Page 1 EVOLUTION-VII WORKSHOP MANUAL Pub. No. S0105CT9A TECHNICAL INFORMATION MANUAL Pub. No. N0104CT9A RA-0111...
Page 2: Table Of Contents
RALLIART Inc. Since the EVOLUTION-VII is a rally- based model, it will not be warranted and will not be homologated for general production. Therefore, any service matters on the EVOLUTION-VII should be inquired to RALLIART Inc. as usual. E Mitsubishi Motors Corporation April 2001...
Page 3 NOTES...
Page 4 GENERAL CONTENTS HOW TO USE THIS MANUAL ....Active Center Differential (ACD), Active Yaw Control (AYC) ....... . Model Indications .
Page 5: General
Mitsubishi brand. Furthermore, enhancement of competitiveness as well as driving performance in various motor sport events has been sought.
Page 6 GENERAL - Product Features Further improve- (1) Mitsubishi original revolutionary technology with all wheel control ment in handling Newly developed active center differential system (ACD) (to be performance compatible with steering response to cornering and rising traction made performance) hancement of the...
Page 7: Technical Features
GENERAL - Technical Features TECHNICAL FEATURES EXTERIOR DESIGN FEATURES The 7th generation EVOLUTION has acquired the (3) Exclusive blister fender to appeal good road image of “high performance sports sedan” equipped hanging (traction characteristics) and brisk with guaranteed quality and fearless determination driving capability as “high quality driving sedan”...
Page 8 Technical Features INTERIOR DESIGN FEATURES High performance interior to provide an impression (2) The Mitsubishi original design made by MOMO of sports minded vehicle as the 7th generation used for the steering has the same design used EVOLUTION for horn pad as the shift lever to express...
Page 9 GENERAL - Technical Features BODY DIMENSIONS AND SPACIOUS CABIN Body Dimensions The dimensions of the EVOLUTION-VII except for the overall width have been altered in comparison with those of EVOLUTION-VI. Dimensions mm Dimensions mm Item Item Overall length 4 455 (+105) Rear overhang 935 ( - 15) 1 770 (±0)
Page 10: Feature
GENERAL - Technical Features ACTIVE CENTER DIFFERENTIAL (ACD), ACTIVE YAW CONTROL (AYC) ACD, which is designed for improving drive characteristics by electronically controlling center differential movement, and AYC, which has been adopted since EVOLUTION-IV are featured by combing two systems for integrated control so that further improvements in driving performance can be achieved.
Page 11 GENERAL - Technical Features ENGINE The turbo charger specifications have been Since adoption of magnesium diecasting rocker optimized by reducing the size of the turbine nozzle cover and hollow camshaft is intended for light diameter to increase the engine torque at weight of the upper part of the engine, vibration low - middle speed range as well as high speed of engine - transmission at acceleration can be...
Page 12 GENERAL - Technical Features Strut insulator Lower arm bushing (Pillow ball bushing with rubber) Coil spring Stabilizer bar Crossmember Strut assembly (shock absorber) Stabilizer link Lower arm Crossmember bar <RS (option), RS-II> Coil spring Shock absorber Stabilizer bar Upper arm Crossmember Toe control arm Differential...
Page 13 0-10 GENERAL - Technical Features SAFETY ACTIVE SAFETY BRAKING SYSTEM All models feature fade-resistant 14-inch ventilated New for the Lancer, EBD works with the ABS discs up front and rear 8-inch drums for sure, linear computer to evenly modulate each channel’s stopping power.
Page 14: Passive Safety
0-11 GENERAL - Technical Features PASSIVE SAFETY SRS AIR BAGS Dual SRS (Supplemental Restraint System) front Seat belt with pretensioner featured for the driver’s airbags deploy only upon detection of frontal impact. and front passenger’s seats is designed for instantly When used in combination with the 3-point ELR taking up the slack in the seat belt at the time seatbelts, they significantly mitigate head and upper...
Page 15 0-12 GENERAL - Technical Features BODY CONSTRUCTION EVOLUTION-VII safety-enhanced body Adding to all-round occupant protection is a structure comprises front and rear crushable zones deformation-resistant, highly rigid cabin structure that effectively absorb the impact energy of front that features strategic reinforcements plus large and rear collisions.
Page 16 0-13 GENERAL - GENERAL - Technical Features Technical Features SAFETY-ENHANCED FRONT SEATS The front seats are designed to minimise the risk In-house tests show a roughly 40% improvement of whiplash in a collision from the rear. in occupant injury figures. The headrestraints have been ideally angled forward, while the seat frame was moved toward the rear.
Page 17: Vehicle Identification
16 valves intercooler turbo) 16 valves-intercooler turbo) SNGFZL/R RS-II MODEL CODE Items Contents CT 9 A S N D F Development MITSUBISHI LANCER EVOLUTION-VII Engine type 1,997 mL petrol engine 2 3 4 5 6 7 8 9 Sort Passenger car Body style...
Page 18: Major Specifications
0-15 GENERAL - Major Specifications MAJOR SPECIFICATIONS Items CT9A SNDFZL/R SNGFZL/R Vehicle Front track 1 1,500, 1,515 dimensions Overall width 2 1,770 Front overhang 3 855 Wheel base 4 2,625 Rear overhang 5 975 Overall length 6 4,455 Ground clearance 7 140 (unladen) Overall height (unladen)
Page 19 NOTES...
Page 20: Engine
ENGINE CONTENTS GENERAL INFORMATION ....System Block Diagram ....Control System Diagram .
Page 21 ENGINE - General Information GENERAL INFORMATION This engine has the same basic structure as the previous 4G63-T/C engine, however, the following enhancements have been added in order to provide improved performance. The piston shape has been changed. The width of the piston rings has been reduced in order to reduce engine friction. The turbocharger type has been changed.
Page 22: Base Engine
ENGINE - Base Engine BASE ENGINE PISTON The top land height has been changed from 5 mm to 6 mm, and the second land height has been changed from 4.5 mm to 5 mm. <NEW> <OLD> 6 mm 5 mm 5 mm 4.5 mm PISTON RING...
Page 23: Lubrication System
ENGINE - Lubrication System LUBRICATION SYSTEM ENGINE OIL COOLER The drawn cup air-cooled type engine oil cooler has been adopted. The engine oil cooler is installed below the right head lamp assembly and brings in the air through the oil cooler duct of the front bumper to cool the engine oil.
Page 24: Cooling System
ENGINE - Cooling System COOLING SYSTEM The cooling system is a water-cooled pressurized, forced circulation type which offers the following features. To improve the reliability of cavitation at a high engine speed and to increase the amount of engine coolant, output control system in which a thermostat is installed at the outlet of engine coolant from the engine to the radiator has been adopted.
Page 25: Intake And Exhaust
ENGINE - Intake and Exhaust INTAKE AND EXHAUST AIR INTAKE SYSTEM AIR DUCT, AIR CLEANER By introducing fresh cool air from the top of the radiator efficiently, the engine performance has been enhanced and intake air noise has been reduced. Burnable used paper mixed with plastic materials have been adopted in consideration for reduction of industrial wastes and protection of global environment.
Page 26 ENGINE - Intake and Exhaust INTER COOLER WATER SPRAY To complement the intercooler efficiency in ranges where the cooling efficiency of the air cooled intercooler is insufficient, and attain high performance in various operating environments, a system which cools by spraying water from a special washer tank for the intercooler to the front of the intercooler has been adopted.
Page 27 ENGINE - Intake and Exhaust SYSTEM DIAGRAM Ignition switch (IG2) Ignition switch (IG1) Fuse 7.5A 7.5A Front-ECU (Tail lamp relay) Water spray relay Combination meter Fuse 7.5A Water spray motor Engine-ECU Water spray switch MANUAL AUTO...
Page 28: Exhaust System
ENGINE - Exhaust System EXHAUST SYSTEM EXHAUST FITTING BRACKET An exhaust fitting bracket has been added in order to provide greater rigidity. Exhaust fitting Exhaust manifold heat protector Exhaust fitting bracket TURBOCHARGER The turbocharger type TD05HR-16G6-9.8T and TD05HRA-16G6-9.8T have been adopted. Compared to previous types of turbocharger, these new types have a smaller turbine housing nozzle area which improves response at medium to low speeds.
Page 29 1-10 ENGINE - Intake and Exhaust EXHAUST PIPE AND MUFFLER Exhaust pipe consisting of 3 separation system: front exhaust pipe, center exhaust pipe, and exhaust main muffler, has the following features: The adoption of a seal ring has reduced vibrations during idling and driving noise. A main muffler incorporating a back pressure variable valve is adopted.
Page 30: Fuel System
1-11 ENGINE - Fuel System FUEL SYSTEM The fuel system consists of parts such as electromagnetic-type fuel injectors, a delivery pipe and a fuel pressure regulator. In addition, a fuel pressure control solenoid valve has been provided in order to maintain idling stability after the engine is re-started when it is hot.
Page 31: Fuel Tank
1-12 ENGINE - Fuel System FUEL TANK A steel fuel tank is located under the floor of the For better serviceability, the fuel tank has been rear seats to provide increased safety and increase coupled with the main line by a one-touch joint the amount of luggage compartment space.
Page 32: Control System
1-13 ENGINE - Control System CONTROL SYSTEM The control system is based on the system for 4G63-DOHC-Tubocharger which has been installed in the EVOLUTION-VI, with the following improvements added. Improvements/Additions Remarks Adoption of compact throttle position sensor Smaller size and light weight Higher resistance to vibration Idle position switch disused Basically the same as that used in the SPACE...
Page 33: System Block Diagram
1-14 ENGINE - Control System SYSTEM BLOCK DIAGRAM No.1 injector Engine-ECU Air flow sensor No.2 injector Fuel injection control No.3 injector Intake air temperature sensor Idle speed control No.4 injector Barometric pressure sensor Idle speed control servo Ignition timing control (stepper motor) Engine coolant temperature sensor No.1, No.4 ignition coil...
Page 34: Control System Diagram
1-15 ENGINE - Control System CONTROL SYSTEM DIAGRAM L1 Oxygen sensor (front) l1 Injector l2 Idle speed control servo L2 Oxygen sensor (rear) l3 Fuel pressure control solenoid valve L3 Air flow sensor l4 Waste gate solenoid valve L4 Intake air temperature sensor Engine-ECU L5 Throttle position sensor l5 EGR control solenoid valve...
Page 35: List Of Component Functions
1-16 ENGINE - Control System LIST OF COMPONENT FUNCTIONS Name Function Engine-ECU Uses the signals input from the various sensors to control operation of actuators in accordance with the driving conditions. Sensors Ignition switch-IG Detects the ON/OFF position of the ignition switch. When this signal is input to the engine-ECU, power is supplied to components such as the injectors, air flow sensor, idle speed control servo and crank angle sensor.
Page 36 1-17 ENGINE - Control System Name Function Sensors A/C load signal Inputs the compressor drive state (low load/high load) to the engine-ECU. The engine-ECU controls the A/C idle-up revolution speed using this signal. Intercooler water spray switch Sprays water when certain driving conditions are satisfied. (automatic) Intercooler water spray switch Sprays water while the switch is being pressed by the driver.
Page 37 1-18 ENGINE - Control System Name Function Actuators Alternator G terminal Controls the current generated by the alternator in accordance with the signal from the engine-ECU. A/C relay Controls the A/C compressor operation. Engine warning lamp Illuminates when a sensor malfunction is detected to warn the driver (check engine lamp) of the problem.
Page 38: Idle Speed Control
1-19 ENGINE - Control System FUEL INJECTION CONTROL The fuel injection control system is basically the same as the control system for the 4G63-DOHC-Turbocharger engine installed in the Evolution-VI. SYSTEM CONFIGURATION DIAGRAM Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Throttle position sensor Fuel pressure control...
Page 39: Ignition Timing And Distribution Control
1-20 ENGINE - Control System IGNITION TIMING AND DISTRIBUTION CONTROL The ignition timing and distribution control system is basically the same as the control system for the 4G63 - DOHC-Turbocharger engine installed in the Evolution-VI. SYSTEM CONFIGURATION DIAGRAM Ignition switch Battery Air flow sensor Barometric pressure sensor...
Page 40: Fuel Pump Relay Control
1-21 ENGINE - Control System FUEL PUMP RELAY CONTROL The fuel injection amount is controlled by the fuel pump relay 3 in order to reduce the amount of return fuel when the engine is running at low speeds and fuel consumption is low, and also to reduce noise.
Page 41: Diagnosis System
1-22 ENGINE - Control System EGR CONTROL AND PURGE CONTROL Refer to the EMISSION CONTROL SYSTEM. DIAGNOSIS SYSTEM The engine-ECU is prvided with the following functions to make system inspection easier. Engine warning lamp control Diagnosis function Service data output Actuator test NOTE Refer to the Workshop Manual for details on each item.
Page 42: Emission Control System Diagram
1-23 ENGINE - Emission Control System EMISSION CONTROL SYSTEM The following improvements in the control details have been made to the system, which is basically the same as the previous system used in the 4G63-DOHC-Turbocharger engine for the EVOLUTION-VI. An electronically-controlled EGR system utilizing an EGR control solenoid valve has been adopted. An electronically-controlled purge control system utilizing purge control solenoid valve has been adopted.
Page 43 1-24 ENGINE - Mount MOUNT The inertia axial system based on the past achievements in COLT/LANCER has been adopted for the engine mount system. Longitudinal installation type of cylindrical liquid-filled engine mount has been adopted for reduction of idle vibration and improvement of ride feeling. The liquid-filled mount system has been adopted for transmission mount to improve ride feeling by optimizing the insulator.
Page 44 1-25 ENGINE - ENGINE - Mount Mount <Engine roll stopper/Crossmember/Centermember : L.H. drive vehicles> Rear roll mount bracket Rear roll rod assembly Rear roll rod bracket Crossmember Front roll mount bracket Front roll stopper Crossmember bar Centermember <Engine roll stopper/Crossmember/Centermember : R.H. drive vehicles> Rear roll mount bracket Rear roll stopper Crossmember...
Page 45: Accelerator System
1-26 ENGINE - Accelerator System ACCELERATOR SYSTEM The accelerator system is a cable and suspended vent noise and vibration when the cable and accel- pedal combination. erator arm contact. Plastic bushing and rubber damper have been at- tached to the end of the accelerator cable, to pre- CONSTRUCTION DIAGRAM Plastic bushing Rubber...
Page 46: Power Train
POWER TRAIN CONTENTS CLUTCH ....... . System Structure ......Oil Pressure Unit .
Page 47 POWER TRAIN - Clutch CLUTCH SPECIFICATIONS Items Specifications Engine model 4G63-DOHC-Intercooler Turbocharger Clutch disc type Dry single plate type Clutch disc facing diameter O.D.×I.D. mm 240×160 Clutch cover type Diaphragm spring pull type Clutch cover set load N 9,320 ± 750 Control system Hydraulic type Release cylinder I.D.
Page 48 POWER TRAIN - Manual Transmission MANUAL TRANSMISSION The manual transmission is a W5M5 transmission. This transmission incorporates the following changes from the F5M4 type transmission mounted to GALANT. With the incorporation of 4WD, the center differential has been positioned at the front differential of the 2WD, and the front differential has been positioned inside the transfer.
Page 49 POWER TRAIN - Manual Transmission SECTIONAL VIEW W5M51 <Vehicle with VCU> 1. 4th gear 11. Transfer cover 2. 3rd - 4th synchronizer 12. Hypoid pinion 3. 3rd gear 13. Center differential 4. Transmission case 14. 1st gear 5. Clutch housing 15.
Page 50 POWER TRAIN - Manual Transmission W5M51 <Vehicle with ACD> 1. 4th gear 12. Piston 2. 3rd - 4th synchronizer 13. Transfer hydraulic case 3. 3rd gear 14. Hypoid pinion 4. Transmission case 15. Center differential 5. Clutch housing 16. 1st gear 6.
Page 51 POWER TRAIN - Manual Transmission W5M51 <Vehicle with Helical Gear LSD and VCU> 1. 4th gear 11. Transfer cover 2. 3rd - 4th sychronizer 12. Hypoid pinion 3. 3rd gear 13. Center differential 4. Transmission case 14. 1st gear 5. Clutch housing 15.
Page 52 POWER TRAIN - Manual Transmission W5M51 <Vehicle with Helical Gear LSD and ACD> 1. 4th gear 12. Piston 2. 3rd - 4th sychronizer 13. Transfer hydraulic case 3. 3rd gear 14. Hypoid pinion 4. Transmission case 15. Center differential 5. Clutch housing 16.
Page 53 POWER TRAIN - Manual Transmission 4WD SYSTEM The 4WD system is a center differential full-time 4WD with limited slip differential. The center differential has been positioned at the front differential of the 2WD transmission, and the front differential has been positioned inside the transfer. The limited slip differential of the center differential has been positioned at the back of the front differential in the transfer.
Page 54 POWER TRAIN - Manual Transmission POWER TRAIN Helical Gear LSD The helical gear LSD is composed of four long pinions, four short pinions, three thrust washers, side gears A and B, and cases A and B. The long pinions are in contact with the side gear B and short pinions, while the short pinions are in contact with the side gear A and long pinions.
Page 55 2-10 POWER TRAIN - Manual Transmission Operations during differential (when there is rotational difference between the left and right wheels) When the frictional coefficient of the left and right wheels are more or less equal, and a slight rotational difference occurs at the left and right wheels (normal turning), rotational difference will also occur between side gears A and B.
Page 56 2-11 POWER TRAIN - Manual Transmission Driving power Forward direction Thrust washer Torque High speed side Low speed side Long pinion Thrust washer Differential case Short pinion Side gear A Side gear B TRANSMISSION CONTROL The shift lever construction adopted the The shift and select cable securing portions spherical rotary shaft fulcrum type to assure have been elastically supported to reduce...
Page 57 POWER TRAIN - ACD and AYC ACTIVE CENTER DIFFERENTIAL (ACD) AND ACTIVE YAW CONTROL (AYC) The LANCER EVOLUTION-VII adopts the newly developed active center differential (ACD). The driving performance of the ACD has been improved by varying the center differential drive by electronic control.
Page 58: Components
2-13 POWER TRAIN - ACD and AYC COMPONENT VIEW ACD mode indicator lamp AYC torque transfer differential Parking brake switch Steering wheel sensor Throttle position sensor (TPS) Reserve tank ABS-ECU Hydraulic unit assembly Lateral G sensor Wheel speed sensor Longitudinal ACD transfer G sensor Engine-ECU...
Page 59 2-14 POWER TRAIN - ACD and AYC LIST OF MAIN COMPONENTS Components Outline of function ACD transfer Controls the transmission torque of the hydraulic multi plate clutch by the hydraulic unit, and adjusts the center differential. 4WD-ECU Processes information of various sensors and switches, calculates the hydraulic multi plate clutch transmission torque and amount of AYC torque movement and direction, and controls the hydraulic unit on the basis of them.
Page 60 2-15 POWER TRAIN - ACD and AYC OUTLINE OF ACD AND AYC Idling information Engine-ECU <ACD and AYC Equipped Vehicle> ACD mode switch ABS monitor signal Parking brake switch Wheel speed sensor <FL> Wheel speed sensor <RL> ABS- ACD mode indicator lamp Wheel speed sensor <RR>...
Page 61 2-16 POWER TRAIN - ACD and AYC DESCRIPTION OF STRUCTURE AND OPERATIONS The ACD system adopts a transfer limited slip differential as the hydraulic multi plate clutch, and electronically controls it using sensors, 4WD-ECU, and hydraulic unit. NOTE Refer to P.2-30 for details on the AYC structure and operations. SYSTEM STRUCTURE AYC torque transfer differential...
Page 62 2-17 POWER TRAIN - ACD and AYC TRANSFER LIMITED SLIP DIFFERENTIAL During acceleration and deceleration, the piston is moved in the right direction according to the oil pressure from the hydraulic unit to connect the hydraulic multi plate clutch (friction plate and disc) and set the center differential to the direct engagement state as much as possible.
Page 63 2-18 POWER TRAIN - ACD and AYC HYDRAULIC UNIT The hydreaulic unit is composed of the accumulator (electric pump, pressure sensor, accumulator) and pressure controller (proportional valve, directional valve). The pressure accumulator intermittently operates the pump, and accumulates the control pressure required in the accumulator.
Page 64 2-19 POWER TRAIN - ACD and AYC When the proportional valve is OFF, the oil pressure from the electric pump will be cut off by the proportional valve. Proportional From electric pump valve (OFF) For this reason, oil pressure will be supplied to the ACD or AYC and each system will be set into the non-operating state.
Page 65 2-20 POWER TRAIN - ACD and AYC ELECTRONIC CONTROL SYSTEM THROTTLE POSITION SENSOR For detecting the throttle valve opening angle. Also used as throttle position sensor for engine control. LONGITUDINAL G SENSOR/LATERAL G SENSOR The longitudinal G sensor are sensors detecting the acceleration in the longitudinal directions of the vehicle, and are basically the same as those used conventionally.
Page 66 2-21 POWER TRAIN - ACD and AYC Output waveform of each sensor N (Neutral point) 2° Steering wheel sensor 4° 4° ST-1 θ 4° 4° ST-2 θ Slit 11° ST-N θ Slit plate Slit plate Neutral position Photointerruptor detection slit (ST-2) Zener diode for disconnec-...
Page 67 2-22 POWER TRAIN - ACD and AYC ACD MODE SWITCH When the ACD mode switch is pressed, the mode switches to TARMAC, GRAVEL, or SNOW. ACD mode TARMAC GRAVEL SNOW Good condi- paved roads, Snowy roads tion roads roads gravel roads ACD mode switch ACD MODE INDICATOR LAMP ACD mode indicator lamp...
Page 68 2-23 POWER TRAIN - ACD and AYC The terminals of the 4WD-ECU are arranged as follows. 1. Proportional valve <ACD> 25. - 2. - 26. ECU earth 3. Proportional valve <AYC>* 31. ECU backup power supply 4. - 32. Pressure sensor 5.
Page 69 2-24 POWER TRAIN - ACD and AYC Code Diagnosis Item Mode indica- Main diagnosis details tor lamp (f: all lit, – : normally displayed) Steering wheel sensor <ST-N> system short-circuit Steering wheel sensor <ST-N> ST N Fixing of steering wheel sensor <ST-N> system Steering wheel sensor Short-circuit or fixing of output of steering wheel sensor <ST-1, <ST-1, ST-2>...
Page 70 2-25 POWER TRAIN - ACD and AYC SERVICE DATA Item No. Item Unit Wheel speed sensor <FR> km/h (Displayed for every 1 km/h) Wheel speed sensor <FL> km/h (Displayed for every 1 km/h) Wheel speed sensor <RR> km/h (Displayed for every 1 km/h) Wheel speed sensor <RL>...
Page 71 2-26 POWER TRAIN - ACD and AYC ACTUATOR TEST Item No. Content Drive Specifications Driving Check time Bleeding Outputs current to the 5 minutes Check that no air is discharged from the <ACD> proportional valve accord- bleeder screw installed on the ACD ing to the steering angle.
Page 72 2-27 POWER TRAIN - POWER TRAIN - Propeller Shaft Propeller Shaft PROPELLER SHAFT 3 way split 4-joint type propeller shaft with center bearing is adopted. SPECIFICATIONS Item Vehicles without AYC Vehicles with AYC 3 way split 4-joint type propeller shaft Propeller Type shaft...
Page 73: Front Axle
2-28 DRIVETRAIN - Front Axle FRONT AXLE The front axle consists of front hubs, knuckles, The drive shaft incorporates B.J.-T.J. type wheel bearings and drive shafts, and it has the constant velocity joints with high transmission following features. efficiency and low vibration and noise. The wheel bearing is unit bearing (Double-row ABS rotors for detecting the wheel speeds are angular contact ball bearing) which is integrated...
Page 74: Rear Axle
2-29 DRIVETRAIN - Rear Axle REAR AXLE The rear axle consists of rear hubs, wheel bearings, The drive shaft incorporates B.J.-T.J. type drive shafts, and rear differentialand, it has the constant velocity joints with high transmission following features. efficiency and low vibration and noise. The wheel bearing is a unit bearing (double-row ABS rotors for detecting the wheel speeds are angular contact ball bearing).
Page 75 2-30 DRIVETRAIN - Differential DIFFERENTIAL Mechanical type Limited Slip Differential <Vehicles without AYC> or Torque transfer differential <Vehicles with AYC> is adopted. About the structure of AYC, refer to P.2-3, manual transmission. MECHANICAL LIMITED SLIP DIFFERENTIAL SPECIFICATIONS Item Mechanical LSD Reduction gear type Hypoid gear Reduction ratio...
Page 76 2-31 DRIVETRAIN - Differential TORQUE TRANSFER DIFFERENTIAL The torque transfer differential consists of differential mechanism,acceleration/decelation gear and two pairs of wet multi-plate clutch. The hipoid gear oil is used to lublicate differential part, ATF-SP III is used to lublicate torque movement part (acceleration/decelation gear and clutch). L.H.
Page 77 2-32 DRIVETRAIN - Differential TORQUE TRANSFER DIFFERENTIAL MECHANISM High When high speed clutch is pushed, the driving power always speed speed side side moves from high speed side to low speed side, and controls the driving power with the aid of the property which the movement of driving power is proportional to the pushing force of clutch.
Page 78 2-33 DRIVETRAIN - Differential Mount DIFFERENTIAL MOUNT The front of differential carrier is suported with the The front of torque transfer differential is supported differential support member via the differential with the differential support member with insulator mount bracket with insulator,and the rear is via the differential mount bracket,and the rear is suported with the differential support arm.
Page 79 NOTES...
Page 80: Drive-Control
DRIVE-CONTROL COMPONENTS CONTENTS SUSPENSION ......Steering Gear ......Features .
Page 81: Body
DRIVE-CONTROL COMPONENTS - Suspension/Front Suspension SUSPENSION The suspension which has been adjusted to new A McPherson strut-type suspension has been used body dimension with the optimal tuning has im- at the front, and a multi-link suspension has been proved its cornering ability. used at the rear.
Page 82: Front Suspension
Strut assembly (shock absorber) Stabilizer link Lower arm Crossmember bar <RS (option), RS-II> SPECIFICATIONS SUSPENSION SYSTEM Items Lancer EVOLUTION-VII Lancer EVOLUTION-VI Tommi Makinen Edition Suspension method McPherson strut with coil springs McPherson strut with coil springs WHEEL ALIGNMENT Items Lancer EVOLUTION-VII...
Page 83: Lower Arm
DRIVE-CONTROL COMPONENTS - Front Suspension COIL SPRING Item Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi Makinen Edition RS (standard), RS-II RS (option) Tarmac suspension Normal suspension Wire diameter mm Average diameter mm Free length mm LOWER ARM Like Lancer EVOLUTION-VI Tommi Makinen Improved the reliability and steering feeling by Edition, an aluminium forged lower arm has been reducing friction as well as making the ball size...
Page 84: Stabilizer Bar
DRIVE-CONTROL COMPONENTS - Front Suspension/Rear Suspension STABILIZER BAR Following modifications have been made to Lancer Prevents the occurance of unusual noise EVOLUTION-VI Tommi Makinen Edition. caused by lateral sliding of brackets with Prevents the occurance of unusual noise by installation of two mounting bolts to the increasing the volume of stabilizer bushing.
Page 85 DRIVE-CONTROL COMPONENTS - Rear Suspension SPECIFICATIONS SUSPENSION SYSTEM Item Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi Makinen Edition Suspension method Multi-link Multi-link WHEEL ALIGNMENT Items Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi Makinen Edition - 1_00’ - 1_00’ Camber Toe-in COIL SPRING Items Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ...
Page 86 DRIVE-CONTROL COMPONENTS - Wheel and Tyre WHEEL AND TYRE FEATURES Following modifications have been made to Lancer Equipped with 205/65R15 94H tyre <RS EVOLUTION-VI Tommi Makinen Edition to improve (standard)> the vehicle performance. Exclusively EVOLUTION-VII 17-inch Exclusively to EVOLUTION-VII 17 - inch tyre aluminium wheel has been newly deeveloped has been newly developed by widening the by widening rim width from 7 1/2JJ to 8JJ <RS...
Page 87: Power Steering
DRIVE CONTROL COMPONENTS - Power Steering POWER STEERING FEATURES To improve steering feeling and response of the A variable capacity pump has been adopted to steering system, the following steering system has reduce power losses improve fuel been adopted. consumption. When the engine speed increases, The system has been equipped with the MOMO pump chamber...
Page 88 DRIVE CONTROL COMPONENTS - Power Steering CONSTRUCTION DIAGRAM <L.H. drive vehicles> Steering wheel Steering column and shaft Reservoir tank Return hose Suction hose Pressure hose Oil pump Assembly Steering gear Cooler tube and linkage <R.H. drive vehicles> Steering wheel Steering column and shaft Reservoir tank Return hose Suction hose...
