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P.00-15 - Outlander Forum

1. I 991827 ZC5019680000 System Select System List Model Year Up to 2005 1 MPI GDl Diesel Fromto2006m Y 2 Keyless TPM S ATICVI AM T Vehicle formatio n Model OUTLANDER 4 ABS ASC ASTC A Model Year 2007 5 SAS Model Code 6 Multi Select WD Loading Option Setu T SRS Airbag w Option Name With Option 8 AIC 9 ETACS z 10 Meter M t Yer e OK button ZC6037850000 00 29 11 Push the OK button after ENG Key Code Reg is displayed 12 Push the OK button after Completed is displayed 13 Turn off scan tool MB991958 14 Turn the ignition switch to the LOCK OFF position and then disconnect scan tool MB991958 VIN WRITING STEPS FOR WCM AND KOS ECU Check that diagnostic trouble code B2416 ECU internal error is not set When diagnostic trouble code B2416 ECU internal error is set the WCM and the KOS ECU cannot store the VIN even if the VIN is written If this diagnostic trouble code is set troubleshoot the WCM or the KOS ECU and repair Then write the VIN to the WCM or the KOS ECU Connect scan tool 991958 to the 16 pin data link connector as follows NOTE For details on how to use scan tool 45991958 refer to the MU T III Owner s Manual 1 Ensure that the ignition switch is atth
2. 7 TIMING BELT REPLACE M10001000023USA0000010001 Replace the belt with a new one according to the maintenance schedule P 00 53to assure proper engine performance For removal and installation procedures refer to GROUP 11A Engine Mechanical Timing Belt Removal and Installation P 11A 49 8 DRIVE BELT FOR GENERATOR WATER PUMP POWER STEERING OIL PUMP CHECK CONDITION M10001000025USA0000010001 Power steering oil pump drive belt tension check When using special tool MB992080 recommendation Required Special Tools 992080 Belt tension meter set GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 00 59 992081 Belt tension meter MB992082 Microphone assembly NOTE The vibration frequency measuring method is recommended for check and adjustment of the drive belt tension Belt tension meter set MB992080 1 Connect the special tool MB992082 to the special tool MB992081 of the Special tool MB992080 Press the POWER button to turn on the power supply Press the numeral key of 1 and check that No 1 appears on the upper left of the display N MB992081 NOTE This operation is to temporarily set the preset data such as the belt specifications because if the measurement is taken without inout of the belt specifications conversion to tension value M cannot be 2 5012270000 made resulting judgement of error
3. ZC6037940000 10 Select VIN Writing on Coding screen 11 Push the OK button after the VIN written in the engine control module is displayed 12 Push the OK button after VIN Writing will start Are you sure is displayed 13 Push the OK button after Completed is displayed 14 Result of VIN writing is displayed 15 Resister the other ID code Refer to GROUP 42B Troubleshooting ID Code Registration Judgment Table P 42B 12Vehicles with KOS or GROUP 42C Troubleshooting ID Code Registration Judgment Table P 42C 8Vehicles with WCM INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE M10001000117USA0000010000 When the following service is performed initialize the learning value Replacing engine assembly Replacing throttle body and at cleaning Replacing knock sensor NOTE Initialize A T related learning value INITIALIZATION PROCEDURE Required Special Tools MB991958 Scan Tool M U T III Sub Assembly 991824 V C I 991827 M U T III USB Cable MB991910 M U T III Main Harness MB991824 GENERAL BODY AND CHASSIS PRECAUTIONS BEFORE SERVICE 00 31 N gt 991 827 2 5019680000 Connect scan tool 991958 to the 16 pin data link connector as follows NOTE For details on how to use scan tool 45991958 refer to the MU T III Owner s Manual 1 Ensure that the ignit
4. on cylinder piston is at the top dead center on the compression 5 stroke and on rocker arms indicated by black arrow mark when the No 4 cylinder piston is at the top dead center on the o 6 compression stroke Measure the valve clearance for intake side If the valve clearance is not as specified loosen the rocker arm lock nut and adjust the clearance using a thickness gauge while turning the adjusting screw Standard value hot engine 0 20 mm 0 008 inch NOTE Valve clearance check and adjustment is unnecessary for exhaust side due to auto lash adjuster SIEBEN instal led ZK6003240000 While holding the adjusting screw with a screwdriver to prevent it from turning tighten the lock nut to the specified torque Tightening torque 9 1 N m 80 9 in Ib 9 Turn the crankshaft 360 degrees to line up the notch on the crankshaft pulley with the T mark on the timing indicator 10 Repeat steps 7 and 8 on other valves for clearance adjustment 11 Install the rocker cover 12 Install the ignition coils og a lt lt 2
5. 00 56 1 FUEL SYSTEM TANK PIPE LINE AND CONNECTION AND FUEL TANK FILLER TUBE CAP CHECK FOR LEAKS 00 56 Continued on next page 00 2 2 FUEL HOSES CHECK CONDITION 23 AIR FILTER REPLACE 00 71 4 EVAPORATIVE EMISSION SYSTEM EXCEPT EVAPORATIVE EMISSION CANISTER CHECK FOR CLOGGING 5 SPARK PLUGS 00 57 6 INTAKE AND EXHAUST VALVE CLEARANCE lt INTAKE SIDE ONLY INSPECT AND ADJUST 00 57 7 TIMING BELT REPLACE 00 58 8 DRIVE BELT FOR GENERATOR WATER PUMP POWER STEERING OIL PUMP CHECK GUNDTTION acetum rs ent 00 58 9 EXHAUST SYSTEM CONNECTIONS PORTION OF MUFFLER MUFFLER PIPES AND CONVERTER HEAT SHIELDS CHECK AND SERVICE AS REQUIRED 00 61 10 ENGINE OIL CHANGE 00 62 11 ENGINE OIL FILTER REPLACE be 00 63 12 TRANSMISSION FLUID 00 64 13 TRANSFER 01L 00 67 14 ENGINE COOLANT CHANGE 00 67 15 COOLANT HOSES RADIATOR HOSE HEATER HOSE INSPECT 00 69 16 DISC BRAKE PADS INSPECT FOR WEAR a ed re bees 00 69 17 BRAKE HOSES CHECK FOR DETERIORATION OR LEAKS 00 69 18 BALL JOINT AND STEERING LINKAGE SEALS INSPECT FOR GREASE LEAKS AND DAMAGE 00 69 19 DRIVE SHAFT BOOTS INSPECT FOR GREASE LEAKS AND DAMAGE 00 70 20 SUSPENSION SYSTEM INSPECT FOR LOOSENESS AND DAMAGE 00 70 21 REA
6. In order to protect against theft a Vehicle Identification Number VIN is attached as a plate or label to the following major parts of the engine and transaxle as well as main outer panels Engine cylinder block Transaxle housing Front end crossmember Front fender Front floor crossmember front Doors liftgate Hood In addition a theft protection label is attached to replacement parts for the body outer panel main components and the same data is stamped into replacement parts for the engine and the transaxle Cautions regarding panel repairs When repainting original parts do so after first masking the theft protection label After painting be sure to peel off the masking tape The theft protection label for replacement parts is covered by masking tape so such parts can be painted as is The masking tape should be removed after painting is finished theft protection label should not be removed from original parts or replacement parts GENERAL BODY AND CHASSIS VEHICLE IDENTIFICATION CODE PLATE 00 23 LOCATIONS 2 6009470000 Engine ZC601875 0001 ZC601574 0001 GENERAL lt BODY AND CHASSIS 00 24 VEHICLE IDENTIFICATION CODE PLATE Label area x for original equipment parts y for replace
7. 4 in 5 0 1 0 N m 44 9 in 6 0 1 0 N m 53 9 in Ib Ib Ib 1 0 5 0 1 0 44 9 in 8 5 1 5 76 13 10 2 N m 89 17 in Ib Ib 11 2 98 17 in 20 4 N m 15 3 ft Ib 24 4 N m 18 3 ft lb Ib 23 4 Ncm 17 3 ft lb 42 8 N m 31 6 ft lb 53 7 N m 39 5 ft lb 42 8 Nm 31 6 ft lb 80 10 N m 59 7 ft lb 93 12 N m 68 9 ft lb M14 1 5 70 10 N m 52 7 ft lb 130 20 N m 96 15 ft 150 20 N m 111 14 Ib ft lb M16 1 5 105 15N m 78 11 ft 195 25 N m 144 18 230 30 170 22 Ib ft lb ft lb M18 1 5 150 20 N m 111 14 290 40 N m 214 291335 45 Nm 247 33 ft lb ft lb ft lb M20 1 5 210 30 N m 155 22 400 60 N m 295 44 465 65 Nm 343 48 ft lb ft lb ft lb M22 1 5 290 40 N m 214 29 540 80 N m 398 59 630 90 N m 465 66 ft lb ft lb ft lb M24 1 5 375 55 N m 277 40 705 105 N m 520 77 820 120 N m 605 88 ft lb ft lb ft lb FLANGE BOLT AND NUT TIGHTENING TORQUE Standard tightening torque Nominal bolt Head mark 4 Head mark 7 Head mark 8 diameter mm 5 0 1 0N m 44 9 in 10 2 N m 89 17 in 12 2 N m 107 17 in Ib Ib Ib 13 2N m 111 22 in 24 4 N m 18 3 ft lb 28 5 N m 20 4 ft lb Ib t t 26 5 19 4 ft lb 50 5 N m 37 4 ft lb 58 7 N m 43 5 ft lb 25 4 N m
8. GROUP 00 GENERAL BODY AND CHASSIS CONTENTS HOW TO USE THIS MANUAL 00 3 TROUBLESHOOTING GUIDELINES 00 6 HOW TO USE TROUBLESHOOT I NG INSPECTION SERVICE POINTS 00 6 TROUBLESHOOTING CONTENTS 00 6 HOW TO USE THE INSPECTION PROCEDURES UTERE 00 9 CONNECTOR MEASUREMENT SERVICE POINTS 00 1 CONNECTOR INSPECTION SERVICE POINTS TE Tere rer ers oer 00 14 HOW TO COPE WITH INTERMITTENT MALFUNCTIONS 00 15 HOW TO TREAT PAST TROUBLE 00 17 INSPECTION SERVICE POINTS FOR A BLOWN UUSEE 00 18 VEHICLE IDENTIFICATION 00 18 PRECAUTIONS BEFORE SERVICE 00 26 SUPPLEMENTAL RESTRAINT SYSTEM SRS c 00 26 HOW TO PERFORM VEHICLE IDENTIFICATION NUMBER VIN WRITING 00 26 INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE 00 30 ENGINE IDLING LEARNING PROCEDURE Pn 00 31 SERVICING ELECTRICAL SYSTEM 00 32 VEHICLE 6 00 33 APPLICATION OF ANTI CORROSION AGENTS AND UNDERCOATS o a aaaaaaaaan 00 33 SCAN TOOL MULTI USE TESTER M U T SUB ASSEMBLY 00 33 CODING 00 34 TOWING AND HOISTING 00 42 GENERAL DATA AND SPECIFICATIONS TET 00 46 TIGHTENING TORQUE 00 48 LUBRICATION AND MAINTENANCE 00 49 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE 00 51 MAINTENANCE SERVICE
9. If the transmission fluid is greater than the specified level drain the excess fluid through the drain plug to adjust the transmission fluid to the specified level 14 Firmly insert the dipstick into the oil filler tube 13 TRANSFER OIL M10001000030USA0000010000 Checking transfer oil level 1 Remove the oil filler plug 2 Check that the oil level is just below the lower edge of the oil Filler plug hole filler plug hole 3 Check that the oil is not excessively foul and has moderate Transfer oil viscosity 4 Install the oil filler plug and tighten to the specified torque Tightening torque 32 2 N m 23 2 ft Ib Filler plug ZC5016410000 Change transfer oil 1 Remove the oil drain plug to drain the transfer oil Filler plug 2 Install the oil drain plug and tighten to the specified torque di Tightening torque 32 2 N m 23 2 ft Ib 3 Remove the oil filler plug and fill the transfer oil up to the lower edge of the oil filler plug hole Brand name Hypoid gear oil API classification GL 5 SAE 90 Filling amount 0 53 dm 0 56 quarts 4 Install the oil filler plug and tighten to the specified torque Front exhaust ape aio Tightening torque 32 2 N m 23 2 ft lb 14 ENGINE COOLANT CHANGE M10001000031USA0000010000 Check the cooling system parts such as the radiator heater and oil cooler hoses thermostat and their connections for leakage and damage GENERAL BODY AND CHA
10. Premium or 6 speakers GENERAL BODY AND CHASSIS 00 38 PRECAUTIONS BEFORE SERVICE emmme Front fog light 2 Not present or Present Manner switch 2 Not present ChgNg Remote engine starter 2 Panic Alarm Front wiper Comfort flasher type Dome light Center Switch Wiper washer check bulb H L leveling type AFS type ARS type Compressor type Temparature type Rear view camera Nose view camera Side view camera Average speed Language status Fuel amount Fuel consumption scale Speed gauge tolerance Coolant temp gauge threshold Frost warning threshold Distance to empty Average fuel consumption Instant fuel consumption Time traveled Distance traveled Fuel used Trip autoreset IG OFF gt Variable speed alarm Rest reminder Instant speed Seat belt reminder type Seat belt reminder flashing Seat belt reminder indicator Reverse alarm Key reminder Lighting monitor GCC speed alarm GENERAL BODY AND CHASSIS PRECAUTIONS BEFORE SERVICE 00 39 Initial value Not present GENERAL lt BODY AND CHASSIS 00 40 PRECAUTIONS BEFORE SERVICE Wemmme NOTE 1 TPMS is an abbreviation of Tire Pressure Monitoring System DRL of Daytime Running Light AFS of Adaptive Front lighting System and ARS of Advanced Rear lighting System However the systems are not used for this vehicle 2 The setting can be changed by the option coding Refer to 3 The
11. e Disassembly steps The part designation number corresponds to the number in the illustration to indicate dis assembly steps REMOVAL STEPS REMOVAL STEPS Cont 1 BRAKE HOSE CONNECTION gt gt lt lt 3 DISC BRAKE ASSEMBLY 2 GASKET 4 BRAKE DISC vided near the front of each section in order to give the reader a better understanding of the installed condition of component parts Repair kit or parts sets are shown Only very frequently used parts are shown e Installation steps Specified in case installation is impossible in reverse order of removal steps Omitted if installation is possible in reverse order of removal steps Assembly steps Specified in case installation is impossible in reverse order of removal steps Omitted if assembly is possible in reverse order of disassembly steps ZC6012870000 GENERAL BODY AND CHASSIS HOW TO USE THIS MANUAL 00 5 Classifications of major maintenance service points When there are major points relative to maintenance and servicing procedures such as essential maintenance and service points maintenance and service standard values information regarding the use of special tools etc These are arranged together as major maintenance and service points and explained in detail A Indicates that there are essential points for removal or disassembly gt gt A lt lt Indicates that there are essential points for i
