1997-2002 Mitsubishi L200 Service & Repair Manual

GENERAL

GENERAL – How to Use This Manual 00-2 HOW TO USE THIS MANUAL 00100010210 SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission. ON-VEHICLE SERVICE “On-vehicle Service” is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed. INSPECTION Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well. DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance. LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time). CAUTION Indicates the presentation of information particularly vital to the worker during the performance of maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or damage to component parts, or a reduction of component or vehicle function or performance, etc. INDICATION OF TIGHTENING TORQUE The tightening torque shown in this manual is a basic value with a tolerance of ±10% except the following cases when the upper and lower limits of tightening torque are given. (1) The tolerance of the basic value is within ±10%. (2) Special bolts or the like are in use. (3) Special tightening methods are used.

GENERAL – How to Use This Manual 00-3 MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. M/T: Indicates the manual transmission, or models equipped with the manual transmission. A/T: Indicates the automatic transmission, or models equipped with the automatic transmission. SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such an engine. MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection. DIESEL: Indicates a diesel engine, or models equipped with such an engine. 2WD: Indicates the rear wheel-drive vehicles. 4WD: Indicates the 4 wheel-drive vehicles.

GENERAL – How to Use This Manual 00-4 EXPLANATION OF MANUAL CONTENTS Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Indicates (by symbols) where lubrication is necessary. Maintenance and Servicing Procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. D Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. D Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps. D 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. D Reassembly steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassemby is possible in reverse order of disassembly steps. 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 ar- ranged together as major maintenance and service points and explained in detail. AA" : Indicates that there are essential points for removal or disassembly. "AA : Indicates that there are essential points for installation or reassembly. Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained. : Grease (multipurpose grease unless there is a brand or type specified) : Sealant or adhesive : Brake fluid or automatic transmission fluid : Engine oil, gear oil or air conditioner compressor oil : Adhesive tape or butyl rubber tape Component Diagram A diagram of the component parts is provided near the front of each section in order to give a reader a better under- standing of the installed condition of component parts.

GENERAL – How to Use This Manual 00-5 Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Parts- tightening-torque Table”. indicates that there is a continuity between the terminals. indicates terminals to which battery voltage is applied. Indicates the section title. Indicates the group number. Indicates the page number. Indicates the group title. Denotes non-reus- able part. Repair kit or set parts are shown. (Only very frequently used parts are shown.) Operating procedures, cau- tions, etc. on removal, installation, disassembly and reassembly are described. The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.

GENERAL – How to Use Troubleshooting/Inspection Service Points 00-6 HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS 00100020091 Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems still follow this outline. TROUBLESHOOTING CONTENTS 1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed. Diagnosis method Gathering information from the customer. Check trouble symptom. Reoccurs Does not reoccur. Read the diagnosis code No diagnosis code or communication with MUT-II not possible Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group.) Diagnosis code displayed. Read the diagnosis code Diagnosis code displayed. No diagnosis code After taking note of the malfunction code, erase the diagnosis code memory Recheck trouble symptom. Diagnosis code displayed. Read the diagnosis codes. No diagnosis code Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group.) INTERMITTENT MALFUNCTIONS (Refer to P.00-12.) 2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble symptoms are shown. 3. DIAGNOSIS FUNCTION Details which are different from those in the “Diagnosis Function” section on the next page are listed.

GENERAL – How to Use Troubleshooting/Inspection Service Points 00-7 4. INSPECTION CHART FOR DIAGNOSIS CODES 5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-9 for how to read the inspection procedures.) 6. INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms even though the results of inspection using the MUT-II show that all diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means of this chart. 7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection Chart for Trouble Symptoms. (Refer to P.00-9 for how to read the inspection procedures.) 8. SERVICE DATA REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart 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. 10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed here. DIAGNOSIS FUNCTION METHOD OF READING DIAGNOSIS CODES WHEN USING THE MUT-II Connect the MUT-II to the diagnosis connector and take a reading of the diagnosis codes. Caution Turn off the ignition switch before connecting or disconnecting the MUT-II. MUT-II

GENERAL – How to Use Troubleshooting/Inspection Service Points 00-8 WHEN USING THE WARNING LAMP 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. 2. To check ABS system, remove the valve relay. NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS system. 3. Turn off the ignition switch. 4. Read out a diagnosis code by observing how the warning lamp flashes. Applicable systems System name Warning lamp name MPI Engine warning lamp ABS ABS warning lamp Indication of diagnosis code by warning lamp When the diagnosis code No.24 is output When no diagnosis code is output* On Off 1.5 s 0.5 s 0.5 s Pause time 3 s Tens signal Place division 2 s Units signal On Off 0.5 s NOTE *: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.51 to be output. METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT-II Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Turn off the ignition switch before connecting or disconnecting the MUT-II. WHEN NOT USING THE MUT-II (1) Turn the ignition switch to OFF. (2) After disconnecting the battery cable from the battery (–) terminal for 10 seconds or more, reconnect the cable. (3) After the engine has warmed up, run it at idle for about 15 minutes. Diagnosis connector MB991529

GENERAL – How to Use Troubleshooting/Inspection Service Points 00-9 HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component. D Indicator does not turn on or off even if control mode switch is pressed. D Indicator switch should not be illuminated is illuminated. Probable cause OK OK OK Measure at switch connector A-44 D Disconnect the connector, and measure at the harness side. D Voltage between terminal 6 – earth and terminal 8 – earth OK: Approx. 5V OK NG Check the following connector. A-44 Repair OK Check trouble symptom. Replace the ECS-ECU. In the above cases, the ECS switch circuit is defective or the indicator circuit is defective. CHECKING PROCEDURE 4 2. Indicates inspection carried out using the MUT-II. Indicates the operation and inspection procedures. Indicates the OK judgement conditions. 3. Detailed inspection procedures (methods) such as component inspection and circuit inspection are listed on a separate page, and are given here for reference. 5. Inspect the contact condition at each connector terminal. (Refer to Connector Inspection Service Points.) The connector position can be located in the wiring diagram in the electrical wiring manual by means of this symbol. Caution After carrying out connector inspection, always be sure to reconnect the connector as it was before. 6. Confirm that there are trouble symptoms. If trouble symptoms have disappeared, the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection. If it seems that trouble symptoms still remain, proceed to the next page of instructions. 7. If trouble symptoms still remain up to this stage, there is a possibility that there is an open or short circuit in the harness between the connectors, so check the harness. Alternatively, the cause may be a defective ECU, so try replacing the ECU and check if the trouble symptom disappears. NG ECU switch component inspection (Refer to P.3-44.) NG 1. Comments on the diagnosis code or trouble symptom above. MUT-II Data list 17 Control mode selection switch OK: Voltage changes between approx. 0V ! approx. 2.5V ! approx. 5V when the switch is operated. 4. Indicates voltage and resistance to be measured at a particular connector. (Refer to Connector Measurement Service Points.) The connector position can be located in the wiring diagram in the electrical wiring manual by means of this symbol. Indicates operation and inspection procedures, inspection terminals and inspection conditions. Indicates the OK judgement conditions. HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were defective according to the connector measurements. Carry out this inspection while referring to the electrical wiring manual. Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses. For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown Fuse.” 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.

1997-2002 Mitsubishi L200 Service & Repair Manual

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