Page 89: Steering Shaft And Column
3-10 DRIVE CONTROL COMPONENTS - Power Steering STEERING WHEEL There are two types of MOMO leather 3-spoke-type steering wheels (built-in SRS air bag) with different desigins. <RS (standard)> <RS(option), RS-II> STEERING SHAFT AND COLUMN For the steering column, an impact absorbing mechanism which absorbs impact energy in the event of a collision as well as a tilt steering mechanism which enables the driver to obtain an...
Page 90 3-11 DRIVE CONTROL COMPONENTS - DRIVE CONTROL COMPONENTS - Power Steering Power Steering SHOCK ABSORBING MECHANISM BEFORE COLLISION 1. Primary impact When the vehicle collides with something and there is a load added to the shaft sub assembly from the gearbox, the shaft sub assembly slides above the pipe sub assembly to absorb the shock load.
Page 91: Oil Pump
3-12 DRIVE CONTROL COMPONENTS - Power Steering (2) At the same time that tilt bracket (A) separates, the clevis BEFORE COLLISION U - section pin comes out of the U - section groove in the tilt plate, groove allowing the steering column assembly to move forward. Clevis pin Tilt plate Tilt bracket (B)
Page 92: Steering Gear
3-13 DRIVE CONTROL COMPONENTS - Power Steering STEERING GEAR Using the following parts have contributed to The installation accuracy, rigidity and steering save weight; an aluminium steering gear and stability have been improved by using an eye linkage valve housing, a plastic tie-rod bellows, bushing, which secures the steering gear to and the hollow-type tie-rod stud.
Page 93 3-14 DRIVE-CONTROL COMPONENTS - Brakes BRAKES The brake system has been designed to give greater reliability and durability and to provide excellent braking performance. FEATURES Improved braking perfor- 1. A 8+9-inch brake booster has been adopted to provide mance large braking force with a small pedal depression force. 2.
Page 94 3-15 DRIVE-CONTROL COMPONENTS - Brakes CONSTRUCTION DIAGRAM <Vehicles with ABS> Brake booster* Hydraulic unit* Rear disc brake Parking brake Master cylinder* Front disc brake <Vehicles without ABS> Brake booster* Master cylinder and proportioning valves* Rear disc brake Parking brake Front disc brake NOTE For R.H.
Page 95: Service Brakes
3-16 DRIVE-CONTROL COMPONENTS - Service Brakes SERVICE BRAKES SPECIFICATIONS Lancer EVOLUTION-VI Tommi Items Lancer EVOLUTION-VII Makinen Edition Master Type Tandem type Tandem type cylinder cylinder I.D. mm 26.9 26.9 Brake Type Vacuum type, tandem Vacuum type, tandem booster booster Effective dia. of power...
Page 96: Master Cylinder
3-17 DRIVE-CONTROL COMPONENTS - Service Brakes MASTER CYLINDER The master cylinder is a tandem-type, with a structure that emphasises safety. Reserve tank Master cylinder body Primary piston assembly Piston retainer Secondary piston assembly BRAKE BOOSTER A 8+9-inch tandem-type brake booster has been adopted.
Page 97: Disc Brakes
3-18 DRIVE-CONTROL COMPONENTS - Service Brakes DISC BRAKES Brakes with the following specifications have been brake pads equipped with adopted. mechanical-type audible wear indicators V5-W43 2-piston ventilate discs for front brakes notify the driver when the usage limit (2 mm) <RS (standard)>...
Page 98: Brake Line
3-19 DRIVE-CONTROL COMPONENTS - Service Brakes DISC BRAKE NOMENCLATURE Item Contents V 7 – Z 40 46 Brake disc type V: Ventilated Brake size 5: 15-inch (Minimum applicable 6: 16-inch disc wheel) 7: 17-inch No. of pistons S: 1 piston (floating type) W: 2 piston (floating type) X: 2 piston (opposed type) Z: 4 piston (opposed type)
Page 99 ABS-ECU outputs ABS signal to 4WD-ECU. Following system for Lancer EVOLUTION-VII has G sensor (lateral), steering wheel sensor and been modified from Lancer EVOLUTION-VI Tommi parking brake switch have been added to the Makinen Edition.
Page 100 3-21 DRIVE-CONTROL COMPONENTS - 4ABS CONSTRUCTION DIAGRAM 7*, 10* NOTE For R.H. drive vehicles, only the position indicated by the * is symmetrical. Name of part Number Outline of functions Wheel speed sensor Send alternating current signals at frequencies which are Sensor proportional to the rotation speeds of each wheel to the ABS-ECU...
Page 101: System Configuration Diagram
3-22 DRIVE-CONTROL COMPONENTS - 4ABS SYSTEM CONFIGURATION DIAGRAM Motor FR solenoid valve (OUT) Wheel speed sensor (FL) FR solenoid valve (IN) Wheel speed sensor (RL) FL solenoid valve (OUT) Wheel speed sensor (RR) FL solenoid valve (IN) Wheel speed sensor (FR) RR solenoid valve (OUT) Longitudinal G sensor RR solenoid valve (IN)
Page 102: Abs Electrical Circuit Diagram
3-23 DRIVE-CONTROL COMPONENTS - 4ABS ABS ELECTRICAL CIRCUIT DIAGRAM Ignition Switch Ignition Switch Fusible link Fusible link Battery (IG2) (IG1) No. 1 No. 3 Junction block (Multi- purpose fuse) Dedicated fuse 7.5A 7.5A 7.5A Stop lamp switch Combination meter (ABS warning lamp) Longitudinal Lateral G sensor G sensor...
Page 103 3-24 DRIVE-CONTROL COMPONENTS - 4ABS SENSORS WHEEL SPEED SENSOR The wheel speed sensors consist of fixed ABS The ABS rotors (43 teeth) are installed to the speed sensors and the ABS rotors that rotate at drive shafts, and the ABS speed sensors are the same speed as the wheels, and output installed to knuckles.
Page 104 3-25 DRIVE-CONTROL COMPONENTS - 4ABS STOP LAMP SWITCH This switch turns on when the brake pedal is stop lamp switch is on or off by means of fluctuations depressed, and turns off when the brake pedal in voltage (ON: system voltage; OFF: Approximately is released.
Page 105 3-26 DRIVE-CONTROL COMPONENTS - DRIVE-CONTROL COMPONENTS - 4ABS 4ABS ABS-ECU The ABS-ECU is basically the same as that of the PININ <Europe> except for the followings: 1999 PAJERO io <General Export>/2000 PAJERO FAIL-SAFE FUNCTION Diagnosis code No Diagnosis code No. Item Item Open circuit or short-circuit in wheel speed sensor (FR)
Page 106: Parking Brake
3-27 DRIVE-CONTROL COMPONENTS - 4ABS/Parking Brake Item No. Check item Display unit or words Lateral G sensor Steering wheel sensor (ST-N) ON/OFF Steering wheel sensor (ST-1) Steering wheel sensor (ST-2) Steering angle _ or OFF (When the steering angle is straight ahead position) SYSTEM OPERATION In terms of operation, the system is basically the...
Page 107 NOTES...
Page 108: Body
BODY CONTENTS GENERAL DESCRIPTION ....STRUT TOWER BAR ..... . . Features .
Page 109: General Description
BODY - General Description GENERAL DESCRIPTION FEATURES Weight reduction 1. Use of high-tensile steel panels and steel plate with uneven thickness 2. Use of aluminum for fender and hood High rigidity 1. Use of high-tensile steel panels and steel plate with uneven thickness 2.
Page 110: Main Body
BODY - Main Body MAIN BODY BODY PANELING The body has been given enhanced impact safety performance. It has been made lighter by adopting aluminum alloy panels for the hood panel and front fender. : Anti-corrosion steel panels : High-tensile steel panels...
Page 111: Body Shell
BODY - Main Body BODY SHELL IMPACT SAFETY BODY The following structure ensures survival space during impact and facilitaty to rescue passengers. 1. Application of enlarged and linear cross section of front side member 2. Addition of dash panel cross member 3.
Page 112 BODY - Main Body STEEL PLATE WITH UNEVEN THICKNESS Due to the adoption of steel plate with uneven thickness* for the following parts, the incorporate structure of uneven thickness has improved impact safety and has reduced weight. 1. The thickness of the front end crossmember outer applied at the right side of the vehicle has been increased.
Page 113 BODY - Main Body OPERATIONAL STABILITY The adoption of the following structure to increase rigidity of the suspension mounting part has improved driving stability and has reduced noise from the road. 1. By directly joining a spring house bracket with increased thickness to the cowl top lower panel, and adding an upper frame to the front pillar brace, the rigidity of the top, bottom, left, and right sides of the front suspension has been improved.
Page 114 BODY - Main Body QUIETNESS The adoption of the following items has improved quietness. 1. Foaming sound absorption materials have been filled into the front pillar, the roof side rail, the center pillar, the rear pillar, and the inside the wheel house arch to prevent noise getting inside the vehicle. 2.
Page 115 BODY - Main Body BODY COLOUR CHARTS Engine compartment and Colour Body Colour number Body colour name Composition luggage compartment colour colour of film code Colour number Colour name SILVER AC11169 Satellite Silver Metallic AC10595 GRAY BRIGHT CMT10010 French Blue Solid CMB17004 BRIGHT...
Page 116: Hood And Fender
BODY - Hood and Fender/Strut Tower Bar HOOD AND FENDER The body has been made lightweight with the use of aluminum hood and fender. The hood has also been equipped with the air outlet and air inlet garnish. Hood Air inlet garnish Air outlet garnish Fender STRUT TOWER BAR...
Page 117: Rear End Cross Bar
4-10 BODY - Rear End Cross Bar <RS> REAR END CROSS BAR <RS> The rear floor pan has been equipped with a rear end cross bar to improve body rigidity. Rear end cross bar...

Page 118: Door Lock
4-11 BODY - Door DOOR DOOR LOCK The central door lock to lock/unlock all doors with a key cylinder at the driver’s door has been installed. <RS: option, RS - II: standard> CONSTRUCTION DIAGRAM <Front> Section A – A Inside lock cable Clip Inside lock cable Inside handle...
Page 119: Window Glass Regulator
4-12 BODY - Door WINDOW GLASS REGULATOR 1. Small-size and lightweight wire winding style has been adopted for the window glass regulator. 2. The power window with the safety function to activate the descending movement of the door window glass for 150 mm when jammed hand or neck is detected during the ascending movement of the door window glass has been adopted to increase safety.
Page 120: Trunk Lid
Downsizing of the trunk lid hinge and reduction of the hinge protrusion has increased practicality. Trunk lid hinge Approximately 128 mm Trunk lid hinge (the previous LANCER EVOLUTION-VII) WINDOW GLASS Laminated glasses for the windshield and tempered glasses for other areas have been used.
Page 121 NOTES...
Page 122: Exterior
EXTERIOR CONTENTS SUMMARY OF EXTERIOR PARTS ..WIPER AND WASHER ....Feature ....... . . Windshield Wiper .
Page 123 EXTERIOR - Summary of Exterior Parts SUMMARY OF EXTERIOR PARTS Sophisticated and bold exterior designs have been given to every detail. FEATURE 1. A radiator grill integrated front bumper has been Improvements in equipped. appearance 2. An air dam integrated rear bumper has been equipped. 3.
Page 124: Aero Parts
EXTERIOR - Aero Parts AERO PARTS Installation of airdams and elevation adjustable large rear spoilers have improved aerodynamic characteris- tics and appearance. CONSTRUCTION DIAGRAM Front air dam Rear spoiler Side air dam...
Page 125 EXTERIOR - Aero Parts ELEVATION-ADJUSTABLE LARGE REAR SPOILER Remove the cap of the rear spoiler, loosen the elevation fulcrum nut, and change the four installing holes of the adjustment bolts to adjust the elevation of the spoiler wing according to the driving conditions. Rear spoiler Wing View A <Adjustment Bolt Installing Hole...
Page 126: Outside Mirror
EXTERIOR - Outside Mirror OUTSIDE MIRROR A power remote control type <RS-II>, or manual type <RS> outside mirror has been installed. CONSTRUCTION DIAGRAM Power remote control mirror switch...
Page 127: Wiper And Washer
EXTERIOR - Wiper and Washer WIPER AND WASHER WINDSHIELD WIPER Two-speed type windshield wipers to be operable in a low or high speed have been adopted. Intermittent wipers with the variable intermittent time have been adopted. Due to the installation of wiper link assembly with frames, higher rigidity of link assembly has achieved reduction of incomplete cleaning by smoother wiper operation and improvements in quiet wiper operation.
Page 128 EXTERIOR - Wiper and Washer WINDSHIELD WASHER 2-nozzle and 4-jet type indoor shield washers have been installed. Furthermore, the wiper related to washers function has been adopted. A washer tank has been installed in the trunk room. CONSTRUCTION DIAGRAM Trunk lid hinge Washer tank Washer tank Washer nozzle...
Page 129 NOTES...
Page 130: Interior
INTERIOR CONTENTS GENERAL INFORMATION ....INTERIOR TRIMS ..... . Features .
Page 131 INTERIOR – General Information GENERAL INFORMATION The interiors to value functionality, habitation, and safety brings a new sense of good quality and security. Furthermore, it is also intended for getting actively involved with global environmental protection and natural resource recycling. FEATURES Improvements in quality Fully trim-covered interior...
Page 132: Instrument Panel And Floor Console
INTERIOR – Instrument Panel and Floor Console INSTRUMENT PANEL AND FLOOR CONSOLE The instrument panel and the floor console have the A pad incorporating the front passenger’s air following features: bag door has improved appearance. The center panel with a new sense of design glove compartment convenient...
Page 133 INTERIOR – Accessories ACCESSORIES A vanity mirror has been installed to improve A folding assistant grip has been installed to usability. <RS-II> improve safety. Vanity mirror Folding assistant grip...
Page 134 INTERIOR – INTERIOR – Seat Seat SEAT FRONT SEAT The most suitable driving position can be set RECARO seat adopting non-step adjustment by the sliding and reclining mechanism. <RS> slide and reclining mechanism have been Height adjustment function to secure the most equipped.
Page 135 INTERIOR – Seat Belt SEAT BELT FRONT SEAT BELT The adoption of 3-point seat belt with ELR which The seat belt retractor with the pre-tensioner has belt adjustment device for height and the and the force limiter for the driver’s seat and buckle fixed at the seat have secured the most the front passenger’s seat has been adopted suitable fitting for the wearer.
Page 136 INTERIOR – Seat Belt SEAT BELT RETRACTOR WITH FORCE LIMITER The driver’s/front passenger’s seat belt retractor has been equipped with a force limiter. The force lim- iter is a device which operates when a predeter- mined force is applied, and limits the force. Seat belt retractor with force limiter OPERATION...
Page 137: Interior Trims
INTERIOR – Interior Trims INTERIOR TRIMS The interiors are fully covered by trims to Use of inflammable materials for the trims has enhance product value. increased safety as outstanding interiors. Also, The adoption of the energy absorption rib mold material codes are indicated to deal with located in the rear of the front pillar trim and recycling easily.
Page 138 INTERIOR – Supplemental Restraint System (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS air bag is a system to be effective once Seat belt with pre - tensioner featured for the the seat belt is worn. The system is designed driver’s and front passenger’s seats is designed to be a supplemental system of the seat belt.
Page 139 6-10 INTERIOR – Supplemental Restraint System (SRS) SRS SYSTEM CIRCUIT DIAGRAM Ignition switch (IG SRS-ECU N_23 (multi-purpose fuse) 7.5A 7.5A Combination meter Connector lock switch* Connector short-circuit system* Connector short-circuit system* Driver’s side air bag module (squib) C-207 C-22 Clock spring C-204 Connector short-circuit system* Diagnosis connector...
Page 140 6-11 INTERIOR – Supplemental Restraint System (SRS) CAUTION LABELS Labels to indicate cautions regarding the handling and the services of SRS air bag are attached on the position shown in the following illustration. <TYPE 2> <TYPE 1> Steering wheel Driver’s side bag module Cover Clock spring Front passenger’s side air bag module...
Page 141 6-12 INTERIOR – Supplemental Restraint System (SRS) A. CAUTION: SRS G. WARNING: SRS BEFORE REPLACING STEERING WHEEL, FIX STRG. WHEEL AT TIRES STRAIGHT READ SERVICE MANUAL,THIS AIR BAG AHEAD BEFORE GEARBOX REMOVAL. MODULE CANNOT BE REPAIRED. DO NOT OTHER WISE, MAY DAMAGE SRS CLOCK DISASSEMBLE OR TAMPER.
Page 142 6-13 INTERIOR – Supplemental Restraint System (SRS) CONSTRUCTION AND OPERATION NOTE for more information regarding the inflator and the Refer to ’99 PAJERO in Technical Information clock spring of the front passenger’s side air bag Manual (Pub. No. PYJE9805) or ’00 PAJERO PININ module.
Page 143 6-14 INTERIOR – Supplemental Restraint System (SRS) FRONT PASSENGER’S SIDE AIR BAG MODULE The front passenger’s side air bag module consists gas from two bores at the rear of the air bag to re- of air bag, inflator, module cover (incorporating the duce the shock from the impact.
Page 144 6-15 INTERIOR – Supplemental Restraint System (SRS) SRS-ECU The SRS-ECU incorporates an analog G sensor Backup power supply in case of power failure and safing G sensor for frontal collisions. in collisions In frontal collisions, the driver’s and front passen- Boosting function in case of battery voltage ger’s air bags deploy only when both the analog drop...
Page 145 6-16 INTERIOR – Supplemental Restraint System (SRS) Code Major Contents of Diagnosis Driver’s side front air bag squib activating circuit open-circuited Front passenger’s side front air bag squib activating circuit short-circuited Front passenger’s side front air bag squib activating circuit open-circuited Driver’s side front seat belt pretensioner activating circuit short-circuited Driver’s side front seat belt pretensioner activating circuit open-circuited Front passenger’s side front seat belt pretensioner activating circuit short-circuited...
Page 146: Equipment
EQUIPMENT CONTENTS GENERAL DESCRIPTION ....COMBINATION METER ..... Features .
Page 147: Engine
EQUIPMENT – General Description GENERAL DESCRIPTION The adoption of new accessories and functions has enhanced a lineup of equipment. FEATURES 1. Adoption of waterproof connector in the engine compartment Enhanced reliability 2. Installation of fuse box and relay box Enhanced visibility and 1.
Page 148: Diagnostic System
EQUIPMENT – Diagnostic System DIAGNOSTIC SYSTEM Service quality has been improved by fitting diagnostic connectors for MUT-II inspection near the left knee area of the driver’s seat on the instrument panel. Diagnostic function Immobilizer air bag ETACS Column Front switch Diagnosis code output –...
Page 149 EQUIPMENT – Diagnostic System/Battery/Immobilizer Diagnosis connector (Black) Battery Diagnostic connector (White) 21 - 25 – 27 - 32 – BATTERY Light and compact batteries have been adopted. Item Specifications 44B20L Voltage V Capacity (5-hour rate Ah) Electrolytic fluid specific gravity 1.280 (fully charged state at 20_C) IMMOBILIZER SYSTEM...
Page 150 EQUIPMENT – Immobilizer System DISPOSITION WHEN REPLACING IMMOBILIZER SYSTEM RELATED PARTS To replace immobilizer related parts, observe the table below. When the ignition key is re-registered with the MUT-II, the originally registered ignition key registration information will be lost. Engine-ECU Immobilizer-ECU Ignition key When replacing engine-ECU –...
Page 151: Exterior Lamps
EQUIPMENT – Lighting LIGHTING EXTERIOR LAMPS The large lens adjusted to the exclusive body has been equipped with model specific 4 bulb type headlamp incorporating front turn signal lamp, position lamp. The low beam is a projector type used as a compact but efficient wide light distributor. The front turn signal lamp adopts an aluminum metal evaporated reflector to improve visibility.
Page 152 EQUIPMENT – Lighting CONSTRUCTION DIAGRAM Headlamp (High beam) Headlamp assembly Headlamp (Low beam) Side turn signal lamp Position lamp Front turn signal lamp Back up lamp or rear fog lamp ∗ Tail lamp Rear combination lamp Tail / stop lamp Rear turn signal lamp High mount stop lamp NOTE...
Page 153: Interior Lamps
EQUIPMENT – Lighting INTERIOR LAMPS A map lamp serving also as front room lamp which can be used at both the driver’s seat and passenger sea is provided. A rear room lamp to light the backseat and trunk lamp to light the trunk are provided. SPECIFICATIONS Item Specifications...
Page 154 EQUIPMENT – Combination Meter COMBINATION METER The combination meter is an easy-to-read pointer type meter. At the center is a tachometer, on the left side a speedometer, on the right side a fuel meter, engine coolant thermometer, and indicator lamp. It has a sport and efficient design to allow the driver to read the meters clearly.
Page 155 7-10 EQUIPMENT – Smart Wiring System (SWS) SMART WIRING SYSTEM (SWS) SWS is a minimal line system which transmits numerous signals using one wiring to control against increased weight and complication of harnesses which result from the increase in electronic accessories. Basically the same as the new SPACE RUNNER.
Page 156 7-11 EQUIPMENT – Smart Wiring System (SWS) COMMUNICATION METHOD The exclusive signal lines for transmitting the multi-distribution data are connected as follows between the ETACS-ECU, column switch (incorporated inside the column ECU), front ECU, power window main switch (incorporated inside the power window ECU) and power window motor assemblies (incorporated inside the power window motor ECU) for internal communication.
Page 157 7-12 EQUIPMENT – Smart Wiring System (SWS) Circuit and input switch and sensor ECUs and switches con- Output side nected by multi-distribution 3. Windshield wiper washer D Windshield mist wiper D Windshield low speed wiper D Windshield high speed wiper D Windshield washer ETACS-ECU Column switch...
Page 158 7-13 EQUIPMENT – EQUIPMENT – Smart Wiring System (SWS) Smart Wiring System (SWS) DIAGNOSTIC FUNCTION DIAGNOSIS CODE SET The ETACS-ECU sends diagnosis codes if the communication line is faulty when the MUT-ll is connected. NOTE Refer to the Workshop Manual for details of the diagnostic items.
Page 159 7-14 EQUIPMENT – Smart Wiring System (SWS) FUNCTIONS AND CONTROL OF SWS ECUS The following functions are controlled by the SWS ECUs: Functions Control ECU Lamp still ON reminder warning function ETACS-ECU, column switch Central door lock control function ETACS-ECU Power window timer function ETACS-ECU, power window main switch Windshield wiper washer control function...
Page 160 7-15 EQUIPMENT – EQUIPMENT – Smart Wiring System (SWS) Smart Wiring System (SWS) POWER WINDOW TIMER FUNCTION Ignition switch (IG) When the ignition switch is turned to the ON position, the power window relay and power window switch reception (Open) ON Driver’s seat door (Closed) OFF...
Page 161 7-16 EQUIPMENT – Smart Wiring System (SWS) 2. Low Speed Wiper, High Speed Wiper Control When the ignition switch is at the ACC or ON position, if the windshield low speed wiper switch of the column switch is turned ON, the front ECU turns ON the windshield wiper drive signal, turns OFF (LO) the windshield wiper speed relay, and operates the windshield wiper at low speed.
Page 162 7-17 EQUIPMENT – Smart Wiring System (SWS) HEADLAMP AUTO-CUT FUNCTION Even if the headlamp switch is ON, the head lamp will automatically go off in the following conditions to prevent the battery from discharging as a result of forgetting to turn off lights. (1) When the ignition key is turned from ON to OFF with the headlamp switch turned ON, and this state continues for 3 minutes, the headlamp will automatically be turned off.
Page 163 7-18 EQUIPMENT – Smart Wiring System (SWS) (2) Detects the signal where the hazard warning lamp switch input changes from OFF to ON, and reverse the flashing state according to this signal. (Flashes when the hazard Hazard warn- ing lamp lamp is not flashing and turns off when flashing.) switch NOTE...
Page 164 7-19 EQUIPMENT – Smart Wiring System (SWS) DIMMER TYPE ROOM LAMP CONTROL FUNCTION When the room lamp switch is at the door position, the ETACS-ECU controls the lighting of the room lamp as follows. (1) When a door is opened to get on or get off the vehicle (when the ignition switch is OFF), the lamp lights up (100%), when closed, the lamp dims (65%), and goes off 15 seconds later.
Page 165: Heater And Air Conditioner
7-20 EQUIPMENT – Heater and Air Conditioner HEATER AND AIR CONDITIONER The heater and air conditioner system incorporating the heater and cleaning unit has reduced ventilation resistance to increase air volume and reduce noise. FEATURES 1. Installation of two-ray blow full air mix heater Improvements in comfort 2.
Page 166 7-21 EQUIPMENT – Heater and Air Conditioner CONSTRUCTION DIAGRAM Blower assembly Liquid pipe B Liquid pipe A Suction flexible hose Heater unit Compressor Suction pipe Condenser fun Condenser Discharge flexible hose...
Page 167 7-22 EQUIPMENT – Heater And Air Conditioner HEATER AND AIR CONDITIONER SYSTEM CONSTRUCTION AND DESCRIPTION BLOWER ASSEMBLY AND HEATER UNIT The following blower assembly and heater unit has been adopted to increase air volume, reduce noise, improve air-conditioning performance, as well as improve the car interior air environment. Installation of two-ray blow full air mix heater Incorporation of heater and cleaning unit Increase in the outside air intake duct area size of the blower assembly and optimization of the...
Page 168 7-23 EQUIPMENT – Heater And Air Conditioner Two-Ray Blow Full Air Mix Heater Air flow passing In the heater unit, there are two rays of air;one which passes through heater Air flow not core through the heater core, and air which does not pass through passing the core.
Page 169: Ventilation System
7-24 EQUIPMENT – Heater And Air Conditioner HEATER AND AIR CONDITIONER CONTROL Adoption of the following heater and air conditioner control has improved operation performance and visual observation. Installation of dial type switch Incorporation of rear window defogger switch with timer Improved appearance by incorporating the center panel Temperature Blower switch...
Page 170 7-25 EQUIPMENT – Heater And Air Conditioner Air outlet RJST104003 - 170...
Page 171 NOTES...
Page 172 TECHNICAL INFORMATION MANUAL EVOLUTION-VII Pub. No. N0104CT9A...
Page 173 BODY CONSTRUCTION CONTENTS BODY COMPONENTS ....UNDER BODY ......DOOR .
Page 174 BODY CONSTRUCTION - Body Components BODY COMPONENTS : Anticorrosion steel plates : High-tensile steel panels...
Page 175 BODY CONSTRUCTION - Body Components Headlamp support panel 42. Rear combination lamp housing Hood lock stay 43. Side roof rail inner Front end crossmember 44. Front pillar inner upper Front end upper bar 45. Front pillar inner lower Headlamp support panel side 46.
Page 176 BODY CONSTRUCTION - Body Main Cross-sectional Views BODY MAIN CROSS-SECTIONAL VIEWS Front pillar Roof panel Roof panel reinforcement upper Side outer Map lamp panel bracket Front roof rail Side roof rail inner Cowl top Front end crossmember upper reinforcement panel Front cross- member...
Page 177 BODY CONSTRUCTION - Body Main Cross-sectional Views Front pillar rein- Roof panel Front pillar forcement upper inner upper Rear roof rail Side outer panel Rear pillar Center pillar Center pillar inner seatbelt inner reinforcement Side Side outer outer Center pillar panel panel reinforcement...
Page 178 BODY CONSTRUCTION - Maintenance, Serviceability MAINTENANCE, SERVICEABILITY Fender Shield Positioning holes, marks, and notches have been provided at the following overlapped areas to improve operation performance when replacing panels.
Page 179 BODY CONSTRUCTION - Maintenance, Serviceability Side Structure Panel positioning notches have been provided at the door opening section to improve operation performance when replacing panels. Panel positioning notch Side Outer Panel Spare parts are provided in the following cut form with the adoption of the pillar integral type side outer panel.
Page 180 BODY CONSTRUCTION - Body Construction Characteristics BODY CONSTRUCTION CHARACTERISTICS FRONT BODY Headlamp Support 1. By adopting a steel sheet with variable thickness* for the front end crossmember outer, the steel sheet thickness on the right side of the vehicle has been increased to improve safety in collision and body rigidity.
Page 181: Transmission
BODY CONSTRUCTION - Body Construction Characteristics Fender Shield 1. The cross section of the front sidemember has been increased and a steel sheet with variable thickness* has been adopted for the front sidemember inner to increase the thickness of the cabinet side in the aim to improve safety in collision, body rigidity, and realize lightweight.