12. 18 3 40 46 8 N m 34 6 ft lb 55 5 N m 41 3 ft lb 3 ft lb 46 47 9 N m 35 6 ft Ib 93 12 N m 68 9 ft 105 15 Nm 78 11 Ib ft Ib 43 8 N m 32 6 ft lb 83 12 N m 61 9 ft 98 12 N m 72 9 ft Ib Ib LUBRICATION AND MAINTENANCE M10001000012USA0000010000 Maintenance and lubrication service recommendations have been compiled to provide maximum protection for the vehicle owner s investment against all reasonable types of driving GENERAL BODY AND CHASSIS 00 50 conditions Since these conditions vary with the individual vehicle owner s driving habits the area in which the vehicle is operated and the type of driving to which the vehicle is subjected it is necessary to prescribe lubrication and maintenance service on a time frequency as well as mileage interval basis Oils lubricants and greases are classified and graded according to standards recommended by the Society of Automotive Engineers SAE the American Petroleum Institute API and the National Lubricating Grease Institute NLGI MAINTENANCE SCHEDULES Information for service maintenance is provided in the SCHEDULED MAINTENANCE TABLE Three schedules provided one for Required Maintenance one for General Maintenance and one for Severe Usage Service The item numbers in SCHEDULED MAINTENANCE TABLE correspond to the section numbers in MAINTENANCE SERVICE SEVERE SERVICE Vehicle
13. 2 Any loose protruding or damaged parts such as hoods doors fenders trim etc should be secured or removed prior to moving the vehicle 3 Refrain from going under a vehicle when it is lifted by the towing equipment unless the vehicle is adequately supported by safety stands 4 Never allow passengers to ride in a towed vehicle 5 State and local rules and regulations must be followed when towing a vehicle LIFTING JACKING SUPPORT LOCATION FLOOR JACK Never support any point other than the specified one or that point will be deformed For lifting put rubber or similar material between the side sill and rigid rack or the side sill area will be damaged GENERAL BODY AND CHASSIS 00 44 TOWING AND HOISTING Front side Rear side 2 2 m Spare tire Rigid rack Notch Notch J C D GREEN id Rubber Rubber T iM i f A 7 ZC501944 0000 POST TYPE Special care should be taken when raising the vehicle equipped with the proper adapters in order to support on a frame contact type hoist The hoist must be the vehicle at the proper locations GENERAL BODY AND CHASSIS TOWING AND HOISTING 00 45 When service procedures require removing rear suspension fuel tank and spare tire place additional weight on the rear end of vehicl
14. 2 Start the engine Sensor MB991827 AC206894 AB 10 Provides the inspection procedure for that DTC step by step Goto Step 2 HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were faulty according to the connector measurements out this inspection while referring to GROUP 00 Harness Connector Inspection 00 2 Here Check harness between power supply and terminal xx also includes checking for blown fuse For inspection 6 Describes the conditions for that DTC being set stored The PCM checks whether this voltage is within a specified range TROUBLESHOOTING HINTS The most likely causes for this code to be set are Engine coolant temperature sensor failed Open or shorted engine coolant temperature sen Sor circuit or loose connector PCM failed DIAGNOSIS 25 277 Required Special Tool e MB991958 Scan Tool e MB991824 V C I MB991827 USB Cable MB991910 Main Harness A STEP 1 Using scan tool MB991958 check data list item 15 Transmission Fluid Temperature Sensor To prevent damage to scan tool MB991958 always turn the ignition switch to the LOCK OFF position before con necting or disconnecting scan tool MB991958 1 Connect scan tool MB991958 to the data link connector 3 Set scan tool MB991958 to the data reading mode for item 15 Transmission Fluid Temperature Sensor When
15. Genuine Steering Fluid Power steering fluid Brakes fluid Engine coolant equivalent Door hinges back door hinges LUBRICANT CAPACITY TABLE Description Engine oil Engine oil dm3 qt Oil filter Mitsubishi Hypoid gear oil API classification Power Conforming to Brake fluid DOT 3 or DOT 4 Long Life Antifreeze Coolant or an Specification Oil pan excluding oil filter 4 0 4 2 0 0 Transfer dm qt 0 53 0 56 0 3 7 Transmission fluid dm3 qt 8 4 8 9 Rear differential gear dm3 qt 0 5 0 53 Power steering fluid dm3 qt 1 0 1 06 GENERAL BODY AND CHASSIS RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE Specification Fuel tank dm3 gal 00 52 ILSAC certification symbol Starburst symbol ZC6011140000 API service symbol ZC604408 AA00 o 80 100 120 F 30 40 50 c i SAE 5W 20 Preferred ZC601066 AA00 SELECTION OF COOLANT COOLANT LUBRICANT SELECTION ENGINE OIL Never use nondetergent or straight mineral oil Use only engine oils displaying the ILSAC certification symbol Starburst symbol on the container If these oils are not available classification SM or higher can be used OIL VISCOSITY The SAE grade number indicates the viscosity of the oil A proper SAE grade number should be selected according to ambient temperature NOTE SAE 5W 20 engine oil is strongly recommended for opt
16. but a momentary short has probably caused the fuse to blow The main causes of a short circuit are the following Harness being clamped by the vehicle body Damage to the outer casing of the harness due to wear or heat Water getting into the connector or circuitry Human error mistakenly shorting a circuit etc VEHICLE IDENTIFICATION M10001000004USA0000010000 VEHICLES IDENTIFICATION NUMBER LOCATION The vehicle identification number VIN is located on a plate attached to the left top side of the instrument panel GENERAL BODY AND CHASSIS VEHICLE IDENTIFICATION 00 19 VEHICLE IDENTIFICATION CODE CHART PLATE vehicle identification numbers contain 17 digits The vehicle number is a code which tells country make vehicle type etc tem Content Others GROSS VEHICLE WEIGHT RATING BRAKE SYSTEM M 5001 6000 Ibs HYDRAULIC 5 Line S OUTLANDER FWD T OUTLANDER AWD Price class 3 Medium 4 High e AIR BAG QX JA4MS31X17U000001 1234567 8 91011 ZC6009480000 Boy 1 5 doorwagon E NOTE Check digit means a single number or letter X used to verify the accuracy of transcription of vehicle identification number VEHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR USA FOR FEDERAL EMISSION REGULATION displacement JA4MS31X_7U MITSUBISHI 3 0L JAAMS41X_TU OUTLANDER ed UJ o lt 0 No 8 9 JA4MT31X_7U CW6WXLSYZL2M JA4MT41X_7U CW6WXLHYZL2M CW6WXLXY
17. indicated m 2 d Qo ii m z No 1 4 AXLE 6 59 4 TIRE AND LOADING INFORMATION PLACARD The tire and loading information placard is located on the inside sill of the driver s door VEHICLE SAFETY CERTIFICATION LABEL The vehicle safety certification label is attached to the face of the driver s door sill This label indicates the month and year of manufacture Gross Vehicle Weight Rating GVWR front and rear Gross Axle Weight Rating GAWR and Vehicle Identification Number VIN GENERAL BODY AND CHASSIS 00 22 2 6015750001 Theft protection label For original parts Main outer panels MITSUBISAT WITSUBEHI MITSUBISHI MITSUB MITSUBISHI MITSUBISHI MITSUBISHI MITSUBI ITSU MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI BIS SUBIS ISUB B Engine transaxle gt MITSUBISHI MOTORS For replacement parts R A DOT ZC6026920000 VEHICLE IDENTIFICATION CODE PLATE ENGINE MODEL STAMPING The engine model is stamped on the cylinder block These engine model numbers are as shown as follows Engine model Engine displacement ET The engine serial number is stamped near the engine model number THEFT PROTECTION When replacing a part that has the theft protection plate label or stamp on it be sure that the part has either A or B shown in the figure It is illegal if both A and B are attached or neither A nor B is attached
18. 680 66 1 1 720 67 7 1 680 66 1 1 720 67 7 unladen Vehicles Vehicles with Vehicles Vehicles with without roof roof rail without roof roof rail rail rail 1 720 67 7 1 720 67 7 Vehicles with Vehicles with roof rail roof rail Frreac rear e 1 540 60 6 1 540 60 6 1 540 60 6 1540609 Overhang rear 8 1 005 39 6 1005995 1 005 39 6 1 005 39 6 Ground clearance 9 21585 25 89 uses 2565 kg Ib Gross vehicle weight 2 300 5 071 2 350 5 181 2 300 5 071 2 350 5 181 rating Gross axle weight 1 090 2 403 rating front Gross axle weight 1 100 2 425 rating rear Engine 6831 Transaxle 6 speed automatic TIGHTENING TORQUE M10001000011USA0000010000 Each torque value in the table is a standard value for The values in the table are not applicable tightening under the following conditions 1 If toothed washers are inserted 1 Bolts nuts and washers are all made of steel and 2 If plastic parts are fastened plated with zinc 3 If bolts are tightened to plastic or die cast inserted 2 The threads and bearing surface of bolts and nuts nuts are all in dry condition 4 If self tapping screws or self locking nuts are used GENERAL BODY AND CHASSIS LUBRICATION AND MAINTENANCE 00 49 STANDARD BOLT AND NUT TIGHTENING TORQUE Standard tightening torque Nominal bolt Head mark 4 Head mark 7 Head mark 8 diameter mm M5 2 5 0 5 N m 23
19. CHASSIS PRECAUTIONS BEFORE SERVICE 00 35 MB991824 QL 991827 2 5019680000 The coding data can be checked by operating scan tool MB991958 NOTE For details on how to use the scan too MB991958 refer to the MU T I1I Owner s manual To prevent damage to scan tool MB991958 always turn the ignition switch to the LOCK OFF position before connecting or disconnecting scan tool MB991958 1 Ensure that the ignition switch is atthe LOCK OFF position 2 Start up the personal computer 3 Connect special tool MB991827 to special tool MB991824 and the personal computer 4 Connect special tool MB991910 to special tool MB991824 5 Connect special tool MB991910 to the data link connector 6 Turn the power switch of special tool MB991824 to the ON position NOTE When special tool MB991824 is energized special too MB991824 indicator light will be illuminated a green color 7 Start the M U T III system on the personal computer 8 Turn the ignition switch to the ON position 9 Select System select from the start up screen 10 Select From 2006 MY under Model Year Check that Vehicle Information contents are correct 11 On the system list screen select GasolineENG to check the engine control module data and ETACS to check the ETACS ECU data NOTE If Loading Option Setup list is shown click appropriate box When
20. No 08090 Super Trim Adhesive Sealant of various flange 3 7 AAD Part 08730 octite 272 High Strength faces and threaded parts High Strength Red and High Temperature Packing of fuel gauge unit Threadlock or 3M AAD Part 27200 No 08731 Medium Strength Blue Threadlocker GENERAL BODY AND CHASSIS MAIN SEALANT AND ADHESIVE TABLE 00 73 Application 3M No Loctite permatex No Sealing of various threaded 3 74 AAD Part No 08672 Permatex The Right Stuff parts dust covers Ultrapro High Temp Silicone No 25223 Differential carrier packing Gasket or 3M AAD Part No dust covers and ball joint 8679 black or 3M AAD linkage Packing and shims of Part No 8678 black Press steering box sealing of rack In Place Silicone gasket support cover and top cover of strips 3M AAD Part No steering box housing seal of 08661 or 3M AAD Part No junction face of knuckle arm 08663 Super Silicone sealant flange Seal of brake shoe hold down 3M AAD Part No 08633 and wheel cylinder of Windo weld Resealant drum brakes QUICK FIX 3M AAD Part No 08155 octite8 amp Quicktite Super ADHESIVE Quick Fix Adhesive Glue 21309 ANAEROBIC STRONG SEALING AGENT Fixing of various threads 3M AAD Part 08730 octite 271 High bolts screws Fixing of High Strength Threadlocker Strength Threadlocker differential drive gear bolt 3M AAD Part No 08731 274
21. SRS 1 Items to review when servicing SRS 1 Be sure to read GROUP 52B Supplemental Restraint System SRS For safe operation please follow the directions and heed all warnings 2 Wait at least 60 seconds after disconnecting the battery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected 3 Warning labels must be heeded when servicing or handling SRS components Warning labels can be found in the following locations Air bag module driver s and passenger s Clock spring SRS ECU Sunvisor Seat belt with pre tensioner driver s seat and passenger s seat Side airbag module passenger s seat Curtain air bag module right side and left side Lap pre tensioner driver s side Glove box 4 Always use the designated special tools and test equipment b Store components removed from the SRS in a clean and dry place The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward drivers seat and M10001000116USA0000010000 6 Never attempt to disassemble or repair the SRS components SRS ECU air bag module and clock spring If there is a defect replace the defective part 7 Whenever you finish servicing
