............................................................................................................................................................................................................312 REMOVAL AND INSTALLATION...................................................................................................................................................................................................312 INSTALLATION SERVICE POINT.............................................................................................................................................................................................312 DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................313 <MANUAL SEAT>..........................................................................................................................................................................................................313 <POWER SEAT>...........................................................................................................................................................................................................314 DISASSEMBLY SERVICE POINT..............................................................................................................................................................................................315 REAR SEAT ASSEMBLY <DOUBLE CAB>................................................................................................................................................................................................315 REMOVAL AND INSTALLATION...................................................................................................................................................................................................315 DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................316 DISASSEMBLY SERVICE POINT..............................................................................................................................................................................................317 FRONT SEAT BELT................................................................................................................................................................................................................317 REMOVAL AND INSTALLATION...................................................................................................................................................................................................317 INSPECTION.................................................................................................................................................................................................................318 SEAT BELT BUCKLE SWITCH CONTINUITY CHECK...............................................................................................................................................................................318 REAR SEAT BELT <DOUBLE CAB>....................................................................................................................................................................................................319 REMOVAL AND INSTALLATION...................................................................................................................................................................................................319 54.pdf.................................................................................................................................................................................................................................321 CHASSIS ELECTRICAL.................................................................................................................................................................................................................321 54A.pdf................................................................................................................................................................................................................................323 CHASSIS ELECTRICAL.................................................................................................................................................................................................................323 BATTERY........................................................................................................................................................................................................................326 GENERAL INFORMATION........................................................................................................................................................................................................326 SERVICE SPECIFICATIONS.....................................................................................................................................................................................................326 ON-VEHICLE SERVICE.........................................................................................................................................................................................................326 FLUID LEVEL AND SPECIFIC GRAVITY CHECK.....................................................................................................................................................................................326 CHARGING...................................................................................................................................................................................................................327 BATTERY TEST...............................................................................................................................................................................................................327 TEST STEPS.............................................................................................................................................................................................................327 STEP 1. Battery no-load voltage check..............................................................................................................................................................................327 STEP 2. Battery charging...........................................................................................................................................................................................327 STEP 3. Load test check............................................................................................................................................................................................327 IGNITION SWITCH................................................................................................................................................................................................................328 SPECIAL TOOL...............................................................................................................................................................................................................328 REMOVAL AND INSTALLATION...................................................................................................................................................................................................329 REMOVAL SERVICE POINT..................................................................................................................................................................................................329 INSPECTION.................................................................................................................................................................................................................330 IGNITION SWITCH CONTINUITY CHECK.......................................................................................................................................................................................330 KEY REMINDER SWITCH CONTINUITY CHECK <3200>............................................................................................................................................................................330 COMBINATION METER..............................................................................................................................................................................................................331 SERVICE SPECIFICATIONS.....................................................................................................................................................................................................331 SEALANT....................................................................................................................................................................................................................331 SPECIAL TOOLS..............................................................................................................................................................................................................332 TROUBLESHOOTING............................................................................................................................................................................................................333 TROUBLE SYMPTOM CHART......................................................................................................................................................................................................333 SYMPTOM PROCEDURES.........................................................................................................................................................................................................334 Inspection Procedure 1: Power Supply Circuit System Check. Inspection Procedure 2: Odometer and Trip Meter is not Displayed. Ins...........................................................................................334 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................335 STEP 1. Connector check: Combination meter connector C-111, C-112 and C-113........................................................................................................................................335 STEP 2. Voltage measurement at combination meter connector C-112...................................................................................................................................................335 STEP 3. Check the harness wire between the battery (fusible link No.20) and combination meter connector C-112 (terminal No.42).....................................................................................336 STEP 4. Voltage measurement at combination meter connector C-112...................................................................................................................................................337 STEP 5. Check the harness wire between the ignition switch (IG1) and combination meter connector C-112 (terminal No.36)............................................................................................337 STEP 6. Resistance measurement at combination meter connector C-111 and C-113......................................................................................................................................338 STEP 7. Check the harness between combination meter connector C-111 (terminal No.57), C-113 (terminal No.13) and body earth........................................................................................338 STEP 8. Retest the system..........................................................................................................................................................................................338 Inspection Procedure 5: Speedometer does not Work (other meters work)......................................................................................................................................................339 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................339 STEP 1. M.U.T.-III other system diagnosis code.....................................................................................................................................................................339 STEP 2. M.U.T.-III other system data list..........................................................................................................................................................................339 STEP 3. Connector check: Joint connector C-127 and combination meter connector C-112...............................................................................................................................340 STEP 4. Check the wiring harness between joint connector C-127 (terminal 15) and combination meter connector C-112 (terminal 35)...................................................................................340 STEP 5. Retest the system..........................................................................................................................................................................................340 STEP 6. Pulse check................................................................................................................................................................................................341 Inspection Procedure 6: Tachometer does not Work (other meters work).......................................................................................................................................................341 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................342 STEP 1. M.U.T.