Page 182 A-10 BODY CONSTRUCTION - Body Construction Characteristics Front Sidemember Reinforcement Right side 1. Front sidemember inner 10. Pipe nut 2. Front sidemember bulkhead A 11. Front sidemember rear 3. Front sidemember outer 12. Dash crossmember extension 4. Engine mount bracket 13.
Page 183 A-11 BODY CONSTRUCTION - Body Construction Characteristics Left side 1. Suspension crossmember support bracket 12. Front sidemember outer 2. Dash crossmember extension 13. Front sidemember bulkhead A 3. Front sidemember rear 14. Pipe 4. Pipe nut 15. Square head bolt 5.
Page 184 A-12 BODY CONSTRUCTION - BODY CONSTRUCTION - Body Construction Characteristics Body Construction Characteristics Front Deck Strut house gussetandupper frame to front pillar brace have been added to improve body rigidity. 1. Strut tower bar bracket 9. Clutch pedal support bracket 2.
Page 185 A-13 BODY CONSTRUCTION - Body Construction Characteristics SIDE BODY Side Structure 1. Front pillar reinforcement lower extension 24. Quarter inner extension rear 2. Front pillar inner lower extension 25. Quarter corner panel 3. Front pillar reinforcement lower 26. Rear combination lamp housing 4.
Page 186 A-14 BODY CONSTRUCTION - Body Construction Characteristics Side Structure Reinforcement 1. The thickness of the reinforcements of the front pillar and center pillar has been increased to improve collision safety. 2. The front pillar reinforcement upper, side outer panel, and front roof rail have been joined to improve twisting rigidity.
Page 187 A-15 BODY CONSTRUCTION - Body Construction Characteristics REAR BODY Rear Deck A rear shelf extension has been added to form closed surface structure. Then, the rear shelf and the rear floor have been joined to improve the torsion rigidity of the seat back plate. 1.
Page 188 A-16 BODY CONSTRUCTION - Body Construction Characteristics ROOF The cross section of the roof bow has been made large to improve safety in collision. 1. Roof panel 4. Front roof bow 2. Rear roof rail 5. Map lamp bracket 3. Rear roof bow 6.
Page 189 A-17 BODY CONSTRUCTION - Body Construction Characteristics UNDER BODY Front Floor The cross section of the front floor sidemember has been made large to improve safety in collision. 1. Installment panel center bracket 8. Front floor sidemember reinforcement 9. Front floor sidemember reinforcement front 2.
Page 190 A-18 BODY CONSTRUCTION - Body Construction Characteristics Rear Floor 1. Rear floor pan 11. Rear floor sidemember 2. Seat back plate extension 12. Fuel tank rear bracket (Vehicles with AYC) 3. Jack bracket 13. Differential/fuel support bracket front (Vehicles 4. Spare tire bracket with mechanical LSD) 5.
Page 191 A-19 BODY CONSTRUCTION - Body Construction Characteristics Rear Floor Sidemember Reinforcement 1. Trailing arm outer bracket 12. Muffler hanger center 2. Rear floor sidemember support 13. Rear floor sidemember reinforcement front 3. Trailing arm inner bracket 14. Muffler hanger rear 4.
Page 192 A-20 BODY CONSTRUCTION - Body Construction Characteristics DOOR The front and back of the side door beam has been made large to cope with the force from the front and sides during collision. Front door 14 15 Rear door 1. Front door hinge panel 11.
Page 193 A-21 BODY CONSTRUCTION - Silencer Application Locations SILENCER APPLICATION LOCATIONS Silencers (MD - 12 and melting sheets) are attached to the top of the floor to reduce vibration and insulate against the heat from exhaust gas. NOTE MD - 12 is a high performance sheet composed of asphalt applied with mica and thermosetting resin for improving anti-vibration performance.
Page 194 A-22 BODY CONSTRUCTION - Locations Using Urethane Foam and Foam Material LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL 1. Urethane foam is inserted into the center pillar to prevent the penetration of noise. 2. By filling the top of the front pillar, bottom of the front pillar, center pillar, side roof rail, rear pillar and inside the wheel house arch with foam acoustic material, penetration of noise is prevented.
Page 195 A-23 BODY CONSTRUCTION - Locations Using Urethane Foam and Foam Material Rear pillar inner Roof panel Foam acoustic Side outer material panel Side roof rail inner Foam acoustic material <RS-II> <RS-II> Rear door hinge reinforcement Center Foam acoustic lower Side outer panel pillar inner material Urethane...
Page 196 A-24 BODY CONSTRUCTION - Stiffener and Dump Sheet Application Locations STIFFENER AND DUMP SHEET APPLICATION LOCATIONS Stiffener is pasted to the inside of the side outer panel, and dump sheets are pasted on the inside of the front doors to increase surface rigidity, thus improving soundproof qualities with the anti-vibration effects.
Page 197 BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND MEASUREMENT TYPE B (ACTUAL-MEASUREMENT METHODS ......DIMENSIONS) .
Page 198 BODY DIMENSIONS - Body Dimensions and Measurement Methods BODY DIMENSIONS AND MEASUREMENT METHODS Projecteddimension 1. Type A (projected dimensions) Height Indicates the dimension when a measurement location Probe is projected onto a plane. The difference in height of the measurement points should be taken into consideration when measuring.
Page 199 BODY DIMENSIONS - Body Dimensions and Measurement Methods NOTES...
Page 200 BODY DIMENSIONS - Type A (Projected Dimensions) <EVOLUTION-Ⅶ> TYPE A (PROJECTED DIMENSIONS) UNDER BODY 1,239 1,010 1,232 1,225 1,461 1,232 1,157 1,028 1,641...
Page 201 BODY DIMENSIONS - Type A (Projected Dimensions) 1,335 1,230 1,545 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of under cover mounting hole ○ - 8 Front edge of center bearing mounting bolt Notch of front sidemember inner Front edge of center bearing mounting bolt Centre of crossmember mounting hole ○...
Page 202 BODY DIMENSIONS - Type A (Projected Dimensions) INSTALLATION OF SUSPENSION 1,110 1,186 18 19 1,127 1,073 1,025...
Page 203 BODY DIMENSIONS - Type A (Projected Dimensions) Centre of vehicle Ａ ° ′ 4°24′ Centre of vehicle 3°12′ 1° 22 23 14 15 1,257 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of crossmember mounting hole ○...
Page 204 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY 1,250 1,010 1,232 1,463 1,170 1,241 1,225 1,028 1,649...
Page 205 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of under cover mounting hole ○ - 8 Front edge of center bearing mounting bolt Notch of front sidemember inner Front edge of center bearing mounting bolt Centre of crossmember mounting hole ○...
Page 206 B-10 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) INSTALLATION OF SUSPENSION 1,186 1,137 1,075 1,025...
Page 207 B-11 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of crossmember mounting hole ○ - 18 Trailing arm mounting position Centre of crossmember mounting hole ○ - 14 Control link mounting position Front edge of crossmember mounting bolt (Left Front edge of differential support mounting bolt...
Page 208 B-12 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) FRONT BODY 1,091 1,508 Body centre point 1,390 1,437 1,532 1,040 1,382 1,050...
Page 209 B-13 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of front end crossmember upper drain hole ○ - 8 Centre of hood hinge mounting hole ○ - 9 Centre of harness clip mounting hole ○...
Page 210 B-14 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) SIDE BODY 1,127 1,174 1,084 1,100 1,067 1,094 1,124 1,041 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Front pillar positioning notch (Upper section) Quarter panel positioning notch (Upper section) Front pillar positioning notch (Lower section) Quarter panel positioning notch (Lower section) Side roof rail positioning notch (Front section)
Page 211: Rear Body
B-15 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) REAR BODY 1,271 Body centre point 1,200 1,269 1,104 1,562 1,018 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Corner of roof panel Centre of rear combination lamp mounting hole ○...
Page 212 B-16 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) INTERIOR 1,112 1,145 1,235 1,297 1,289 1,379 1,395 1,368 1,407 1,388 1,072 1,100 1,085 1,016 1,136 1,041 Body centre point 1,106...
Page 213 B-17 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Body centre point 1,266 1,268 1,266 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Front pillar positioning notch (Upper section) Quarter panel positioning notch (Lower section) Front pillar positioning notch (Lower section) Centre of rear end trim mounting hole ○...
Page 214 NOTES...
Page 215 WELDED PANEL REPLACEMENT CONTENTS HEADLAMP SUPPORT ....ROOF ........FENDER SHIELD .
Page 216 NOTES...
Page 217: Headlamp Support
WELDED PANEL REPLACEMENT - Headlamp Support HEADLAMP SUPPORT Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
Page 218: Fender Shield
WELDED PANEL REPLACEMENT - Fender Shield FENDER SHIELD Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
Page 219 WELDED PANEL REPLACEMENT - Fender Shield (With the upper frame extension outer removed)
Page 220 WELDED PANEL REPLACEMENT - Fender Shield 17 points, left side only 5 points, left side only <LHD> 4 points, left side only <RHD(Right side)> <RHD>...
Page 221: Front Pillar
WELDED PANEL REPLACEMENT - Front Pillar FRONT PILLAR Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
Page 222 WELDED PANEL REPLACEMENT - Front Pillar NOTE ON REPAIR WORK REMOVAL Weld points As the front pillar reinforcement lower and side sill outer Front pillar reinforce- reinforcement front are welded at the side sill, cut the side ment lower outer panel at the position shown in the illustration where the weld points of the reinforcement can be seen, remove, and then remove the weld points of the front pillar reinforcement lower.
Page 223: Center Pillar
WELDED PANEL REPLACEMENT - Center Pillar CENTER PILLAR Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
Page 224 C-10 WELDED PANEL REPLACEMENT - Center Pillar NOTE ON REPAIR WORK Weld Center pillar points reinforcement REMOVAL 1. As the center pillar reinforcement and side sill outer reinforcement center are welded at the side sill, cut the side outer panel at the position shown in the illustration where the weld points of the reinforcement can be seen, remove, and then remove the weld points of the center pillar reinforcement.
Page 225 C-11 WELDED PANEL REPLACEMENT - Center Pillar <The following service procedures are only applied to RS-II.> 5. When attaching the center pillar inner, attach the center Center pillar silencer pillar silencer protector to the center pillar inner, and seal protector the holes of the center pillar silencer protector with butyl tape.
Page 226 C-12 WELDED PANEL REPLACEMENT - Side Sill SIDE SILL Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
Page 227 C-13 WELDED PANEL REPLACEMENT - Side Sill NOTE ON REPAIR WORK INSTALLATION 1. Release the side outer panel from the new parts and remove unnecessary front pillar reinforcement lower, front pillar reinforcement lower extension, and center pillar reinforcement from side sill outer reinforcement.
Page 228 C-14 WELDED PANEL REPLACEMENT - Quarter, Outer QUARTER, OUTER Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
Page 229 C-15 WELDED PANEL REPLACEMENT - Quarter, Outer NOTE ON REPAIR WORK Left side only INSTALLATION 1. When attaching the quarter outer, apply sealant to the areas indicated in the illustration. For RS-II, attach the rear pillar silencer protector, and fill the gaps with butly tape.
Page 230 C-16 WELDED PANEL REPLACEMENT - Quarter, Outer <The following service procedures are only applied to RS-II.> 2. After attaching the quarter outer, seal the holes and flanges with bolts and plate tape, and fill foam material from hole shown in the illustration. Foam material Type Brand Used...
Page 231 C-17 WELDED PANEL REPLACEMENT - Roof ROOF Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPAIR WELDS...
Page 232: Rear End Panel
C-18 WELDED PANEL REPLACEMENT - Rear End Panel REAR END PANEL Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded...
Page 233: Rear Floor
C-19 WELDED PANEL REPLACEMENT - Rear Floor REAR FLOOR Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
Page 234 C-20 WELDED PANEL REPLACEMENT - Rear Floor (Vehicles with ACD) Right side only NOTE For details on the weld points with the rear end panel refer to REAR END PANEL on P.C-18. NOTE ON REPAIR WORK Rear seat back REMOVAL reinforcement 1.
Page 235 C-21 WELDED PANEL REPLACEMENT - Quarter, Inner QUARTER, INNER Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
Page 236 C-22 WELDED PANEL REPLACEMENT - Quarter, Inner Left side (Vehicles with ACD) (With the side sill outer reinforcement rear removed.)
Page 237: Front Door Outer Panel
C-23 WELDED PANEL REPLACEMENT - Front Door Outer Panel FRONT DOOR OUTER PANEL Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded...
Page 238: Rear Door Outer Panel
C-24 WELDED PANEL REPLACEMENT - Rear Door Outer Panel REAR DOOR OUTER PANEL Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded...
Page 239 BODY REPAIR CONTENTS BODY CONSTRUCTION ........... BODY DIMENSIONS .
Page 240 NOTES...
Page 241 CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS ... . UNDERCOAT APPLICATION LOCATIONS . . . FLOOR ........UPPER BODY .
Page 242 CORROSION PROTECTION - Body Sealing Locations BODY SEALING LOCATIONS NOTES REGARDING REPAIR WORK In places where the sealant can be directly seen on surfaces such as the drip rails, pillars, or clinch, and where the appearance of the paint surface is important, apply sealant or wipe away sealant after ▄...
Page 243 CORROSION PROTECTION - Body Sealing Locations...
Page 244 CORROSION PROTECTION - Body Sealing Locations Front door Hood Rear door Trunk lid...
Page 245 CORROSION PROTECTION - Undercoat Application Locations UNDERCOAT APPLICATION LOCATIONS In order to provide resistance to rust, corrosion, chipping, and vibration, an undercoat is applied to certain areas of the underbody. After completing body repairs, restore this undercoat if necessary. * Mark the areas indicated with asterisks to make sure no undercoat adheres to these areas. : Undercoat (Film thickness of at least 0.5 mm)
Page 246 NOTES...
Page 247 SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS...
Page 248 SYNTHETIC-RESIN PARTS - Location of Synthetic-resin Parts LOCATION OF SYNTHETIC-RESIN PARTS The following shows the main locations of synthetic-resin parts.
Page 249 SYNTHETIC-RESIN PARTS - Location of Synthetic-resin Parts Part number Material Abbreviation of Heat-resistant material temperature (_C) Outside mirror Acrylonitrile Rear spoiler Butadiene styrene Roof antenna Acrylonitrile Ethylene butadiene Headlamp Polycarbonate Front bumper bezel Polycarbonate + PC + ABS 125 - 135 Rear door outside handle Acrylonitrile butadiene styrene Front door outside handle...
Page 250 NOTES...
Page 251 BODY COLOUR CONTENTS BODY COLOUR CODE ....BODY COLOURING ..... . BUMPER .
Page 252 BODY COLOUR - Body Colour Code/Body Colour Charts BODY COLOUR CODE 1. The body colour code is imprinted on the plate, which is mounted on the front deck. 2. The body colour code is imprinted at the areas indicated in the illustration. Body colour code BODY COLOUR CHARTS Check the vehicle’s body colour code, and then use this body colour chart to determine the refinishing...
Page 253: New Colour Numbers
BODY COLOUR - Body Colour Charts NEW COLOUR NUMBERS Example (Body colour code T10) Item Content Identification code C: The colour number is indicated. Manufacture center code M: Japan (Automobile Engineering Center) T: Japan (Truck and Bus Engineering Center) System colour code W (N): White H (A, U): Silver/Gray X (J): Black...
Page 254 BODY COLOUR - Body Colouring BLACK PAINT Headlamp support : Black (AC10657) Door sash Front door Rear door : Black (AC10790) Wheel house : Black (AC10657)
Page 255 WIRING AND PIPING DIAGRAM CONTENTS WIRING AND PIPING DIAGRAM ..
Page 256: Wiring And Piping Diagram
WIRING AND PIPING DIAGRAM - Wiring and Piping Diagram WIRING AND PIPING DIAGRAM Pole antennas are routed in some parts of closed-section structures of the body construction. These pole antennas must be removed before body panels in these areas can be replaced. Pole antenna (Vehicles with pole antennas) Antenna feeder-line...
Page 257 HOW TO READ THE WIRING DIAGRAMS CONTENTS COMPOSITION AND CONTENTS OF WIRING MARKING FOR CONNECTOR EARTHING . . . DIAGRAMS ....... . WIRE COLOUR CODES .
Page 258 HOW TO READ THE WIRING DIAGRAMS - Composition and Contents of Wiring Diagrams COMPOSITION AND CONTENTS OF WIRING DIAGRAMS (1) This manual consists of wiring harness diagrams, installation locations of individual parts, circuits diagrams and index. (2) In each section, all specifications are listed, including optional specifications. Accordingly, some specifications may not be applicable for individual vehicles.
Page 259 HOW TO READ THE WIRING DIAGRAMS - How to Read Configuration Diagrams HOW TO READ CONFIGURATION DIAGRAMS The wiring harness diagrams clearly show the connector locations and harness routings at each site on actual vehicles. Denotes connector No. The same connector No. is used throughout the circuit diagrams to facilitate connector location searches.
Page 260 HOW TO READ THE WIRING DIAGRAMS - How to Read Circuit Diagrams HOW TO READ CIRCUIT DIAGRAMS The circuit of each system from fuse (or fusible link) to earth is shown. The power supply is shown at the top and the earth at the bottom to facilitate understanding of the current flow. Indicates connector No.
Page 261: Equipments
HOW TO READ THE WIRING DIAGRAMS - How to Read Circuit Diagrams Indicates input/output to/from Indicates a wiring connector which is inside control unit (current flow direction). the equipment and which is not shown in the wiring harness configuration diagram. Input/ Input Output...
Page 262 HOW TO READ THE WIRING DIAGRAMS - Markings for Connector Earthing MARKINGS FOR CONNECTOR EARTHING...
Page 263 HOW TO READ THE WIRING DIAGRAMS - Markings for Connector Earthing Item Connector/Earthing Symbol Contents Connector The male and female terminals are Male connector Male terminal and terminal indicated as shown. The connector marking with male terminal(s) is called as male connector and indicated by double connector contour linens, while the connector with female...
Page 264 HOW TO READ THE WIRING DIAGRAMS - Markings for Connector Earthing Item Connector/Earthing Symbol Contents Connector Direct connection type A connection between a device connection and connector on the harness side marking is either by direct insertion in the device (direct connection type) or by connection with a harness connector on the device side furnished...
Page 265: Wire Colour Codes
HOW TO READ THE WIRING DIAGRAMS - Wire Colour Codes WIRE COLOUR CODES Wire colours are identified by the follow colour codes. Code Wire colour Code Wire colour Black Pink Brown Green Sky blue Gray Silver Blue Violet Light green White Orange Yellow...
Page 266 A-10 HOW TO READ THE WIRING DIAGRAMS - Abbreviation Symbols ABBREVIATION SYMBOLS The abbreviation symbols used in wiring diagrams are defined below. 1. Abbreviation symbols used for system name Abbreviation Meaning Abbreviation Meaning symbols symbols Air conditioner Exhaust gas recirculation Anti-skid braking system ETACS Electronic time alarm control system...
Page 267 A-11 HOW TO READ THE WIRING DIAGRAMS - HOW TO READ THE WIRING DIAGRAMS - Abbreviation Symbols Abbreviation Symbols Name of switches and Abbreviation Operation relays symbols Dimmer passing Low beams ON switch switch High beams ON PASS Door lock actuator LOCK Door lock UNLOCK...
Page 268 A-12 HOW TO READ THE WIRING DIAGRAMS - Abbreviation Symbols Name of switches and Abbreviation Operation relays symbols Windshield wiper MIST Wiper operates once switch switch Wiper operates intermittently Wiper operates at low speed Wiper operates at high speed 4. Other abbreviation symbols Abbreviation Meaning Abbreviation...
Page 269 ELECTRICAL WIRING CONTENTS WIRING HARNESS CONFIGURATION SINGLE PART INSTALLATION DIAGRAMS ......POSITION ......OVERALL WIRING DIAGRAM RELAY .
Page 270 IGNITION SYSTEM STOP LAMP L.H. drive vehicles ..... . . L.H. drive vehicles ..... . R.H.
Page 271 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT PRETENSIONER L.H. drive vehicles ..... . L.H. drive vehicles ..... . R.H.
Page 272 WIRING HARNESS CONFIGURATION DIAGRAMS WIRING HARNESS CONFIGURATION DIAGRAMS OVERALL WIRING DIAGRAM L.H. drive vehicles Control wiring Instrument panel Roof wiring Floor wiring harness wiring harness harness harness (RH) Front wiring harness (RH) Rear door wiring harness* Battery wiring Front wiring Front door Floor wiring Fuel wiring...
Page 273 WIRING HARNESS CONFIGURATION DIAGRAMS R.H. drive vehicles Control wiring Instrument panel Roof wiring Floor wiring harness wiring harness harness harness (RH) Front wiring harness (RH) Rear door wiring harness* Battery wiring Front wiring Front door Floor wiring Fuel wiring harness harness (LH) wiring harness* harness (LH)
Page 274: Engine Compartment
WIRING HARNESS CONFIGURATION DIAGRAMS ENGINE COMPARTMENT L.H. drive vehicles Connector symbol A-01 A-37 A-36 A-48 A-40 Connector colour code B:Black Y:Yellow L:Blue A-31 G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white A-28 A-47 A-46 A-45 A-01 (2-GR) Side turn signal lamp (RH) A-09X (4) Radiator fan relay A-02 (2-GR)
Page 275 WIRING HARNESS CONFIGURATION DIAGRAMS A-02 A-03 A-04X A-05X A-06X A-07X A-08X A-09X A-10X A-11X A-12 A-13 A-43 A-39 A-44 A-25 A-21 A-23 A-16 A-21 (3-GR) Fan controller A-40 (8-B) Front combination lamp (RH) A-23 (1-B) Horn (HI) A-43 (8-B) Front wiring harness (LH) and control A-25 (1-B) Horn (LO) wiring harness combination...
Page 276 WIRING HARNESS CONFIGURATION DIAGRAMS ENGINE COMPARTMENT R.H. drive vehicles Connector symbol A-01 A-37 A-36 A-34 A-48 A-40 A-31 Connector colour code A-28 B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange A-47 A-46 A-45 GR:Gray None: Milk white A-01 (2-GR) Side turn signal lamp (RH) A-09X (4) Radiator fan relay A-02 (2-GR)
Page 277 WIRING HARNESS CONFIGURATION DIAGRAMS A-02 A-03 A-04X A-05X A-06X A-07X A-08X A-09X A-10X A-11X A-12 A-39 A-44 A-16 A-25 A-21 A-23 A-23 (1-B) Horn (HI) A-40 (8-B) Front combination lamp (RH) A-25 (1-B) Horn (LO) A-44 (2) Intercooler water spray motor A-28 (2-B) Headlamp (HI: RH) A-45 (2-B)
Page 278: Engine And Transmission
B-10 WIRING HARNESS CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION L.H. drive vehicles Connector symbol thru Earth cable B-01 B-27 B-26 B-37 B-34 B-23 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red B-21 B-22 BR:Brown V:Violet O:Orange GR:Gray None: Milk white B-01 (5-GR) Windshield wiper motor B-08X (4) No connection...
Page 279 B-11 WIRING HARNESS CONFIGURATION DIAGRAMS B-25 B-24 B-02 B-04 B-05X B-06X B-07X B-08X B-09X B-10X B-11X B-12X B-14 B-03 B-36 B-18 B-19 B-20 B-31 B-18 (1) Starter B-25 (2-B) Injector 3 B-19 (1-B) Starter B-26 (2-B) Injector 2 B-20 (1-B) Oil pressure switch B-27 (2-B) Injector 1...
Page 280 B-12 WIRING HARNESS CONFIGURATION DIAGRAMS L.H. drive vehicles Connector symbol -108 thru -142 Earth cable B-123 B-138 B-139 B-140 B-141 B-119 B-121 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red B-122 B-112 B-142 BR:Brown V:Violet O:Orange GR:Gray None: Milk white B-108 (2-B) Back-up lamp switch B-115 (6-B)
Page 281 B-13 WIRING HARNESS CONFIGURATION DIAGRAMS B-115 B-118 B-108 B-114 B-116 B-110 B-121 (3-B) Crank angle sensor B-139 (5-B) Electric pump relay <ACD> B-122 (2-GR) Detonation sensor B-140 (4) Fuel pump relay 3 B-123 (34-B) ABS-ECU B-141 (2-B) Fuel pump resistor B-138 (6-B) Resistor B-142 (2-B)
Page 282 B-14 WIRING HARNESS CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION R.H. drive vehicles Connector symbol thru Earth cable B-04 B-27 B-26 B-37 B-34 B-23 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red B-21 B-22 BR:Brown V:Violet O:Orange GR:Gray None: Milk white B-01 (5-GR) Windshield wiper motor B-08X (4) No connection...
Page 283 B-15 WIRING HARNESS CONFIGURATION DIAGRAMS B-25 B-24 B-02 B-01 B-05X B-06X B-07X B-08X B-09X B-10X B-11X B-12X B-14 B-03 B-36 B-18 B-19 B-20 B-31 B-18 (1) Starter B-25 (2-B) Injector 3 B-19 (1-B) Starter B-26 (2-B) Injector 2 B-20 (1-B) Oil pressure switch B-27 (2-B) Injector 1...
Page 284 B-16 WIRING HARNESS CONFIGURATION DIAGRAMS R.H. drive vehicles Connector symbol -108 thru -142 Earth cable B-119 B-121 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red B-122 B-112 B-142 BR:Brown V:Violet O:Orange GR:Gray None: Milk white B-108 (2-B) Back-up lamp switch B-115 (6-B) Idle speed control servo B-110 (1-B)
Page 285 B-17 WIRING HARNESS CONFIGURATION DIAGRAMS B-115 B-139 B-140 B-138 B-141 B-123 B-118 B-114 B-116 B-110 B-108 B-121 (3-B) Crank angle sensor B-139 (5-B) Electric pump relay <ACD> B-122 (2-GR) Detonation sensor B-140 (4) Fuel pump relay 3 B-123 (34-B) ABS-ECU B-141 (2-B) Fuel pump resistor B-138 (6-B)
Page 286: Dash Panel
B-18 WIRING HARNESS CONFIGURATION DIAGRAMS DASH PANEL L.H. drive vehicles Connector symbol thru C-01 C-02 C-32 C-03 C-04 C-05 C-29 C-36 C-26 C-24 C-45 C-23 C-22 C-42 C-41 C-21 C-01 (21) Combination meter C-14 (2) Blower motor C-02 (21-L) Combination meter C-16 (4) Resistor C-03 (4)
Page 287 B-19 WIRING HARNESS CONFIGURATION DIAGRAMS C-08 C-10 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet C-16 C-44 C-43 C-14 O:Orange GR:Gray None: Milk white C-26 (22-B) J/C (4) C-43 (22-Y) 4WD-ECU <ACD> C-29 (22-B) J/C (5) C-44 (26-Y) 4WD-ECU <ACD>...
Page 288 B-20 WIRING HARNESS CONFIGURATION DIAGRAMS L.H. drive vehicles Connector symbol -101 thru C-101 C-138 C-142 C-102 C-103 C-104 C-141 C-108 -146 C-137 C-135 C-134 C-133 C-132 C-131 C-130 C-129 C-128 C-101 (1) Spare connector (for front fog lamp C-110 (16) Instrument panel wiring harness and front switch) door wiring harness (RH) combination...
Page 289 B-21 WIRING HARNESS CONFIGURATION DIAGRAMS C-107 C-109 C-110 C-111 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange C-115 C-118 C-122 C-126 C-112 C-146 GR:Gray None: Milk white C-128 (22-L) Instrument panel wiring harness and C-134 (11-GR) Instrument panel wiring harness and floor control wiring harness combination wiring harness (LH) combination C-129 (10-GR) Instrument panel wiring harness and...
Page 290 B-22 WIRING HARNESS CONFIGURATION DIAGRAMS L.H. drive vehicles Connector symbol -201 thru -230 STEERING COLUMN C-207 C-206 Connector colour code B:Black Y:Yellow C-205 C-204 C-230 C-203 C-202 C-201 L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white C-201 (6) Ignition switch C-209 (14) Instrument panel wiring harness and J/B...