22. Stored carry out the following procedure 1 Establish from the customer whether a fuse or connector has been replaced or disconnected 2 If yes erase the diagnostic trouble code and then check that no diagnostic code is reset If no diagnostic trouble code is reset the diagnosis is complete twist the wiring of each of these examples to duplicate the intermittent malfunction Shake the connector up and down and right and left Shake the wiring harness up and down and right and left Especially check the splice points of wiring harnesses carefully Refer to GROUP 00 Harness Connector Inspection 00 2 Shake the part or sensor M10001000141USA0000010000 3 If no follow the applicable Diagnostic Trouble Code Chart Then check the wiring harness and connector and refer to How to Cope with Intermittent Malfunction P 00 15 GENERAL lt BODY AND CHASSIS 00 18 Battery Short circuit Load occurrence Switch section 2 5019200000 2 6012650000 VEHICLE IDENTIFICATION INSPECTION SERVICE POINTS FOR A BLOWN FUSE M10001000138USA0000010000 Remove the blown fuse and measure the resistance between the load side of the blown fuse and the ground Close the switches of all circuits which are connected to this fuse If the resistance is almost 0 O at this time there is a short somewhere between these switches and the load If the resistance is not 0 there is no short at the present time
23. adjusting bolt The tension will increase when turning the adjusting bolt clockwise and decrease when turning counterclockwise Standard value ltem When adjusted When replaced Vibration 138 157 frequency Hz Tension N Ib 343 441 490 686 77 99 110 154 Deflection 12 7 14 6 9 2 11 9 Reference mm 0 50 0 57 0 36 0 47 in 3 Tighten the lock nut to the specified torque Tightening torque 47 11 35 8 ft Ib Check after turning the crankshaft one or more rotations clockwise 4 Check the belt deflection amount and tension and readjust if necessary 5 When the belt tension is adjusted by measuring the belt deflection adjust it with a tool for vibration frequency measurement or tension measurement afterward 9 EXHAUST SYSTEM CONNECTIONS PORTION OF MUFFLER MUFFLER PIPES AND CONVERTER GENERAL BODY AND CHASSIS 00 62 MAINTENANCE SERVICE HEAT SHIELDS CHECK AND SERVICE AS REQUIRED M10001000058USA0000010000 1 Check for holes and exhaust gas leaks due to damage corrosion etc 2 Check the joints and connections for looseness and exhaust gas leaks 3 Check the rubber hangers and brackets for damage 2 6038990000 10 ENGINE OIL CHANGE M10001000026USA0000010000 1 Start the engine and allow it to warm up unt
24. customer s responses it should be reasoned which condition is most likely 00 16 GENERAL lt BODY AND CHASSIS HOW TO USE TROUBLESHOOT NG INSPECTION SERVICE POINTS 3 USE SIMULATION TEST Use the simulation tests below to attempt to duplicate the customer s complaint Determine the most likely circuit s and perform the simulation tests on the connectors and parts of that circuit s Be sure to use the inspection procedures provided for diagnostic trouble codes and trouble symptoms For temperature and or moisture condition related intermittent malfunctions try to change the conditions of the suspected circuit components then use the simulation tests below 4 VERIFY THE INTERMITTENT MALFUNCTION IS ELIMINATED Repair the malfunctioning part and try to duplicate the condition s again to verify the intermittent malfunction has been eliminated SIMULATION TESTS NOTE In case of difficulty finding the cause of the intermittent malfunction the data recorder function the scan tool is effective GENERAL BODY AND CHASSIS HOW TO USE TROUBLESHOOT NG INSPECTION SERVICE POINTS 00717 For these simulation tests shake then gently bend pull and 2 5019170000 HOW TO TREAT PAST TROUBLE Since the trouble may still be present even the status is Stored set the vehicle to the diagnostic trouble code detection condition and check that the status changes to Active If the status does not change from
25. item is actually installed to a vehicle but its initial setting is Not present This is because the item does not adapt CAN and does not indicate abnormal coding data OPTION CODING Required Special Tools MB991958 Scan Tool Sub Assembly 991824 Vehicles Communication Interface V C 1 MB991827 M U T IIl USB Cable 991910 M U T III Main Harness A Vehicles with CAN communication system If there is any item indicated by the option coding after equipment change set ETACS ECU so that the option coding data corresponds with the equipment content Functions and systems do not work normally if the setting does not correspond with the equipment GENERAL BODY AND CHASSIS PRECAUTIONS BEFORE SERVICE The ETACS ECU option coding data can be checked or changed by operating scan tool MB991958 How to check option coding data 1 2 3 Connect the scan tool MB991958 Refer to P 00 34 Turn the ignition switch to the ON position Select System select from the start up screen Select From 2006 MY under Model Year Check that Vehicle Information contents are correct Select ETACS from System List and then press OK button NOTE If Loading Option Setup list is shown click appropriate box Select Coding Select Option Coding Information 8 00 41 Check the information displayed option coding How to change option coding data 1 2
26. probable causes have been identified the next step M10001000088USA0000010001 is to make step by step checks of the suspected system components junctions and links in logical order Use the diagnostic procedures in the service manual whenever possible Follow these procedures carefully to avoid missing an important step in the diagnosis sequence It might be the skipped step that leads to the solution of the problem If the service manual doesn t have step by step procedures to help diagnose the problem make a series of checks based on the ranked list of probable causes Troubleshooting checks should be made in the order that the list of causes was ranked general to specific most likely to least likely easy to check to hard to check REPAIR THE PROBLEM When the step by step troubleshooting checks find a fault perform the proper repairs Make sure to fix the root cause of the problem not just the symptom Just fixing the symptom without fixing the root cause will cause the symptom to eventually return VERIFY THE REPAIR After repairs are made recheck the operation of the system to confirm that the problem is eliminated Be sure to check the system thoroughly Sometimes new problems are revealed after repairs have been made HOW TO USE TROUBLESHOOT ING INSPECTION SERVICE POINTS TROUBLESHOOTING CONTENTS The SRS ECU adopts the rollover specification that the curtain airbag and seat belt pre tensioner operate at the o
27. s for wear Every 12 months or every 24 000 km 15 000 rotors Brake hoses Check for deterioration or leaks Every 12 months or every 24 000 km 15 000 M Ball joint and steering Inspect for grease leaks and linkage seals damage A GENERAL BODY AND CHASSIS SCHEDULED MAINTENANCE TABLE 00 55 Mileage in 30 75 mounds 6 4 6 4 8 mme Months 12 24 36 48 60 72 84 96 19 shaft boots Inspect for grease leaks 12 months or every 24 000 km 15 000 damage miles General Service Kilometers in 72 maintenance intervals thousands 20 Suspension system Inspect for looseness X X X X damage Check oil lev Every 12000 km 7 600 miles Air filter Every 18 months or every 24 000 km 15 000 miles NOTE This maintenance is recommended but is not required to maintain the emissions warranty SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS Maintenance should be carried out according to the following table Service Kilometers in 72 intervals thousands Mileage in 30 75 thousands 12 24 36 48 60 72 84 96 Every 12 months or every 24 000 km 15 000 miles Every 3 months or every 6 000 km 3 750 miles Engine oil filter Every 3 months or every 6 000 km 3 750 miles Change X X X X X X X X chec chec chec chec k k k k 16 Disc rake Inspect for wear Every 6 months or every 12 000 km 7 500 miles pads rotors Che
28. while the vehicle s engine is running 5 Hold special tool MB991668 to the middle of the drive belt between the pulleys at the place indicated by the arrow about 10 20 mm 0 4 0 8 inch away from the rear surface of the belt and so that it is perpendicular to the belt within an angle of 15 degree angle 6 Gently tap the middle of the belt between the pulleys the place indicated by the arrow with your finger as shown in the illustration and check that the vibration frequency of the belt is within the standard value Standard value 128 165 Hz WHEN USING A TENSION GAUGE Use a belt tension gauge to check that the belt tension is within the standard value Standard value 294 490 N 66 110 Ib GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 00 61 Belt deflection check Apply approximately 100 N 22 Ib of force to the middle of the Approximately drive belt between the pulleys at the place indicated by the ON 100 N 22 Ib arrow and check that the amount of deflection is within the 503 J standard value x C RE Ree m Standard value 11 9 15 6 mm 0 47 0 61 in Power steering oil pump pulley Power steering drive belt tension adjustment If the tension or deflection is outside the standard value adjust by the following procedure Adjusting bolt 1 Loosen the tensioner pulley lock nut 2 Adjust the belt tension to the standard value by turning the
29. you select GasolineENG system a selection screen appears asking whether MITSUBISHI Select a button that the engine belongs to 12 Select Coding 13 Select Coding Information 14 If the displayed coding information is different from the corresponding initial setting in the list replace the ECU with a correctly coded one For replacement of the engine control module refer to GROUP 13 engine control module P 13Aa 37 For replacement of the ETACS ECU refer to GROUP 54Ad ETACS P 54Ad 93 ENGINE CONTROL MODULE CODING DATA LIST Initial value Vehicle Model OUTLANDER Model year ee the model year Destination Detail Destination USA GOSTATES GENERAL lt BODY AND CHASSIS 00 36 PRECAUTIONS BEFORE SERVICE emmme ETACS ECU CODING DATA LIST int value SSCS DRL 1 Dimming DRL W P or Independent DRL P Smart entry system Not present or Type C Keyless entry SKIM Type B Corner sensor Head light auto leveling device Oil level warning Water separate warning Speed meter scale Idle neutral control ENG CVT unit control NVECS control Lock up slip control Side air bag 2 Number of speaker Seat material 2 Auto light control Front differential Rear differential Power window type Sunroof type WCM OCM RC C AUDIO 2 AND 3 DISP 3 NAVI 3 CAMERA 3 TURNER 3 PSD L PSD R ETG MSMD HF BS A S C S GENERAL BODY AND CHASSIS PRECAUTIONS BEFORE SERVICE 00737
30. 00 or 27200 Connecting of tilt steering Medium bolt Fan pulley gear Sealing Threadlocker of small gaps and flange faces 3M AAD Part No 08883 permatex Heavy Duty Rubberized Undercoating Undercoating 81833 Aerosol or 3M AAD Part No 08864 Body Schutz Undercoating qt GENERAL lt BODY AND CHASSIS 00 74 MEMO
31. 013090000 MAINTENANCE SERVICE 00 65 5 Check transmission fluid level is at the HOT mark on the dipstick If the transmission fluid level is less than this add DIA QUEEN J2 until the level reaches the HOT mark NOTE f the transmission fluid level is too low the oil pump will draw in air along with the transmission fluid Which will form bubbles f the transmission fluid level is too high rotating components inside the transaxle will churn the fluid and air into a foamy liquid Both conditions level too low or too high will cause the hydraulic pressure to drop which will result in late shifting and slipping of the clutches and brakes NOTE In either case air bubbles can interfere with normal valve clutch and brake operation Also foaming can cause transmission fluid to escape from the transaxle vent where it may be mistaken for a leak 6 Securely insert the dipstick NOTE The transmission fluid should always be replaced under the following conditions When troubleshooting the transaxle When overhauling the transaxle When the transmission fluid is noticeably dirty or burnt driving under severe conditions Change transmission fluid If you have a transmission fluid changer use this changer to replace the transmission fluid If you do not have a transmission fluid changer replace the transmission fluid by the following procedure 1 Disconnect the hose shown in the illustration which connects the trans
32. 040000 17 BRAKE HOSES CHECK FOR DETERIORATION OR LEAKS M10001000034USA0000010000 Inspection of brake hoses should be included in all brake service operations The hoses should be checked for 1 Incorrect length severe surface cracking pulling scuffing or worn spots If the fabric casing of the hoses is exposed by cracks or abrasion in the rubber hose cover the hoses should be replaced Eventual deterioration of the hose and possible bursting failure may occur 2 Incorrect installation twisting or interference with wheel tire or chassis 18 BALL JOINT AND STEERING LINKAGE SEALS INSPECT FOR GREASE LEAKS AND DAMAGE M10001000035USA0000010000 1 These components which are permanently lubricated at the factory do not require periodic lubrication Damaged seals and bellows should be replaced to prevent leakage or grease contamination 2 Inspect the dust cover and bellows for proper sealing leakage and damage and replace them if defective Bellows Dust cover ZC6011060000 GENERAL lt BODY AND CHASSIS 00 70 MAINTENANCE SERVICE 19 DRIVE SHAFT BOOTS INSPECT FOR GREASE LEAKS AND DAMAGE M10001000036USA0000010000 1 These components which are permanently lubricated at the factory do not require periodic lubrication Damaged seals and boots should be replaced to prevent leakage or grease contamination 2 Inspect the boots for proper sealing leakage and damage Replace them if defective ZC0001