-III other system diagnosis code.....................................................................................................................................................................342 STEP 2. Connector check: Combination meter connector C-112 and engine-ECU connector C-102 <2500-SOHC>, C-103 <2500-DOHC, 3200>.....................................................................................342 STEP 3. Retest the system..........................................................................................................................................................................................342 STEP 4. Check the wiring harness between combination meter connector C-112 (terminal 34) and engine ECU connector C-102 (terminal 58) <2500-SOHC>, C-103 (terminal 91) <2500-DOHC,3200>............................342 Inspection Procedure 7: Fuel Gauge does not Work (other meters work).......................................................................................................................................................343 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................343 STEP 1. Check the fuel gauge circuit...............................................................................................................................................................................343 STEP 2. Connector check: Combination meter connector C-113 and fuel pump and gauge unit connector F-09.............................................................................................................344 STEP 3. Check the wiring harness between combination meter connector C-113 (terminal 22) and fuel pump and gauge unit connector F-09 (terminal 2)..................................................................344 STEP 4. Retest the system..........................................................................................................................................................................................345 STEP 5. Check the wiring harness between fuel pump and gauge unit connector F-09 (terminal 1) and earth............................................................................................................345 STEP 6. Retest the system..........................................................................................................................................................................................345 STEP 7. Check the fuel gauge circuit...............................................................................................................................................................................345 STEP 8. Retest the system..........................................................................................................................................................................................345 Inspection Procedure 8: Engine Coolant Temperature Gauge does not Work (other meters work).................................................................................................................................346 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................347 STEP 1. Check the engine coolant temperature gauge circuit.........................................................................................................................................................347 STEP 2. Connector check: Combination meter connector C-113 and engine coolant temperature gauge unit connector A-108...............................................................................................347 STEP 3. Retest the system..........................................................................................................................................................................................348 STEP 4. Check the wiring harness between combination meter connector C-113 (terminal 21) and engine coolant temperature gauge unit connector A-108 (terminal 1)....................................................348 STEP 5. Check the engine coolant temperature gauge circuit.........................................................................................................................................................349 STEP 6. Retest the system..........................................................................................................................................................................................350 CHECK AT ECU TERMINALS.....................................................................................................................................................................................................350 ON-VEHICLE SERVICE.........................................................................................................................................................................................................352 CHECK THE SPEEDOMETER......................................................................................................................................................................................................352 TACHOMETER CHECK...........................................................................................................................................................................................................353 FUEL TANK GAUGE UNIT CHECK.................................................................................................................................................................................................353 NOMINAL RESISTANCE OF THE FUEL GAUGE UNIT..............................................................................................................................................................................353 FUEL GAUGE UNIT FLOAT HEIGHT...........................................................................................................................................................................................354 ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK................................................................................................................................................................................354 COMBINATION METER ASSEMBLY.................................................................................................................................................................................................355 REMOVAL AND INSTALLATION...................................................................................................................................................................................................355 INSPECTION.................................................................................................................................................................................................................355 CHECK OF COMBINATION METER INTERNAL RESISTANCE.........................................................................................................................................................................355 DISASSEMBLY AND REASSEMBLY.................................................................................................................................................................................................356 HEADLAMP.......................................................................................................................................................................................................................357 SERVICE SPECIFICATIONS.....................................................................................................................................................................................................357 PRECAUTIONS ON HOW TO USE THE HEADLAMP ASSEMBLY........................................................................................................................................................................357 TROUBLESHOOTING............................................................................................................................................................................................................357 ON-VEHICLE SERVICE.........................................................................................................................................................................................................357 HEADLAMP AIMING............................................................................................................................................................................................................357 <USING A BEAM SETTING EQUIPMENT>.......................................................................................................................................................................................357 <USING A SCREEN>.......................................................................................................................................................................................................357 HEADLAMP INTENSITY MEASUREMENT.............................................................................................................................................................................................359 BULB REPLACEMENT...........................................................................................................................................................................................................359 HEADLAMP BULB REPLACEMENT..............................................................................................................................................................................................359 POSITION LAMP BULB REPLACEMENT.........................................................................................................................................................................................359 FRONT TURN-SIGNAL LAMP BULB REPLACEMENT................................................................................................................................................................................360 INSPECTION OF HEADLAMP AUTOMATIC-SHUTDOWN FUNCTION.........................................................................................................................................................................360 REMOVAL AND INSTALLATION...................................................................................................................................................................................................361 INSPECTION.................................................................................................................................................................................................................362 HEADLAMP RELAY (LO) CHECK..............................................................................................................................................................................................362 HEADLAMP RELAY (HI) CHECK..............................................................................................................................................................................................362 SIDE TURN-SIGNAL LAMP..........................................................................................................................................................................................................363 SPECIAL TOOL...............................................................................................................................................................................................................363 REMOVAL AND INSTALLATION...................................................................................................................................................................................................363 REMOVAL SERVICE POINT..................................................................................................................................................................................................363 INSTALLATION SERVICE POINT.............................................................................................................................................................................................363 INTERIOR LAMP..................................................................................................................................................................................................................364 SPECIAL TOOLS..............................................................................................................................................................................................................364 TROUBLESHOOTING............................................................................................................................................................................................................365 DIMMER INTERIOR LAMP CONTROL FUNCTION..................................................................................................................................................................................365 CHECK CHART FOR TROUBLE SYMPTOMS...........................................................................................................................................................................................365 SYMPTOM PROCEDURES.........................................................................................................................................................................................................367 Inspection Procedure 1: The Interior Lamps (front room lamp, rear room lamp and ignition key cylinder illumination lamp) does not Illuminate or Extinguish Normally........................................................367 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................368 STEP 1. M.U.T.-III other system diagnosis code.....................................................................................................................................................................368 STEP 2. M.U.T.-III data list.......................................................................................................................................................................................368 STEP 3. Check the door lock actuator (RH)..........................................................................................................................................................................368 STEP 4. Retest the system..........................................................................................................................................................................................368 Inspection Procedure 2: The Front Room Lamp does not Illuminate Normally...................................................................................................................................................369 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................369 STEP 1. Check that the rear room lamp and ignition key cylinder illumination lamp illuminates......................................................................................................................369 STEP 2. Retest the system..........................................................................................................................................................................................370 STEP 3. Connector check: D-03 front room lamp connector............................................................................................................................................................370 STEP 4. Check the bulb.............................................................................................................................................................................................370 STEP 5. Check the front room lamp..................................................................................................................................................................................370 STEP 6. Check the wiring harness from D-03 front room lamp connector terminal No.2 to battery......................................................................................................................370 STEP 7. Connector check: C-218 ETACS-ECU connector and D-03 front room lamp connector..............................................................................................................................371 STEP 8. Check the wiring harness from C-218 ETACS-ECU connector terminal No.18 to D-03 front room lamp connector terminal No.1.....................................................................................371 Inspection Procedure 3: The Rear Room Lamp does not Illuminate Normally....................................................................................................................................................372 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................372 STEP 1. Check if the front room lamp and ignition key cylinder illumination lamp illuminates.......................................................................................................................372 STEP 2. Retest the system..........................................................................................................................................................................................373 STEP 3. Connector check: D-06 rear room lamp connector.............................................................................................................................................................373 STEP 4. Check the bulb.............................................................................................................................................................................................373 STEP 5. Check the rear room lamp...................................................................................................................................................................................373 STEP 6. Check the wiring harness from D-06 rear room lamp connector terminal No.1 to battery.......................................................................................................................373 STEP 7. Connector check: C-218 ETACS-ECU connector and D-06 rear room lamp connector...............................................................................................................................374 STEP 8. Check the wiring harness from C-218 ETACS-ECU connector terminal No.18 to D-06 rear room lamp connector terminal No.2......................................................................................374 Inspection Procedure 4: The Ignition Key Cylinder Illumination Lamp does not Illuminate Normally...........................................................................................................................375 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................376 STEP 1. Check the operation of the front room lamp and rear room lamp..............................................................................................................................................376 STEP 2. M.U.T.