Page 291 B-23 WIRING HARNESS CONFIGURATION DIAGRAMS JUNCTION BLOCK (Front view) (Rear view) C-208 C-209 C-210 C-226 C-211 C-225 C-224 C-213 C-223 C-222 C-214 C-221 C-215 Dedicated fuse C-220 C-219 C-218 C-216 C-228 C-227 C-214 (5) Defogger relay C-222 (4) Intercooler water spray relay C-215 (5) Blower relay C-223 (4)
Page 292 B-24 WIRING HARNESS CONFIGURATION DIAGRAMS DASH PANEL R.H. drive vehicles Connector symbol C-10 C-28 C-05 C-03 C-04 C-32 thru C-46 C-24 C-14 C-16 C-44 C-43 C-35 C-41 C-21 C-01 (21) Combination meter C-14 (2) Blower motor C-02 (21-L) Combination meter C-16 (4) Resistor C-03 (4)
Page 293 B-25 WIRING HARNESS CONFIGURATION DIAGRAMS C-01 C-08 C-02 C-26 C-36 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet C-22 C-23 C-34 O:Orange GR:Gray None: Milk white C-26 (22-B) J/C (4) C-41 (22-Y) SRS-ECU C-28 (13) J/C (5) C-43 (22) 4WD-ECU <ACD>...
Page 294 B-26 WIRING HARNESS CONFIGURATION DIAGRAMS R.H. drive vehicles Connector symbol -101 C-109 C-107 C-108 C-141 C-104 C-131 thru -147 C-136 C-135 C-134 C-133 C-132 C-115 C-118 C-122 C-126 C-130 C-129 C-128 C-147 C-101 (1) Spare connector (for front fog lamp C-111 (25) Front wiring harness (RH) and instrument switch)
Page 295 B-27 WIRING HARNESS CONFIGURATION DIAGRAMS C-101 C-142 C-138 C-137 C-110 C-111 C-146 C-112 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange C-102 C-103 GR:Gray None: Milk white C-130 (25) Instrument panel wiring harness and C-136 (16) Front wiring harness (LH) and control control wiring harness combination wiring harness combination C-131 (6)
Page 296 B-28 WIRING HARNESS CONFIGURATION DIAGRAMS R.H. drive vehicles Connector symbol -201 thru -230 STEERING COLUMN C-207 C-206 Connector colour code B:Black C-201 C-202 C-203 C-230 C-204 C-205 Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white C-201 (6) Ignition switch C-209 (14) Instrument panel wiring harness and J/B...
Page 297 B-29 WIRING HARNESS CONFIGURATION DIAGRAMS JUNCTION BLOCK (Front view) (Rear view) C-209 C-208 C-210 C-226 C-211 C-225 C-213 C-224 C-214 C-223 C-215 C-222 C-221 Dedicated fuse C-227 C-228 C-220 C-217 C-219 C-218 C-214 (5) Defogger relay C-222 (4) Intercooler water spray relay C-215 (5) Blower relay C-223 (4)
Page 298 B-30 WIRING HARNESS CONFIGURATION DIAGRAMS FLOOR AND ROOF L.H. drive vehicles Connector symbol D-01 D-26 D-02 D-03 D-04 D-05 D-06 D-23 D-22 D-21 D-20 D-19 D-18 D-34 D-15 D-33 D-32 D-30 D-29 D-01 (3) Door switch (Front: RH) D-08 (3) Door switch (Rear: LH) D-02 (8) Floor wiring harness (RH) and rear door...
Page 299 B-31 WIRING HARNESS CONFIGURATION DIAGRAMS D-27 D-08 D-09 D-10 D-12 D-28 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray D-13 None: Milk white D-18 (1) Cigarette lighter D-29 (1) Floor wiring harness (RH) and fuel wiring D-19 (1-B) Cigarette lighter harness combination...
Page 300 B-32 WIRING HARNESS CONFIGURATION DIAGRAMS FLOOR AND ROOF R.H. drive vehicles Connector symbol D-01 D-26 D-02 D-03 D-04 D-05 D-06 D-23 D-22 D-21 D-20 D-19 D-18 D-34 D-15 D-33 D-32 D-30 D-29 D-01 (3) Door switch (Front: RH) D-09 (5-GR) Fuel pump and fuel gauge unit (Main) D-02 (8) Floor wiring harness (RH) and rear door...
Page 301 B-33 WIRING HARNESS CONFIGURATION DIAGRAMS D-27 D-08 D-09 D-10 D-12 D-28 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white D-13 D-18 (1) Cigarette lighter D-29 (1) Floor wiring harness (RH) and fuel wiring D-19 (1-B) Cigarette lighter harness combination...
Page 302 B-34 WIRING HARNESS CONFIGURATION DIAGRAMS DOOR L.H. drive vehicles Driver’s side Connector symbol E-02 Front door E-08 E-07 E-05 E-04 Rear door E-12 E-11 E-10 E-02 (3) Remote controlled mirror (LH) E-08 (6-B) Door lock actuator (Front: LH) E-04 (2) Spare connector <for front door speaker E-10 (6-GR) Power window motor (Rear: LH)
Page 303 B-35 WIRING HARNESS CONFIGURATION DIAGRAMS Passenger’s side E-13 E-16 Front door E-21 E-20 E-19 E-18 Rear door Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white E-25 E-24 E-23 E-16 (3-B) Door lock key cylinder switch (RH) E-21 (2) Spare connector <for front door speaker E-18 (6-B)
Page 304 B-36 WIRING HARNESS CONFIGURATION DIAGRAMS DOOR R.H. drive vehicles Driver’s side Connector symbol E-07 E-13 Front door E-18 E-21 E-20 Rear door E-25 E-24 E-23 E-02 (3) Remote controlled mirror (LH) E-08 (6-B) Door lock actuator (Front: LH) E-04 (2) Spare connector <for front door speaker E-10 (6-GR) Power window motor (Rear: LH)
Page 305 B-37 WIRING HARNESS CONFIGURATION DIAGRAMS Passenger’s side E-17 E-19 E-02 Front door E-08 E-05 E-04 Rear door Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray E-12 E-11 E-10 None: Milk white E-13 (3) Remote controlled mirror (RH) E-21 (2) Spare connector <for front door speaker E-17 (3-B)
Page 306: Luggage Compartment
B-38 WIRING HARNESS CONFIGURATION DIAGRAMS LUGGAGE COMPARTMENT L.H. drive vehicles Connector symbol F-01 F-04 F-05 F-06 F-08 F-19 F-21 F-09 F-10 F-16 F-12 F-13 F-29 F-28 F-27 F-26 F-25 F-24 F-23 F-14 F-01 (2) Spare connector <for rear speaker (LH)> F-16 (6-B) Rear combination lamp (LH) F-04 (2)
Page 307 B-39 WIRING HARNESS CONFIGURATION DIAGRAMS LUGGAGE COMPARTMENT R.H. drive vehicles Connector symbol F-01 F-04 F-05 F-08 F-19 F-21 F-06 F-09 F-10 F-16 F-12 F-29 F-13 F-28 F-27 F-26 F-25 F-24 F-23 F-14 F-01 (2) Spare connector <for rear speaker (LH)> F-16 (6-B) Rear combination lamp (LH) F-04 (2)
Page 308 B-40 SINGLE PART INSTALLATION POSITION - Relay SINGLE PART INSTALLATION POSITION RELAY Name Symbol Name Symbol A/C compressor relay Fuel pump relay 2 Blower relay L.H. drive vehicles Fuel pump relay 3 Condenser fan relay (HI) R.H. drive vehicles Condenser fan relay (LO) Horn relay Defogger relay Ignition coil relay <R.H.
Page 309 B-41 SINGLE PART INSTALLATION POSITION - Relay/ECU Power window Fuel relay pump relay 1 Defogger relay Intercooler water spray relay Fuel pump Blower relay relay 2 Rear fog lamp relay Name Symbol Name Symbol 4WD-ECU <AYC> L.H. drive vehicles Front-ECU R.H.
Page 310 B-42 SINGLE PART INSTALLATION POSITION - ABS-ECU ABS-ECU Fan controller Front-ECU ETACS- Column switch <incorporating column-ECU> Immobilizer- Heater control unit <without manual A/C> or A/C-ECU Ignition key cylinder <with manual A/C> Engine-ECU SRS-ECU...
Page 311 B-43 SINGLE PART INSTALLATION POSITION - ECU/Sensor 4WD-ECU Glove box Door check (front door: RH side) 4WD-ECU Power window main switch (incorporating ECU) Power window motor (Front) <incorporating ECU> Power window motor (Rear) <incorporating ECU> SENSOR Name Symbol Name Symbol Air flow sensor Oxygen sensor Air thermo sensor <A/C>...
Page 312 B-44 SINGLE PART INSTALLATION POSITION - Sensor Intake manifold Throttle position sensor Detonation sensor Crank angle sensor Transfer Vehicle speed sensor Crankshaft sprocket...
Page 313 B-45 SINGLE PART INSTALLATION POSITION - Sensor Oxygen sensor Engine coolant temperature sensor Camshaft position sensor Air flow sensor Steering wheel sensor Parking brake lever G sensor G sensor (Lateral) Air thermo sensor (Longitudinal) Oxygen sensor (rear) Wheel speed sensor (front) Pressure sensor Wheel speed sensor (rear)
Page 314: Solenoid Valve
B-46 SINGLE PART INSTALLATION POSITION - Solenoid Valve SOLENOID VALVE Name Symbol Name Symbol EGR solenoid valve Hydraulic unit (incorporating solenoid valve) <ACD> (incorporating solenoid valve) <ACD> Fuel pressure solenoid valve Purge control solenoid valve Hydraulic unit (incorporating solenoid valve) <ABS>...
Page 315 B-47 Solenoid Valve/Inspection SINGLE PART INSTALLATION POSITION - Connector and Spare connector Hydraulic unit Proportioningvalve (for ACD control) Direction valve (RH, LH) Proportion- ing valve (for AYC control) INSPECTION CONNECTOR AND SPARE CONNECTOR Name Symbol Name Symbol Diagnosis connector Spare connector (for front fog lamp relay) Engine speed detection connector Spare connector (for front fog lamp switch) Spare connector (for front fog lamp)
Page 316: Fusible Link And Fuse
B-48 Inspection Connector Spare SINGLE PART INSTALLATION POSITION - connector/Fusible Link and Fuse <L.H. drive vehicles> <R.H. drive vehicles> Spare connector Spare connector (for front fog lamp (for front fog lamp switch) switch) 10029AU Diagnosis connector FUSIBLE LINK AND FUSE Name Symbol Name...
Page 317: Earth Cable
B-49 SINGLE PART INSTALLATION POSITION - Fusible Link and Fuse/Earth Cable <L.H. drive vehicles> Multi-purpose fuses Dedicated fuses (No.1-19,25) Dedicated fuses (No.21) <R.H. drive vehicles> Dedicated fuses (No.21) Multi-purpose fuses EARTH CABLE...
Page 318 B-50 - Earth SINGLE PART INSTALLATION POSITION EARTH L.H. drive vehicles R.H. drive vehicles NOTE Same earth numbers are used in the circuit diagram.
Page 319 B-51 - Earth SINGLE PART INSTALLATION POSITION Door check (front door: RH side) Front deck crossmember <L.H. drive vehicles> <L.H. drive vehicles> <R.H. drive vehicles> Windshield wiper (driver’s side) Rear seat back hook (LH) Rear seat back hook (RH)
Page 320 B-52 - Earth SINGLE PART INSTALLATION POSITION Transmission assembly Heat protector Air duct <L.H. drive vehicles> <R.H. drive vehicles>...
Page 321 B-53 NOTES...
Page 322 B-54 CIRCUIT DIAGRAMS CIRCUIT DIAGRAMS H1J00X08AA...
Page 323 B-55 CIRCUIT DIAGRAMS Front side Rear side ETACS-ECU To instrument panel wiring harness To instrument C-208 C-210 panel wiring harness C-209 C-225 C-211 C-226 Power window relay C-213 Blower relay Fuel pump C-223 relay (1) Defogger C-224 C-215 C-214 relay C-222 Inter cooler water spray...
Page 324 B-56 CIRCUIT DIAGRAMS L.H. drive vehicles H1J00X06AA...
Page 325 B-57 CIRCUIT DIAGRAMS H1J00X06AB...
Page 326 B-58 CIRCUIT DIAGRAMS J/C <L.H. drive vehicles> (CONTINUED) H1J00X06BA...
Page 327 B-59 CIRCUIT DIAGRAMS H1J00X06BB...
Page 328 B-60 CIRCUIT DIAGRAMS J/C <L.H. drive vehicles> (CONTINUED) H1J00X06CA...
Page 329 B-61 CIRCUIT DIAGRAMS H1J00X06CB...
Page 330 B-62 CIRCUIT DIAGRAMS R.H. drive vehicles H1J00X09AA...
Page 331 B-63 CIRCUIT DIAGRAMS H1J00X09AB...
Page 332 B-64 CIRCUIT DIAGRAMS J/C <R.H. drive vehicles> (CONTINUED) H1J00X09BA...
Page 333 B-65 CIRCUIT DIAGRAMS H1J00X09BB...
Page 334 B-66 CIRCUIT DIAGRAMS J/C <R.H. drive vehicles> (CONTINUED) H1J00X09CA...
Page 335 B-67 CIRCUIT DIAGRAMS H1J00X09CB...
Page 336: Centralized Junction
B-68 CIRCUIT DIAGRAMS CENTRALIZED JUNCTION FUSIBLE LINK Circuit Type Housing colour Rated capacity Multi-purpoes fuses No. 15, 16, 17, 19, 20 Screwed type Yellow Cooling circuit and manual air conditioner circuit Connector type ABS circuit Connector type Yellow Ignition switch Connector type Green Power window circuit...
Page 337 B-69 CIRCUIT DIAGRAMS DEDICATED FUSE Power supply Rated Identification Circuit circuit capacity (A) colour Battery/alternator Blue Spare connectors (Fusible link No 6) (Fusible link No. 6) Horn relay Yellow Engine control relay and ignition control relay A/C compressor Blue ABS-ECU, 4WD-ECU, high-mounted stop lamp and rear combination lamp Green Condenser fan motor...
Page 338 B-70 CIRCUIT DIAGRAMS (Relay box in engine compartment) 2 3 4 5 6 7 8 9 10 Front of vehicles 17 18 (in junction block) <L.H. drive vehicles> 23 24 <R.H. drive vehicles> 23 24...
Page 339 B-71 CIRCUIT DIAGRAMS MULTI-PURPOSE FUSE (In junction block) Power supply Rated Identification Circuit circuit capacity (A) colour Ignition Ignition coil switch switch Brown Column switch, combination meter, ETACS-ECU, SRS-ECU, vehicle speed sensor and ACD mode changeover switch Brown ETACS-ECU and SRS-ECU Brown A/C compressor relay, A/C-ECU, blower relay, condenser fan relay, defogger relay, front-ECU,...
Page 340 B-72 CIRCUIT DIAGRAMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...
Page 341 B-73 CIRCUIT DIAGRAMS CENTRALIZED RELAY (relay box in engine compartment) Connector Name Connector Name A-04X Spare connector (for front fog lamp relay) B-05X Engine speed detection connector A-05X Horn relay B-06X A-06X Condenser fan relay (LO) B-07X A-07X Condenser fan relay (HI) B-08X A-08X B-09X...
Page 342: Power Distribution System
B-74 CIRCUIT DIAGRAMS POWER DISTRIBUTION SYSTEM H1J01X08AA...
Page 343 B-75 CIRCUIT DIAGRAMS H1J01X08AB...
Page 344 B-76 CIRCUIT DIAGRAMS POWER DISTRIBUTION SYSTEM (CONTINUED) H1J01X08BA...
Page 345 B-77 CIRCUIT DIAGRAMS H1J01X08BB...
Page 346 B-78 CIRCUIT DIAGRAMS POWER DISTRIBUTION SYSTEM (CONTINUED) H1J01X08CA...
Page 347 B-79 CIRCUIT DIAGRAMS STARTING SYSTEM H1J02X06AA...
Page 348 B-80 CIRCUIT DIAGRAMS STARTING SYSTEM (See P.B-79.) OPERATION TROUBLESHOOTING HINTS When the ignition switch is turned to the ST position, 1. Starter motor does not turn over at all. the starter contacts (magnet switch) turns ON and Check starter (coil). the starter motor starts turning over.
Page 349 B-81 CIRCUIT DIAGRAMS NOTES...
Page 350: Ignition System
B-82 CIRCUIT DIAGRAMS IGNITION SYSTEM L.H. drive vehicles H1J03X08AA...
Page 351: R.h. Drive Vehicles
B-83 CIRCUIT DIAGRAMS IGNITION SYSTEM R.H. drive vehicles H1J03X07AA...
Page 352: Charging System
B-84 CIRCUIT DIAGRAMS CHARGING SYSTEM H1J04X04AA...
Page 353 B-85 CIRCUIT DIAGRAMS CHARGING SYSTEM (See P.B-84.) OPERATION TROUBLESHOOTING HINTS 1. Charging indicator lamp does not illuminate When engine is stationary when the ignition switch is turned to ON When the ignition switch is turned to the ON position, before the engine starts. position, current flows the alternator L terminal Check multi-purpose fuse No.(2).
Page 354 B-86 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM L.H. drive vehicles...
Page 355 B-87 CIRCUIT DIAGRAMS H1J05X17AB...
Page 356: Engine Control System L.h. Drive Vehicles
B-88 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <L.H. drive vehicles> (CONTINUED)
Page 357 B-89 CIRCUIT DIAGRAMS...
Page 358 B-90 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <L.H. drive vehicles> (CONTINUED)
Page 359 B-91 CIRCUIT DIAGRAMS...
Page 360 B-92 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <L.H. drive vehicles> (CONTINUED)
Page 361 B-93 CIRCUIT DIAGRAMS H1J05X17DB...
Page 362: R.h. Drive Vehicles
B-94 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM R.H. drive vehicles...
Page 363 B-95 CIRCUIT DIAGRAMS...
Page 364 B-96 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <R.H. drive vehicles> (CONTINUED)
Page 365 B-97 CIRCUIT DIAGRAMS...
Page 366 B-98 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <R.H. drive vehicles> (CONTINUED)
Page 367 B-99 CIRCUIT DIAGRAMS...
Page 368 B-100 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <R.H. drive vehicles> (CONTINUED)
Page 369 B-101 CIRCUIT DIAGRAMS H1J05X16DB...
Page 370: Cooling System
B-102 CIRCUIT DIAGRAMS COOLING SYSTEM H1J06X03AA...
Page 371 B-103 CIRCUIT DIAGRAMS HEADLAMP L.H. drive vehicles H1J08X20AA...
Page 372: Headlamp L.h. Drive Vehicles
B-104 CIRCUIT DIAGRAMS HEADLAMP <L.H. drive vehicles> (CONTINUED)
Page 373 B-105 CIRCUIT DIAGRAMS...
Page 374: R.h. Drive Vehicles
B-106 CIRCUIT DIAGRAMS HEADLAMP R.H. drive vehicles H1J08X19AA...
Page 375 B-107 CIRCUIT DIAGRAMS H1J08X19AB...
Page 376 B-108 CIRCUIT DIAGRAMS HEADLAMP <R.H. drive vehicles> (CONTINUED) H1J08X19BA...
Page 377 B-109 CIRCUIT DIAGRAMS NOTES...
Page 378 B-110 CIRCUIT DIAGRAMS TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER L.H. drive vehicles H1J08X23AA...
Page 379 B-111 CIRCUIT DIAGRAMS H1J08X23AB...
Page 380: Tail Lamp, Position Lamp, Licence Plate Lamp And Lighting Monitor Buzzer L.h. Drive Vehicles
B-112 CIRCUIT DIAGRAMS TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <L.H. drive vehicles> (CONTINUED) H1J08X23BA...
Page 381 B-113 CIRCUIT DIAGRAMS H1J08X23BB...
Page 382 B-114 CIRCUIT DIAGRAMS TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER R.H. drive vehicles H1J08X21AA...
Page 383 B-115 CIRCUIT DIAGRAMS H1J08X21AB...
Page 384 B-116 CIRCUIT DIAGRAMS TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <R.H. drive vehicles> (CONTINUED) H1J08X21BA...
Page 385 B-117 CIRCUIT DIAGRAMS H1J08X21BB...
Page 386: L.h. Drive Vehicles
B-118 CIRCUIT DIAGRAMS ROOM LAMP AND LUGGAGE COMPARTMENT LAMP L.H. drive vehicles H1J08X26AA...
Page 387 B-119 CIRCUIT DIAGRAMS H1J08X26AB...
Page 388: Room Lamp And Luggage Compartment Lamp L.h. Drive Vehicles
B-120 CIRCUIT DIAGRAMS ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <L.H. drive vehicles> (CONTINUED) H1J08X26BA...
Page 389: R.h. Drive Vehicles
B-121 CIRCUIT DIAGRAMS ROOM LAMP AND LUGGAGE COMPARTMENT LAMP R.H. drive vehicles H1J08X24AA...
Page 390 B-122 CIRCUIT DIAGRAMS ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <R.H. drive vehicles > (CONTINUED) H1J08X24BA...
Page 391 B-123 CIRCUIT DIAGRAMS H1J08X24BB...
Page 392 B-124 CIRCUIT DIAGRAMS REAR FOG LAMP L.H. drive vehicles H1J08X28AA...
Page 393 B-125 CIRCUIT DIAGRAMS H1J08X28AB...
Page 394: Rear Fog Lamp L.h. Drive Vehicles
B-126 CIRCUIT DIAGRAMS REAR FOG LAMP <L.H. drive vehicles> (CONTINUED) H1J08X28BA...
Page 395: R.h. Drive Vehicles
B-127 CIRCUIT DIAGRAMS REAR FOG LAMP R.H. drive vehicles H1J08X29AA...
Page 396 B-128 CIRCUIT DIAGRAMS REAR FOG LAMP <R.H. drive vehicles> (CONTINUED)
Page 397 B-129 CIRCUIT DIAGRAMS...
Page 398: Headlamp Leveling System
B-130 CIRCUIT DIAGRAMS HEADLAMP LEVELING SYSTEM L.H. drive vehicles...
Page 399 B-131 CIRCUIT DIAGRAMS...
Page 400: R.h. Drive Vehicles
B-132 CIRCUIT DIAGRAMS HEADLAMP LEVELING SYSTEM R.H. drive vehicles...
Page 401 B-133 CIRCUIT DIAGRAMS...
Page 402 B-134 CIRCUIT DIAGRAMS TURN-SIGNAL LAMP AND HAZARD WARNING LAMP L.H. drive vehicles H1J09X15AA...
Page 403 B-135 CIRCUIT DIAGRAMS H1J09X15AB...
Page 404: Turn-Signal Lamp And Hazard Warning Lamp L.h. Drive Vehicles
B-136 CIRCUIT DIAGRAMS TURN-SIGNAL LAMP AND HAZARD WARNING LAMP <L.H. drive vehicles> (CONTINUED) H1J09X15BA...
Page 405 B-137 CIRCUIT DIAGRAMS H1J09X15BB...
Page 406: R.h. Drive Vehicles
B-138 CIRCUIT DIAGRAMS TURN-SIGNAL LAMP AND HAZARD WARNING LAMP R.H. drive vehicles H1J09X13AA...
Page 407 B-139 CIRCUIT DIAGRAMS H1J09X13AB...
Page 408 B-140 CIRCUIT DIAGRAMS TURN-SIGNAL LAMP AND HAZARD WARNING LAMP <R.H. drive vehicles > (CONTINUED) H1J09X13BA...
Page 409 B-141 CIRCUIT DIAGRAMS H1J09X13BB...
Page 410: Back-Up Lamp
B-142 CIRCUIT DIAGRAMS BACK-UP LAMP L.H. drive vehicles...
Page 411: R.h. Drive Vehicles
B-143 CIRCUIT DIAGRAMS BACK-UP LAMP R.H. drive vehicles...
Page 412: Stop Lamp
B-144 CIRCUIT DIAGRAMS STOP LAMP L.H. drive vehicles H1J09X17AA...
Page 413: R.h. Drive Vehicles
B-145 CIRCUIT DIAGRAMS STOP LAMP R.H. drive vehicles H1J09X18AA...
Page 414: Horn
B-146 CIRCUIT DIAGRAMS HORN...
Page 415 B-147 CIRCUIT DIAGRAMS METER AND GAUGE (See P.B-148,152.) OPERATION TROUBLESHOOTING HINTS 1. Fuel gauge does not operate, or registers <Fuel gauge> incorrectly. When the ignition switch is at the “ON” position, (1) The fuel gauge indicates “F” when the fuel the fuel gauge is activated.
Page 416 B-148 CIRCUIT DIAGRAMS METER AND GAUGE L.H. drive vehicles...
Page 417 B-149 CIRCUIT DIAGRAMS...
Page 418: Meter And Gauge L.h. Drive Vehicles
B-150 CIRCUIT DIAGRAMS METER AND GAUGE <L.H. drive vehicles> (CONTINUED) H1J10X08BA...
Page 419 B-151 CIRCUIT DIAGRAMS NOTES...
Page 420: R.h. Drive Vehicles
B-152 CIRCUIT DIAGRAMS METER AND GAUGE R.H. drive vehicles...
Page 421 B-153 CIRCUIT DIAGRAMS...
Page 422 B-154 CIRCUIT DIAGRAMS METER AND GAUGE <R.H. drive vehicles> (CONTINUED) H1J10X06BA...
Page 423 B-155 CIRCUIT DIAGRAMS FUEL WARNING LAMP (See P.B-156.) OIL PRESSURE WARNING LAMP (See P.B-157.) BRAKE WARNING LAMP (See P.B-157.) OPERATION TROUBLESHOOTING HINTS <Fuel warning lamp> 1. No warning lamps illuminate. Check multi-purpose fuse No.(2). When the ignition switch is at the “ON” position, 2.
Page 424: Fuel Warning Lamp
B-156 CIRCUIT DIAGRAMS FUEL WARNING LAMP H1J10X10AA...
Page 425: Oil Pressure Warning Lamp
B-157 CIRCUIT DIAGRAMS OIL PRESSURE WARNING LAMP BRAKE WARNING LAMP H1J10X10AB...
Page 426 B-158 CIRCUIT DIAGRAMS POWER WINDOWS L.H. drive vehicles H1J11X10AA...
Page 427 B-159 CIRCUIT DIAGRAMS H1J11X10AB...
Page 428: Power Windows L.h. Drive Vehicles
B-160 CIRCUIT DIAGRAMS POWER WINDOWS <L.H. drive vehicles> (CONTINUED) H1J11X10BA...
Page 429 B-161 CIRCUIT DIAGRAMS H1J11X10BB...
Page 430 B-162 CIRCUIT DIAGRAMS POWER WINDOWS <L.H. drive vehicles> (CONTINUED) H1J11X10CA...
Page 431 B-163 CIRCUIT DIAGRAMS H1J11X10CB...
Page 432: R.h. Drive Vehicles
B-164 CIRCUIT DIAGRAMS POWER WINDOWS R.H. drive vehicles H1J11X14AA...
Page 433 B-165 CIRCUIT DIAGRAMS H1J11X14AB...
Page 434 B-166 CIRCUIT DIAGRAMS POWER WINDOWS <R.H. drive vehicles> (CONTINUED) H1J11X14BA...
Page 435 B-167 CIRCUIT DIAGRAMS H1J11X14BB...
Page 436 B-168 CIRCUIT DIAGRAMS POWER WINDOWS <R.H. drive vehicles> (CONTINUED) H1J11X14CA...
Page 437 B-169 CIRCUIT DIAGRAMS H1J11X14CB...
Page 438: Central Door Locking System
B-170 CIRCUIT DIAGRAMS CENTRAL DOOR LOCKING SYSTEM L.H. drive vehicles H1J11X12AA...
Page 439 B-171 CIRCUIT DIAGRAMS H1J11X12AB...
Page 440: R.h. Drive Vehicles
B-172 CIRCUIT DIAGRAMS CENTRAL DOOR LOCKING SYSTEM R.H. drive vehicles H1J11X15AA...
Page 441 B-173 CIRCUIT DIAGRAMS H1J11X15AB...
Page 442 B-174 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER L.H. drive vehicles...
Page 443 B-175 CIRCUIT DIAGRAMS...
Page 444: Heater And Manual Air Conditioner L.h. Drive Vehicles
B-176 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER <L.H. drive vehicles> (CONTINUED)
Page 445 B-177 CIRCUIT DIAGRAMS...
Page 446 B-178 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER <L.H. drive vehicles> (CONTINUED)
Page 447 B-179 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER (See P.B-174,180.) OPERATION TROUBLESHOOTING HINTS <Blower motor control> <Blower motor control> When the ignition switch is turned “ON”, the 1. Blower motor is energized at one switch position blower relay is energized. If the blower switch and not energized at another.
Page 448: R.h. Drive Vehicles
B-180 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER R.H. drive vehicles...
Page 449 B-181 CIRCUIT DIAGRAMS...
Page 450 B-182 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER <R.H. drive vehicles> (CONTINUED)
Page 451 B-183 CIRCUIT DIAGRAMS...
Page 452 B-184 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER <R.H. drive vehicles> (CONTINUED)
Page 453: Defogger
B-185 CIRCUIT DIAGRAMS DEFOGGER H1J13X19AA...