33. 090000 20 SUSPENSION SYSTEM INSPECT FOR LOOSENESS AND DAMAGE M10001000096USA0000010000 Visually inspect the front rear suspension components for deterioration and damage Re tighten the front rear suspension components retaining bolts to specified torque 21 REAR AXLE OIL CHECK OIL LEVEL M10001000075USA0000010000 Rear differential oil check 1 Remove the filler plug 2 Check that gear oil level is not 8 mm 0 3 inch below the bottom of filler plug hole 3 Tighten the filler plug to the specified torque Tightening torque 32 2 N m 23 2 ft Ib Gear oil Upper limit Lower limit g mm 0 3 in ZC6011100000 GENERAL BODY AND CHASSIS SB Crs Ss ZC6011110000 MAINTENANCE SERVICE 00 71 22 TIRES ROTATE M10001000089USA0000010000 Rotate tires regularly to equalize tire wear and help extend tire life Recommended tire rotation is every 12 000 km 7 500 miles Timing for the rotation may vary according to vehicle condition road surface conditions and individual driver s habits When rotating tires check for uneven wear damage and wheel alignment Abnormal wear is usually caused by incorrect tire pressure improper wheel alignment out of balance wheels or severe braking The first rotation is the most important to achieve more uniform wear for all tires on the vehicle 23 AIR FILTER REPLACE M10001000090USA0000010000 1 Remove the glove box Refer t
34. 3 4 Connect the scan tool MB991958 Refer to Turn the ignition switch to the ON position Select System select from the start up screen Select From 2006 MY under Model Year Check that Vehicle Information contents are correct Select ETACS from System List and then press OK button NOTE If Loading Option Setup list is shown click appropriate box Select Coding Select Option Coding Change to correct option coding data LIST emmme S RS OSS SATR Compressor type DRL function Wiper washer check bulb RLS HFM GENERAL BODY AND CHASSIS 00 42 TOWING AND HOISTING TOWING AND HOISTING M10001000008USA0000010000 WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP lt FWD gt Sling type CAUTION This vehicle cannot be towed by a wrecker using sling type VT equipment as the bumper may become deformed If this vehicle is towed use wheel lift or flat bed equipment The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released It is recommended that vehicles be towed using the front pickup whenever possible 7 FRONT TOWING PICKUP lt AWD gt If only the front wheels or only the rear wheels are lifted for towing the bumper will be damaged In addition lifting of the rear wheels causes the transfer case oil to flow forward and may result in heat damage to the rear bushing
35. 4 Press HZ button twice to change the display to the frequency display Hz MB992082 10 15mm Wi 15 ge The temperature of the surface of the belt should be as Q close to normal temperature as possible O Do not allow any contaminants such as water or oil to get onto the microphone If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby the values measured by the microphone may not correspond to actual values If the microphone is touching the belt while the measurement is being made the values measured by the microphone may not correspond to actual values Do not take the measurement while the vehicle s engine is running 5 Hold special tool MB992080 to the middle of the drive belt between the pulleys at the place indicated by arrow approximately 10 15 mm 0 4 0 59 inch away from the rear surface of the belt so that it is perpendicular to the belt within an angle of 15 degree 6 Press the MEASURE button 7 Gently tap the middle of the belt between the pulleys the place indicated by the arrow with your finger as shown in the illustration and measure that the vibration frequency of the belt is within the standard value Standard value 128 165 Hz Power steering oil pump pulley with a finger When using scan tool MB991958 recommendation Required Special Tools MB991958 Scan Tool M U T II Sub Assembly 991824
36. ATCVTAM T EE RU 9 Select Special Function on the next screen 4 ABS ASC ASTC Model Year 2007 5 SAS Model Code 6 Multi Select 4WD Loading Option Setup 7 SRS Airbag Y Option With Option 8 AIC 9 ETACS v 10 Meter Y lodel Year and Sy Ue OK button ZC6037850000 Vehicles for KOS 10 Select ENG Key Code Reg from the Special Function System Select kosmwo 5 Special Function Screen Key amp KOS Key Reg Key Barcode No amp KOS Key Reg ENG Key Code Reg Stee ring lo ck unit Reg Comm Test Tre Pressure Sensor ID Regist Tire Pressure SensorID Che Tire Pressure Sensor Che Vehicles for WCM 5 Special Function Key Regist ratio n Additonal key regist ration KeyRegist ration BarcodeN ENG Key Code Keyless ID Reg Tire Pressure Sensor ID Regist Tire Pressure Sensor ID Che ck Tire Pressure Sensor Che ck Pease select function 2 6037870000 GENERAL BODY AND CHASSIS PRECAUTIONS BEFORE SERVICE Item Key Code Registration OK button ajel aM ZC6037880000 Data link T
37. ES TABLE LUBRICANT SELECTION P 00 51 LUBRICANTS AND GREASES Semi solid lubricants bear the NLGI designation and are further classified as grades 0 1 2 3 etc Whenever Chassis Lubricant is specified Multipurpose Grease NLGI grade Number 2 should be used FUEL USAGE STATEMENT Using leaded gasoline in this car will damage the catalytic converters and heated oxygen sensors and affect the warranty coverage validity This vehicle must use unleaded gasoline only This vehicle has a fuel filler tube which is especially designed to accept only the smaller diameter unleaded gasoline dispensing nozzle The 2 4L model is designed to operate on unleaded gasoline having a minimum octane rating of 87 RON 2 or 91 RON NOTE MON Motor Octane Number RON Research Octane Number GASOLINE CONTAINING ALCOHOL Some gasoline sold at service stations contain alcohol although they may not be so identified Using fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory Gasohol A mixture of 10 ethanol grain alcohol and 90 unleaded gasoline may be used in your vehicle If driveability problems are experienced as a result of using gasohol it is recommended that the vehicle be operated on gasoline Methanol Do not use gasoline containing methanol wood alcohol Using this type of alcohol can result in vehicle performance deterioration and damage critical part
38. IN CONTROL MODULE PCM 2 For connector color refer to GROUP 80A How to read configuration diagrams Connector B 48 222222 9 9 AES Inta ke air 1 2 OY tempe rature SS K NS 3 Shows the location of the connector s from a the circuit s above Sy WEAN P eco 4 Explains about the operation principle of the component or its relevant parts in that circuit CIRCUIT OPERATION The intake air temperature sensor is a negative Approximately 5 volts are applied to the intake air temperature coefficient type of resistor When the temperature sensor output terminal terminal 6 intake air temperature rises the resistance from the PCM terminal 64 via the resistor in the decreases PCM The ground terminal terminal 5 is The intake air temperature sensor output voltage grounded with or PCM terminal 57 increases when the resistance increases and decreases when the resistance decreases 2 6012890000 GENERAL BODY AND CHASSIS HOW TO USE TROUBLESHOOT NG INSPECTION SERVICE POINTS 00 11 5 Explains about technical details TECHNICAL DESCRIPTION e The engine coolant temperature seps r converts the engine coolant temperature to voltage and output it DTC SET CONDITIONS Check Conditions Engine coolant temperature was 7 C 45 F or more immediately before the engine was stopped at the last drive CAUTION Data link connector
39. R AXLE OIL CHECK OIL LEVEL 00 70 GENERAL BODY AND CHASSIS HOW TO USE THIS MANUAL 00 3 HOW TO USE THIS MANUAL MAINTENANCE REPAIR AND SERVICING EXPLANATIONS This manual provides explanations etc concerning procedures for the inspection maintenance repair and servicing of the subject model Unless otherwise specified each service procedure covers all models Procedures covering specific models are identified by the model codes or similar designation engine type transaxle type etc description of these designations is covered in this manual under VEHICLE IDENTIFICATION ON VEHICLE SERVICE The ON VEHICLE SERVICE section has procedures for performing inspections and adjustments of particularly important components These procedures are done with regard to maintenance and servicing but other inspections looseness play cracking damage etc must also be performed SERVICE PROCEDURES The service steps are arranged in numerical order Attention to be paid in performing vehicle service are described in detail in SERVICE POINTS DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging whether or not a part or adjustment is correct LIMIT Shows the maximum or minimum value for judging whether or not a part or adjustment is acceptable REFERENCE VALUE Indicates the adjustment value prior to starting the work presented in order to facilitate
40. SSIS 00 68 MAINTENANCE SERVICE Change Coolant When removing the radiator cap use care to avoid contact with hot coolant or steam Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube After relieving the steam pressure remove the cap by Slowly turning it counterclockwise 1 Remove the radiator cap and drain plug to drain the coolant MAT ge 2 Remove the water feed hose B and drain the coolant in the Water feed water jacket lt those B 3 Remove the radiator condenser tank assembly and drain the coolant 4 Drain the coolantthen clean the path of the coolant by injecting water into the radiator from the radiator cap area 5 Install the water feed hose B 6 Securely tighten the radiator drain plug 1 Assemble the radiator condenser tank assembly Do not use alcohol or methanol anti freeze or any engine coolants mixed with alcohol or methanol anti freeze The use of an improper anti freeze can cause corrosion of the aluminum components Vehicles for California emission regulation If the coolant contact the PremAir amp direct ozone reduction DOR radiator wash it with water at once 8 By referring to the section on coolant select an appropriate concentration for safe operating temperature within the range of to 60 9o Use special tool MB991871 to refill the coolant A convenient mixture is a 50 water and 50 antifreeze solu
41. TO USE TROUBLESHOOT 6 SERVICE POINTS CONNECTOR MEASUREMENT SERVICE POINTS M10001000136USA0000010001 Turn the ignition switch to the LOCK OFF position when connecting and disconnecting the connectors Turn the ignition switch to ON when measuring unless there are instructions to the contrary IF INSPECTING WITH THE CONNECTOR CONNECTED WATERPROOF CONNECTORS Be sure to use special tool Never insert a test probe from the harness side as this will reduce the waterproof performance and result in corrosion IF INSPECTING WITH THE CONNECTOR CONNECTED ORDINARY NON WATERPROOF CONNECTORS Required Special Tool 992006 Extra Fine Probe Inspect by inserting a test probe from the harness side If the connector is too small to insert a test probe e g control unit connector do not insert it forcibly Use special tool MB992006 extra fine probe IF INSPECTING WITH THE CONNECTOR DISCONNECTED When Inspecting a Female Pin From front side of the connector Required Special Tool MB991219 Inspection Harness Included in MB991223 Harness Set The inspection harness for connector pin contact pressure should be used The test probe should never be forcibly inserted as it may cause a defective contact From back side of the connector SRS ECU harness side connector GENERAL BODY AND CHASSIS HOW TO USE TROUBLESHOOT ING INSPECTION SERVICE POINTS 00 13 Since the SRS ECU harness connector is plate
42. VICE NS CTS yp Data link 2 connector Connect scan tool 991958 to the 16 pin data link connector as follows NOTE For details on how to use scan tool MB991958 refer to the MU T 111 Owner s Manual SA lt 1 Ensure that the ignition switch is at the LOCK OFF position 2 Start up the personal computer MT MB99191 aw 8 3 Connect special tool MB991827 to special tool MB991824 xS P od the personal computer N SSS 4 Connect special tool MB991910 to the special tool MB991824 5 Connect special tool MB991910 to the data link connector of 991824 the vehicle 6 Turn the special tool MB991824 power switch to the ON position NOTE When the special tool MB991824 is energized the special tool 15991824 indicator light will be illuminated n a green color E 7 Start the M U T III system on the personal computer and X turn the ignition switch to the ON position MB991827 2 5019680000 8 Select KOS IMMO Keyless TPMS button from the System PUTET Select screen Then select the applicable option code item BESSEL Fomozmew Y and push the OK button 2 KOS IMMOBI Keyless TPM S 2 5 3