-III data list.......................................................................................................................................................................................376 STEP 3. Check the key reminder switch..............................................................................................................................................................................376 STEP 4. Connector check: C-301 key reminder switch connector.......................................................................................................................................................376 STEP 5. Check the bulb of the ignition key cylinder illumination lamp..............................................................................................................................................376 STEP 6. Voltage measurement at C-301 key reminder switch connector.................................................................................................................................................376 STEP 7. Check the wiring harness from C-301 key reminder switch connector terminal No.2 to battery.................................................................................................................377 STEP 8. Connector check: C-220 ETACS-ECU connector.................................................................................................................................................................377 STEP 9. Check the wiring harness from C-220 ETACS-ECU connector terminal No.32 to C-301 key reminder switch connector terminal No.1................................................................................377 STEP 10. Retest the system.........................................................................................................................................................................................378 ON-VEHICLE SERVICE.........................................................................................................................................................................................................378 HOW TO ADJUST THE ROOM LAMP DELAY-OFF TIME.............................................................................................................................................................................378 REMOVAL AND INSTALLATION...................................................................................................................................................................................................378 REAR COMBINATION LAMP..........................................................................................................................................................................................................379 SPECIAL TOOL...............................................................................................................................................................................................................379 REMOVAL AND INSTALLATION...................................................................................................................................................................................................379 REFLECTOR......................................................................................................................................................................................................................380 SPECIFICATIONS.............................................................................................................................................................................................................380 REMOVAL AND INSTALLATION...................................................................................................................................................................................................380 HIGH-MOUNTED STOP LAMP.........................................................................................................................................................................................................381 REMOVAL AND INSTALLATION...................................................................................................................................................................................................381 LICENCE PLATE LAMP.............................................................................................................................................................................................................381 SPECIAL TOOL...............................................................................................................................................................................................................381 REMOVAL AND INSTALLATION...................................................................................................................................................................................................382 REMOVAL SERVICE POINT..................................................................................................................................................................................................382 HAZARD WARNING LAMP SWITCH.....................................................................................................................................................................................................383 SPECIAL TOOL...............................................................................................................................................................................................................383 REMOVAL AND INSTALLATION...................................................................................................................................................................................................383 INSPECTION.................................................................................................................................................................................................................383 HAZARD WARNING LAMP SWITCH CONTINUITY CHECK............................................................................................................................................................................383 HORN...........................................................................................................................................................................................................................384 REMOVAL AND INSTALLATION...................................................................................................................................................................................................384 INSPECTION.................................................................................................................................................................................................................384 HORN RELAY CONTINUITY CHECK............................................................................................................................................................................................384 CIGARETTE LIGHTER..............................................................................................................................................................................................................385 INSPECTION.................................................................................................................................................................................................................385 ACCESSORY SOCKET...............................................................................................................................................................................................................385 INSPECTION.................................................................................................................................................................................................................385 ACCESSORY SOCKET RELAY CHECK...........................................................................................................................................................................................385 COLUMN SWITCH..................................................................................................................................................................................................................386 SPECIAL TOOL...............................................................................................................................................................................................................386 REMOVAL AND INSTALLATION...................................................................................................................................................................................................386 INSPECTION.................................................................................................................................................................................................................386 LIGHTING SWITCH CONTINUITY CHECK.......................................................................................................................................................................................386 COLUMN SWITCH (SWITCH BODY) CONTINUITY CHECK...........................................................................................................................................................................387 CLOCK <VEHICLES WITHOUT RV METER>..............................................................................................................................................................................................388 REMOVAL AND INSTALLATION...................................................................................................................................................................................................388 RADIO AND TAPE PLAYER OR CD PLAYER.............................................................................................................................................................................................389 SPECIAL TOOLS..............................................................................................................................................................................................................389 TROUBLESHOOTING............................................................................................................................................................................................................389 INTRODUCTION TO AUDIO SYSTEM DIAGNOSIS.....................................................................................................................................................................................389 AUDIO ERROR CODES......................................................................................................................................................................................................389 TROUBLESHOOTING............................................................................................................................................................................................................390 STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING.............................................................................................................................................................................390 TROUBLE SYMPTOM CHART......................................................................................................................................................................................................391 SYMPTOM PROCEDURES.........................................................................................................................................................................................................392 Inspection Procedure 1: Power of Radio and Tape Player or CD Player does not Turn ON when the Ignition Switch is in the "ACC" Position or "ON" Position....................................................................392 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................392 STEP 1. Check to see that the power turns ON when the power switch is turned ON....................................................................................................................................392 STEP 2. Connector check: radio and tape player or CD player connector C-125........................................................................................................................................393 STEP 3. Voltage measurement at radio and tape player or CD player connector C-125 in order to check the battery circuit of power supply system to the radio and tape player or CD player (ignition switch ACC).....393 STEP 4. Check the wiring harness between radio and tape player or CD player connector C-125 (terminal 10) and ignition switch (ACC)................................................................................394 