Page 454 B-186 CIRCUIT DIAGRAMS WINDSHIELD WIPER AND WASHER L.H. drive vehicles...
Page 455 B-187 CIRCUIT DIAGRAMS...
Page 456: Windshield Wiper And Washer L.h. Drive Vehicles
B-188 CIRCUIT DIAGRAMS WINDSHIELD WIPER AND WASHER <L.H. drive vehicles> (CONTINUED) H1J13X17BA...
Page 457: R.h. Drive Vehicles
B-189 CIRCUIT DIAGRAMS WINDSHIELD WIPER AND WASHER R.H. drive vehicles H1J13X16AA...
Page 458 B-190 CIRCUIT DIAGRAMS WINDSHIELD WIPER AND WASHER <R.H. drive vehicles> (CONTINUED)
Page 459 B-191 CIRCUIT DIAGRAMS...
Page 460: Remote Controlled Mirror
B-192 CIRCUIT DIAGRAMS REMOTE CONTROLLED MIRROR L.H. drive vehicles H1J13X22AA...
Page 461: R.h. Drive Vehicles
B-193 CIRCUIT DIAGRAMS REMOTE CONTROLLED MIRROR R.H. drive vehicles H1J13X21AA...
Page 462: Clock
B-194 CIRCUIT DIAGRAMS CLOCK H1J14X12AA...
Page 463: Cigarette Lighter And Ashtray Illumination Lamp
B-195 CIRCUIT DIAGRAMS CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LAMP H1J14X13AA...
Page 464: Audio System
B-196 CIRCUIT DIAGRAMS AUDIO SYSTEM...
Page 465 B-197 CIRCUIT DIAGRAMS...
Page 466: L.h. Drive Vehicles
B-198 CIRCUIT DIAGRAMS L.H. drive vehicles...
Page 467 B-199 CIRCUIT DIAGRAMS...
Page 468 B-200 CIRCUIT DIAGRAMS ABS <L.H. drive vehicles> (CONTINUED)
Page 469 B-201 CIRCUIT DIAGRAMS...
Page 470 B-202 CIRCUIT DIAGRAMS ABS <L.H. drive vehicles> (CONTINUED) H1J15X28CA...
Page 471 B-203 CIRCUIT DIAGRAMS H1J15X28CB...
Page 472 B-204 CIRCUIT DIAGRAMS ABS <L.H. drive vehicles> (CONTINUED)
Page 473: R.h. Drive Vehicles
B-205 CIRCUIT DIAGRAMS R.H. drive vehicles...
Page 474 B-206 CIRCUIT DIAGRAMS ABS <R.H. drive vehicles> (CONTINUED)
Page 475 B-207 CIRCUIT DIAGRAMS...
Page 476 B-208 CIRCUIT DIAGRAMS ABS <R.H. drive vehicles> (CONTINUED)
Page 477 B-209 CIRCUIT DIAGRAMS...
Page 478 B-210 CIRCUIT DIAGRAMS ABS <R.H. drive vehicles> (CONTINUED) H1J15X42DA...
Page 479 B-211 CIRCUIT DIAGRAMS H1J15X42DB...
Page 480: Acd
B-212 CIRCUIT DIAGRAMS Vehicles without AYC <L.H. drive vehicles>...
Page 481 B-213 CIRCUIT DIAGRAMS...
Page 482 B-214 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (L.H. drive vehicles)> (CONTINUED)
Page 483 B-215 CIRCUIT DIAGRAMS...
Page 484 B-216 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (L.H. drive vehicles)> (CONTINUED)
Page 485 B-217 CIRCUIT DIAGRAMS H1J15X30CB...
Page 486 B-218 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (L.H. drive vehicles)> (CONTINUED) H1J15X30DA...
Page 487 B-219 CIRCUIT DIAGRAMS H1J15X30DB...
Page 488: Vehicles Without Ayc
B-220 CIRCUIT DIAGRAMS Vehicles without AYC <R.H. drive vehicles>...

Page 489 B-221 CIRCUIT DIAGRAMS...
Page 490 B-222 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (R.H. drive vehicles)> (CONTINUED)
Page 491 B-223 CIRCUIT DIAGRAMS...
Page 492 B-224 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (R.H. drive vehicles)> (CONTINUED)
Page 493 B-225 CIRCUIT DIAGRAMS...
Page 494 B-226 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (R.H. drive vehicles)> (CONTINUED) H1J15X43DA...
Page 495 B-227 CIRCUIT DIAGRAMS H1J15X43DB...
Page 496 B-228 CIRCUIT DIAGRAMS ACD AND AYC L.H. drive vehicles...
Page 497 B-229 CIRCUIT DIAGRAMS...
Page 498: Acd And Ayc L.h. Drive Vehicles
B-230 CIRCUIT DIAGRAMS ACD AND AYC <L.H. drive vehicles> (CONTINUED)
Page 499 B-231 CIRCUIT DIAGRAMS...
Page 500 B-232 CIRCUIT DIAGRAMS ACD AND AYC <L.H. drive vehicles> (CONTINUED) H1J15X32CA...
Page 501 B-233 CIRCUIT DIAGRAMS H1J15X32CB...
Page 502 B-234 CIRCUIT DIAGRAMS ACD AND AYC <L.H. drive vehicles> (CONTINUED) H1J15X32DA...
Page 503 B-235 CIRCUIT DIAGRAMS H1J15X32DB...
Page 504 B-236 CIRCUIT DIAGRAMS ACD AND AYC <L.H. drive vehicles> (CONTINUED)
Page 505 B-237 CIRCUIT DIAGRAMS...
Page 506: R.h. Drive Vehicles
B-238 CIRCUIT DIAGRAMS ACD AND AYC R.H. drive vehicles...
Page 507 B-239 CIRCUIT DIAGRAMS...
Page 508 B-240 CIRCUIT DIAGRAMS ACD AND AYC <R.H. drive vehicles> (CONTINUED)
Page 509 B-241 CIRCUIT DIAGRAMS...
Page 510 B-242 CIRCUIT DIAGRAMS ACD AND AYC <R.H. drive vehicles> (CONTINUED) H1J15X44CA...
Page 511 B-243 CIRCUIT DIAGRAMS H1J15X44CB...
Page 512 B-244 CIRCUIT DIAGRAMS ACD AND AYC <R.H. drive vehicles> (CONTINUED) H1J15X44DA...
Page 513 B-245 CIRCUIT DIAGRAMS H1J15X44DB...
Page 514 B-246 CIRCUIT DIAGRAMS ACD AND AYC <R.H. drive vehicles> (CONTINUED)
Page 515 B-247 CIRCUIT DIAGRAMS...
Page 516: Supplemental Restraint System (Srs) And Seat Belt Pretensioner
B-248 CIRCUIT DIAGRAMS SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT PRETENSIONER L.H. drive vehicles...
Page 517 B-249 CIRCUIT DIAGRAMS...
Page 518: R.h. Drive Vehicles
B-250 CIRCUIT DIAGRAMS SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT PRETENSIONER R.H. drive vehicles...
Page 519 B-251 CIRCUIT DIAGRAMS...
Page 520: Immobilizer System
B-252 CIRCUIT DIAGRAMS IMMOBILIZER SYSTEM L.H. drive vehicles H1J15X26AA...
Page 521 B-253 CIRCUIT DIAGRAMS H1J15X26AB...
Page 522: R.h. Drive Vehicles
B-254 CIRCUIT DIAGRAMS IMMOBILIZER SYSTEM R.H. drive vehicles H1J15X25AA...
Page 523 B-255 CIRCUIT DIAGRAMS H1J15X25AB...
Page 524: Intercooler Water Splay
B-256 CIRCUIT DIAGRAMS INTERCOOLER WATER SPLAY...
Page 525 B-257 CIRCUIT DIAGRAMS...
Page 526: Spare Connector
B-258 CIRCUIT DIAGRAMS SPARE CONNECTOR (FOR FRONT FOG LAMP) H1J15X47AA...
Page 527 INDEX - In order of connector No. INDEX In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page A A-01 Side turn signal lamp (RH) B-135,139 B-6,8 A-02 Side turn signal lamp (LH) B-134,138 B-6,8 A-03 Wheel speed sensor (Front:LH) B-203,211,217,225,233,243 B-6,8...
Page 528 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page A A-45 Condenser fan motor B-177,183 B-7,9 A-46 Condenser fan motor B-177,183 B-7,9 A-47 A/C compressor B-178,184 B-7,9 A-48 Power steering oil pressure switch B-90,98 B-7,9 B B-01...
Page 529 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page B B-108 Back-up lamp switch B-142,143 B-12,16 B-110 Engine coolant temperature gauge unit B-148,152 B-12,16 B-112 EGR solenoid valve B-91,99 B-12,16 B-114 Ignition coil 1 B-82,83 B-12,16 B-115...
Page 530 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-10 Outside/Inside air selection damper B-175,181 B-18,24 control motor and potentiometer C-14 Blower motor B-174,180 B-18,24 C-16 Resistor B-174,180 B-18,24 C-21 SRS-ECU B-248,249,250,251 B-18,24 C-22 Diagnosis connector...
Page 531 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-46 Control wiring harness and floor wiring B-224,244 B-25 harness (LH) combination <ACD> <RHD> C-101 Spare connector (for front fog lamp B-258 B-20,26 switch) C-102 J/C (2)
Page 532 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-130 Instrument panel wiring harness and B-84,87,92,95,100,142,143,148,150, B-21,27 control wiring harness combination 152,154,157,175,178,198,200,201, 204,205,206,212,213,216,219,228, 229,232,235,237,252,254,255,256, C-131 Blower switch B-174,180 B-21,27 C-132 Front wiring harness (LH) and instru- B-74,78,92,100,105,108,113,117,119, B-21,27 ment panel wiring harness combination...
Page 533 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-207 Air bag module (squib) <Driver’s side> B-248,250 B-22,28 C-208 Instrument panel wiring harness and B-54,55,126,129,256 B-22,28 J/B combination C-209 Instrument panel wiring harness and B-54,55,87,95,104,105,107,108,110, B-22,28 J/B combination...
Page 534 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-223 Fuel pump relay 1 B-54,55,87,95 B-23,29 C-224 Power window relay B-54,55,158,159,165 B-23,29 C-225 No connection B-54,55,78 B-23,29 C-226 ETACS-ECU B-54,55,105,108,112,113,116,117,118, B-23,29 119,120,121,122,123,125,126,128, 129,134,136,137,138,140,141,158, 164,165, 170,171,172,173,188,189 C-227...
Page 535 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page D D-27 Fuel gauge unit (Sub) B-148,152,156 B-31,33 D-28 Seat belt pretensioner (LH) B-249,251 B-31,33 D-29 Floor wiring harness (RH) and fuel B-93,101 B-31,33 wiring harness combination D-30 Floor wiring harness (RH) and fuel...
Page 536 C-10 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page F F-08 Spare connector <for rear speaker B-197 B-38,39 (RH)> F-09 Rear combination lamp (RH) B-111,115,129,134,138,142,144,145 B-38,39 F-10 Trunk lid latch switch B-119,123 B-38,39 F-12 Licence plate lamp (RH)
Page 537 C-11 INDEX - In order of parts name INDEX In order of parts name Parts name Connector Circuit diagram page Wiring diagram page 4WD-ECU <ACD> C-43 B-201,209,212,213,214,215,216,218, B-19,25 219,220,221,222,223,224,226,227, 228,230,231,232,234,236,237,238, 240,241,242,244, 246,247 4WD-ECU <ACD> C-44 B-201,209,212,213,216,217,219,220, B-19,25 221,224,225,227,228,229,232,234, 235,237,238,239,242,244,245,247 A A/C compressor A-47 B-178,184 B-7,9...
Page 538 C-12 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page C Column switch C-203 B-104,107,112,116,125,128,137,141, B-22,28 187,191 Combination meter C-01 B-84,87,95,103,106,118,122,126,129, B-18,24 135,139,148,149,152,153,156,157, 198,206,214,222,230,240,248,250, 256, 258 Combination meter C-02 B-110,115,118,122,126,129,135,139, B-18,24 148,149,152,153,156,157,198,206, 248, 250,256,258 Condenser fan motor A-45 B-177,183...
Page 539 C-13 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page D Door switch (Rear:LH) D-08 B-120,121 B-30,32 Door switch (Rear:RH) D-06 B-120,121 B-30,32 Dual pressure switch A-36 B-178,184 B-7,9 E EGR solenoid valve B-112 B-91,99 B-12,16...
Page 540 C-14 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page F Floor wiring harness (RH) and J/B C-217 B-54,55,108,115,116,121,123,138, B-29 combination <RHD> 164, 173,185 Floor wiring harness (RH) and rear door D-02 B-160,166,171,173 B-30,32 wiring harness (RH) combination Fog lamp switch...
Page 541 C-15 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page G G sensor (Lateral) D-33 B-200,208,213,221,229,239 B-31,33 G sensor (Longitudinal) D-32 B-200,208,213,221,229,239 B-31,33 H Hazard warning switch C-03 B-136,140 B-18,24 Headlamp (HI:LH) A-16 B-103,106 B-6,8 Headlamp (HI:RH)
Page 542 C-16 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page Instrument panel wiring harness and C-42 B-216,234 B-19 control wiring harness combination <ACD> <LHD> Instrument panel wiring harness and C-147 B-209,210,215,223,224,225,231,241, B-27 control wiring harness combination 242,244 <RHD>...
Page 543 C-17 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page Instrument panel wiring harness and C-211 B-54,55,78,92,100,105,108,113,117, B-22,28 J/B combination 119,123,125,128,137,141,150,154, 158,164,170,172,174,180,185,188, 189,204,205,219,227,237,247,248, 250,252,254 Instrument panel wiring harness and C-213 B-54,55,78,82,83,84,87,92,95,100, B-22,28 J/B combination 104,105,107,108,110,112,113,115, 116,117,119,120,121,123,125,126, 128,129,135,136,137,139,140,141,...
Page 544 C-18 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page K Key reminder switch C-202 B-253,255 B-22,28 Licence plate lamp (LH) F-13 B-110,114 B-38,39 Licence plate lamp (RH) F-12 B-110,114 B-38,39 Luggage compartment lamp F-04 B-119,123 B-38,39...
Page 545 C-19 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page P Purge control solenoid valve B-23 B-91,99 B-11,15 R Radiator fan relay A-09X B-73,102,176,182 B-6,8 Rear combination lamp (LH) F-16 B-110,114,126,134,138,143,144,145 B-38,39 Rear combination lamp (RH) F-09 B-111,115,129,134,138,142,144,145 B-38,39...
Page 546 C-20 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page S SRS-ECU C-41 B-249,251 B-19,25 Starter B-18 B-79 B-11,15 Starter B-19 B-79 B-11,15 Steering wheel sensor C-230 B-202,210,218,226,236,246 B-23,29 Stop lamp switch C-103 B-144,145,198,206,212,220,228,238 B-20,26 T Throttle position sensor...
Page 547 ELECTRICAL WIRING CONTENTS HOW TO READ THE WIRING DIAGRAMS ....... . . ELECTRICAL WIRING .
Page 548 NOTES...
Page 549 Electrical Wiring ....Body Repair ....Mitsubishi Motors Corporation May 2001...
Page 550 (3) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any SRS component or any SRS-related component.
Page 551: General
00-1 GENERAL CONTENTS HOW TO USE THIS MANUAL ....Models ........Model Code .
Page 552: How To Use This Manual
00-2 GENERAL - How to Use This Manual HOW TO USE THIS MANUAL SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS AND SERVICING EXPLANATIONS STANDARD VALUE This manual provides explanations, etc. concerning Indicates the value used as the standard for judging procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection and servicing of the subject model.
Page 553 00-3 GENERAL - How to Use This Manual MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection. DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an engine.
Page 554: Explanation Of Manual Contents
00-4 GENERAL - How to Use This Manual 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. 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-...
Page 555 00-5 GENERAL - How to Use This Manual Indicates the Indicates the Indicates the Indicates the page number. group title. section title. group num- ber. denotes non-re- usable part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Parts- tightening-torque Table”.
Page 556: Troubleshooting Contents
00-6 GENERAL - How to Use Troubleshooting/Inspection Service Points HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS 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.
Page 557 00-7 GENERAL - How to Use Troubleshooting/Inspection Service Points 4. INSPECTION CHART FOR DIAGNOSIS CODES 5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-10 for how to use the inspection procedures.) 6.
Page 558 00-8 GENERAL - How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP MB991529 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. 2. Turn the ignition switch to “ON” position. 3. Read out a diagnosis code by observing how the warning lamp flashes.
Page 559 00-9 GENERAL - How to Use Troubleshooting/Inspection Service Points INPUT SIGNAL CHECK <SWS> MUT- Ⅱ WHEN USING THE MUT-II 1. Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Turn the ignition switch to “LOCK”(OFF) position before connecting or disconnecting the MUT-II.
Page 560: How To Use The Inspection Procedures
00-10 GENERAL - How to Use Troubleshooting/Inspection Service Points 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.
Page 561: Connector Measurement Service Points
00-11 GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED Harness connector (WITH CIRCUIT IN A CONDITION OF CONTINUITY)
Page 562 00-12 GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR INSPECTION Connector disconnected or improperly connected VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out Due to harness tension at terminal section Low contact pressure between male and female terminals Low connection pressure due to rusted terminals or foreign matter lodged in terminals Defective connector contact...
Page 563: Inspection Service Points For A Blown Fuse
00-13 GENERAL - How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition Battery of continuity.
Page 564: Vehicle Information Code Plate
00-14 GENERAL - Vehicle Identification VEHICLE IDENTIFICATION VEHICLE INFORMATION CODE PLATE LOCATION Vehicle information code plate is riveted on the toeboard inside the engine compartment. CODE PLATE DESCRIPTION The plate shows model code, engine model, transmission model, and body colour code. Item Contents Contents...
Page 565: Model Code
00-15 GENERAL - Vehicle Identification MODEL CODE Items Contents CT 9 A S N D F Development MITSUBISHI LANCER EVOLUTION-VII Engine type 1,997 mL petrol engine 2 3 4 5 6 7 8 9 Sort Passenger car Body style 4-door sedan...
Page 566: Chassis Number
Distribution channel Japan channel Destination For Europe and General Export Body style 4-door sedan Transmission type 5-speed manual transmission Development order MITSUBISHI LANCER EVOLUTION-VII Engine 4G63: 1,997 mL petrol engine Sort Passenger car Model year 2002 Plant MIZUSHIMA-1 Serial number ENGINE MODEL NUMBER 1.
Page 567 00-17 GENERAL - Major Specifications MAJOR SPECIFICATIONS Items CT9A SNDFZL/R SNGFZL/R Vehicle Front track 1 1,500, 1,515 dimensions Overall width 2 1,770 Front overhang 3 895 Wheel base 4 2,625 Rear overhang 5 935 Overall length 6 4,455 Ground clearance 7 140 (unladen) Overall height (unladen)
Page 568: Precautions Before Service
00-18 GENERAL - Precautions Before Service PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B - Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
Page 569 00-19 GENERAL - GENERAL - Precautions Before Service Precautions Before Service SERVICING THE ELECTRICAL SYSTEM Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative ( - ) cable from the battery in order to avoid damage caused by short-circuiting.
Page 570 00-20 GENERAL - GENERAL - Precautions Before Service Precautions Before Service MUT-II MUT-II sub-assembly Refer to the “MUT-II REFERENCE MANUAL” or “MUT-II OPERATING INSTRUCTIONS” for instructions on handling the MUT-II. ROM pack Connect the MUT-II to the diagnosis connector as shown MUT- Ⅱ...
Page 571 00-21 GENERAL - Supplemental Restraint System (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) To improve safety, the SRS and seat belts with instrument panel indicates the operational status pre-tensioner. These systems enhance collision of the SRS. The clock spring is installed in the safety by restraining the front passengers in case steering column.
Page 572 00-22 GENERAL - Supplemental Restraint System (SRS) SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others NOTE from accidental deployment of the air bag and If any of these components are diagnosed as accidental operation of the seat belt with faulty, they should only be replaced, in pre-tensioner during servicing,...
Page 573 00-23 GENERAL - Supplemental Restraint System (SRS) SRS-ECU Destination of harness Corrective action Terminal No. Instrument panel wiring harness → Earth Repair or replace each wiring harness harness Instrument panel wiring harness → Combination meter (SRS warning lamp) 9, 10 Instrument panel wiring harness →...
Page 574: Support Locations For Lifting And Jacking
00-24 GENERAL - Support Locations for Lifting and Jacking SUPPORT LOCATIONS FOR LIFTING AND JACKING Caution Do not support the vehicles at locations other than specified supporting points. Doing so will cause damage, etc. SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS GARAGE JACK Caution Never support any point other than the specified ones, or deformation will result.
Page 575: Double-Post Lift
00-25 GENERAL - Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT Caution 1. If rubber attachments with grooves that are too thick are used at the front support positions, the front fender may become bent, so be sure to use rubber attachments with groove thicknesses of 18 mm or less.
Page 576 00-26 GENERAL - Support Locations for Lifting and Jacking PLATE TYPE LIFT To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift. NOTE The wooden block should be 100 mm wide and 50 mm high. SUPPORT POSITIONS AND SUPPORT METHOD H-bar lift FOR AN H-BAR LIFT...
Page 577 00-27 GENERAL - Support Locations for Lifting and Jacking PREPARATION OF “ATTACHMENTS” Block (A) 1. Prepare the blocks (wooden) and nails as shown in the figure. 1,800 Item Dimensions mm Quantity Block (A) 90 × 95 × 1,800 Block (B) 60 ×...
Page 578 00-28 GENERAL - Standard Part/Tightening-Torque Table STANDARD PART/TIGHTENING-TORQUE TABLE Each torque value in the table is a standard value The values in the table are not applicable: for tightening under the following conditions. (1) If toothed washers are inserted. (1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
Page 579: Engine
11A-1 ENGINE CONTENTS ENGINE ............ENGINE OVERHAUL .
Page 580 11A-2 ENGINE CONTENTS GENERAL INFORMATION ....Manifold Vacuum Check ..... Lash Adjuster Check .
Page 581: General Information
11A-3 ENGINE <4G6> - General Information GENERAL INFORMATION Items 4G63 Total displacement mL 1,997 Bore × Stroke mm 85.0 × 88.0 Compression ratio Combustion chamber Pentroof type Camshaft arrangement DOHC Number of valve Intake Exhaust Valve timing Intake Opening BTDC 21_ Closing ABDC 59_ Exhaust...
Page 582: Service Specifications
Auto-tensioner rod protrusion amount mm 3.8 - 4.5 Auto-tensioner rod sink in amount mm Within 1 SEALANTS Items Specified Sealants Remarks Rocker cover MITSUBISHI GENUINE PART MD970389 or Semi-drying equivalent equivalent sealant sealant Rocker cover gasket Cylinder head Camshaft position sensor support...
Page 583: Special Tools
11A-5 ENGINE - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub Measuring the drive belt tension assembly Checking the ignition timing Checking the idle speed Erasing diagnosis code Measuring the timing belt B tension MB991668 Belt tension meter Measuring the drive belt tension (used together with MUT-II) Measuring the timing belt B tension...
Page 584 11A-6 ENGINE - Special Tools Tool Number Name MB991367 Special spanner For retaining the crankshaft sprocket MB991385 MB991704 Battery harness Measuring the timing belt B tension (used together with MUT-II) MD998767 Tensioner pulley For adjusting timing belt tension socket wrench MD998738 Adjusting bolt For retaining the tensioner arm and the...
Page 585: On-Vehicle Service
11A-7 ENGINE - On-vehicle Service ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK 1. Check that the indicator marking of the auto-tensioner is within the range as shown in the illustration A of the tensioner bracket. Caution Inspection must be carried out after turning the Indicator crankshaft clockwise for more than once.
Page 586 11A-8 ENGINE - On-vehicle Service (4) Hold the special tool (MB991668) to the middle of Power steering 10 - 20 mm the belt between the pulleys (at the place indicated oil pump pulley by the arrow) about 10 - 20 mm away from the rear MB991668 15°...
Page 587: Ignition Timing Check
11A-9 ENGINE - ENGINE - On-vehicle Service On-vehicle Service IGNITION TIMING CHECK MUT-II 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to “LOCK” (OFF) position and then connect the MUT-II to the diagnosis connector. 3.
Page 588: Idle Mixture Check
11A-10 ENGINE - ENGINE - On-vehicle Service On-vehicle Service Standard value: 5_ BTDC ± 3_ 5. Run the engine at idle for 2 minutes. 6. Check the idle speed. Select item No. 22 and take a reading of the idle speed. Curb idle speed: 850 ±...
Page 589: Compression Pressure Check
11A-11 ENGINE - ENGINE - ENGINE - On-vehicle Service On-vehicle Service On-vehicle Service 10. Turn the ignition switch to the “LOCK” (OFF) position and then remove the MUT-II. COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal.
Page 590: Manifold Vacuum Check
11A-12 ENGINE - On-vehicle Service 12. Install the ignition coils and spark plugs. 13. Use the MUT-II to erase the self-diagnosis codes or disconnect the battery cable from the battery ( - ) terminal for 10 seconds or more and then reconnect the cable. NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.
Page 591 11A-13 ENGINE - On-vehicle Service (2) If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick.
Page 592 11A-14 ENGINE - On-vehicle Service 1. Check the engine oil and replenish or replace the oil if necessary. NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage.
Page 593: Crankshaft Pulley
11A-15 ENGINE - Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) Side Cover Removal and Installation...
Page 594: Camshaft And Camshaft Oil Seal
11A-16 ENGINE - Crankshaft Pulley/Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINT AA" DRIVE BELT REMOVAL Due to the adoption of the Serpentine drive system with the auto-tensioner, the following operation is required: 1. Insert the 12.7sq. spinner handle and etc. into the tool hole of the auto-tensioner and rotate it counterclockwise until the auto-tensioner gets to the stopper.
Page 595 11A-17 ENGINE - Camshaft and Camshaft Oil Seal 3.0 ± 0.5 N·m 3.5 ± 0.5 N·m 11 ± 1 N·m 11 ± 1 N·m 8.8 ± 1.0 N·m 5.0 ± 1.0 N·m Removal steps 1. Accelerator cable connection 6. Camshaft position sensor connector <L.H.
Page 596 11A-18 ENGINE - Camshaft and Camshaft Oil Seal 20 ± 1 N·m 10 ± 2 N·m 89 ± 9 N·m 11 ± 1 N·m 22 ± 4 N·m 14 ± 1 N·m Apply engine oil to all sliding parts at the time of installation.
Page 597 Camshaft and Camshaft Oil Seal LUBRICATION AND SEALING POINTS <The bottom view of the rocker cover> 10 mm 10 mm Rocker Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent cover Cylinder <View A> head 10 mm Sealant: 3M ATD Part No.8660...
Page 598 11A-20 ENGINE - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS AA" RADIATOR UPPER HOSE DISCONNECTION Indicate the mating marks on the radiator upper hose and the hose clamp for release. AB" CAMSHAFT SPROCKET REMOVAL Hold the hexagon part of the camshaft with a wrench and loosen the mounting bolt, then remove the camshaft sprocket.
Page 599 3. Apply sealant to the positions (6 areas) of the upper side Engine Front of the cylinder head as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent 4. Position the camshaft bearing cap rear in the direction as shown in the illustration for installation.
Page 600 2. Apply sealant to the flange of the camshaft position sensor support and install to the cylinder head. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent ø3 mm 3. Tighten the camshaft position sensor support mounting bolt to the specified torque.
Page 601: Oil Pan
Engine Front 1. Apply sealant to the positions of the rocker cover gasket (6 areas) as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent 2. Install the rocker cover to the cylinder head. OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
Page 602 11A-24 ENGINE - Oil Pan 9.0 ± 1.0 N·m 22 ± 4 N·m 14 ± 1 N·m 42 ± 2 N·m 9.0 ± 3.0 N·m 26 ± 5 N·m <Bolt with washer> 39 ± 5 N·m 9.0 ± 1.0 N·m <Flange bolt>...
Page 603 ø4 mm Specified sealant: MITSUBISHI GENUINE PART MD970389 or at the groove at the bolt hole equivalent 3. Tighten the mounting bolt of oil pan to the specified torque.
Page 604: Crankshaft Oil Seal
11A-26 ENGINE - Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. (at the lip) (at the lip) Engine oil...
Page 605 11A-27 ENGINE - Crankshaft Oil Seal REMOVAL SERVICE POINT AA" FLYWHEEL BOLT REMOVAL MD998781 INSTALLATION SERVICE POINTS Oil Seal "AA CRANKSHAFT REAR OIL SEAL INSTALLATION Crankshaft 1. Apply small quantity of engine oil on the circumference MB990938 of oil seal lip. 2.