43. Vehicle Communication Interface V C 1 MB991910 Main Harness GENERAL BODY AND CHASSIS 00 60 Tap lightly with a finger Power steering oil pump pulley Power steering oil pump pulley 2 6004520000 MAINTENANCE SERVICE 991668 Belt Tension Meter Set NOTE The vibration frequency measur ing method is recommended for check and adjustment of the drive belt tens on To prevent damage to special tool MB991824 always turn the ignition switch to the LOCK OFF position before connecting or disconnecting special tool MB991824 1 Connect special tool MB991668 to special tool MB991824 2 Connect special tool MB991910 to special tool MB991824 3 Connect scan tool MB991910 to the data link connector 4 Turn the ignition switch to the ON position and select Belt Tension from the menu special tool MB991824 screen The temperature of the surface of the belt should be as close to normal temperature as possible Do not allow any contaminants such as water or oil to get onto the microphone If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby the values measured by the microphone may not correspond to actual values If the microphone is touching the belt while the measurement is being made the values measured by the microphone may not correspond to actual values Do not take the measurement
44. ZL2M FOR CALIFORNIA EMISSION REGULATION VIN except sequence number Brand Engine Model code displacement JA4MS31X_7U MITSUBISHI CW6WXLSYL7M JA4MS41X_7U OUTLANDER CW6WXLHYL7M CW6WXLXYL7M GENERAL BODY AND CHASSIS 00 20 VEHICLE IDENTIFICATION CODE PLATE displacement JAAMTATX TU pom l VEHICLES FOR PUERTO RICO VIN except sequence number Brand Engine Model code displacement JAAMS31X 70 MITSUBISHI 3 0L CW6WXLSYL2M OUTLANDER CW6WXLMYL2M JA4MS41X_7U CW6WXLXYL2M JA4MT31X_7U CW6WXLSYZL2M VEHICLES FOR CANADA VIN except sequence number Brand Engine Model code displacement JA4MS31X_7U MITSUBISHI 3 0L CW6WXLSYL3M JA4MS41X_7U CW6WXLXYL3M JA4MT31X_7U CW6WXLSYZL3M CW6WXLXYZL3M VEHICLE IDENTIFICATION CODE PLATE M10001000054USA0000010000 The vehicle information code plate is riveted to the face of the passenger s door sill The plate shows model code engine model transaxle model and body color code MITSUBISHI MOTORS CORPORATION MODEL 1 ENGINE 2 ext 3 O TRANS 4 O COLORING 5 6 7 ZC6012860000 GENERAL BODY AND CHASSIS VEHICLE IDENTIFICATION CODE PLATE 2 6012630000 2 6012640000 00 21 tem Content MODEL CW6WXLS YL2M TRANS F6AJA Transaxle model COLOR Body color code 11E Interior code Equipment code For monotone color vehicles the body color code shall be
45. applied the sensor may malfunction Protect the heated oxygen sensor with a cover before applying anti corrosion agent etc SCAN TOOL MULTI USE TESTER M U T Ill SUB ASSEMBLY M10001000122USA0000010000 Turn the ignition switch to the LOCK OFF position before disconnecting or connecting the scan tool NOTE M U T III trigger harness is not necessary when pushing V C 1 ENTER key GENERAL BODY AND CHASSIS 00734 PRECAUTIONS BEFORE SERVICE Vehicle communication interface 1 M U T Ill USB cable M U T Ill main harness A MB991910 M U T Ill main harness B M U T Ill main harness C M U T Ill measurement adapter MB991826 ZC5019290000 CODING LIST M10001000147USA0000010000 Before troubleshooting check that the coding data written into the engine control module and ETACS ECU are normal If they are not the same as the initial settings various functions and systems will not work correctly VARIANT CODING Required Special Tools 991958 Scan Tool M U T IIl Sub Assembly MB991824 Vehicle Communication Interface V C 1 991827 USB Cable 991910 Main Harness A Vehicles with CAN communication system The items marked with 3are actually installed to a vehicle but their initial settings are Not present This is because the items do not adapt and does not indicate abnormal coding data 722 K SAY E GENERAL BODY AND
46. assembly and adjustment procedures and so they can be completed in a shorter time M10001000001USA0000010001 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 TIGHTENING TORQUE INDICATION The tightening torque indicates a median and its tolerance by a unit of Nm in Ib or Nm ft lb For fasteners with no assigned torque value refer to P 00 48 SPECIAL TOOL NOTE Only MMC special tool part numbers are called out in the repair sections of this manual Please refer to the special tool cross reference chart located at the beginning of each group for the special tool number that is available in your market ABBREVIATIONS The following abbreviations are used in this manual for classification of model types NOTE A T Automatic transaxle or models equipped with automatic transaxle MFI Multiport fuel injection or engines equipped with multiport fuel injection FWD 2 wheel drive vehicles AWD 4 wheel drive vehicles Air conditioning 3 0L Engine 2 998 liter 6B31 engine or a model equipp
47. axle and the oil cooler inside the radiator Place a container under the hose to collect the fluid The engine should be stopped within one minute after it is started If all the transmission fluid has drained out before then the engine should be stopped at that point 2 Start the engine and let the transmission fluid drain out Running conditions N range with engine idling Approximately 3 5 dm 3 7 quarts of transmission fluid should be removed 3 Remove the drain plug from the bottom of the transaxle case to drain the transmission fluid Approximately 2 0 dm 2 1 quarts of transmission fluid should be removed 4 Install the drain plug with a new gasket and tighten it to the specified torque GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 00 66 2 6022350000 Back side view 2 6027800001 FLUID LEVEL mm in 20 0 8 10 0 4 0 0 10 0 4 DIPSTICK 60 80 104 140 176 FLUID TEMPERATURE F 2 602774 00 Tightening torque 32 2 N m 23 2 ft Ib Stop pouring if the full volume of transmission fluid cannot be added 5 6 7 8 9 10 11 12 Add new transmission fluid DIA QUEEN J2 through the oil filter tube Approximately 5 5 dm 5 8 quarts of transmission fluid should be added Repeat the procedure in Step 2 to pump out the rest of the contaminated transmission fluid Add new trans
48. ccurrence of rollover Therefore do not tilt the vehicle to the right and left with the IG ON or tilt the SRS ECU to the right and left with the IG ON and the harness installed During diagnosis a diagnostic trouble code associated with other system may be set when the M10001000133USA0000010001 GENERAL BODY AND CHASSIS HOW TO USE TROUBLESHOOT NG INSPECTION SERVICE POINTS ignition switch is turned ON with connector s disconnected On completion confirm all systems for diagnostic trouble code s If diagnostic trouble code s are set erase them all Since the radiator fan rotates during CAN bus line diagnostics make sure that no one is servicing the engine compartment before diagnosing the CAN bus line Since the CAN communication 00 7 stops when diagnosing the CAN bus line the ETACS ECU detects the time out of the engine control module and activates the radiator fan to prevent overheating as fail safe Troubleshooting of electronic control systems for which scan tool MB991958 can be used follows the basic outline described below Even in systems for which scan tool MB991958 cannot be used some of these systems still follow this outline 1 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Troubleshooting sections are based on the diagnostic flow as below If the diagnostic flow is different from that given below or if additional explanation is Diagnostic method required the details of such differences or additi
49. ck for deterioration or leaks Every 12 months or 24 000 km 15 000 miles 19 Drive shaft Inspect for grease leaks and Every 12 months or 24 000 km 15 000 miles boots damage 20 Suspension Inspect for looseness 6 month or 12 000 km 7 500 miles system damage 23 Air filter Inspect for clogging Every 3 months or every 6 000 km 3 750 miles NOTE inspect and replace alternately Severe usage conditions GENERAL lt BODY AND CHASSIS 00 56 MAINTENANCE SERVICE Driving on dusty rough muddy or salt spread 5 Extended use of brakes while driving roads 6 Driving in sandy areas Towing or police taxi or commercial operation 7 More than 50 operation in heavy city traffic Extensive idling and or low speed operation during hot weather above 32 C 90 F Repeated short trip operation at freezing temperatures engine not thoroughly warmed up MAINTENANCE SERVICE 1 FUEL SYSTEM TANK PIPE LINE AND CONNECTION AND FUEL TANK FILLER TUBE CAP CHECK FOR LEAKS M10001000016USA0000010000 Fuel high pressure tube ZC603331 0000 Check for damage or leakage in the fuel lines and connections 2 FUEL HOSES CHECK CONDITION M10001000017USA0000010000 1 Inspect the surface of fuel hoses for heat and mechanical damage Hard and brittle rubber cracking tears cuts abrasions and excessive swelling indicate deterioration of the rubber If the fabric casing of the rubber hose
50. d to improve conductivity observe the warning below when checking this connector Insert the backprobing tool into the connector from the harness side and connect the tester to the backprobing tool If any tool other than the backprobing tool is used it may cause damage to the harness and other components Furthermore measurement should not be carried out by touching the backprobing tool directly against the terminals from the front of the connector The terminals are plated to increase their conductivity so that if they are touched directly by the backprobing tool the plating may break which will decrease reliability SRS ECU harness connector ZC5019080000 When Inspecting a Male Pin At this time be careful not to short the connector pins with the test probes Doing so may damage the circuits inside the ECU Touch the pin directly with the test probe ZC5019090000 GENERAL lt BODY AND CHASSIS 00 14 HOW TO USE TROUBLESHOOT 6 SERVICE POINTS CONNECTOR INSPECTION SERVICE POINTS M10001000137USA0000010001 VISUAL INSPECTION Connector disconnected or improperly connected Harness wire breakage at terminal section Low contact r r pressure Good 2 5019100000 Connector is disconnected or improperly connected Connector pins are pulled out Stretched an broken wires at terminal section Low contact pressure between male and female terminals Low co
51. difficult take some time approx 30 sec and try again Information label indicating the engine oil check process on the rocker cover 9 Check that the engine oil is not excessively dirty that there is no coolant or gasoline mixed in and that it is sufficiently thick and slippery 10 Start the engine and run it at idle for a few minutes 11 Check the level range indicated on the dipstick 11 ENGINE OIL FILTER REPLACE M10001000027USA0000010000 The quality of replacement filters varies considerably Only high quality filters should be used to assure most efficient service Genuine oil filters require that the filter is capable of withstanding a pressure of 1 765 kPa 256 psi are high quality filters and are recommended as follows Mitsubishi Oil Filter Part Number MD332687 MD365876 MD360935 or equivalent Engine Oil Filter Selection This vehicle is equipped with a full flow throw away oil filter The same type of filter is recommended as a replacement filter for this vehicle It is possible particularly in cold weather that this vehicle may develop high oil pressure for a short duration Make sure that any replacement filter used on this vehicle is a high quality filter The filter must withstand a pressure of 1 765 kPa 256 psi manufacturer s specifications to avoid filter and ultimately engine damage The following is a high quality filter and is strongly recommended for use on this vehicle Mitsubishi Engine Oil Fi
52. e LOCK OFF position 2 Start up the personal computer 3 Connect special tool MB991827 to special tool MB991824 and the personal computer 4 Connect special tool MB991910 to the special tool MB991824 5 Connect special tool MB991910 to the data link connector of the vehicle 6 Turn the special tool MB991824 power switch to the ON position NOTE When the special tool MB991824 is energized the special tool 18991824 indicator light will be illuminated in a green color Start the system on the personal computer and turn the ignition switch to the ON position N Select KOS IMMO Keyless TPMS button from the System Select screen Then select the applicable option code item and push the OK button Select Coding on the next screen 00 30 GENERAL lt BODY AND CHASSIS PRECAUTIONS BEFORE SERVICE VIN W riting 8 ZC6037890000 VIN W riting VIN Engine ECU 00000000000000000 IN currently written in ECM Vi is displ Write the number displ ayed on the screen in Immobili zer U ayed OK button amp e 8 by ZC6037900000 Result of VIN W ritin g VIN W riting 00000000000000000
53. e or anchor vehicle to hoist to prevent tipping when the center of gravity changes ZC501945 0000 GENERAL lt BODY AND CHASSIS 00 46 GENERAL DATA AND SPECIFICATIONS GENERAL DATA AND SPECIFICATIONS M10001000009USA0000010000 lt Except vehicles for CANADA gt XLSYL2M 7M XLHYL2M 7M XLSYZL2M 7M XLHYZL2M 7M Vehicle Overall length 4 640 182 7 4 640 182 7 4 640 182 7 4 640 182 7 dimension mm Overall width 1 800 70 9 1 800 70 9 1 800 70 9 1 800 70 9 am Overall height 3 1 680 66 1 1 720 67 7 1 680 66 1 1 720 67 7 unladen Vehicles Vehicles with Vehicles Vehicles with without roof roof rail without roof roof rail rail rail 1 720 67 7 1 720 67 7 Vehicles with Vehicles with roof rail roof rail Wheelbase 2 670 105 1 2 670 105 1 2 670 105 1 2 670 105 1 105 Tread front 1 540 60 6 11 540 60 6 1 540 60 6 1 540 60 6 Tread rear 1 540 60 6 11 540 60 6 1 540 60 6 1 540 60 6 Overhang front 7 96 Overhang rear 1 005 39 6 1 005 39 6 Ground clearance 9 215 8 5 215 85 215 85 215 6 5 Vehicle weight kg Ib Gross vehicle weight 2 300 5 071 2 350 5 181 2 350 5 181 rating Gross axle wei