STEP 5. Check the assembling state of the radio and tape player or CD player.......................................................................................................................................394 Inspection Procedure 2: No Sound from One Speaker..........................................................................................................................................................................395 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................396 STEP 1. Check to see which speaker the sound is not output from....................................................................................................................................................396 STEP 2. Check the front door speaker (LH)..........................................................................................................................................................................396 STEP 3. Connector check: Front door speaker (LH) connector E-19 and radio and tape player or CD player connector C-125.............................................................................................396 STEP 4. Check the wiring harness between front door speaker (LH) connector E-19 (terminal 1 and 2) and radio and tape player or CD player connector C-125 (terminals 5 and 13).....................................397 STEP 5. Check the front door speaker (RH)..........................................................................................................................................................................397 STEP 6. Connector check: Front door speaker (RH) connector E-11 and radio and tape player or CD player connector C-125.............................................................................................397 STEP 7. Check the wiring harness between front door speaker (RH) connector E-11 (terminal 1 and 2) and radio and tape player or CD player connector C-125 (terminal 6 and 14)......................................398 STEP 8. Check the rear door speaker (LH)...........................................................................................................................................................................398 STEP 9. Connector check: Rear door speaker (LH) connector E-22 and radio and tape player or CD player connector C-125..............................................................................................398 STEP 10. Check the wiring harness between rear door speaker (LH) connector E-22 (terminal 1 and 2) and radio and tape player or CD player connector C-125 (terminal 2 and 8).......................................399 STEP 11. Check the rear door speaker (RH)..........................................................................................................................................................................399 STEP 12. Connector check: Rear door speaker (RH) connector E-09 and radio and tape player or CD player connector C-125.............................................................................................399 STEP 13. Check the wiring harness between rear door speaker (RH) connector E-09 (terminals 1 and 2) and radio and tape player or CD player connector C-125 (terminals 1 and 7).....................................400 Inspection Procedure 3: Noise Appears at Certain Places when Travelling (AM)...............................................................................................................................................401 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................401 STEP 1. Check the noise occur when entering or near a particular structure (building, tunnel, mountain, etc).......................................................................................................401 STEP 2. After taking the following measures to prevent the noise, check that no noise appears......................................................................................................................401 STEP 3. Ask the owner about the state of the noise.................................................................................................................................................................401 STEP 4. Check that there is no noise...............................................................................................................................................................................401 Inspection Procedure 4: Noise is Present while Moving (FM).................................................................................................................................................................401 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................401 Inspection Procedure 5: Mixed with Noise, Only at Night (AM)...............................................................................................................................................................402 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................402 STEP 1. Check that the noise still obvious even when the lamps are off.............................................................................................................................................402 STEP 2. Check hat the following actions............................................................................................................................................................................402 STEP 3. Check that the noise fades away when the vehicle harness is moved away from the radio (if the harness is not in the proper position).......................................................................402 Inspection Procedure 6: Broadcasts can be Heard but Both AM and FM have a lot of Noise.....................................................................................................................................403 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................403 STEP 1. Check the state of the antenna.............................................................................................................................................................................403 STEP 2. Check that the noise occur when the engine is stopped or the engine is running.............................................................................................................................403 STEP 3. Check that the following actions disappear the noise.......................................................................................................................................................403 STEP 4. Check that the radio is correctly earthed..................................................................................................................................................................403 STEP 5. Check the connection of the antenna plug and radio and tape player or CD player............................................................................................................................403 STEP 6. Check that the noise is eliminated when the antenna plug is properly attached..............................................................................................................................403 STEP 7. Check that the antenna is in good condition and is it properly mounted.....................................................................................................................................403 Inspection Procedure 7: There is More Noise on Either AM or FM.............................................................................................................................................................404 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................404 STEP 1. Check that there is noise under the following state(s).....................................................................................................................................................404 STEP 2. Continue to check for static; when static is detected, check for the conditions listed above...............................................................................................................404 STEP 3. Check noise prevention on the radio side is difficult......................................................................................................................................................404 Inspection Procedure 8: There is Noise when Starting the Engine............................................................................................................................................................405 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................405 Inspection Procedure 9: Some Noise Appears when there is Vibration or Shocks During Travelling.............................................................................................................................407 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................407 STEP 1. Connector check: Radio and tape player or CD player connector C-125........................................................................................................................................407 STEP 2. Check that noise appear when the radio switch is turned on while the vehicle is stopped and the radio is tapped while tuned away from a station............................................................407 STEP 3. Check that the radio correctly earthed.....................................................................................................................................................................407 STEP 4. Check by replacing the radio and tape player or CD player..................................................................................................................................................407 Inspection Procedure 10: Noise Sometimes Appears on FM during Travelling...................................................................................................................................................408 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................408 STEP 1. Check the state of the antenna.............................................................................................................................................................................408 STEP 2. The check after adjusting the radio........................................................................................................................................................................408 STEP 3. Check with several broadcasting stations...................................................................................................................................................................408 STEP 4. Check that noise appears when the radio switch is turned on while the vehicle is stopped...................................................................................................................408 STEP 5. Check that the radio is correctly earthed..................................................................................................................................................................408 STEP 6. Check by replacing the radio and tape player or CD player..................................................................................................................................................408 Inspection Procedure 11: Ever-Present Noise................................................................................................................................................................................408 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................408 Inspection Procedure 12: There is Noise but No Reception for Both AM and FM or No Sound from AM, or No Sound from FM.......................................................................................................409 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................409 STEP 1. Check the state of the antenna.............................................................................................................................................................................409 STEP 2. Check to see if inspections are taking place is an area exposed to special electric fields.................................................................................................................409 STEP 3. Relocate and check.........................................................................................................................................................................................409 STEP 4. Tune then check............................................................................................................................................................................................409 STEP 5. Check the connection of the antenna plug and the radio and tape player or CD player........................................................................................................................409 STEP 6. Check by replacing the radio and tape player or CD player..................................................................................................................................................409 Inspection Procedure 13: Poor Reception....................................................................................................................................................................................409 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................409 STEP 1. Check the state of the antenna.............................................................................................................................................................................409 STEP 2. Check to see if inspections are taking place is an area exposed to special electric fields.................................................................................................................409 STEP 3. Relocate and check.........................................................................................................................................................................................409 STEP 4. Tune then check............................................................................................................................................................................................409 STEP 5. Check with several broadcasting stations...................................................................................................................................................................410 STEP 6. Check the connection of the antenna plug and the radio and tape player or CD player........................................................................................................................410 STEP 7. Check by replacing the radio and tape player or CD player..................................................................................................................................................410 Inspection Procedure 14: Distortion on AM or on Both AM and FM.............................................................................................................................................................410 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................410 STEP 1. Check the degree in which distortion is