Page 606: Cylinder Head Gasket
11A-28 ENGINE - Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Pre-removal and Post-installation Operation Fuel Outflow Preventive Operation (Refer to GROUP 13A - On-vehicle Service.) <Before removal only>...
Page 607 11A-29 ENGINE - Cylinder Head Gasket 5.0 ± 1.0 N·m 5.0 ± 1.0 N·m 9.0 ± 1.0 N·m 9.0 ± 1.0 N·m 13 ± 1 N·m (Engine oil) Removal steps 1. Ignition coil connector 12. Engine coolant temperature sensor 2. Crank angle sensor connector connector 3.
Page 608 11A-30 ENGINE - Cylinder Head Gasket 78 ± 2 N·m to 0 N·m to 20 ± 2 N·m 5.0 ± 1.0 N·m to +90_ to +90_ (cold start) (Engine oil) (Engine oil) 44 ± 5 N·m 31 ± 3 N·m 35 ±...
Page 609 11A-31 ENGINE - Cylinder Head Gasket REMOVAL SERVICE POINT AA" CYLINDER HEAD BOLTS REMOVAL Use the special tool to loosen the bolt in 2 to 3 times in the order of the numbers shown in the illustration for removal. MB991654 Engine Front INSTALLATION SERVICE POINTS "AA CYLINDER HEAD GASKET INSTALLATION...
Page 610 11A-32 ENGINE - Cylinder Head Gasket 3. Use special tool to tighten bolts according to the following procedure (tightening for plastic zone) (1) According to the sequence specified in the figure, tighten the bolt to the specified torque 78 ± 2 N·m. (2) In the reverse sequence of the figure, fully loosen MB991654 bolts.
Page 611 11A-33 ENGINE - Cylinder Head Gasket 3. In case of not rotating smoothly, remove the fuel high pressure hose and insert it to the delivery pipe again after checking damage of the O-ring since there is a possibility of O-ring engagement. 4.
Page 612: Timing Belt And Timing Belt B
11A-34 ENGINE - Timing Belt and Timing Belt B TIMING BELT AND TIMING BELT B REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) Side Cover Removal and Installation...
Page 613 11A-35 ENGINE - Timing Belt and Timing Belt B 19 ± 3 N·m (Engine oil) 8.8 ± 1.0 N·m 162 ± 5 N·m 12. Crank angle sensor "BA D Timing belt B tension adjustment AB" "CA 13. Crankshaft sprocket "AA 15. Timing belt B tensioner "CA 14.
Page 614 11A-36 ENGINE - Timing Belt and Timing Belt B AC" TIMING BELT B REMOVAL Caution When the timing belt B is reused, use a chalk to indicate an arrow of rotation direction on the back of the belt so that it can be re-assembled in the same direction as before.
Page 615 11A-37 ENGINE - Timing Belt and Timing Belt B <When using MUT-II> (1) Connect the special tool (MB991668) to the MUT-II. (2) Connect the special tool (MB991704) to the MUT-II and the battery. (3) Rotate the crankshaft clockwise for two rounds to position No.1 cylinder at compression TDC and check that timing marks of each sprocket are aligned with each other.
Page 616 11A-38 ENGINE - Timing Belt and Timing Belt B "CA CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION Engine Front 1. Clean and degrease the crankshaft sensing blade and the crankshaft sprocket mounting surfaces of the Crankshaft crankshaft sprocket and the crankshaft. 2. Install the crankshaft sensing blade and crankshaft Crankshaft sprocket sprocket to the direction as shown in the illustration.
Page 617 11A-39 ENGINE - Timing Belt and Timing Belt B "FA TIMING BELT INSTALLATION 1. Check that timing marks of camshaft sprocket, crankshaft Timing Mark sprocket, and oil pump sprocket are aligned with each other. Camshaft sprocket Crankshaft sprocket Timing Mark Timing Mark Oil pump...
Page 618 11A-40 ENGINE - Timing Belt and Timing Belt B (2) Hook the timing belt with exhaust side of the camshaft sprocket and retain the specified position indicated in the figure with paper clips. Paper clip (3) Use two wrenches to hook the timing belt to the intake Timing Mark side of the camshaft sprocket while aligning the timing marks on the rocker cover and camshaft sprocket.
Page 619 11A-41 ENGINE - Timing Belt and Timing Belt B 2. Rotate the crankshaft counterclockwise for 1/4 round. 3. Rotate the crankshaft clockwise and mate timing marks with each other to position No.1 cylinder at compression TDC. 4. Loosen the temporarily tightened tensioner pulley mounting bolt.
Page 620 11A-42 ENGINE - Timing belt and timing belt B INSPECTION AUTO-TENSIONER CHECK 1. Check the sealant for oil leakage and replace if necessary. 2. Check the rod end for wear or damage and replace if necessary. 3. Measure the deflection of the rod end pressed against the metal (cylinder block, etc) with the force of 98 - 196 98 - 196 N N while holding the auto-tensioner with a hand.
Page 621: Engine Assembly
11A-43 ENGINE - Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. 2.
Page 622 11A-44 ENGINE - Engine Assembly 5.0 ± 1.0 N·m 5.0 ± 1.0 N·m 26 ± 5 N·m 14 ± 3 N·m 11 ± 1 N·m Removal steps 1. Ignition coil connector 11. Engine coolant temperature gauge 2. Crank angle sensor connector unit connector 3.
Page 623 11A-45 ENGINE - Engine Assembly 5.0 ± 1.0 N·m (Engine oil) 67 ± 7 N·m* 12 ± 2 N·m 22 ± 4 N·m 22 ± 4 N·m 98 ± 10 N·m* 40 ± 5 N·m 42 ± 2 N·m 42 ± 2 N·m 19.
Page 624 11A-46 ENGINE - Engine Assembly REMOVAL SERVICE POINTS AA" DRIVE BELT REMOVAL Due to the adoption of the Serpentine drive system with the auto-tensioner, the following operation is required: 1. Insert the 12.7sq. spinner handle into the tool hole of the auto-tensioner and rotate it counterclockwise until the auto-tensioner reaches to the stopper.
Page 625 11A-47 ENGINE - Engine Assembly AD" ENGINE ASSEMBLY REMOVAL After checking that all the cables, hoses, and harness connectors have been disconnected, lift the engine with a chain block slowly and remove the engine assembly located at the upper engine room. INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly while checking that none of cables,...
Page 626 NOTES...
Page 627 11B-1 ENGINE OVERHAUL CONTENTS GENERAL DESCRIPTION ....SECONDARY AIR SYSTEM AND INTAKE MANIFOLD ....... SPECIFICATIONS .
Page 628: General Description
11B-2 ENGINE OVERHAUL - General Description GENERAL DESCRIPTION LIST OF MODELS Vehicle name Vehicle model Engine model Displacement mL Specifications LANCER Evolution VII CT9A 4G63 - 7 2000 DOHC 16 valve T/C SPECIFICATIONS Items Specifications Bore × stroke mm 85 × 88 Total displacement mL 1,997 Combustion chamber shape...
Page 629: Service Specifications
11B-3 ENGINE OVERHAUL - Specifications SPECIFICATIONS SERVICE SPECIFICATIONS Unit: mm Items Standard value Limited value Timing belt Timing belt B Vibration frequency Hz (during inspection) 56 - 92 Vibration frequency Hz (when re-tensing working belt) 76 - 92 Vibration frequency Hz (when mounting new belt) 76 - 92 Deflection amount <reference value>...
Page 630 11B-4 ENGINE OVERHAUL - Specifications Unit: mm Items Standard value Limited value Oil pump, oil pan Oil pump Side clearance Drive gear 0.08 - 0.14 Driven gear 0.06 - 0.12 Piston, connecting rod Piston Press-in load N 7,355 - 17,162 Piston ring Clearance between ring and ring groove No.
Page 631: Machining Standards
11B-5 ENGINE OVERHAUL - Specifications MACHINING STANDARDS Unit: mm Items Standard value Limited value Cylinder head, valve Cylinder head Oversize valve guide hole diameter 0.05 O.S. 12.05 - 12.07 0.25 O.S. 12.25 - 12.27 0.50 O.S. 12.50 - 12.52 Oversize valve seat hole diameter Intake 0.3 O.S.
Page 632 11B-6 ENGINE OVERHAUL - Specifications Items Tightening torque N·m Camshaft sprocket bolt 88 ± 10 Fuel system Throttle body bolt 19 ± 3 EGR valve bolt 20 ± 2 Fuel pressure regulator bolt 8.8 ± 2.0 Delivery pipe and injector bolt 11 ±...
Page 633 11B-7 ENGINE OVERHAUL - Specifications Items Tightening torque N·m Water outlet fitting bolt 10 ± 1 Thermostat housing bolt 23 ± 4 Water inlet pipe bolt (M6) 10 ± 1 Water inlet pipe bolt (M8) 13 ± 2 Water pump bolt 14 ±...
Page 634: Sealants
AAD Part No. 8672 or equivalent As required Rocker cover AAD Part No. 8672 or equivalent As required Water outlet fitting Mitsubishi Genuine Part No. MD970389 or As required equivalent Engine coolant temperature gauge unit AAD Part No. 8672 or equivalent As required Engine coolant temperature sensor AAD Part No.
Page 635: Special Tools
11B-9 ENGINE OVERHAUL - Special Tools SPECIAL TOOLS Tool Number Name MD998781 Flywheel stopper Fixing of flywheel MD998778 Crankshaft Removal of crankshaft sprocket and sprocket crankshaft sprocket B MB998785 Sprocket stopper Holding of counter balance shaft sprocket MB991704 Battery harness Measurement of timing belt B tension (Use together with MUT-II.) MB991502...
Page 636 11B-10 ENGINE OVERHAUL - Special Tools Tool Number Name MD998442 Air bleed wire Bleeding of lash adjuster MB991654 Cylinder head bolt Loosening/tightening of cylinder head bolt wrench MD998772 Valve spring Compression of valve spring compressor MD998735 Valve spring Compression of valve spring compressor MD998737 Valve stem seal...
Page 637 11B-11 ENGINE OVERHAUL - Special Tools Tool Number Name MD998372 Silent shaft bearing Removal of counter balance shaft rear bearing puller MB991603 Silent shaft Guide stopper when removing/pressing in bearing installer counter balance shaft rear bearing stopper MD998705 Silent shaft bearing Press in of counter balance shaft front and rear installer bearings...
Page 638: Alternator And Ignition System
11B-12 ENGINE OVERHAUL - Alternator and Ignition System ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 3 ± 0.5 N•m 10 ± 2 N•m 8.8 ± 1.0 N•m 25 ± 5 N•m 13 ± 1 N•m 22 ± 4 N•m 44 ± 10 N•m 8.8 ±...
Page 639: Timing Belt
11B-13 ENGINE OVERHAUL - Timing Belt TIMING BELT REMOVAL AND INSTALLATION 3.5 ± 0.5 N•m 11 ± 1 N•m 49 ± 6 N•m 21 ± 4 N•m 23 ± 3 N•m 11 ± 1 N•m 11 ± 1 N•m 162 ± 5 N•m 49 ±...
Page 640 11B-14 ENGINE OVERHAUL - Timing Belt REMOVAL SERVICE POINTS AA" TIMING BELT REMOVAL 1. To ensure that the timing belt is assembled in the same direction when reused, using chalk, etc., make an arrow showing the rotation direction on the back surface of the timing belt.
Page 641 11B-15 ENGINE OVERHAUL - Timing Belt AE" TIMING BELT B REMOVAL To ensure that the timing belt is assembled in the same direction when reused, using chalk, etc., make an arrow showing the rotation direction on the back surface of the timing belt.
Page 642 11B-16 ENGINE OVERHAUL - Timing Belt "BA ENGINE SUPPORT BRACKET INSTALLATION Before tightening, apply sealant on the bolt at the position shown in the illustration. Sealant Specified sealant: AAD Part No. 8672 or equivalent "CA SEMI-CIRCULAR PACKING INSTALLATION Apply sealant at the position shown in the illustration. Sealant Specified sealant: AAD Part No.
Page 643 11B-17 ENGINE OVERHAUL - Timing Belt 3. Apply form-in-place gasket on the rocker cover at the Timing belt side position shown in the illustration. Sealant Specified sealant: AAD Part No. 8672 or equivalent 4. Install the rocker cover onto the cylinder head before the form-in-place gasket hardens.
Page 644 11B-18 ENGINE OVERHAUL - Timing Belt 3. Confirm that the tensioner B centre and bolt centre are Belt tension side positioned as shown in the illustration. Tensioner Timing belt B Tensioner B centre Installation bolt centre 4. Apply tension on the timing belt by lifting tensioner B in the direction of the arrow with a finger, and tension the tension side until it is “tight”.
Page 645 11B-19 ENGINE OVERHAUL - Timing Belt Caution (1) Measure when the belt’s surface temperature is close to room temperature. (2) Make sure that water or oil, etc., do not get on the mike. (3) If strong winds contact the mike or if noise is generated in the area while measuring, a value that differs from the actual value may be indicated.
Page 646 11B-20 ENGINE OVERHAUL - Timing Belt "JA OIL PUMP SPROCKET INSTALLATION 1. Stop the rotation of the counter balance shaft in the same manner as for removal. 2. Install the oil pump sprocket. 3. Apply the minimum required amount of engine oil on the flange nut seat surface.
Page 647 11B-21 ENGINE OVERHAUL - Timing Belt 2. Align the timing mark of the intake side camshaft sprocket to the timing mark on the rocker cover. Timing marks NOTE Even when the sprocket and rocker cover timing marks are aligned, the intake camshaft will rotate slightly in the clockwise direction by the force of the valve spring and will stabilize.
Page 648 11B-22 ENGINE OVERHAUL - Timing Belt 8. Rotate the intake side camshaft sprocket in the counterclockwise direction. Attach the belt at a position where the timing mark is deviated by one tooth in the counterclockwise direction, and then fix with a paper clip. NOTE Even if the belt is attached at a position deviated by one tooth, the intake camshaft will rotate slightly in the...
Page 649 11B-23 ENGINE OVERHAUL - Timing Belt 14. Using the special tool, rotate the tensioner pulley in the counterclockwise direction to tense the timing belt, and then fix by temporarily tightening the tensioner fixing bolt. MD998767 NOTE Remove the deflection of the timing belt between the intake side and exhaust side camshafts.
Page 650 11B-24 ENGINE OVERHAUL - Timing Belt INSPECTION 1. TIMING BELT Inspect each section of the belt in detail, and if any of the following type of damage is found, replace the belt with a new part. (1) Hardening of backface rubber. The backface is glossy, marks are not made even when a fingernail is run cross it, and there is no elasticity.
Page 651 11B-25 ENGINE OVERHAUL - Timing Belt (4) Measure the depression amount when the rod is pressed with a force of 98 to 196 N. If not at the 98 - 196 N standard value, replace the auto tensioner. Standard value: 1 mm or less Depression amount...
Page 652: Fuel System
11B-26 ENGINE OVERHAUL - Fuel System FUEL SYSTEM REMOVAL AND INSTALLATION 11 ± 1 N•m 19 ± 3 N•m 9 ± 1 N•m 11 ± 1 N•m 20 ± 2 N•m 8.8 ± 2.0 N•m 9 ± 1 N•m 9 ± 1 N•m 9 ±...
Page 653 11B-27 ENGINE OVERHAUL - Fuel System INSTALLATION SERVICE POINTS "AA INJECTOR INSTALLATION 1. Apply a small amount of new engine oil on the O-ring. 2. While rotating the injector to the left and right, insert the O-ring into the delivery pipe while taking care not to damage it.
Page 654: Secondary Air System And Intake Manifold
11B-28 ENGINE OVERHAUL - Secondary Air System and Intake Manifold SECONDARY AIR SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION 22 ± 4 N•m 24 ± 3 N•m 22 ± 4 N•m 11 ± 1 N•m 23 ± 4 N•m 36 ± 6 N•m 5 ±...
Page 655 11B-29 ENGINE OVERHAUL - Secondary Air System and Intake Manifold INSTALLATION SERVICE POINTS "AA INTAKE MANIFOLD STAY INSTALLATION Check that the intake manifold stay is seated against the intake manifold and cylinder block boss, and then tighten at the specified torque 31 ± 3 N•m. Intake manifold stay "BA MANIFOLD DIFFERENTIAL PRESSURE (MDP) SENSOR INSTALLATION...
Page 656: Exhaust Manifold
11B-30 ENGINE OVERHAUL - Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION 17 ± 2 N•m 59 ± 5 N•m 19 ± 3 N•m 11 ± 1 N•m 33 ± 6 N•m 31 ± 2 N•m 10 ± 1 N•m 55 ± 10 N•m 42 ±...
Page 657 11B-31 ENGINE OVERHAUL - Exhaust Manifold INSTALLATION SERVICE POINTS "AA EXHAUST MANIFOLD INSTALLATION 1. Lightly tighten the installation nut for the exhaust manifold. 2. Following the tightening order shown in the illustration, tighten the M8 nuts at the tightening torque 29 N•m. 3.
Page 658: Water Pump And Water Hose
11B-32 ENGINE OVERHAUL - Water Pump and Water Hose WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION 10 ± 1 N•m 23 ± 4 N•m 13 ± 2 N•m 29 ± 10 N•m 23 ± 4 N•m 10 ± 1 N•m 10.8 ±...
Page 659 Squeeze out form-in-place gasket at a 3 mm width, and apply at the position shown in the illustration. Form-in-place gasket Specified gasket: Mitsubishi Genuine Part No. MD970389 or equivalent "CA ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION When reusing the bolts, apply the specified sealant on the threads.
Page 660: Rocker Arms And Camshaft
11B-34 ENGINE OVERHAUL - Rocker Arm and Camshaft ROCKER ARM AND CAMSHAFT REMOVAL AND INSTALLATION 10 ± 2 N•m 14 ± 1 N•m 20 ± 1 N•m 22 ± 4 N•m 8.8 ± 1.0 N•m 11 ± 1 N•m Apply engine oil on all sliding sections before installing.
Page 661 11B-35 ENGINE OVERHAUL - Rocker Arm and Camshaft REMOVAL SERVICE POINT AA" LASH ADJUSTER REMOVAL Caution When reusing the lash adjuster, always clean and inspect it before installing. (Refer to the section on checking the lash adjuster.) INSTALLATION SERVICE POINTS "AA LASH ADJUSTER INSTALLATION Caution When reusing the lash adjuster, always clean and inspect...
Page 662 INSTALLATION Apply a 3 mm width of form-in-place gasket at the position shown in the illustration. Form-in-place gasket Specified gasket: Mitsubishi Genuine Part No. MD970389 or equivalent "FA CAM POSITION SENSING CYLINDER Vane (small) INSTALLATION 1. Set the exhaust camshaft at the No. 1 compression top dead centre.
Page 663 11B-37 ENGINE OVERHAUL - Rocker Arm and Camshaft INSPECTION 1. CAMSHAFT Measure the cam height (length). Replace if it exceeds the limit value. Standard value: Intake 35.79 mm Exhaust 35.49 mm Limit value: Intake 35.29 mm Exhaust 34.99 mm 2. LASH ADJUSTER Caution (1) The lash adjuster is a sophisticated part, so make sure that foreign matter, such as dirt, does not...
Page 664 11B-38 ENGINE OVERHAUL - Rocker Arm and Camshaft (3) Lightly press down on the steel ball inside using the special tool MD998442. Remove all matter and deteriorated oil adhered on the plunger by pressing the tool back and forth five to ten times until the plunger moves smoothly.
Page 665 11B-39 ENGINE OVERHAUL - Rocker Arm and Camshaft (7) Submerge the lash adjuster in vat C, and lightly press down on the steel ball inside using the special tool MD998442. Caution Do not use vat C for cleaning. If vat C is used for cleaning, foreign matter, etc., could enter the pressure chamber when filling it with diesel oil.
Page 666: Cylinder Head And Valve
11B-40 ENGINE OVERHAUL - Cylinder Head and Valve CYLINDER HEAD AND VALVE REMOVAL AND INSTALLATION 78 ± 2 N•m → Completely loosen 20 ± 2 N•m → 90_ + 90_ Apply engine oil on all sliding sections before installing. Removal steps 11.
Page 667 11B-41 ENGINE OVERHAUL - Cylinder Head and Valve REMOVAL SERVICE POINTS AA" CYLINDER HEAD BOLT REMOVAL Remove the cylinder head bolt using the special tool. MB991654 AB" RETAINER LOCK REMOVAL Compress the valve spring using the special tool, and remove the retainer lock.
Page 668 11B-42 ENGINE OVERHAUL - Cylinder Head and Valve "BA VALVE SPRING INSTALLATION Spring Install the valve spring so that the painted surface faces the retainer Painted rocker arm. surface Stem seal Spring seat "CA RETAINER LOCK INSTALLATION Compress the valve spring using the special tool, and install the retainer lock.
Page 669 11B-43 ENGINE OVERHAUL - Cylinder Head and Valve 3. Following the tightening order, tighten at 78 ± 2 N•m. Timing belt side 4. Completely loosen the bolts. 5. Next, following the tightening order, tighten the loosened bolts at the torque 20 ± 2 N•m again. 6.
Page 670 11B-44 ENGINE OVERHAUL - Cylinder Head and Valve 2. VALVE (1) If there is a faulty contact, one - sided contact or improper seating with the valve seat, correct the valve seat. Contact (2) Replace the valve if the margin exceeds the limit (Must be at centre of face) value.
Page 671 11B-45 ENGINE OVERHAUL - Cylinder Head and Valve 5. VALVE SEAT Valve shaft end Assemble the valve, and measure the amount that the valve protrudes from the valve shaft end between the Valve protrusion spring seat surfaces when the valve is pressed against amount the valve seat.
Page 672 11B-46 ENGINE OVERHAUL - Cylinder Head and Valve Valve Guide Replacement 1. Using a press, push the valve guide to the cylinder block side. 2. Machine the valve guide hole on the cylinder head to match the oversized valve guide into which it is to be pressed in.
Page 673: Oil Pump And Oil Pan
11B-47 ENGINE OVERHAUL - Oil Pump and Oil Pan OIL PUMP AND OIL PAN REMOVAL AND INSTALLATION 19 ± 3 N•m Apply engine oil on all sliding sections before installing. 23 ± 3 N•m 54 ± 5 N•m 10 ± 2 N•m 17 ±...
Page 674 11B-48 ENGINE OVERHAUL - Oil Pump and Oil Pan REMOVAL SERVICE POINTS MD998727 AA" OIL PAN REMOVAL 1. Remove the oil pan tightening bolts. 2. Tap the special tool between the oil pan and cylinder block. 3. Tap on the edge of the special tool, slide the tool and remove the oil pan.
Page 675 11B-49 ENGINE OVERHAUL - Oil Pump and Oil Pan AE" COUNTER BALANCE SHAFT REAR BEARING REMOVAL MB991603 1. Pull out the counter balance shaft rear bearing right from the cylinder block using the special tool (MD998372). 2. When removing the counter balance shaft rear bearing MD998372 left, install the special tool (MB991603) onto the front of the cylinder block, and then remove the bearing using...
Page 676 11B-50 ENGINE OVERHAUL - Oil Pump and Oil Pan 3. Align and insert the special tool into the guide pin, and tap in the counter balance shaft rear bearing right. MD998705 Guide pin MD998705 "CA COUNTER BALANCE SHAFT FRONT BEARING INSTALLATION 1.
Page 677 11B-51 ENGINE OVERHAUL - Oil Pump and Oil Pan 4. Align and insert the special tool into the guide pin, and tap in the counter balance shaft front bearing. MD998705 Guide pin "DA OIL PUMP OIL SEAL INSTALLATION Install the oil pump oil seal using an appropriate socket wrench. Socket wrench Oil seal Oil pump case...
Page 678 11B-52 ENGINE OVERHAUL - Oil Pump and Oil Pan "GA OIL PUMP DRIVE GEAR/OIL PUMP DRIVEN GEAR INSTALLATION Apply sufficient engine oil onto the gears, align the match Match marks marks, and assemble. "HA OIL PUMP CASE INSTALLATION Counter balance 1.
Page 679 2. Squeeze out form-in-place gasket at a 4 mm width, and apply onto the entire periphery of the oil pan flange. Form-in-place gasket Specified gasket: Mitsubishi Genuine Part No. MD970389 or equivalent Bolt hole section Groove 3. Note that the lengths of the bolts shown in the illustration Timing belt side differ, so take care when installing.
Page 680 11B-54 ENGINE OVERHAUL - Oil Pump and Oil Pan "MADRAIN PLUG GASKET INSTALLATION Drain plug Replace the gasket with a new part, and install at the direction shown in the illustration. Caution Incorrect installation direction will lead to oil leaks. Oil pan Gasket Oil pan side...
Page 681 11B-55 ENGINE OVERHAUL - Oil Pump and Oil Pan 3. OIL PUMP (1) Assemble the drive gear and driven gear into the oil pump case. (2) Inspect the side clearance with a thickness gauge. Standard value: Drive gear 0.08 - 0.14 mm Driven gear 0.06 - 0.12 mm...
Page 682: Piston And Connecting Rod
11B-56 ENGINE OVERHAUL - Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Apply engine oil on all sliding sections before installing. 20 ± 2 N•m + 90_ - 94_ Removal steps "GA 1. Connecting rod cap nut "CA 7.
Page 683 11B-57 ENGINE OVERHAUL - Piston and Connecting Rod REMOVAL SERVICE POINTS AA" CONNECTING ROD CAP REMOVAL Note the cylinder No. on the side of the connecting rod’s Cylinder No. large end for identification during reassembly. AB" PISTON PIN REMOVAL Guide A: 17.9 mm The special tool’s piston pin setting tool (MD998780) is Push rod Guide B...
Page 684 11B-58 ENGINE OVERHAUL - Piston and Connecting Rod INSTALLATION SERVICE POINTS "AA PISTON PIN INSTALLATION 1. Measure the length of the following parts. A : Piston pin installation section B : Between piston boss C : Piston pin D : Connecting rod 2.
Page 685 11B-59 ENGINE OVERHAUL - Piston and Connecting Rod "BA OIL RING INSTALLATION 1. Assemble the oil ring’s spacer into the piston ring groove. Next, assemble the upper side rail, and then assemble the lower side rail. Upper Lower side side NOTE rail rail...
Page 686 11B-60 ENGINE OVERHAUL - Piston and Connecting Rod "DA PISTON AND CONNECTING ROD ASSEMBLY Side rail No. 1 ring INSTALLATION 1. Apply sufficient engine oil on the piston ring’s periphery, piston ring and oil ring. 2. Align the piston ring and oil ring (side rail, spacer) closed Piston pin gap positions as shown in the illustration.
Page 687 11B-61 ENGINE OVERHAUL - Piston and Connecting Rod 4. If there is no identification, measure the oil clearance and select. "FA CONNECTING ROD CAP INSTALLATION 1. Align the marks made during disassembly, and install the bearing cap onto the connecting rod. When using a new connecting rod that has no match marks, assemble Cylinder No.
Page 688 11B-62 ENGINE OVERHAUL - Piston and Connecting Rod 9. Check that the thrust clearance at the large end of the connecting rod is correct. Standard value: 0.10 - 0.25 mm Limit value: 0.4 mm INSPECTION 1. PISTON RING (1) Inspect the clearance between the piston ring and ring groove.
Page 689 11B-63 ENGINE OVERHAUL - Piston and Connecting Rod 2. CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Wipe off the oil from the crankshaft pin and connecting rod bearing. (2) Set a plastic gauge as long as the bearing width on the pin shaft so that straightly aligned with the shaft centre.
Page 690: Crankshaft And Cylinder Block
11B-64 ENGINE OVERHAUL - Crankshaft and Cylinder Block CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION 11 ± 1 N•m 132 ± 5 N•m 9 ± 1 N•m 11 ± 1 N•m 32 ± 2 N•m Apply engine oil on all sliding sections before installing.
Page 691 11B-65 ENGINE OVERHAUL - Crankshaft and Cylinder Block INSTALLATION SERVICE POINTS "AA THRUST BEARING INSTALLATION 1. Install the thrust bearing onto the cylinder block side of the No. 3 bearing section. The bearing can be installed easily by applying engine oil. 2.
Page 692 11B-66 ENGINE OVERHAUL - Crankshaft and Cylinder Block 3. Select the bearing from the above table according to Crankshaft bearing side the identification confirmed in steps 1 and 2. identification mark position [Example of selecting bearing] (1) If the measured outer diameter of the crankshaft journal is 57.000 mm, Class 1 applies, and the identification colour is yellow.