54. e and connection and fuel tank filler tube cap x 2 and pipes Check condition pe x kx 3 Ardeanerelemet Replace X X kI Evaporative emission Check for leaks X X control system except clogging evaporative emission canister GENERAL BODY AND CHASSIS 00 54 SCHEDULED MAINTENANCE TABLE Emission control Service Kilometers 72 system maintenance intervals in thousands Mileage 30 75 E 36 48 60 72 84 Spark plugs Iridium Monts KREN 84 months or every 168 000 km BEA tipped type miles Intake valve clearance Inspect and adjust If valve noise increases adjust valve clearance Timing belt a 168 000 km 105 000 mes Drive belts for the Check condition generator water pump and power Steering pump Exhaust system Check and service connection portion of muffler muffler pipes and converter heat shields GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE General Service Kilometers in 72 maintenance intervals thousands Mileage in 30 75 12 24 36 48 60 72 84 Change 6 months or every 12 000 km IN miles Engine oil filter Every 6 months or every 12 000 km 7 500 miles 3 Transfer oil Change eL qi d Engine coolant Change X at first Coolant hoses Inspect radiator hose heater hose Disc brake pads pss
55. ed with such an engine PCM Powertrain control module SWS Simplified wiring system Keyless Operation System KOS Free hand Advanced Security Transmitter F A S T key GENERAL BODY AND CHASSIS 00 4 HOW TO USE THIS MANUAL EXPLANATION OF MANUAL CONTENTS Indicates the section title Indicates the group title Denotes tightening torque If there is no indication of tightening torque refer to tightening torque BASIC BRAKE SYSTEM FRONT DISC BRAKE ASSEMBLY FRONT DISC BRAKE ASSEMBLY Indicates the group number Indicates the page number Indicates procedures to be performed be 113 9 Nem REMOVAL AND INSTALLATION Pre removal Operiition Post installation Operation Brake Fluid Draihing Brake Fluid Supplying anc Air Bleeding Refer to fore the work in that section is started and procedures to be performed after the work in that section is finished Component diagram A diagram of the component parts is pro Seal and boot kit Brake caliper kit Pad set Required Special Tool MB990520 Disc Brake Piston Expander Maintenance and servicing procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures e Removal steps The part designation number corresponds to the number in the illustration to indicate removal steps
56. ght 1 090 2 403 rating front Gross axle weight 1 280 2 822 rating rear Engine 6B31 3 01 Transaxle 6 speed automatic 50280 GENERAL BODY AND CHASSIS GENERAL DATA AND SPECIFICATIONS 00 47 CW6W XLMYL2M XLXYL2M 7M XLXYZL2M 7M Vehicle Overall length 1 4 640 182 7 4 640 182 7 4 640 182 7 dimension mm Overall width 1 800 70 9 1 800 70 9 1 800 70 9 un Overall height 3 1 680 66 1 1 720 67 7 1 680 66 1 unladen lt Vehicles without Vehicles with roof lt Vehicles without roof rail rail roof rail 1 720 67 7 1 720 67 7 Vehicles with roof Vehicles with roof rail rail Frread rear e t540605 1 540 60 6 1540005 Overnang rear 8 1 005 39 6 1 005 39 6 1005996 Ground clearance 9 215 5 26 89 2689 kg Ib Gross vehicle weight 2 300 5 071 2 350 5 181 rating Gross axle 1 090 2 403 rating front Gross axle 1 280 2 822 rating rear Seating capacity Engine 6B31 3 0L Transaxle lt Vehicles for CANADA gt 2 5019470000 GENERAL lt BODY AND CHASSIS 00 48 TIGHTENING TORQUE CW6W XLSYL3M XLSYZL3M XLXYL3M XLXYZL3M Vehicle Overall length 1 4 640 182 7 4 640 182 7 4 640 182 7 4 640 182 7 dimension mm overall wigth 2 1 800 70 9 1 800 70 9 1 800 70 9 1 800 70 9 height 1
57. il the temperature of the coolant reaches 80 90 C 176 194 F Use care as oil could be hot 2 Remove the engine oil filler cap 3 Remove the drain plug to drain oil 4 Install a new drain plug gasket so that it faces in the direction shown in the illustration and then tighten the drain plug to the specified torque le ee Tightening torque 39 5 N m 29 3 ft Ib 0 ei NE 5 Refill the specified quantity of oil Specified Engine Oil Engine oils displaying ILSAC certification symbol Starburst symbol or conforming to the API classification SL SL CF or 20 5 s higher Total quantity 4 3 dm 4 5 quarts NOTE SAE 5W 20 engine oil is strongly recommended for optimum fuel economy and cold starting If the ambient temperature is not within the usable temperature range of SAE 5W 30 shown in the above illustration use SAE 101 30 engine oil 6 Install the engine oil filler cap ZC601066 AA00 Cil dipstick engine cover side Maximum Good Minimum ZC604409 AA00 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 00 63 7 Pull out the dipstick clean off the engine on the dipstick and then reinsert the oil dipstick 8 Pull out the oil dipstick and check the engine oil level is within the marks on one side of the oil dipstick engine cover side NOTE Check might be difficult shortly after the engine stopping or the engine oil replacement If
58. imum fuel economy and cold starting f the ambient temperature is not within the usable temperature range of SAE 5W 20 shown the above illustration use SAE 10W 30 engine oil Relationship between Coolant Concentration and Specific Gravity If the concentration of the coolant is below 30 the anti corrosion property will be adversely GENERAL BODY AND CHASSIS SCHEDULED MAINTENANCE TABLE 00 53 affected In addition if the concentration is maintain the concentration level within the above 6096 both the anti freeze and engine specified range cooling properties will decrease affecting the Do not use a mixture of different brands of anti engine adversely For these reasons be sure to freeze Coolant temperature C F and Freezing Safe operating Coolant specific gravity temperature temperature concentration specific volume Example The safe operating temperature is 15 C 5 F when the specific gravity is 1 058 at the coolant temperature of 20 C 68 F SCHEDULED MAINTENANCE TABLE M10001000014USA0000010000 SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE Inspection and service should be performed any time if a malfunction is observed or suspected Emission control Service Kilometers system maintenance intervals in thousands Mileage in 30 75 Meme 4 4 m mmm Months 12 24 84 96 36 48 60 72 Fuel system tank Check for leaks X X pipe lin
59. ing under the condition shown below and then confirm the engine has the normal idling Transaxle P range Operation in ignition related fan and attachments Not to be operated Engine coolant temperature 80 C 176 F or more NOTE If the engine stalls while idling check for dirty on the throttle valve of the throttle body and GENERAL BODY AND CHASSIS 00 32 PRECAUTIONS BEFORE SERVICE clean if needed Then perform the service from Procedure again INITIALIZATION PROCEDURE FOR THROTTLE ACTUATOR CONTROL MOTOR When the battery cable is disconnected and reconnected throttle actuator control motor valve Fully closed position is eliminated so that the throttle valve opening angle control would not be performed correctly When the battery cable is disconnected and reconnected initialize the throttle actuator control motor using the following procedure 1 Turn the ignition switch to the ON position and then place the ignition switch in LOCK OFF position 2 For 10 seconds or more keep the ignition switch in LOCK OFF position SERVICING ELECTRICAL SYSTEM M WARNING Battery posts terminals and related accessories contain lead and lead compounds WASH HANDS AFTER HANDLING 1 Note the following before proceeding with working on the electrical system Never perform unauthorized modifications to any electrical device or wiring Such modifications might lead to a vehicle malfunction over capacity
60. ion switch is at the LOCK OFF position 2 Start up the personal computer 3 Connect special tool MB991827 to special tool MB991824 and the personal computer 4 Connect special tool MB991910 to the special tool MB991824 5 Connect special tool MB991910 to the data link connector of the vehicle 6 Turn the special tool MB991824 power switch to the ON position NOTE When the special tool MB991824 is energized the special tool MB991824 indicator light will be illuminated in a green color Turn the ignition switch to the ON position Select Special Function form the menu screen 9 Select Learned Value Reset form the menu screen 10 Initialize the learning value 11 After initialization of the learning value learn the idling in MFI engine Refer to LEARNING PROCEDURE FOR IDLING IN MFI ENGINE P 00 31 Co ENGINE IDLING LEARNING PROCEDURE M10001000118USA0000010000 PURPOSE When the ECM is replaced or when the learned value is initialized the idle may not be stabilized Carry out the learning method by following the procedures below LEARNING PROCEDURE 1 Start the engine and warm to reach 80 C 176 F or more NOTE When the engine coolant temperature is 80 C 176 F or more the warm up is not needed if the ignition switch is 0 7 position once 2 Turn the ignition switch to LOCK OFF position 3 After 10 seconds or more start the engine again 4 For 10 minutes carry out the idl
61. is exposed by cracks and abrasions in the fuel system the hoses should be replaced N 3 AIR CLEANER ELEMENT REPLACE M10001000018USA0000010000 The air cleaner element will become dirty during use reducing its effectiveness Replace it with a new one Replacement of air cleaner element 1 Unclasp the air cleaner housing 2 Remove the air cleaner element and install a new one 3 When clamping the air cleaner housing in place be sure that the cover is completely closed 2 6038320000 Platinum tip Iridium tip 2 600368 00 GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 00 57 4 EVAPORATIVE EMISSION SYSTEM EXCEPT EVAPORATIVE EMISSION CANISTER CHECK FOR CLOGGING M10001000019USA0000010000 If the fuel vapor vent line is clogged or damaged fuel vapor will escape into the atmosphere causing excessive emissions Disconnect the line at both ends and blow it clean with compressed air Remove the fuel tank filler tube cap from the filler tube and check to see if there is evidence that the seal makes improper contact to the filler tube 5 SPARK PLUGS REPLACE M10001000020USA0000010001 Iridium plugs are used Use care not to damage the iridium tips of the plugs Do not adjust the spark plug gap 1 Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission level Therefore they should be replaced periodically with new ones Spark p
62. its display informs users whether a mechanical problem currently exists or whether it existed before The message for the former state identifies it as an Active and the message for the latter identifies it as a Stored 74 For how to treat past trouble refer to P 00 17 9 For how to cope with intermittent malfunctions refer to P 00 15 6 For coding data refer to P 00 34 2 SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the symptom s is difficult procedures for checking operation and verifying symptoms are shown 3 DIAGNOSTIC FUNCTION The following trouble code diagnosis are shown How to read diagnostic trouble codes How to erase diagnostic trouble codes Input inspection service points 4 DIAGNOSTIC TROUBLE CODE CHART If the scan tool displays a diagnostic trouble code find the applicable inspection procedure according to this chart 5 SYMPTOM CHART If there are symptoms even though the scan tools show that no DTCs are set inspection procedures for each symptom will be found by using this chart 6 DIAGNOSTIC TROUBLE CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnostic trouble code Refer to P 00 9 7 SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptom listed in the Symptom Chart Refer to P 00 9 8 SERVICE DATA REFERENCE TABLE Inspection items and normal judgment values have been provided in this cha
63. l D Engine oil gear oil or air conditioning compressor oil emp Adhesive tape or butyl rubber tape ZC6012880000 GENERAL BODY AND CHASSIS 00 6 TROUBLESHOOTING GUIDELINES TROUBLESHOOTING GUIDELINES VERIFY THE COMPLAINT Make sure the customer s complaint and the service writer s work order description are understood before starting work Make sure the correct operation of the system is understood Read the service manual description to verify normal system operation Operate the system to see the symptoms Look for other symptoms that were not reported by the customer or on the work order that may be related to the problem DETERMINE POSSIBLE CAUSES Compare the confirmed symptoms to the diagnostic symptom indexes to find the right diagnosis procedure If the confirmed symptoms cannot be found on any symptom index determine other possible causes Analyze the system diagrams and list all possible causes for the problem symptoms Rank all these possible causes in order of probability based on how much of the system they cover how likely they are to be the cause and how easy they will be to check Be sure to take experience into account Consider the causes of similar problems seen in the past The list of causes should be ranked in order from general to specific from most likely to least likely and from easy to check to hard to check FIND THE PROBLEM After the symptoms have been confirmed and