generated..........................................................................................................................................................410 STEP 2. Check by the transmission antenna..........................................................................................................................................................................410 STEP 3. Check how the speakers are setup...........................................................................................................................................................................410 STEP 4. Check the speakers.........................................................................................................................................................................................410 STEP 5. Check how the speakers are setup...........................................................................................................................................................................410 Inspection Procedure 15: Distortion on FM Only.............................................................................................................................................................................411 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................411 STEP 1. Check with another broadcasting station....................................................................................................................................................................411 STEP 2. Relocate the reception area and check......................................................................................................................................................................411 Inspection Procedure 16: Using the Auto Select Function, Too Few Automatic Stations are Selected...........................................................................................................................411 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................411 STEP 1. Check the state of the antenna.............................................................................................................................................................................411 STEP 2. Check the number of radio stations.........................................................................................................................................................................411 STEP 3. Check the distance from the transmission antenna...........................................................................................................................................................411 STEP 4. The check if there are not that many radio stations and when there is no transmission antenna in the vicinity..............................................................................................411 STEP 5. Check to see if inspections are taking place is an area exposed to special electric fields.................................................................................................................411 STEP 6. Relocate and check.........................................................................................................................................................................................411 STEP 7. Check the connection of the antenna plug and the radio and tape player or CD player........................................................................................................................411 Inspection Procedure 17: Preset Station are Erased.........................................................................................................................................................................412 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................412 STEP 1. Voltage measurement at radio and tape player or CD player connector C-125..................................................................................................................................412 STEP 2. Connector check: Radio and tape player or CD player connector C-125........................................................................................................................................413 STEP 3. Check the wiring harness between radio and tape player or CD player connector C-125 (terminal 11) and battery..............................................................................................413 Inspection Procedure 18: Cassette Tape can Not be Inserted.................................................................................................................................................................414 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................414 STEP 1. Check that there are any foreign objects inside the cassette player........................................................................................................................................414 STEP 2. Check that the radio with cassette player works when another tape is inserted..............................................................................................................................414 Inspection Procedure 19: Sound Quality is Poor, or Sound is Weak...........................................................................................................................................................414 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................414 STEP 1. Check that the player works normally if the tape is changed................................................................................................................................................414 STEP 2. Check that the player play OK if the tape player head is cleaned...........................................................................................................................................414 STEP 3. Check that the proper operation is obtained when the tape player is replaced...............................................................................................................................414 Inspection Procedure 20: Cassette Tape can Not be Ejected..................................................................................................................................................................414 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................414 Inspection Procedure 21: Uneven Revolution. Tape Speed is Fast or Slow.....................................................................................................................................................415 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................415 STEP 1. Check that the cassette player work normally when the tape is changed......................................................................................................................................415 STEP 2. Check that there are any foreign objects inside the cassette player........................................................................................................................................415 STEP 3. Check that the head or capstan roller is dirty.............................................................................................................................................................415 Inspection Procedure 22: Automatic Search does Not Work....................................................................................................................................................................415 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................415 STEP 1. Check that the "APS" (automatic search) button be depressed properly.......................................................................................................................................415 STEP 2. Check that the player works when the tape is changed.......................................................................................................................................................415 Inspection Procedure 23: Malfunction of the Auto Reverse...................................................................................................................................................................416 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................416 STEP 1. Check that the cassette player works normally when the tape is changed.....................................................................................................................................416 STEP 2. Check that the problem only occur while the vehicle is being driven........................................................................................................................................416 STEP 3. Check that the cassette player is properly installed to the vehicle........................................................................................................................................416 Inspection Procedure 24: Tape gets Caught in Mechanism.....................................................................................................................................................................416 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................416 Check that the player works normally if tape is changed............................................................................................................................................................416 Inspection Procedure 25: CD can Not be Inserted............................................................................................................................................................................417 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................417 STEP 1. Check that a CD has been already loaded....................................................................................................................................................................417 STEP 2. Check how a CD is inserted.................................................................................................................................................................................417 STEP 3. Check after the CD is loaded...............................................................................................................................................................................417 STEP 4. Check the CD...............................................................................................................................................................................................417 STEP 5. Check again using a normal CD, which is not dirty or scratched.............................................................................................................................................417 Inspection Procedure 26: No Sound. (CD only)...............................................................................................................................................................................417 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................417 STEP 1. Check again using a normal CD, which is not dirty or scratched.............................................................................................................................................417 STEP 2. Check power supply to the CD player when the ignition switch is at "ACC" or "ACC"..........................................................................................................................417 Inspection Procedure 27: CD Sound Skips....................................................................................................................................................................................418 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................418 STEP 1. Check the state in which the sound on the CD jumps.........................................................................................................................................................418 STEP 2. Check the surface of the CD................................................................................................................................................................................418 STEP 3. Check when replacing with a CD that can be played normally without any scratches or soiling................................................................................................................418 STEP 4. Check by tapping the radio and CD player...................................................................................................................................................................418 Inspection Procedure 28: Sound Quality is Poor.............................................................................................................................................................................418 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................418 Check to see that the CD can be played normally and that it is free of any scratches or soiling....................................................................................................................418 Inspection Procedure 29: CD can not be ejected.............................................................................................................................................................................418 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................418 Check the power of ignition switch "ACC"...........................................................................................................................................................................418 ON-VEHICLE SERVICE.........................................................................................................................................................................................................419 SPEAKER TEST...............................................................................................................................................................................................................419 RADIO AND TAPE PLAYER SPEAKER TEST.....................................................................................................................................................................................419 RADIO AND CD PLAYER SPEAKER TEST.......................................................................................................................................................................................419 RADIO AND TAPE PLAYER OR CD PLAYER.........................................................................................................................................................................................420 REMOVAL AND INSTALLATION...................................................................................................................................................................................................420 SPEAKER........................................................................................................................................................................................................................421 REMOVAL AND INSTALLATION...................................................................................................................................................................................................421 