Page 693 1. Apply form-in-place gasket onto the rear oil seal case at the position shown in the illustration. Form-in-place gasket Specified gasket: Mitsubishi Genuine Part No. MD970389 or equivalent Caution Evenly squeeze out the form-in-place gasket so that it is not insufficient or excessive.
Page 694 11B-68 ENGINE OVERHAUL - Crankshaft and Cylinder Block INSPECTION Plastic gauge 1. CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) The oil clearance can be measured easily by using the “plastic gauge”. Use the following steps to use the “plastic gauge”. (1) Wipe off all oil from the crankshaft’s outer diameter and bearing’s inner diameter.
Page 695 11B-69 ENGINE OVERHAUL - Crankshaft and Cylinder Block 3. CYLINDER BORING (1) Select the oversized piston to be used using the maximum inner diameter cylinder as a reference. (2) There are two types of oversized pistons (0.50 mm, 1.00 mm), so bore so that the clearance is at the specified value that matches the piston’s outer diameter.
Page 696 NOTES...
Page 697 12-1 ENGINE LUBRICATION CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Engine Oil Check .
Page 698: General Information
12-2 ENGINE LUBRICATION - General Information GENERAL INFORMATION The lubrication method is a fully force-fed, full-flow filtration type. The oil pump is a gear type which is driven by the crankshaft via the timing belt. ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil harmful contaminants which may cause skin cancer.
Page 699: Service Specifications
12-3 ENGINE LUBRICATION - Service Specifications/Sealant/Lubricants/Special Tool SERVICE SPECIFICATIONS Items Standard value Oil pressure kPa at idle 29 or more at 3,500 r/min 294 - 686 SEALANT Items Specified sealant Remark Oil pressure switch 3M ATD Part No. 8660 or equivalent Semi-drying sealant LUBRICANTS Items...
Page 700: On-Vehicle Service
12-4 ENGINE LUBRICATION - On-vehicle Service ON-VEHICLE SERVICE ENGINE OIL CHECK 1. Pull out the level gauge slowly and check that the oil level is in the illustrated range. 2. Check that the oil is not excessively dirty, that there is no coolant or petrol mixed in, and that it has sufficient viscosity.
Page 701: Oil Filter Replacement
12-5 ENGINE LUBRICATION - On-vehicle Service OIL FILTER REPLACEMENT 1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80_C to 90_C. 2. Remove the engine oil filler cap. Commercially- available tool 3. Remove the drain plug to drain oil. Caution Use care as oil could be hot.
Page 702 12-6 ENGINE LUBRICATION - On-vehicle Service 4. Install the oil pressure gauge. NOTE Use a adapter of PT 1/8 thread. 5. Run the engine to warm it. 6. After the engine has been warmed up, check that oil pressure is within the standard value. Standard value: At idle: 29 kPa or more At 3,500 r/min: 294 - 686 kPa...
Page 703: Engine Oil Cooler
12-7 ENGINE LUBLICATION - Engine Oli Cooler ENGINE OIL COOLER REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. Pre-removal and Post-installation Operation Engine Oil Draining and Supplying (Refer to P.12-4.) Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
Page 704 NOTES...
Page 705: Fuel
13A-1 FUEL CONTENTS MULTIPOINT FUEL INJECTION (MPI) ........FUEL SUPPLY .
Page 706 13A-2 MULTIPOINT FUEL INJECTION (MPI) CONTENTS GENERAL INFORMATION ....Fuel Pump Relay 3 Continuity Check ..Fuel Pump Resistor Check .
Page 707: General Information
13A-3 MPI - General Information GENERAL INFORMATION The Multipoint Fuel Injection System consists activities such as fuel injection control, idle of sensors which detect the engine conditions, speed control and ignition timing control. In the engine-ECU which controls the system addition, the engine-ECU is equipped with based on signals from these sensors, and several...
Page 708: General Specifications
13A-4 MPI - General Information OTHER CONTROL FUNCTIONS 1. Fuel Pump Control 3. Fan Motor Control Turns the fuel pump relay ON so that current The revolutions of the radiator fan and is supplied to the fuel pump while the engine condenser fan are controlled in response to is cranking or running.
Page 709 13A-5 MPI - General Information MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM L1 Oxygen sensor (front) l1 Injector L2 Oxygen sensor (rear) l2 Idle speed control servo L3 Air flow sensor l3 Fuel pressure control solenoid valve Engine-ECU L4 Intake air temperature sensor l4 Waste gate solenoid valve L5 Throttle position sensor l5 EGR control solenoid valve...
Page 710: Service Specifications
13A-6 MPI - Service Specifications/Sealant SERVICE SPECIFICATIONS Items Specifications Basic idle speed r/min 850 ± 100 Throttle position sensor adjusting voltage mV 535 - 735 Throttle position sensor resistance kΩ 3.5 - 6.5 Idle speed control servo coil resistance (at 20_C) Ω 28 - 33 Intake air temperature sensor - 20_C...
Page 711: Special Tools
13A-7 MPI - Special Tools SPECIAL TOOLS Tool Number Name MB991223 Harness set Check at the ECU terminals A: Connector pin contact pressure inspection A: MB991219 A: Test harness B: Power circuit inspection B: MB991220 B: LED harness C: Power circuit inspection C: MB991221 C: LED harness D: Commercial tester connection...
Page 712 13A-8 MPI - Special Tools Tool Number Name MD998478 Test harness Measurement of voltage during trouble- (3-pin, triangle) shooting Inspection using an analyzer MD998709 Adaptor hose Measurement of fuel pressure MD998742 Hose adaptor MB991637 Fuel pressure gauge set MD998706 Injector test set Checking the spray condition of injectors MB991607 Injector test...
Page 713: Troubleshooting
13A-9 MPI - Troubleshooting TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Point. NOTE If the engine-ECU is replaced, the immobilizer-ECU and ignition key should be replaced together with it. DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the MPI system, the engine warning lamp will illuminate or flash.
Page 714 13A-10 MPI - MPI - Troubleshooting Troubleshooting Code No. Diagnosis item P0443 Purge control solenoid valve system P0500 Vehicle speed sensor system P0505 Idle speed control system P0551 Power steering fluid pressure switch P1104 Waste gate solenoid valve system P1105 Fuel pressure control solenoid valve system NOTE If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication between...
Page 715 13A-11 MPI - MPI - Troubleshooting Troubleshooting CONFIRMING FREEZE FRAME DATA When the engine-ECU detects a malfunction and stores a diagnosis code, it also stores a current status of the engine. This function is called “Freeze frame” data. By analyzing this “Freeze frame” data with MUT-II, an effective troubleshooting can be performed.
Page 716 13A-12 MPI - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page P0100 Air flow sensor system 13A-13 P0105 Barometric pressure sensor system 13A-15 P0110 Intake air temprature sensor system 13A-16 P0115 Engine coolant temperature sensor system 13A-19 P0120 Throttle position sensor system...
Page 717 13A-13 MPI - Troubleshooting DIAGNOSTIC TROUBLE CODE INSPECTION PROCEDURE Code No. P0100 Air flow sensor system Probable cause Inspection Range D Air flow sensor malfunction D Engine speed: More than 500 r/min D Air flow sensor circuit disconnection, short-circuit, Evaluation Conditions or connector contact defect D The sensor output frequency is less than 3 Hz for 4 seconds.
Page 718 13A-14 MPI - Troubleshooting From the previous page Repair Check the following connector: Measure at the B-31 air flow sensor C-126 connector. D Using the test harness (MB991709), connect the connector, and measure at the Repair Check the harness between the air pickup.
Page 719 13A-15 MPI - Troubleshooting Code No. P0105 Barometric pressure sensor system Probable cause Inspection Range D Barometric pressure sensor malfunction D 2 seconds after the ignition switch is set to the “ON” position, or after the D Barometric pressure sensor circuit disconnection, completion of start of engine.
Page 720 13A-16 MPI - Troubleshooting From the previous page (1), (2) NG Measure at the B-31 air flow sensor Check the following connectors: Repair connector. C-115 D Using the test harness (MB991709), connect only connector terminals No. 1, No. 2, Check and repair the harness between and No.
Page 721 13A-17 MPI - Troubleshooting MUT-II Data list Intermittent malfunction D No. 13 Intake air temperature (Refer to GROUP 00 - Points to Note sensor for Intermittent Malfunctions.) OK: Ambient temperature (More or less the same as the air temperature) Repair Check the following connector: B-31 Check the intake air temperature...
Page 722 13A-18 MPI - Troubleshooting From the previous page Measure at the B-31 air flow sensor Check the following connectors: Repair connector. C-115 D Using the test harness (MB991709), connecting only connector terminals No. 5 and Check and repair the harness between No.
Page 723 13A-19 MPI - Troubleshooting Code No. P0115 Engine coolant temperature sensor Probable cause system Inspection Range D Engine coolant temperature sensor malfunction D After setting the ignition switch to the “ON” position, or 2 seconds after D Engine coolant temperature sensor circuit completion of engine start.
Page 724 13A-20 MPI - Troubleshooting From the previous page (1) NG Measure at the B-118 engine coolant Measure at the C-115 engine-ECU Check the following connector: temperature sensor connector. connector. C-115 D Disconnect the connector to D Measure the engine-ECU terminal measure at the harness side voltage.
Page 725 13A-21 MPI - Troubleshooting From the previous page Measure at the B-118 engine coolant Check the following connector: Repair temperature sensor connector. C-115 D Using the test harness (MB991658), connect the connector, and measure at the Check and repair the harness between pickup harness.
Page 726 13A-22 MPI - Troubleshooting From the previous page (1) NG Measure at the B-02 throttle position Measure at the C-115 engine-ECU Check the following connector: sensor connector. connector. C-115 D Disconnect the connector to D Measure engine-ECU terminal measure at the harness side voltage.
Page 727 13A-23 MPI - Troubleshooting From the previous page (1), (2) NG Measure at the B-02 throttle position Check the following connector: Repair sensor connector. C-115 D Using the test harness (MB991536), connect the connector, and measure at the Check and repair the harness between pickup harness.
Page 728 13A-24 MPI - Troubleshooting Code No. P0130 Oxygen sensor (front) system Probable cause Inspection Range D Oxygen sensor (front) malfunction D More than 3 minutes passed after completion of start of engine D Oxygen sensor (front) circuit disconnection, D The engine coolant temperature is approximately more than 80_C. short-circuit, or connector contact defect.
Page 729 13A-25 MPI - Troubleshooting From the previous page Repair Test at the C-115 engine-ECU Check the following connector: connector. C-115 D Measure the engine-ECU terminal voltage. D Engine: After warm-up Check and repair the harness between D Voltage between terminal No. 76 the oxygen sensor (front) and and earth.
Page 730 13A-26 MPI - Troubleshooting Code No. P0135 Oxygen sensor heater (front) system Probable cause Inspection Range D Oxygen sensor heater (front) malfunction D The engine coolant temperature is approximately more than 20_C. D Oxygen sensor heater (front) circuit disconnection, D The oxygen sensor heater (front) is ON. short-circuit, or connector contact defect D The engine speed is more than 50 r/min.
Page 731 13A-27 MPI - Troubleshooting Code No. P0136 Oxygen sensor (rear) system Probable cause Inspection Range D Oxygen sensor (rear) malfunction D More than 3 minutes passed after completion of start of engine D Oxygen sensor (rear) circuit disconnection, D The engine coolant temperature is approximately more than 80_C. short-circuit, or connector contact defect.
Page 732 13A-28 MPI - Troubleshooting From the previous page Repair Test at the C-115 engine-ECU Check the following connector: connector. C-115 D Measure the engine-ECU terminal voltage. D Engine: After warm-up Check and repair the harness between D Voltage between terminal No. 75 the oxygen sensor (rear) and and earth.
Page 733 13A-29 MPI - Troubleshooting Code No. P0141 Oxygen sensor heater (rear) system Probable cause Inspection Range D Oxygen sensor heater (rear) malfunction D The engine coolant water temperature is approximately more than 20_C. D Oxygen sensor heater (rear) circuit disconnection, D The oxygen sensor heater (rear) is ON.
Page 734 13A-30 MPI - Troubleshooting Code No. P0201 No. 1 injector system Probable cause Inspection Range D No. 1 injector malfunction D The engine speed is 50 - 1,000 r/min. D No. 1 injector circuit disconnection, short-circuit, or D The throttle position sensor output voltage is 1.15 V or less. connector contact defect D MUT-II forced drive (actuator test) is not being carried out.
Page 735 13A-31 MPI - Troubleshooting Code No. P0202 No. 2 injector system Probable cause Inspection Range D No. 2 injector malfunction D The engine speed is 50 - 1,000 r/min. D No. 2 injector circuit disconnection, short-circuit, or D The throttle position sensor output voltage is 1.15 V or less. connector contact defect D MUT-II forced drive (actuator test) is not being carried out.
Page 736 13A-32 MPI - Troubleshooting Code No. P0203 No. 3 injector system Probable cause Inspection Range D No. 3 injector malfunction D The engine speed is 50 - 1,000 r/min. D No. 3 injector circuit disconnection, short-circuit, or D The throttle position sensor output voltage is 1.15 V or less. connector contact defect D MUT-II forced drive (actuator test) is not being carried out.
Page 737 13A-33 MPI - Troubleshooting Code No. P0204 No. 4 injector system Probable cause Inspection Range D No. 4 injector malfunction D The engine speed is 50 - 1,000 r/min. D No. 4 injector circuit disconnection, short-circuit, or D The throttle position sensor output voltage is 1.15 V or less. connector contact defect D MUT-II forced drive (actuator test) is not being carried out.
Page 738 13A-34 MPI - Troubleshooting Code No. P0325 Detonation sensor system Probable cause Inspection Range D Malfunction of the detonation sensor D Ignition switch: ON D Detonation sensor circuit disconnection, short-circuit, D Excluding for 2 seconds after ignition switch is set to “ON” position or 2 seconds or connector contact defect after engine start is completed.
Page 739 13A-35 MPI - Troubleshooting Code No. P0335 Crank angle sensor system Probable cause Inspection Range D Malfunction of crank angle sensor D Engine: During cranking D Open or short circuit in the crank angle sensor circuit Evaluation Conditions or loose connector contact D The sensor output voltage does not change for 2 seconds (no pulse signal output) D Malfunction of engine-ECU MUT-II Data list...
Page 740 13A-36 MPI - Troubleshooting From the previous page Measure the output waveform at the Check the following connector: Repair B-121 crank angle sensor connector B-11X (using an analyzer). D Using the test harness (MD998478), connect the Repair Check the harness between the crank connector, and measure at the angle sensor and engine control relay.
Page 741 13A-37 MPI - Troubleshooting Code No. P0340 Camshaft position sensor system Probable cause Inspection Range D Malfunction of camshaft position sensor D Ignition switch: ON D Open or short circuit in the camshaft position sensor D The engine speed is approximately 50 r/min or more. or loose connector contact Evaluation Conditions D Malfunction of engine-ECU...
Page 742 13A-38 MPI - Troubleshooting From the previous page Measure the output waveform at the Check the following connector: Repair B-116 camshaft position sensor B-11X connector (using an analyzer). D Using the test harness (MB991709), connect the Repair Check the harness between the connector, and measure at the camshaft position sensor connector pickup harness.
Page 743 13A-39 MPI - Troubleshooting Code No. P0403 EGR control solenoid valve system Probable cause Inspection Range D EGR control solenoid valve malfunction D The battery voltage is 10 V or more. D EGR control solenoid valve circuit disconnection, Evaluation Conditions short-circuit, or connector contact defect D Solenoid coil’s surge voltage (battery voltage +2 V) is not detected when EGR D Engine-ECU malfunction...
Page 744 13A-40 MPI - Troubleshooting From the previous page Check the harness between the EGR Repair control solenoid valve and engine control relay. D Check for damage of the power cable. MUT-II Actuator test Intermittent malfunction D No. 10: EGR control solenoid valve (Refer to GROUP 00 - Points to Note OK: Operation sound is heard, for Intermittent Malfunctions.)
Page 745 13A-41 MPI - Troubleshooting Code No. P0443 Purge control solenoid valve system Probable cause Range of check D Malfunction of the purge control solenoid valve D Ignition switch: ON D Open or short circuit in the purge control solenoid D Battery voltage is 10 V or more. valve circuit or loose connector contact.
Page 746 13A-42 MPI - Troubleshooting From the previous page Check the harness between the purge Repair control solenoid valve and engine control relay. D Check for damage of the power cable. MUT-II Actuator test Intermittent malfunction D No. 08: Purge control solenoid (Refer to GROUP 00 - Points to Note valve for Intermittent Malfunctions.)
Page 747 13A-43 MPI - Troubleshooting Code No. P0500 Vehicle speed sensor system Probable cause Inspection Range D Vehicle speed sensor malfunction D Ignition switch: ON D Vehicle speed sensor circuit disconnection, D After 2 seconds from setting ignition switch to ON position or completion of engine short-circuit, or connector contact defect starting D Engine-ECU malfunction...
Page 748 13A-44 MPI - Troubleshooting Code No. P0505 Idle speed control system Probable cause Range of Check D Malfunction of idle speed control servo D Vehicle speed has reached 1.5 Km/h at least once. D Open or short circuit in the idle speed control servo D Under the closed loop idle speed control.
Page 749 13A-45 MPI - Troubleshooting Check the following connector: Repair B-115 Measure at the B-115 idle speed Replace the idle speed control servo. control servo connector. D Disconnect the connector to measure at the idle speed control servo side. D Resistance between terminal No. 1 and terminal No.
Page 750 13A-46 MPI - Troubleshooting Code No. P0551 Power steering fluid pressure switch Probable cause system Range of Check D Power steering fliud pressure switch failed D Intake air temperature is - 10_C or higher. D Open or short circuit in the power steering fluid D Barometric pressure is 76 kPa or more.
Page 751 13A-47 MPI - Troubleshooting Code No. P1104 Waste gate solenoid valve system Probable cause Inspection Range D Waste gate solenoid valve malfunction D Battery voltage is more than 10 V. D Engine-ECU malfunction Evaluation Conditions D Solenoid coil’s surge voltage (battery voltage +2 V) is not detected when the waste gate solenoid valve turned from ON to OFF.
Page 752 13A-48 MPI - Troubleshooting Code No. P1105 Fuel pressure control solenoid valve Probable cause system Inspection Range D Fuel pressure control solenoid valve malfunction D Battery voltage is more than 10 V. D Engine-ECU malfunction Evaluation Conditions D Solenoid coil’s surge voltage (battery voltage +2 V) is not detected when the fuel pressure control solenoid valve turned from ON to OFF.
Page 753 13A-49 MPI - Troubleshooting Code No. P1500 Alternator FR terminal system Probable cause Inspection Range D Open circuit in the alternator FR terminal circuit D Engine speed: More than 50 r/min D Malfunction of engine-ECU Evaluation Conditions D The input voltage from the alternator FR terminal is between 4.8 V and 5.2 V or is the battery voltage for 20 seconds.
Page 754 13A-50 MPI - Troubleshooting Code No. P1603 Battery backup line malfunction Probable cause Inspection Range D Battery backup line disconnection, short circuit or D Ignition switch: ON connector contact defect Evaluation Conditions D Engine-ECU malfunction D The backup RAM information set at the last time when the ignition switch was turned to the OFF position is not memorized.
Page 755 13A-51 MPI - Troubleshooting Code No.P1610 Immobilizer system <Europe and Probable cause General Export-spec. models> Inspection Range D Open or short circuit, or loose connector contact D Ignition switch: ON D Malfunction of the immobilizer-ECU Set Conditions D Malfunction of the engine-ECU D Improper communication between the engine-ECU and the immobilizer-ECU NOTE (1) If the registered ignition keys are close each other when starting the engine, radio interference may...
Page 756 13A-52 MPI - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Inspection Check items Reference page procedure Communication between MUT-II and entire system is not possible. 13A-54 Only communication between MUT-II and engine-ECU is not possible. 13A-55 Engine warning lamp does not illuminate immediately after ignition switch is set to ON position. 13A-56 Engine warning lamp stays illuminated and does not turn OFF.
Page 757 13A-53 MPI - Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Starting Won’t start The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won’t start. Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Page 758 13A-54 MPI - Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Communication between MUT-II and entire system is not Probable cause possible. Causes shown on right are suspected. D Diagnosis connector malfunction D MUT-II malfunction Check the following connector: Repair C-22 (1) NG...
Page 759 13A-55 MPI - Troubleshooting Inspection Procedure 2 Only communication between MUT-II and engine-ECU is Probable cause not possible. Causes shown on right are suspected. D Ignition switch malfunction D Engine control relay malfunction D Engine-ECU malfunction Check the engine warning lamp. Check the Inspection Procedure 22: D Ignition switch: ON Engine-ECU power supply, engine...
Page 760: Engine Warning Lamp Does Not Illuminate Immediately After Ignition Switch Is Set To On Position
13A-56 MPI - Troubleshooting Inspection Procedure 3 Engine warning lamp does not illuminate immediately Probable cause after ignition switch is set to ON position. The engine-ECU illuminates the engine warning lamp for 5 seconds immediately after D Engine warning lamp bulb dead ignition switch is set to “ON”...
Page 761: Engine Warning Lamp Stays Illuminated And Does Not Turn Off
13A-57 MPI - Troubleshooting Inspection Procedure 4 Engine warning lamp stays illuminated and does not turn Probable cause OFF. The engine-ECU illuminates the engine warning lamp when the occurrence of a D Engine-ECU malfunction diagnosis code is recorded. MUT-II Self-Diag code INSPECTION CHART FOR DIAGNO- D Is a diagnosis code output? SIS CODE...
Page 762 13A-58 MPI - Troubleshooting Inspection Procedure 5 Starting disabled (Starter does not rotate.) Probable cause Causes shown on right are suspected. D Battery malfunction D Ignition switch malfunction D Starter malfunction Check the battery. Replace the battery. (Refer to GROUP 54 - Battery.) MUT-II Data list Check the following connector: Repair...
Page 763 13A-59 MPI - Troubleshooting Inspection Procedure 6 Starting disabled (Starter rotates but initial combustion Probable cause does not occur.) Causes shown on right are suspected. D Battery malfunction D Ignition switch malfunction D Ignition system malfunction D Fuel system malfunction D Throttle valve malfunction D Timing belt malfunction D Engine-ECU malfunction-...
Page 764 13A-60 MPI - Troubleshooting From the previous page Replace the spark plug cable. Check the spark plug cable. (Refer to GROUP 16 - Ignition Device.) Replace the spark plug. Check the spark plug. (Refer to GROUP 16 - Ignition Device.) Replace the ignition coil.
Page 765 13A-61 MPI - Troubleshooting Inspection Procedure 7 Starting disabled (Initial combustion occurs but is Probable cause incomplete.), improper starting (Starting time is long.) Causes shown on right are suspected. D Battery malfunction D Ignition system malfunction D Fuel system malfunction D Intake system malfunction D EGR valve malfunction D Timing belt malfunction...
Page 766 13A-62 MPI - Troubleshooting From the previous page Replace the spark plug cable. Check the spark plug cable. (Refer to GROUP 16 - Ignition Device.) Replace the spark plug. Check the spark plug. (Refer to GROUP 16 - Ignition Device.) Check the following connectors: B-103, B-119 Repair Replace the ignition coil.
Page 767 13A-63 MPI - Troubleshooting Inspection Procedure 8 Unstable idling (Rough idling, hunting), inappropriate Probable cause idling speed (High or low idling speed), engine stalls (Die out) during idling Causes shown on right are suspected. D Idle speed control system malfunction D Air/fuel ratio control system malfunction D Ignition system malfunction D Fuel system malfunction...
Page 768 13A-64 MPI - Troubleshooting From the previous page Check the Code No. P0136: Oxygen sensor (rear) system. MUT-II Data list (Refer to P.13A-27.) D No. 59: Oxygen sensor (rear) (Refer to P.13A-105.) (1) NG Measure at the C-115 and C-126 Check the following connectors: Repair engine-ECU connectors.
Page 769 13A-65 MPI - Troubleshooting From the previous page Replace the spark plug cable. Check the spark plug cable. (Refer to GROUP 16 - Ignition Device.) Replace the spark plug. Check the spark plug. (Refer to GROUP 16 - Ignition Device.) Check the following connectors: B-114, B-119 Repair Replace the ignition coil.
Page 770: Engine Stalls When Starting Travel. (Pass Out)
13A-66 MPI - Troubleshooting Inspection Procedure 9 Engine stalls when starting travel. (Pass out) Probable cause Causes shown on right are suspected. D Ignition system malfunction D Intake system malfunction D Exhaust gas purifier system malfunction D Throttle body malfunction D Engine-ECU malfunction Has the battery terminal been disconnected recently? After warming up the engine, idle for approximately 10 minutes.
Page 771: Engine Stalls During Deceleration
13A-67 MPI - Troubleshooting Inspection Procedure 10 Engine stalls during deceleration Probable cause Causes shown on right are suspected. D Idle speed control system malfunction D Exhaust gas purifier system malfunction D Throttle valve malfunction D Engine-ECU malfunction Has the battery terminal been disconnected recently? After warming up the engine, idle for approximately 10 minutes.
Page 772 13A-68 MPI - Troubleshooting Inspection Procedure 11 Pulsation (Hesitation, sag), poor acceleration, stumbling, Probable cause surging Causes shown on right are suspected. D Air/fuel ratio control system malfunction D Ignition system malfunction D Fuel system malfunction D Intake and exhaust system malfunction D Exhaust gas purifier system malfunction D Improper compression pressure D Turbocharger system malfunction...
Page 773 13A-69 MPI - Troubleshooting From the previous page Replace the spark plug cable. Check the spark plug cable. (Refer to GROUP 16 - Ignition Device.) Replace the spark plug. Check the spark plug. (Refer to GROUP 16 - Ignition Device.) Check the following connectors: B-123, B-119 Repair Replace the ignition coil.
Page 774: Shock During Acceleration
13A-70 MPI - Troubleshooting Inspection Procedure 12 Shock during acceleration Probable cause The occurrence of ignition leaks, etc., due to the rise in voltage required for the spark D Ignition system malfunction plugs during acceleration is a probable cause. MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODE D Is a diagnosis code output? (Refer to P.13A-12.)
Page 775: Shock During Deceleration
13A-71 MPI - Troubleshooting Inspection Procedure 13 Shock during deceleration Probable cause The idle speed control may be incorrect. D Idle speed control system malfunction MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODE D Is a diagnosis code output? (Refer to P.13A-12.) Check the Code No.P0120: Throttle position sensor system.
Page 776 13A-72 MPI - Troubleshooting Inspection Procedure 14 Knocking Probable cause Causes shown on right are suspected. D Detonation sensor malfunction D Knocking control system malfunction D Spark plug malfunction D Ignition system malfunction D Engine-ECU malfunction MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODE D Is a diagnosis code output? (Refer to P.13A-12.) Replace the spark plug cable.
Page 777: Deviation Of Ignition Interval
13A-73 MPI - Troubleshooting Inspection Procedure 15 Deviation of ignition interval Probable cause Causes shown on right are suspected. D Crank angle sensor malfunction D Camshaft position sensor malfunction D Timing belt malfunction D Engine-ECU malfunction MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODE D Is a diagnosis code output? (Refer to P.13A-12.) Check the trouble symptoms.
Page 778: Run On (Dieseling)
13A-74 MPI - Troubleshooting Inspection Procedure 16 Run on (Dieseling) Probable cause Causes shown on right are suspected. D Injector malfunction D Engine-ECU malfunction Replace the injectors for all cylinders. Check the trouble symptoms. Replace the engine-ECU.
Page 779: Abnormal Odor, White Smoke, Black Smoke, High Co Or Hc Concentration When Idling
13A-75 MPI - Troubleshooting Inspection Procedure 17 Abnormal odor, white smoke, black smoke, high CO or HC Probable cause concentration when idling Causes shown on right are suspected. D Air/fuel ratio control system malfunction D Ignition system malfunction D Fuel system malfunction D Intake and exhaust system malfunction D Exhaust gas purifier system malfunction D Improper compression pressure...
Page 780 13A-76 MPI - Troubleshooting From the previous page Replace the purge control solenoid valve. Check the purge control solenoid valve. (Refer to GROUP 17 - Exhaust Gas Purifier Check.) Replace the EGR control solenoid valve. Check the EGR control solenoid valve. (Refer to GROUP 17 - Exhaust Gas Purifier Check.) Replace the EGR valve.
Page 781: Battery Dies
13A-77 MPI - Troubleshooting Inspection Procedure 18 Battery dies Probable cause Causes shown on right are suspected. D Battery malfunction D G terminal short - circuit D Alternator malfunction D Engine-ECU malfunction Check the battery. Replace the battery. (Refer to GROUP 54 - Battery.) Check the following connector: Repair B-14...