64. leaks at the oil filter 12 TRANSMISSION FLUID M10001000029USA0000010000 Check fluid level and condition FLUID LEVEL mm in 1 Drive the vehicle until the transmission fluid temperature rises 20 0 8 to the normal operating temperature 70 80 C 158 176 10 0 4 NOTE The transmission fluid temperature is measured with scan tool 15991958 NOTE f it takes some amount of time until the 10 7 0 4 X transmission fluid reaches its normal operating DIPSTICK temperature 70 80 C 158 176 F check the RR 140 hee transmission fluid level by referring to the left FLUID TEMPERATURE C F 2 602774 00 diagram 2 Park the vehicle on a level surface 3 Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid and then move the selector lever to the N position 4 After wiping off any dirt around the dipstick remove the dipstick and check the condition of the transmission fluid NOTE If the transmission fluid smells as if it is burnt it means that the transmission fluid has been contaminated by fine particles from the bushings and friction materials Transaxle overhaul and cooler line flushing may be necessar y 0 0 20 0 8 GENERAL BODY AND CHASSIS Top side view HoT lt Back side view gt lt 2 6027800000 2 6022350000 ED Drive shaft SAW 22 ZC6
65. lter Part number MD332687 MD365876 and MD360935 Any replacement oil filter should be installed in accordance with the oil filter manufacturer s installation instructions Oil Filter Replacement 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 90 C 176 194 F Use care as oil could be hot 2 Remove the engine oil filler cap 3 Remove the drain plug to drain oil GENERAL lt BODY AND CHASSIS 00 64 MAINTENANCE SERVICE 4 Use the respective tool in the following table to remove the engine oil filter Number 7 Specialtool 991828 T MB991396 MD332687 or MD365876 filter wrench MB991828 or equivalent or equivalent MD360935 Oil filter wrench MB991396 or equivalent 5 Clean the filter bracket side mounting surface and ensure the 268010810090 old O ring has been removed 6 Apply a small amount of engine oil to the O ring of the new oil filter 7 Screw on the oil filter by hand until it touches the surface of the flange and then tighten it with an oil filter wrench Number Special tool Tightening torque MD332687 MB991828 Approximately 3 4 turn 16 j MD365876 equivalent 4 N m 12 x 3 ft Ib A d MD360935 B991396 or Approximately one turn 14 equivalent 2 N m 124 18 in Ib 8 Install the drain plug and refill engine oil Refer to P 12 4 9 Rev the engine a few times and check to be sure that no engine oil
66. lug type 2 The new plugs should be checked for the proper gap Spark plug gap 0 7 0 8 mm 0 028 0 031 inch 3 Install the spark plugs and tighten to 25 5 Nm 18 4 ft lb 6 INTAKE AND EXHAUST VALVE CLEARANCE lt SIDE ONLY INSPECT AND ADJUST M10001000129USA0000010000 1 Before checks check that the engine oil starter and battery are normal Also set the vehicle in the following condition Engine coolant temperature 80 95 C 176 203 F Lights and all accessories OFF Transaxle P range NOTE vehicles for Canada the headlight taillight etc remain lit even when the lighting switch is in OFF position but this is no problem for checks and adjustment 2 Remove all of the ignition coils 3 Remove the rocker cover 4 Turn the crankshaft clockwise until the notch on the pulley is lined up with the T mark on the timing indicator GENERAL lt BODY AND CHASSIS 00 58 MAINTENANCE SERVICE 5 Move the rocker arms on the No 1 and No 4 cylinders up and Right bank down by hand to determine which cylinder has its piston at the top dead center on the compression stroke If both intake and exhaust valve rocker arms have a valve lash m the piston in the cylinder corresponding to these rocker arms is at the top dead center the compression stroke Valve clearance inspection and adjustment can be performed 9 on rocker arms indicated by white arrow mark when the No 1
67. ment parts View A Front end crossmember View B Front fender x 5 Section b b The illustration indicates left outer side Right side only ZC5018710000 Right side is symmetrically opposite ZC5018700000 View C Front floor crossmember front View D Side outer panel M SN di Right side only 2 5018730000 Right side only ZC5018720000 Front door Rear door i Section d d The illustration indicates left outer side The illustration indicates left outer side y Right side is symmetrically opposite 2 5018740000 Right side is symmetrically opposite 205018750000 GENERAL BODY AND CHASSIS VEHICLE IDENTIFICATION CODE PLATE 00 25 Label area x for original equipment parts y for replacement parts View E Hood View F Side outer panel The illustration indicates left outer side ZC5018710001 Right side is symmetrically opposite ZC5018770000 View H Liftgate upper Sectione e my The illustration indicates left outer side Right side is symmetrically opposite 2 5018770001 2 5018760000 View Liftgate lower ZC5018760001 GENERAL BODY AND CHASSIS 00 26 PRECAUTIONS BEFORE SERVICE PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM
68. mission fluid DIA QUEEN J2 through the oil filter tube Approximately 3 5 dm 3 7 quarts of transmission fluid should be added NOTE Check for contamination or burnt odor the transmission fluid is still contaminated or burnt repeat Steps 6 and 7 before proceeding to Step 8 Reconnect the hose which was disconnected in step 1 above and firmly insert the dipstick Start the engine and run it at idle for one to two minutes Move the selector lever through all positions and then move it to the N position Check that the transmission fluid level is at the COLD mark on the dipstick If the level is less than this add transmission fluid Drive the vehicle until the transmission fluid temperature rises to the normal operating temperature 70 80 C 158 176 F and then check the transmission fluid level again The transmission fluid level must be at the HOT mark NOTE The transmission fluid temperature is measured with scan too 15991958 NOTE The COLD level is for reference only the HOT level should be regarded as the standard eve NOTE f it takes some amount of time until the transmission fluid reaches its normal operating temperature 70 80 158 176 7 check the GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 00 67 transmission flu d level by referring to the left diagram 13 If the transmission fluid is less than the specified level add transmission fluid
69. ndicator illuminate and the diagnostic trouble code is displayed When the ECM WCM and the KOS ECU are replaced follow the procedure below to write the VIN Screen frow of M U T III When is replaced System Select 1 KOS IMMO Keyless TPMS Special Function Key Code Registration OK Key Code Registration Completed GENERAL lt BODY AND CHASSIS gt PRECAUTIONS BEFORE SERVICE 00 27 lt When WCM or KOS ECU are replaced gt System Select KOS IMMO Keyless TPMS VIN Registration VIN Registration Confirmation VIN Registration completed OK Result of VIN Registration 2 6037920000 WRITING PROCEDURE Required Special Tools MB991958 Scan Tool M U T II Sub Assembly 991824 V C I 991827 M U T III USB Cable 991910 M U T III Main Harness Check that diagnostic trouble code P0603 EEPROM fail is not set When diagnostic trouble code P0603 EEPROM fail is set the ECM cannot store the key code even if the key code is registered If this diagnostic trouble code is set troubleshoot the ECM and repair Then register the key code to the ECM Check that diagnostic trouble code P0630 VIN not programmed is not set When diagnostic trouble code P0630 VIN not programmed is set the VIN is not written to the ECM After VIN is written in ECM the Key Code Registration is executed GENERAL lt BODY AND CHASSIS 00 28 PRECAUTIONS BEFORE SER
70. nnection pressure due to rusted terminals or foreign matter lodged in terminals GENERAL BODY AND CHASSIS HOW TO USE TROUBLESHOOT NG INSPECTION SERVICE POINTS 00 15 2 5019110000 991219 2 5019160000 CONNECTOR PIN INSPECTION If the connector pin stopper is damaged the terminal connections male and female pins will not be perfect even when the connector body is connected because the pins may pull out of the back side of the connector Therefore gently pull the wires one by one to make sure that no pins pull out of the connector CONNECTOR ENGAGEMENT INSPECTION Required Special Tool MB991219 Inspection Harness contained in MB991223 Test Harness Use special tool MB991219 to inspect the engagement of the male pins and female pins Pin drawing force 1 N 0 2 pound or more HOW TO COPE WITH INTERMITTENT MALFUNCTIONS M10001000139USA0000010000 Most intermittent malfunctions occur under certain conditions If those conditions can be identified the cause will be easier to find TO COPE WITH INTERMITTENT MALFUNCTION 1 ASK THE CUSTOMER ABOUT THE MALFUNCTION Ask what it feels like what it sounds like etc Then ask about driving conditions weather frequency of occurrence and so on 2 DETERMINE THE CONDITIONS FROM THE CUSTOMER S RESPONSES Typically almost all intermittent malfunctions occur from conditions like vibration temperature and or moisture change poor connections From the
71. nstallation or assembly Operating procedures cautions etc on removal INSTALLATION SERVICE POINT installation disassembly and gt gt lt lt DISC BRAKE ASSEMBLY INSTALLATION 1 To check the brake drag force after mounting the pad assembly are described measure the hub torque in the advancing direction using a Spring balance with the pad is removed CAUTION Do not allow any oil grease or other contamination to contact the friction surfaces of the pads and brake discs 2 After re installing the caliper support to the knuckle install the pad clips and the pads to the caliper support The title of the page following the page on which the diagram of component parts is presented indicating the locations of lubrication and sealing procedures LUBRICATION AND SEALING POINTS Indicates by symbols where lubrication is necessary Symbols for lubrication sealants and adhesives SER Grease Symbols are used to show the locations for lubrication Multi purpose grease unless there is a and for application of sealants and adhesives m brand or type specified These symbols are included in the diagram of component parts or on the page following the Sealant or adhesive 7 component parts page The symbols do not always Brake fluid or automatic transmission fluid have accompanying text to support that symbo
72. o GROUP 52A Instrument Panel Removal and Installation P 52A 2 2 Remove the two screws as shown and replace the clean air filter 3 Install the glove box MAIN SEALANT AND ADHESIVE TABLE M10001000038USA0000010000 Application 3M No Loctite permatex No ENGINE AND Between rocker cover and 3M AAD Part No 08672 Permatex UItra Black 598 DRIVETRAIN camshaft bearing Between rocker semicircular packing cap Ultrapro High Temp Silicone No 82180 cover Gasket or 3M AAD Part No 8679 Black 8678 Black cylinder head Between oil Press In Place Silicone pressure switch and engine gasket strips Between engine coolant 3M AAD Part 08731 octite 242 Blue Service temperature switch engine Medium Strength Blue Tool Removable 24200 coolant temperature sensor Threadlocker thermo valve thermo switch joint engine coolant temperature gauge large size and engine unit Between oil pan and engine 3M AAD Part 08672 PermatexOUltra Gray 599 block 3M AAD Part No 08704 or No 82194 3M AAD 08679 8678 WEATHERSTRI Between tempered 1855 3M AAD Part 08509 PPING FOR body flanges GLASS weatherstrip and Auto Bedding and Glazing Compound or 3M AAD Part No 08633 Windo weld Resealant 00 72 GENERAL BODY AND CHASSIS MAIN SEALANT AND ADHESIVE TABLE Application 3M No Loctite permatex No WEATHERSTRI Bet
73. of the transfer The vehicle must not be towed by placing only its front wheels or only the rear wheels on a rolling dolly This will result in deterioration of the viscous coupling causing the vehicle to jump forward suddenly If this vehicle is towed use flat bed equipment only GENERAL BODY AND CHASSIS TOWING AND HOISTING 00 43 REAR TOWING PICKUP lt FWD gt Sling type NO CAUTION This vehicle cannot be towed by a wrecker using sling type equipment doing so may cause the lower arm to become deformed If this vehicle is towed use a wheel lift or flat bed equipment Do not use the steering column lock to secure the front wheels for towing Make sure the transaxle is in Neutral if vehicle will have drive wheels on the ground If these requirements cannot be met the front wheels must be placed on a tow dolly Automatic transaxle vehicles may be towed on the front wheels at speeds not to exceed 50 km h 30 mph for distances not to exceed 30 km 18 miles ZC5019420000 TOWING WHEN KEYS ARE NOT AVAILABLE When a locked vehicle must be towed and keys are not available the vehicle may be lifted and towed from the front provided the parking brake is released If not released the rear wheels should be placed on a tow dolly SAFETY PRECAUTIONS The following precautions should be taken when towing the vehicle 1 DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER
74. ons will also be listed Gathering information from the customer Coding data Reoccurs Does not reoccur Check trouble symptom NG y CAN bus diagnosis CAN bus diagnosis chart OK Y Read the diagnosis code Diagnosis code displayed Current trouble Y Read the diagnosis code Diagnosis code displayed Current trouble No diagnosis code or communication Diagnosis code displayed Past trouble After taking note of the malfunction code erase the diagnosis code memory Diagnosis code displayed Past trouble No diagnosis code with scan tool MB991958 not Y possible How to treat past trouble Diagnosis code displayed Y Recheck trouble symptom How to treat past trouble Y Read the diagnosis codes No diagnosis code RE Refer to the INSPECTION CHA RT FOR T ROUBLE SYMP TOMS Refer to applica ble group FOR DI AGNOSIS CODES Refer to the INSPECTION CHA RT Refer to applica ble group 5 INTERMITTENT MALFUNCTIONS 1 For how to diagnose CAN bus lines refer to GROUP 54D P 54D 10 2 For the CAN bus diagnosis chart refer to GROUP 54D P 54D 17 ZC6040180000 GENERAL lt BODY AND CHASSIS 00 8 3 When scan tool MB991958 detects diagnostic trouble code
75. or short circuit that could result in a fire in the vehicle Before connecting or disconnecting the negative battery cable be sure to turn the ignition switch to the LOCK OFF position and turn off the lights If this is not done there is the possibility of semiconductor parts being damaged After completion of the work and the negative battery terminals is connected warm up the engine and allow it to idle for approximately 10 minutes under the conditions described below in order to stabilize engine control conditions and then check to be sure that the idle is satisfactory Engine coolant temperature 85 95 C 185 203 F Lights and all accessories OFF Transaxle P position Steering wheel straight forward position 2 When servicing the electrical system disconnect the negative cable terminal from the battery GENERAL lt BODY AND CHASSIS PRECAUTIONS BEFORE SERVICE 00 33 Approximately 40 16 20 2 5012320000 VEHICLE WASHING M10001000120USA0000010000 If high pressure car washing equipment or steam car washing equipment is used to wash the vehicle be sure to maintain the spray nozzle at a distance of at least approximately 40cm 16 inches from any plastic parts and all opening parts doors luggage compartment etc APPLICATION OF ANTI CORROSION AGENTS AND UNDERCOATS M10001000110USA0000010000 Be careful not to apply oil or grease to the heated oxygen sensor If
76. rt as reference information 9 CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors inspection items and standard values have been provided in this chart as reference information TERMINAL VOLTAGE CHECKS HOW TO USE TROUBLESHOOT NG INSPECTION SERVICE POINTS 1 Connect a needle nosed wire probe to a voltmeter probe Short circuiting the positive probe between connector terminal and ground could damage the vehicle wiring the sensor the ECU or all three Use care to prevent this 2 Insert the needle nosed wire probe into each of the ECU connector terminals from the wire side and measure the voltage while referring to the check chart NOTE Measure voltage with the ECU connectors connected You may find it convenient to pull out the ECU to make it easier to reach the connector terminals Checks don t have to be carried out in the order given n the chart voltage readings differ from normal condition values check related sensors actuators and wiring Replace or repair as needed 4 After repair or replacement recheck with the voltmeter to confirm that the repair has corrected the problem TERMINAL RESISTANCE AND CONTINUITY CHECKS 1 the ignition switch to the LOCK OFF position 2 Disconnect the ECU connector If resistance and continuity checks are performed on the wrong terminals damage to the vehicle wiring sensors ECU and or ohmmeter may occur Use care
77. s in the fuel system components Fuel system damage and performance problems resulting from the use of gasoline containing methanol may not be covered by the new vehicle warranty GENERAL BODY AND CHASSIS RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE GASOLINE CONTAINING METHYL TERTIARY BUTYL ETHER MTBE Unleaded gasoline containing 1596 or less MTBE may be used in your vehicle Fuel containing MTBE over 15 in volume may cause reduced engine performance and produce vapor lock or hard starting MATERIALS ADDED TO FUEL Indiscriminate use of fuel system cleaning agents should be avoided Many of these materials intended 00 51 for and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS Lubricant Engine oil Engine oils M10001000013USA0000010000 displaying certification symbol ILSAC For further Starburst LUBRICANTS details refer to SELECTION symbol or conforming to the API section classification SM or higher DIA QUEEN J2 Transmission fluid Transfer oil GL 5 or higher Rear differential gear oil GL 5 or higher Above 85W 90 80W 90 Hypoid gear oil API classification 23 C 10 F 5 90 From 34 C to 23 C 30 F to 10 F SAE80W 80W 90 Below 34 C 30 F SAE75W
78. s operating under severe service conditions will require more frequent service Component service information is included for vehicles operating under one or more of the following conditions 1 Trailer towing or police taxi or commercial type operation 2 Operation of Vehicle 1 Short trip operation at freezing temperature engine not thoroughly warmed up 2 More than 5096 operation in heavy city traffic during hot weather above 32 C 90 F 3 Extensive idling 4 Driving in sandy areas 5 Driving in salty areas 6 Driving in dusty conditions 7 Driving off road ENGINE OIL Test results submitted to EPA have shown that laboratory animals develop skin cancer after prolonged contact with used engine oil Accordingly the potential exists for humans to develop a number of skin disorders including cancer from such exposure to used engine oil Therefore when changing engine oil be careful not to touch it as much as possible Protective clothing and gloves that cannot be penetrated by oil should be worn The skin should be LUBRICATION AND MAINTENANCE thoroughly washed with soap and water or use waterless hand cleaner to remove any used engine oil Do not use gasoline thinners or solvents Either of the following engine oils should be used Engine oils displaying ILSAC certification symbol or conforming to the API classification SL SL CF For further details refer to RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITI
79. the SRS check the SRS warning light operation to make sure that the system functions properly 8 Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag Refer to GROUP 52B Air Bag Module and Seat Belt Pre tensioner Disposal Procedures P 52B 352 2 Observe the following when carrying out operations on places where SRS components are installed including operations not directly related to the SRS air bag 1 When removing or installing parts do not allow any impact or shock to occur to the SRS components 2 If heat damage may occur during paint work remove the SRS ECU the air bag module clock spring the front impact sensor the side impact sensor and the seat belt pre tensioner SRS ECU air bag module clock spring front impact sensor the side impact sensor 93 C 200 F or more Seat belt pre tensioner 90 C 194 F or more HOW TO PERFORM VEHICLE IDENTIFICATION NUMBER VIN WRITING CAUTION The F A S T Key Free hand Advanced Security Transmitter is described as the Keyless Operation System KOS in this manual Follow the procedure below to register the VIN of the Wireless Control Module WCM and the Keyless Operation System KOS M10001000114USA0000010000 The VIN is stored in the engine control module ECM WCM and the KOS ECU If the VIN is improperly erased the engine warning light or the keyless operation system warning i
80. the engine is cool Almost equal to the ambient temperature atmospheric temperature NOTE Set scan tool MB991958 to data reading mode for item number 13 Intake Air Temperature IAT Sensor and note the temperature measurement When the engine is cool the temperature should be almost equal to the ambient temperature atmospheric temperature and the IAT sensor measurement should be approxi mately the same as the Transmission Fluid Temperature When the engine is warm 70 to 80 C 158 to 176 F 4 Turn the ignition switch to the LOCK OFF position Q Is the sensor operating properly YES It can be assumed that this malfunction is intermittent Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points How to Cope with Intermittent Malfunction 7 Describes possible cause s for that DTC 8 Start of the diagnosis procedure for that DTC 7 Assem bly 9 Identifies the special tool s necessary for diagnosing that DTC 2 6012900000 service points when there is a blown fuse refer to Inspection Service Points for a Blown Fuse P 00 18 MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU repeat the inspection procedure from the beginning GENERAL lt BODY AND CHASSIS 00 12 2 5018930000 2 5019070000 HOW
81. tion freezing point 31 C 24 F Recommended antifreeze Long Life Antifreeze Coolant or an equivalent Quantity 9 5 dm 10 0 quarts 10 0 dm 10 6 quarts Vehicles with Towing Package or DOR radiator gt 9 Reinstall the radiator cap 10 Start the engine and let it warm up until the thermostat opens 11 After repeatedly revving the engine up to 3 000 r min several times stop the engine 12 Remove the radiator cap after the engine has cooled and pour in coolant up to the brim Reinstall the cap 2 602532 AA00 Do not overfill the radiator condenser tank assembly 13 coolant to the radiator condenser tank assembly between the FULL and LOW mark if necessary GENERAL BODY AND CHASSIS MAINTENANCE SERVICE 00 69 15 COOLANT HOSES RADIATOR HOSE HEATER HOSE INSPECT M10001000097USA0000010000 Inspect the surface of radiator hoses and heater hoses for heat and mechanical damage Hard and brittle rubber cracking tears cuts abrasions and excessive swelling indicate deterioration of the rubber 16 DISC BRAKE PADS INSPECT FOR WEAR M10001000032USA0000010000 Check for fluid contamination and wear Replace the complete set of pads if any one pad is defective Thickness of lining Minimum limit 2 0 mm 0 08 in The pads for the right and left wheels should be replaced at the same time Never split or intermix brake pad sets All four pads must be replaced as a complete set ZC6011
82. to prevent this 3 Measure the resistance and check for continuity between the terminals of the ECU harness side connector while referring to the check chart NOTE Checks don t have to be carried out in the order given the chart 4 If the ohmmeter shows any deviation from the Normal Condition value check the corresponding sensor actuator and related electrical wiring then repair or replace 5 After repair or replacement recheck with the ohmmeter to confirm that the repair has corrected the problem GENERAL lt BODY AND CHASSIS HOW TO USE TROUBLESHOOT ING INSPECTION SERVICE POINTS 00 9 10 INSPECTION PROCEDURES USING 950 these are listed AN OSCILLOSCOPE When there are inspection procedures using an HOW TO USE THE INSPECTION PROCEDURES M10001000135USA0000010001 The causes of many of the problems occurring in connectors in that order These inspection electric circuitry are generally the connectors procedures follow this order They first try to discover components the ECU and the harnesses between a problem with a connector or a defective component GENERAL BODY AND CHASSIS 00 10 HOW TO USE TROUBLESHOOT NG INSPECTION SERVICE POINTS DTC P0110 Intake Air Temperature Circuit Malfunction INTAKE AIR TEMPERATURE SENSOR INCORPORATED IN VOLUME AIR FLOW SENSOR 1 Relevant circuit s of the component which the DTC indicates are described RED BLUE D 108 MU803781 POWERTRA
83. ween laminated glass and 3M AAD Part No 08633 PPING FOR weatherstrip GLASS INTERIORS BODY SEALANTS CHASSIS SEALANT Adhesive of vinyl chloride 3M V AAD Part No 08088 PermatexSVinyl Repair Kit cloth General Trim Adhesive or No 81786 3M AAD Part No 08064 Vinyl Trim Adhesive Adhesion of door weatherstrip 3M AAD Part 08001 Permatex8Super Black yellow or 3M AAD Part Weatherstrip Adhesive No No 08008 black Super 82 81850 Weatherstrip Adhesive 3M AAD Part No 08011 Black Weatherstrip Adhesive Sealing of various grommets AAD Part No 08509 or and packing 3M AAD Part No 8678 Adhesion of headliners and 3M AAD Part No 08088 Permatex Spray various interior decorative General Trim Adhesive Adhesive No 82019 materials 3M AAD Part No 08090 Super Trim Adhesive Sealing of sheet metal joints 3 7 AAD Part No 08531 drip rail floor side panels Heavy Drip Check Sealer trunk front panel tail gate gray or 3M AAD Part No hinge 08302 Ultrapro Autobody Sealant clear or 3M AAD Part No 08361 Urethane A B Sealant gray or white Miscellaneous body sealants 3M AAD Part No 08633 original mounted Windo weld Resealant w adhesive tape Waterproof door film Fender panel Splash shield Mud guard Rear combination light Fuel Tank and Pad 3M AAD Part No 08088 permatex Spray General Trim Adhesive Adhesive No 82019 3M AAD Part

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