REMOVAL SERVICE POINTS.................................................................................................................................................................................................421 ANTENNA........................................................................................................................................................................................................................422 REMOVAL AND INSTALLATION...................................................................................................................................................................................................422 REMOVAL SERVICE POINT..................................................................................................................................................................................................422 RV METER.......................................................................................................................................................................................................................423 SPECIAL TOOLS..............................................................................................................................................................................................................423 TROUBLESHOOTING............................................................................................................................................................................................................424 TROUBLE DIAGMOSIS SERVICE FUNCTIONS........................................................................................................................................................................................424 BATTERY DISCONNECTION..................................................................................................................................................................................................432 DIAGNOSTIC FUNCTION........................................................................................................................................................................................................433 HOW TO READ DIAGNOSIS CODE.............................................................................................................................................................................................433 HOW TO ERASING DIAGNOSIS CODE..........................................................................................................................................................................................433 DIAGNOSIS CODE CHART.......................................................................................................................................................................................................433 DIAGNOSTIC TROUBLE CODE PROCEDURES.........................................................................................................................................................................................433 Code No. 24: Open circuit in the SWS.......................................................................................................................................................................................433 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................434 STEP 1. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................434 STEP 2. Connector check: RV meter connector C-108 and CAN adapter connector C-110..................................................................................................................................434 STEP 3. Check the harness wires between RV meter connector C-108 (terminal 26) and CAN adapter connector C-110 (terminal 2)........................................................................................435 STEP 4. Check whether the diagnosis code is reset..................................................................................................................................................................435 STEP 5. Check whether the diagnosis code is reset..................................................................................................................................................................435 Code No. 25: Open circuit in the K-LINE....................................................................................................................................................................................436 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................436 STEP 1. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................436 STEP 2. Connector check: RV meter connector C-108 and CAN adapter connector C-110..................................................................................................................................437 STEP 3. Check the harness wires between RV meter connector C-108 (terminal 35) and CAN adapter connector C-110 (terminal 8)........................................................................................437 STEP 4. Check whether the diagnosis code is reset..................................................................................................................................................................437 STEP 5. Check whether the diagnosis code is reset..................................................................................................................................................................438 SYMPTOM CHART..............................................................................................................................................................................................................438 SYMPTOM PROCEDURES.........................................................................................................................................................................................................439 Inspection Procedure 1: The RV Meter does not Show Any Information.........................................................................................................................................................439 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................440 STEP 1. Check the following connector: C-108 RV meter connector....................................................................................................................................................440 STEP 2. Measure the resistance at C-108 RV meter connector.........................................................................................................................................................440 STEP 3. Check the harness wire between C-108 RV meter connector terminal No.8 and body earth.......................................................................................................................440 STEP 4. Measure the voltage at C-108 RV meter connector............................................................................................................................................................440 STEP 5. Check the harness wire between battery (fusible link No.20) and C-108 RV meter connector terminal No.6.....................................................................................................441 STEP 6. Measure the voltage at C-108 RV meter connector............................................................................................................................................................441 STEP 7. Check the harness wire between ignition switch (ACC) and C-108 RV meter connector terminal No.5............................................................................................................442 STEP 8. Replace the RV meter temporarily and retest the system.....................................................................................................................................................442 STEP 9. Retest the system..........................................................................................................................................................................................442 Inspection Procedure 2: "Please Turn the Ignition Key to the ON Position." is continuously displayed.......................................................................................................................443 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................444 STEP 1. Check the communication and connection (ignition switch (IG1)) of the service function.....................................................................................................................444 STEP 2. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................444 STEP 3. M.U.T.-III other system diagnosis code.....................................................................................................................................................................444 STEP 4. M.U.T.-III diagnosis code..................................................................................................................................................................................444 STEP 5. Check the following connector: C-110 CAN adapter connector.................................................................................................................................................444 STEP 6. Measure the resistance at C-110 CAN adapter connector......................................................................................................................................................444 STEP 7. Check the harness wire between C-110 CAN adapter connector terminal No.4 and body earth....................................................................................................................445 STEP 8. Measure the voltage at C-110 CAN adapter connector.........................................................................................................................................................445 STEP 9. Check the harness wire between ignition switch (ACC) and C-110 CAN adapter connector terminal No.1.........................................................................................................446 STEP 10. Replace the RV meter temporarily and retest the system....................................................................................................................................................446 Inspection Procedure 3: The Low Battery Warning Screen is Displayed........................................................................................................................................................447 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................447 STEP 1.Check the RV meter power supply.............................................................................................................................................................................447 STEP 2. Check the following connector: C-108 RV meter connector....................................................................................................................................................447 STEP 3. Measure the voltage at C-108 RV meter connector............................................................................................................................................................448 STEP 4. Check the harness wire between battery (fusible link No.20) and C-108 RV meter connector terminal No.6.....................................................................................................448 STEP 5. Recheck for malfunction....................................................................................................................................................................................448 Inspection Procedure 4: The Drive Information is not Displayed Normal......................................................................................................................................................449 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................450 STEP 1. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................450 STEP 2. M.U.T-III other system diagnosis code......................................................................................................................................................................450 STEP 3. M.U.T.-III diagnosis code..................................................................................................................................................................................450 STEP 4. Connector check: Fuel pump and gauge unit connector F-09...................................................................................................................................................450 STEP 5. Check the Fuel pump and gauge unit.........................................................................................................................................................................450 STEP 6. Check the communication and connection (the fuel pump and gauge unit) of the service function..............................................................................................................450 STEP 7. Measure the resistance at F-09 fuel pump and gauge unit connector..........................................................................................................................................451 STEP 8. Check the harness wire between F-09 fuel pump and gauge unit connector terminal No.2 and body earth........................................................................................................451 STEP 9. Connector check: RV meter connector C-108..................................................................................................................................................................451 STEP 10. Check the wiring harness between C-108 RV meter connector terminal No.13 and F-09 fuel pump and gauge unit connector terminal No.1........................................................................451 STEP 11. Recheck for malfunction...................................................................................................................................................................................452 Inspection Procedure 5: The Ambient Air Temperature is not Displayed Normal................................................................................................................................................452 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................453 STEP 1. Check the following connector: A-36 ambient air temperature sensor.........................................................................................................................................453 STEP 2. Check the ambient air temperature sensor...................................................................................................................................................................453 STEP 3. Check the communication and connection (the ambient air temperature sensor) of the service function........................................................................................................453 STEP 4. Check the following connector: C-108 RV meter connector....................................................................................................................................................453 STEP 5. Check the harness wire between C-108 RV meter connector terminals No.3, 11 and A-36 ambient air temperature sensor connector terminals No.1, 2.............................................................454 STEP 6. M.U.T-III other system data list...........................................................................................................................................................................454 STEP 7. Check the following connector: B-01 vehicle speed sensor connector.........................................................................................................................................455 STEP 8. Check the wiring harness between B-01 vehicle speed sensor connector terminal No.3 and C-108 RV meter connector terminal No.7..............................................................................456 STEP 9. Recheck for malfunction....................................................................................................................................................................................456 Inspection Procedure 6: Icy road surface warning function does not work normally...........................................................................................................................................457 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................458 STEP 1. M.U.T.-III CAN bus diagnostics.............................................................................................................................................................................458 STEP 2. M.U.T-III other system diagnosis code......................................................................................................................................................................458 STEP 3. M.U.T.-III diagnosis code..................................................................................................................................................................................458 Step 4. Recheck for malfunction....................................................................................................................................................................................458 Inspection Procedure 7: The Compass does not Indicate Normally.............................................................................................................................................................458 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................458 STEP 1. Check the geomagnetism sensor mode in service mode.........................................................................................................................................................458 STEP 2.Check of own vehicle position...............................................................................................................................................................................458 STEP 3. Move the vehicle to the geomagnetically stable location to re-check the geomagnetism.......................................................................................................................458 STEP 4. Check of RV meter for magnetization........................................................................................................................................................................458 STEP 5. Recheck for malfunction....................................................................................................................................................................................459 Inspection Procedure 8: The Radio and CD Player Information is not Displayed Normal........................................................................................................................................459 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................460 STEP 1. Connector check: Radio and CD player connector C-126 and RV meter connector C-109..........................................................................................................................460 STEP 2. Check the wiring harness between radio and CD player connector C-126 (terminal 26, 27 and 34) and centre display unit connector C-109 (terminal 27, 37 and 28).............................................460 STEP 3. Retest the system..........................................................................................................................................................................................460 Inspection Procedure 9: Button illumination of RV meter does not illuminate................................................................................................................................................461 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................461 STEP 1.Check the RV meter power supply.............................................................................................................................................................................461 STEP 2. M.U.T-III other system diagnosis code......................................................................................................................................................................461 STEP 3. Check of combination meter trouble symptom.................................................................................................................................................................461 STEP 4. Check the following connector: C-108 RV meter connector, C-113 combination meter connector.................................................................................................................462 STEP 5. Check the harness wire between C-108 RV meter connector terminal No.12 and C-113 combination meter connector terminal No.15................................................................................462 STEP 6. Check the following connector C-220 ETACS-ECU connector....................................................................................................................................................463 STEP 7. Check the harness wire between C-108 RV meter connector terminal No.4 and C-220 ETACS-ECU connector terminal No.34.........................................................................................463 STEP 8. Recheck for malfunction....................................................................................................................................................................................463 CHECK AT ECU TERMINAL......................................................................................................................................................................................................464 RV METER...............................................................................................................................................................................................................464 CAN ADAPTER............................................................................................................................................................................................................466 ON-VEHICLE SERVICE.........................................................................................................................................................................................................467 VEHICLE MAGNETIC COMPENSATION..............................................................................................................................................................................................467 Confirmation of magnetization and demagnetization......................................................................................................................................................................467 Demagnetization and correction method..................................................................................................................................................................................468 RV METER...................................................................................................................................................................................................................470 REMOVAL AND INSTALLATION...................................................................................................................................................................................................470 AMBIENT AIR TEMPERATURE SENSOR.............................................................................................................................................................................................471 REMOVAL AND INSTALLATION...................................................................................................................................................................................................471 INSPECTION.................................................................................................................................................................................................................471 DEFOGGER.......................................................................................................................................................................................................................471 TROUBLESHOOTING............................................................................................................................................................................................................471 ON-VEHICLE SERVICE.........................................................................................................................................................................................................471 PRINTED HEATER LINES CHECK.................................................................................................................................................................................................471 REAR WINDOW DEMISTER RELAY CHECK.......................................................................................................................................................................................472 DEFOGGER SWITCH................................................................................................................................................................................................................472 REMOVAL AND INSTALLATION...................................................................................................................................................................................................472 54C.pdf................................................................................................................................................................................................................................473 CONTROLLER AREA NETWORK (CAN)......................................................................................................................................................................................................473 GENERAL INFORMATION............................................................................................................................................................................................................474 STRUCTURE..................................................................................................................................................................................................................474 SPECIAL TOOL...................................................................................................................................................................................................................475 TEST EQUIPMENT.................................................................................................................................................................................................................476 SERVICE PRECAUTIONS............................................................................................................................................................................................................477 PRECAUTIONS ON HOW TO REPAIR THE CAN BUS LINES.................................................................................................................................................................................478 EXPLANATION ABOUT THE MUT-III CAN BUS DIAGNOSTICS..............................................................................................................................................................................479 CAN BUS LINE DIAGNOSTIC FLOW...............................................................................................................................................................................................479 TROUBLESHOOTING................................................................................................................................................................................................................486 CAN BUS DIAGNOSTICS TABLE..................................................................................................................................................................................................486 CAN BUS DIAGNOSIS..........................................................................................................................................................................................................490 Diagnosis Item 1: Diagnose shorts in the power supply to CAN bus line......................................................................................................................................................490 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................491 STEP 1. Check the CAN bus lines. Voltage measurement at C-22 diagnosis connector...................................................................................................................................491 STEP 2. Check the CAN line. Voltage measurement at C-35 intermediate connector.....................................................................................................................................492 STEP 3. Check the CAN line between joint connector (CAN2) and the engine-ECU. Voltage measurement at C-01 joint connector (CAN2)...................................................................................493 STEP 4. Check the CAN line between joint connector (CAN2) and the A/T-ECU. Voltage measurement at C-01 joint connector (CAN2)......................................................................................494 STEP 5. M.U.T.-III CAN bus diagnostics [A/T-ECU connector disconnected]............................................................................................................................................494 STEP 6. M.U.T.-III CAN bus diagnostics (retest the system).........................................................................................................................................................494 STEP 7. Check the CAN line between joint connector (CAN1) and the ETACS-ECU. Voltage measurement at C-119 joint connector (CAN1)...................................................................................495 STEP 8. Check the CAN line between joint connector (CAN1) and the CAN adapter. Voltage measurement at C-119 joint connector (CAN1).................................................................................496 STEP 9. M.U.T.-III CAN bus diagnostics [CAN adapter connector disconnected]........................................................................................................................................497 STEP 10. Check the CAN line between joint connector (CAN1) and the ABS-ECU. Voltage measurement at C-119 joint connector (CAN1)....................................................................................497 STEP 11. M.U.T.-III CAN bus diagnostics [ABS-ECU connector disconnected]...........................................................................................................................................498 STEP 12. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................499 STEP 13. Check the CAN line between joint connector (CAN1) and the diagnosis connector. Voltage measurement at C-119 joint connector (CAN1)........................................................................499 STEP 14. M.U.T.-III CAN bus diagnostics [engine-ECU connector disconnected]........................................................................................................................................500 STEP 15. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................500 STEP 16. M.U.T.-III CAN bus diagnostics [ETECS-ECU connector disconnected].........................................................................................................................................500 STEP 17. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................501 Diagnosis Item 2: Diagnose shorts in the ground to CAN bus line............................................................................................................................................................502 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................504 STEP 1.Check the CAN bus lines. Resistance measurement at C-22 diagnosis connector.................................................................................................................................504 STEP 2. Check the CAN line. Resistance measurement at C-35 intermediate connector..................................................................................................................................505 STEP 3. Check the CAN line between joint connector (CAN2) and the engine-ECU. Resistance measurement at C-01 joint connector (CAN2)................................................................................506 STEP 4. Check the CAN line between joint connector (CAN2) and the A/T-ECU. Resistance measurement at C-01 joint connector (CAN2)...................................................................................507 STEP 5. M.U.T.-III CAN bus diagnostics [A/T-ECU connector disconnected]............................................................................................................................................507 STEP 6. M.U.T.-III CAN bus diagnostics (retest the system).........................................................................................................................................................508 STEP 7. Check CAN line between joint connector (CAN1) and the ETACS-ECU. Resistance measurement at C-119 joint connector (CAN1)....................................................................................509 STEP 8. Check the CAN line between joint connector (CAN1) and the CAN adapter. Resistance measurement at C-119 joint connector (CAN1)..............................................................................510 STEP 9. M.U.T.-III CAN bus diagnostics [CAN adapter connector disconnected]........................................................................................................................................510 STEP 10. Check the CAN line between joint connector (CAN1) and the ABS-ECU. Resistance measurement at C-119 joint connector (CAN1).................................................................................512 STEP 11. M.U.T.-III CAN bus diagnostics [ABS-ECU connector disconnected]...........................................................................................................................................513 STEP 12. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................513 STEP 13. Check the CAN line between joint connector (CAN1) and the diagnosis connector. Resistance measurement at C-119 joint connector (CAN1).....................................................................514 STEP 14. M.U.T.-III CAN bus diagnostics [engine-ECU connector disconnected]........................................................................................................................................515 STEP 15. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................515 STEP 16. M.U.T.-III CAN bus diagnostics [ETECS-ECU connector disconnected].........................................................................................................................................515 STEP 17. M.U.T.-III CAN bus diagnostics (retest the system)........................................................................................................................................................516 Diagnosis Item 3: Diagnose shorts between CAN_H and L lines................................................................................................................................................................517 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................518 STEP 1. Connector check: C-35 intermediate connector...............................................................................................................................................................518 STEP 2. Resistance measurement at C-35 intermediate connector......................................................................................................................................................518 STEP 3. Connector check: C-01 joint connector (CAN2)...............................................................................................................................................................519 STEP 4. Resistance measurement at C-01 joint connector (CAN2)......................................................................................................................................................519 STEP 5. Resistance measurement at C-106 <2500-SOHC> or C-103 <2500-DOHC, 3200> engine-ECU connector................................................................................................................520 STEP 6. Resistance measurement at C-01 joint connector (CAN2)......................................................................................................................................................520 STEP 7. Resistance measurement at C-18 <2WD> or C-20 <4WD> A/T-ECU connector.......................................................................................................................................522 STEP 8. Connector check: C-119 joint connector (CAN1)..............................................................................................................................................................522 STEP 9. Resistance measurement at C-119 joint connector (CAN1).....................................................................................................................................................523 STEP 10. Resistance measurement at C-219 ETACS-ECU connector.......................................................................................................................................................523 STEP 11. Resistance measurement at C-119 joint connector (CAN1)....................................................................................................................................................524 STEP 12. Resistance measurement at C-110 CAN adapter connector.....................................................................................................................................................524 STEP 13. Resistance measurement at C-119 joint connector (CAN1)....................................................................................................................................................525 STEP 14. Resistance measurement at A-01 ABS-ECU connector..........................................................................................................................................................526 STEP 15. Resistance measurement at C-119 joint connector (CAN1)....................................................................................................................................................526 Diagnosis Item 4: Diagnose the terminator resistors........................................................................................................................................................................527 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................528 STEP 1. Resistance measurement at C-219 ETACS-ECU connector........................................................................................................................................................528 STEP 2. Resistance measurement at C-106 <2500-SOHC> or C-103 <2500-DOHC, 3200> engine-ECU connector................................................................................................................529 Diagnosis Item 5: Diagnose when the M.U.T.-III cannot receive the data sent by ETACS-ECU...................................................................................................................................530 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................531 STEP 1. Connector check: C-119 joint connector (CAN1) and C-219 ETACS-ECU connector................................................................................................................................531 STEP 2. Resistance measurement at C-119 joint connector (CAN1) and C-219 ETACS-ECU connector.......................................................................................................................531 STEP 3. Resistance measurement at C-219 ETACS-ECU connector........................................................................................................................................................533 Diagnosis Item 6: Diagnose when the M.U.T.-III cannot receive the data sent by CAN adapter. <Vehicles with RV meter>.......................................................................................................534 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................535 STEP 1. Connector check: C-119 joint connector (CAN1) and C-110 CAN adapter connector..............................................................................................................................535 STEP 2. Resistance measurement at C-119 joint connector (CAN1) and C-110 CAN adapter connector.....................................................................................................................535 Diagnosis Item 7: Diagnose when the M.U.T.-III cannot receive the data sent by ABS-ECU. <Vehicles with ABS>................................................................................................................537 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................538 STEP 1. Connector check: C-13 intermediate connector, C-119 joint connector (CAN1) and A-01 ABS-ECU connector......................................................................................................538 STEP 2. Resistance measurement at C-119 joint connector (CAN1) and C-13 intermediate connector.....................................................................................................................538 STEP 3. Resistance measurement at C-13 intermediate connector and A-01 ABS-ECU connector...........................................................................................................................540 Diagnosis Item 8: Diagnose the lines between the joint connectors (CAN1 and CAN2)..........................................................................................................................................542 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................543 STEP 1. Connector check: C-35 intermediate connector, C-119 joint connector (CAN1) and C-01 joint connector (CAN2).................................................................................................543 STEP 2. Resistance measurement at C-119 joint connector (CAN1) and C-35 intermediate connector.....................................................................................................................544 STEP 3. Resistance measurement at C-01 joint connector (CAN2) and C-35 intermediate connector......................................................................................................................546 Diagnosis Item 9: Diagnose when the M.U.T.-III cannot receive the data sent by A/T-ECU. <A/T>..............................................................................................................................548 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................549 STEP 1. Connector check: C-01 joint connector (CAN2) and C-18 <2WD> or C-20 <4WD> A/T-ECU connector................................................................................................................549 STEP 2. Resistance measurement at C-01 joint connector (CAN2) and C-18 <2WD> or C-20 <4WD> A/T-ECU connector.......................................................................................................549 Diagnosis Item 10: Diagnose when the M.U.T.-III cannot receive the data sent by engine-ECU.................................................................................................................................552 DIAGNOSIS PROCEDURE....................................................................................................................................................................................................553 STEP 1. Connector check: C-01 joint connector (CAN2) and C-106 engine-ECU connector................................................................................................................................553 STEP 2. Resistance measurement at C-01 joint connector (CAN2) and C-106 <2500-SOHC> or C-103 <2500-DOHC, 3200> engine-ECU connector................................................................................554 STEP 3. Resistance measurement at C-106 <2500-SOHC> or C-103 <2500-DOHC, 3200> engine-ECU connector................................................................................................................556 CAN COMMUNICATION SIGNAL TABLE.................................................................................................................................................................................................557 CAN COMMUNICATION-RELATED DIAGNOSIS CODE (U CODE) TABLE........................................................................................................................................................................558
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