Page 782 13A-78 MPI - Troubleshooting From the previous page Measure at the C-122 engine-ECU Check and repair the harness between connector. the alternator intermediate connector D Disconnect the connector to and engine-ECU. measure at the harness side. D Check for short-circuit of output D Ignition switch: ON cable.
Page 783 13A-79 MPI - Troubleshooting Inspection Procedure 19 Overheating Probable cause Causes shown on right are suspected. D Engine coolant insufficient or deteriorated D Fan controller malfunction D Engine coolant temperature sensor malfunction D Thermostat malfunction D Water pump malfunction D Condenser fan relay malfunction D Radiator core malfunction D Engine-ECU malfunction MUT-II Self-Diag Code...
Page 784: Abnormal Radiator Fan Motor Rotation
13A-80 MPI - Troubleshooting Inspection Procedure 20 Abnormal radiator fan motor rotation Probable cause Causes shown on right are suspected. D Fan controller malfunction D Engine-ECU malfunction Check the following connector: Repair C-126 Check the radiator fan motor drive. Check the trouble symptoms. Intermittent malfunction (Refer to D Disconnect the C-126 GROUP 00 - Points to Note for...
Page 785: A/C Ineffective
13A-81 MPI - Troubleshooting Inspection Procedure 21 A/C ineffective Probable cause Causes shown on right are suspected. D A/C refrigerant insufficient or over- charged D A/C compressor relay malfunction D Condenser fan system malfunction D A/C-ECU malfunction D Engine-ECU malfunction MUT-II Self-Diag cord INSPECTION CHART FOR DIAGNOSIS CODE (Refer to Is a diagnosis code output?
Page 786: Engine-Ecu Power Supply, Engine Control Relay, Ignition Switch-Ig1 System
13A-82 MPI - Troubleshooting Inspection Procedure 22 Engine-ECU power supply, engine control relay, ignition Probable cause switch-IG1 system When the ignition switch ON signal is input to the engine-ECU, the engine-ECU D Ignition switch malfunction turns the engine control relay ON. D Engine control relay malfunction This starts the supply of the battery voltage to the engine-ECU, sensor and D Engine-ECU malfunction...
Page 787 13A-83 MPI - Troubleshooting From the previous page Repair Check the following connector: C-126 Measure at the C-115 engine-ECU Check the following connector: Repair connector. C-115 D Measure the engine-ECU terminal voltage. D Ignition switch: ON Check the ignition switch. (Refer to Replace the ignition switch.
Page 788 13A-84 MPI - Troubleshooting From the previous page Check the following connector: C-126 Repair Check the harness between the engine control relay and Repair engine-ECU. D Check for disconnection, short-circuit and damage of the output cable. Check the harness and connector of the engine control relay Repair output power for short-circuit.
Page 789: Fuel Pump System
13A-85 MPI - Troubleshooting Inspection Procedure 23 Fuel pump system Probable cause D The engine-ECU turns the fuel pump relay ON during cranking and engine D Fuel pump relay 1 malfunction operation, and supplies the drive power to the fuel pump. D Fuel pump relay 2 malfunction D When operating with a low load, the engine-ECU supplies power to the fuel D Fuel pump relay 3 malfunction...
Page 790 13A-86 MPI - Troubleshooting From the previous page Measure at the C-221 fuel pump Check and repair the harness relay 2 connector. between the fuel pump relay 1 and D Disconnect the connector to fuel pump relay 2. measure at the harness side. (1) Voltage between terminal No.
Page 791: Radiator Fan Control Relay System
13A-87 MPI - Troubleshooting Inspection Procedure 24 Radiator fan control relay system Probable cause When the engine control relay turns ON, the radiator fan control relay turns ON D Radiator fan control relay malfunction simultaneously, and power is supplied to the fan controller. D Fan controller malfunction The radiator fan motor is driven when the fan motor drive signal is input to the D Radiator fan motor malfunction...
Page 792 13A-88 MPI - Troubleshooting From the previous page Check the following connector: C-126 Repair Check the radiator fan motor drive. MUT-II Actuator Test Intermittent malfunction (Refer to D Disconnect the C-126 D No. 21: Fan controller GROUP 00 - Points to Note for engine-ECU connector.
Page 793: Condenser Fan Relay System
13A-89 MPI - Troubleshooting Inspection Procedure 25 Condenser fan relay system Probable cause The condenser fan relay turns ON with the signal from the engine-ECU, and D Condenser fan relay (HI) malfunction power is supplied to the condenser fan motor. D Condenser fan relay (LOW) malfunction D Condenser fan motor malfunction D Condenser fan circuit disconnection, short-circuit,...
Page 794 13A-90 MPI - Troubleshooting From the previous page Measure at the A-45 condenser fan Check and repair the harness motor connector. between the condenser fan relay D Disconnect the connector to (LOW) and engine-ECU. measure at the harness side. D Check for disconnection of the D Disconnect the C-122 power cable.
Page 795 13A-91 MPI - Troubleshooting From the previous page Check the following connectors: Measure at the C-122 engine-ECU C-122, C-136 <R.H. drive vehicles>, connector. A-43 <L.H. drive vehicles> D Measure the engine-ECU terminal voltage. D Ignition switch: ON D Voltage between terminal No. 32 Check and repair the harness and earth between the condenser fan relay...
Page 796: A/C Switch System
13A-92 MPI - Troubleshooting Inspection Procedure 26 A/C switch system Probable cause When the A/C switch on the control panel is turned ON, the A/C switch ON D Control panel A/C switch malfunction signal is input to the engine-ECU. After receiving this signal, the engine-ECU D A/C system malfunction turns the A/C compressor ON.
Page 797: A/C Compressor Relay System
13A-93 MPI - Troubleshooting Inspection Procedure 27 A/C compressor relay system Probable cause When the A/C switch ON signal is input to the engine-ECU, the engine-ECU D A/C compressor relay malfunction turns the A/C compressor relay ON. D A/C compressor magnetic clutch malfunction The A/C compressor magnetic clutch starts with this.
Page 798 13A-94 MPI - Troubleshooting From the previous page Measure at the C-126 engine-ECU Check the following connector: C-126 Repair connector. D Measure the engine-ECU terminal voltage. Repair Check the harness between the A/C D Ignition switch: ON compressor relay and engine-ECU. D Voltage between terminal No.
Page 799: A/C Load Signal System
13A-95 MPI - Troubleshooting Inspection Procedure 28 A/C load signal system Probable cause The size of the A/C compressor load is detected according to the difference in D A/C-ECU malfunction set temperature. When the A/C large load signal is input to the engine-ECU, the D Engine-ECU malfunction engine-ECU judges that the A/C compressor load is large, and controls the throttle valve control servo so that the idling speed increases.
Page 800: Secondary Air Control Solenoid Valve System
13A-96 MPI - Troubleshooting Inspection Procedure 29 Secondary air control solenoid valve system Probable cause The secondary air control solenoid valve switches the pressure led into the D Secondary air control solenoid valve malfunction secondary air valve between the intake manifold and the atmospheric pressure. D Engine-ECU malfunction MUT-II Actuator Test Intermittent malfunction (Refer to...
Page 801: Intercooler Water Spray Circuit System
13A-97 MPI - Troubleshooting Inspection Procedure 30 Intercooler water spray circuit system Probable cause D When the intercooler water spray switch (manual) turns ON, the intercooler D Intercooler water spray switch malfunction water spray manual ON signal is input to the engine-ECU. After receiving D Intercooler water spray relay malfunction this signal, the engine-ECU turns the intercooler water spray relay ON.
Page 802 13A-98 MPI - Troubleshooting Form the previous page Measure at the C-222 intercooler water Check the following connectors: Repair spray relay connector. C-209, C-210, C-201, C-208, C-102 <L.H. drive vehicles> D Disconnect the connector to measure at the harness side. D Voltage between terminal No.
Page 803: Intercooler Water Spray Lamp System
13A-99 MPI - Troubleshooting Inspection Procedure 31 Intercooler water spray lamp system Probable cause The engine-ECU illuminates the intercooler water spray lamp when the D Intercooler water spray lamp bulb dead intercooler water spray switch (automatic) is ON. D Ignition switch malfunction D Intercooler water spray lamp circuit disconnection, short-circuit, or connector contact defect D Intercooler water spray switch circuit disconnection,...
Page 804 13A-100 MPI - Troubleshooting Inspection Procedure 32 Ignition coil (integrated power transistor) system Probable cause The engine-ECU allows the ignition coil primary current to flow intermittently by D Ignition coil malfunction turning the power transistor in the unit OFF and ON. D Spark plug malfunction D Spark plug cable malfunction D Ignition primary circuit disconnection, short-circuit, or...
Page 805 13A-101 MPI - Troubleshooting From the previous page Check the harness between the Repair ignition coil and ignition coil relay. D Check for damage of the power cable. Check the harness between the Repair ignition coil and engine-ECU. D Check for damage of the output cable.
Page 806 13A-102 MPI - Troubleshooting DATA LIST REFERENCE TABLE NOTE *1. In a new Vehicle [driven approximately 500 km or less], the air flow sensor output frequency time is sometimes 10% longer than the standard time. *2. The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power supply voltage is 11 V.
Page 807 13A-103 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Throttle Ignition switch: “ON” Set to idle position 535 - 735 mV Code No. 13A-21 position position P0120 P0120 Gradually open Increases in pro- sensor portion to throttle opening angle Open fully...
Page 808 13A-104 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Barometric Ignition switch: ON Altitude: 0 m 101 kPa Code No. 13A-15 pressure pressure P0105 P0105 Altitude: 0 m 95 kPa sensor Altitude: 0 m 88 kPa Altitude: 0 m 81 kPa...
Page 809 13A-105 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Ignition ad- Engine: After Engine: Idle operation 0 - 13_BTDC vance having warmed Timing lamp is set (The timing set. (The timing 2,500 r/min 20 - 40_BTDC lamp is set in order to check actual ignition...
Page 810 13A-106 MPI - Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Oxygen Engine: After having When at 4,000 r/min, 200 mV or less Code No. 13A-24 sensor warmed up engine is suddenly de- P0130 (front) (Air/fuel mixture is celerated made leaner when made leaner when...
Page 811 13A-107 MPI - Troubleshooting ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. Engine: After having warmed Idling condition Code No. 13A-30 1 injector up/Engine is idling becomes different P0201 (becomes unsta...
Page 812 13A-108 MPI - Troubleshooting Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Radiator fan Ignition switch: “ON” Fan motor rotates Procedure 13A-87 controller motor is at high speed. No. 24 driven. Secondary Solenoid valve Ignition switch: “ON” Sound of opera- Procedure 13A-96...
Page 813 13A-109 MPI - MPI - Troubleshooting Troubleshooting Engine-ECU Connector Terminal Arrangement Terminal No. Check item Check condition (Engine condition) Normal condition No. 1 injector While engine is idling after having warmed up, From 11 - 14 V, momentarily suddenly depress the accelerator pedal suddenly depress the accelerator pedal.
Page 814 13A-110 MPI - Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Power supply Ignition switch: “ON” System voltage Air flow sensor reset Engine: Idle operation 0 - 1 V signal signal Engine speed: 3,000 r/min 6 - 9 V Fan controller Radiator fan is not operating 0 - 0.3 V...
Page 815 13A-111 MPI - Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Power steering fluid Engine: Idling after When steering wheel System voltage pressure switch warming up is stationary When steering wheel 1 V or less is turned Engine control relay Ignition switch: “LOCK”...
Page 816 13A-112 MPI - Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Intake air Ignition switch: “ON” Intake air 3.8 - 4.4 V temperature sensor temperature: - 20_C Intake air 3.2 - 3.8 V temperature: 0_C Intake air 2.3 - 2.9 V temperature: 20_C Intake air...
Page 817 13A-113 MPI - Troubleshooting Terminal No. Check item Check condition (Engine condition) Normal condition Vehicle speed sensor Ignition switch: “ON” 0 ↔ 5 V Move the vehicle slowly forward (Changes repeatedly) Camshaft position Engine: Cranking 0.4 - 3.0 V sensor sensor Engine: Idle operation 0.5 - 2.0 V...
Page 818 13A-114 MPI - Troubleshooting CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to “LOCK” (OFF) position. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart.
Page 819 13A-115 MPI - Troubleshooting Terminal No. Inspection item Normal condition (Check condition) 3 - 12 Fuel pressure control solenoid valve 28 - 36 Ω (at 20_C) 4 - 12 Stepper motor coil (A1) 28 - 33 Ω (at 20_C) 17 - 12 Stepper motor coil (A2) 5 - 12 Stepper motor coil (B1)
Page 820 13A-116 MPI - Troubleshooting INSPECTION PROCEDURE USING AN Analyzer ANALYZER AIR FLOW SENSOR Special Measurement Method patterns pickup 1. Disconnect the air flow sensor connector, and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2.
Page 821 13A-117 MPI - Troubleshooting Examples of Abnormal Wave Patterns Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency.
Page 822 13A-118 MPI - Troubleshooting Standard Wave Pattern Observation condition Function Special patterns Pattern height Pattern selector Display Engine r/min Idle speed Standard Wave Pattern 2 engine revolutions (1 camshaft revolution) The time (cycle time) T is reduced when the engine 75_BTDC speed increases 5_BTDC...
Page 823 13A-119 MPI - Troubleshooting Example 2 Cause of problem Loose timing belt Abnormality in sensor disk Wave pattern characteristics Wave pattern is displaced to the left or right. INJECTOR Analyzer Measurement Method 1. Disconnect the injector connector, and then connect the special tool (test harness: MB991348) in between.
Page 824 13A-120 MPI - Troubleshooting Standard wave pattern Point A Solenoid back electromotive force (Approx. 7×10 V) Point B Injector drive time Power voltage Drive signal: ON Drive signal: OFF Time Wave Pattern Observation Points Point A: Height of solenoid back electromotive force Contrast with standard wave pattern Probable cause Solenoid coil back electromotive force is low or doesn’t...
Page 825 13A-121 MPI - Troubleshooting IDLE SPEED CONTROL SERVO (STEPPER MOTOR) Analyzer Measurement Method 1. Disconnect the idle speed control servo connector, and connect the special tool (test harness: MB991709) in Special between. patterns 2. Connect the analyzer special patterns pickup to the idle pickup speed control servo-side connector terminal No.
Page 826 13A-122 MPI - Troubleshooting Wave Pattern Observation Points Check that the standard wave pattern appears when the stepper motor is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small.
Page 827 13A-123 MPI - Troubleshooting IGNITION COIL AND POWER TRANSISTOR Analyzer Ignition coil primary signal Refer to GROUP 16 - Ignition system. Power transistor control signal Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991658) in between. (All Special terminals should be connected.) patterns...
Page 828 13A-124 MPI - Troubleshooting Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage Probable cause Rises from approximately 2 V to approximately 4.5 V at the Normal top-right 2 V rectangular wave...
Page 829: Fuel Pump Operation Check
13A-125 MPI - On-vehicle Service ON-VEHICLE SERVICE FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE) When removing the fuel pipe, hose, etc., since fuel pressure in the fuel pipe line is high, do the following operation so as to release the fuel pressure in the line and prevent fuel from running out.
Page 830: Throttle Body (Throttle Valve Area) Cleaning
13A-126 MPI - On-vehicle Service THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Remove the air intake hose from the throttle body. 2. Spray cleaning fluid on a clean cloth. 15 mm 3. Wipe off the dirt around the throttle valve with the cloth sprayed with cleaning fluid.
Page 831: Basic Idle Speed Adjustment
13A-127 MPI - On-vehicle Service 4. If not within the standard value, loosen the throttle position sensor mounting bolts. Then rotate the sensor body to adjust. 5. Turn the ignition switch to “LOCK” (OFF) position. 6. Remove the MUT-II. If the MUT-II is not used, remove the special tool, and then connect the throttle position sensor connector.
Page 832: Fuel Pressure Test
13A-128 MPI - On-vehicle Service 6. If not within the standard value range, turn the speed adjusting screw to make the necessary adjustment. 7. Press the MUT-II clear key, and release the idle speed control servo from the Actuator test mode. NOTE Unless the idle speed control servo is released, the Actuator test mode will continue 27 minutes.
Page 833 13A-129 MPI - On-vehicle Service <When using the fuel pressure gauge> Fuel pressure gauge set (1) Install the fuel pressure gauge on the special tool (for measuring the fuel pressure) putting a suitable O-ring or gasket O-ring or gasket between them. MD998709 (2) Install the special tool which was set up in step (1) between the high-pressure fuel hose and the delivery...
Page 834 13A-130 MPI - On-vehicle Service 14. If any of fuel pressure measured in steps 10 to 13 is out of specification, troubleshoot and repair according to the table below. Symptom Probable cause Remedy Fuel pressure too low Clogged fuel filter Replace fuel filter Fuel pressure drops after racing Fuel pressure drops after racing...
Page 835: Component Location
13A-131 MPI - On-vehicle Service COMPONENT LOCATION Name Symbol Name Symbol A/C relay Fuel pump relay 1, 2 A/C switch Fuel pump relay 3 Air flow sensor (integrated intake air tempera- Fuel pump resistor ture sensor and barometric pressure sensor) Camshaft position sensor Idle speed control servo (stepper motor) Crank angle sensor...
Page 836: Engine Control Relay Continuity Check
13A-132 MPI - On-vehicle Service ENGINE CONTROL RELAY CONTINUITY CHECK Engine control Equipment Tester Battery voltage Normal state relay side connector connection terminal 2 - 3 Not energized Continuity 1 - 4 Not energized No continuity Energized [Connect terminal No. 2 Continuity to battery (+) terminal, and connect terminal No.
Page 837: Engine Coolant Temperature Sensor Check
13A-133 MPI - On-vehicle Service 3. Measure resistance while heating the sensor using a hair drier. Intake air Normal condition: temperature sensor Temperature (_C) Resistance (kΩ) Higher Smaller 4. If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly.
Page 838: Throttle Position Sensor Check
13A-134 MPI - On-vehicle Service THROTTLE POSITION SENSOR CHECK Throttle position 1. Disconnect the throttle position sensor connector. sensor 2. Measure the resistance between the throttle position sensor side connector terminal No. 1 and terminal No. Throttle Standard value: 3.5 - 6.5 kΩ body 3.
Page 839 13A-135 MPI - On-vehicle Service 5. Use the jumper wire to connect terminal No. 1 of the Jumper oxygen sensor connector to the battery (+) terminal and wire terminal No. 3 to the battery ( - ) terminal. Caution Black Be very careful when connecting the jumper wire;...
Page 840: Injector Check
13A-136 MPI - On-vehicle Service INJECTOR CHECK OPERATION SOUND CHECK Using a sound scope, check the operation sound of the injector (“chh” sound) during idling and cranking. Check that the operation sound increases when the speed increases. Caution The sound of other injectors operating may be heard even when the injector being checked is not operated.
Page 841 13A-137 MPI - On-vehicle Service High-pressure fuel hose MD998741 Return hose MB991607 Fuel pressure regulator Clip (MB991608) MD998706 Injector Battery 4. Connect the MUT-II to the diagnosis connector. 5. Turn the ignition switch to “ON” position. (But do not start the engine.) 6.
Page 842: Resistor (For Injector) Check
13A-138 MPI - On-vehicle Service RESISTOR (FOR INJECTOR) CHECK Resistor 1. Disconnect the resistor connector. (for injector) 2. Measure the resistance between each terminal. Standard value: Measurement terminal Resistance Ω 1 - 3 5.8 - 6.2 (at 20_C) 4 - 3 Fuel pump relay 3 5 - 3 6 - 3...
Page 843 13A-139 MPI - On-vehicle Service Checking the Coil Resistance 1. Disconnect the idle speed control servo connector. 2. Measure the resistance between terminal No. 2 and either terminal No. 1 or terminal No. 3 of the connector at the idle speed control servo side. Standard value: 28 - 33 Ω...
Page 844: Fuel Pressure Control Solenoid Valve Check
13A-140 MPI - On-vehicle Service FUEL PRESSURE CONTROL SOLENOID Fuel pres- VALVE CHECK sure control solenoid OPERATION CHECK valve 1. Disconnect the vacuum hose from the solenoid valve. 2. Separate the harness connector. 3. Connect the hand vacuum pump to the solenoid valve’s A nipple.
Page 845: Injector
13A-141 MPI - Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Fuel Discharge Prevention (Refer to P.13A-125.) Air Hose E, Air By-pass Hose, Air Pipe C Removal Strut Tower Bar Removal and Installation and Installation (Refer to GROUP 15 - Intercooler.) (Refer to GROUP 42.) Fuel Leakage Check 5.0 ±...
Page 846 13A-142 MPI - Injector REMOVAL SERVICE POINT AA" DELIVERY PIPE/INJECTOR REMOVAL Remove the delivery pipe (with the injectors attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector. INSTALLATION SERVICE POINT "AA INJECTOR/FUEL PRESSURE REGULATOR /HIGH-PRESSURE FUEL HOSE INSTALLATION 1.
Page 847: Throttle Body
13A-143 MPI - Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Air Hose E, Air By-pass Hose, Air Pipe C Removal (Refer to GROUP 51 - Front Bumper.) and Installation (Refer to GROUP 15 - Intercooler.) Engine Coolant Draining and Supplying Accelerator Cable Adjustment (Refer to GROUP 17 (Refer to GROUP 14 - On-vehicle Service.)
Page 848 13A-144 MPI - Throttle Body DISASSEMBLY AND REASSEMBLY 2.0 ± 0.5 N•m Removal steps "AA 1. Throttle position sensor 4. Fixed SAS 2. Idle speed control servo 5. O-ring 3. O-ring 6. Throttle body INSTALLATION SERVICE POINT "AA THROTTLE POSITION SENSOR INSTALLATION 1.
Page 849 13A-145 MPI - Throttle Body 3. After installing the Throttle position sensor, check that Throttle position the output voltage is at the standard value. If deviated sensor output from the standard value, loosen the screw, readjust to Throttle position the standard position, and then fix. Repeat this step until Earth sensor power the output voltage is at the standard value.
Page 850: Engine Control Resistor, Relay
13A-146 MPI - Engine Control Resistor, Relay ENGINE CONTROL RESISTOR, RELAY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Strut Tower Bar Removal and Installation (Refer to GROUP 42.) Harness Connector Connection 5.0 ± 1.0 N·m AYC relay 5.0 ± 1.0 N·m <L.H.
Page 851: Engine-Ecu
13A-147 MPI - Engine ENGINE-ECU REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Glove Box Assembly Removal and Installation (Refer to GROUP 52A - Instrument Panel.) 5.0 ± 1.0 N·m Removal steps 1. Engine-ECU connector 2. Engine-ECU...
Page 852 NOTES...
Page 853: Fuel Supply
13B-1 FUEL SUPPLY CONTENTS GENERAL INFORMATION ....FUEL TANK ....... ON-VEHICLE SERVICE .
Page 854 13B-2 FUEL SUPPLY - General Information/On-vehicle Service GENERAL INFORMATION The steel fuel tank is located under the floor of the rear seats to provide increased safety and increase the amount of luggage compartment space. The fuel tank has been equipped with a valve assembly which incorporates a fuel cut-off valve to prevent fuel from leaking out in the event of a collision for adjusting the pressure inside the fuel tank.
Page 855 13B-3 FUEL SUPPLY - On-vehicle Service/Fuel tank FUEL PUMP AND GAUGE ASSEMBLY, PIPE <Fuel pump and gauge assembly> AND GAUGE ASSEMBLY (FUEL GAUGE UNIT) High-pressurefuel tube Harness 1. Remove the rear seat cushion assembly. connector (Refer to GROUP 52A.) 2. Remove the service hole cover. 3.
Page 856 13B-4 FUEL SUPPLY - Fuel Tank <Fuel tank assembly> 2.5 ± 0.5 N·m 2.5 ± 0.5 N·m 26 ± 4 N·m 22 ± 4 N·m Removal steps <Fuel tank assembly> 1. Filler neck pipe, Filler neck vapour "AA 8. Suction hose pipe connection "AA 9.
Page 857 13B-5 FUEL SUPPLY - Fuel Tank <Fuel filler neck assembly> 24 ± 4 N·m Removal steps <Filler neck assembly> 25. Filler neck protector 29. Fuel filler neck assembly 26. Filler neck hose connection 30. Fuel shut-off valve 27. Filler neck vapour hose connection 31.
Page 858 13B-6 FUEL SUPPLY - Fuel Tank INSTALLATION SERVICE POINT Corresponding side High-pressure fuel tube "AA HIGH-PRESSURE FUEL HOSE/SUCTION HOSE INSTALLATION Caution Snap the high-pressure fuel hose or suction hose one-touch joint into place, then pull back slightly on the 3 mm hose to assure it is securely fitted.
Page 859 13B-7 FUEL SUPPLY - Fuel Tank DISASSEMBLY AND REASSEMBLY <FUEL PUMP AND GAUGE ASSEMBLY> Removal steps 1. Fuel gauge unit 8. Assist pump 2. Gauge harness 9. Fuel suction hose 3. Bracket 10. Fuel return hose 4. Fuel pump cushion 11.
Page 860 13B-8 FUEL SUPPLY - Fuel Tank <PIPE AND GAUGE ASSEMBLY> 1.2 ± 0.2 N·m Removal steps 1. Packing 4. Connector 2. Filter "AA 5. O-ring 3. Gauge unit 6. Pipe assembly INSTALLATION SERVICE POINT "AA O-RING/GROMMET INSTALLATION Apply a fuel to O-ring and grommet before installing them, to prevent them from being damaged or twisted.
Page 861 14-1 ENGINE COOLING CONTENTS GENERAL INFORMATION ....Engine Coolant Replacement ....Concentration Measurement .
Page 862: General Information
Valve lift (at 93_C) mm 9.5 or more LUBRICANT Item Specified coolant Quantity L Engine coolant Engine coolant MITSUBISHI GENUINE COOLANT or equivalent MITSUBISHI GENUINE COOLANT or equivalent (including reserve tank) SEALANT Item Specified sealant Remark Cylinder block drain plug 3M Nut Locking Part No.
Page 863: Special Tools
14-3 ENGINE COOLING - Special Tools/Troubleshooting SPECIAL TOOLS Tool Number Name MB991223 Harness set Measurement of terminal voltage Inspection of radiator fan controller A: MB991219 A: Test harness A: Connector pin contact pressure B: MB991220 B: LED harness inspection C: MB991221 C: LED harness B: Power circuit inspection D: MB991222...
Page 864: Engine Cooling
14-4 ENGINE COOLING - Troubleshooting D Fusible link (2) check Replace D Radiator fan relay continuity check (Refer to P.14-8.) D Radiator fan motor check (Refer to P.14-10.) (1) NG Measure at the radiator fan control relay connector A-09X. Check the harness wire between radiator fan relay and fusible link (2), and repair if necessary.
Page 865 14-5 ENGINE COOLING - Troubleshooting Inspection Procedure 2 Radiator fan does not change speed or stop. Probable cause Radiator fan controller uses the signal from engine-ECU to control radiator fan D Malfunction of radiator fan relay motor in a continously variable mode. D Malfunction of radiator fan controller D Malfunction of engine-ECU D Malfunction of harness, connector...
Page 866: On-Vehicle Service
14-6 ENGINE COOLING - On-vehicle Service ON-VEHICLE SERVICE Cap adapter ENGINE COOLANT LEAK CHECKING 1. Confirm that the coolant level is up to the filler neck. Adapter Install a radiator cap tester and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections.
Page 867: Concentration Measurement
Standard value: 30 - 60 % (allowable concentration range) RECOMMENDED ANTI-FREEZE Antifreeze Allowable concentration MITSUBISHI GENUINE COOLANT 30 - 60 % or equivalent Caution If the concentration of the anti-freeze is below 30 %, the anti-corrosion property will be adversely affected.
Page 868: Radiator Fan Relay Continuity Check
14-8 ENGINE COOLING - On-vehicle Service RADIATOR FAN RELAY CONTINUITY CHECK Air cleaner Battery voltage Terminal No. When current is not supplied When current supplied RADIATOR FAN CONTROLLER CHECK Radiator fan controller <Vehicles without A/C> 1. Remove the center under cover. (Refer to GROUP 51 - Front Bumper.) 2.
Page 869 14-9 ENGINE COOLING - On-vehicle Service 5. Connect the special tool (MB991658) to the harness side of the engine coolant temperature sensor connector. 6. Connect the special tool [MB991791(APS)] to the special MB991791(APS) tool (MB991658). 7. Start the engine and let it run at idle. NOTE Since the resistance value of the special tool (APS) indicates a low engine coolant temperature, engine speed...
Page 870: Radiator Fan Motor Check
14-10 ENGINE COOLING - On - vehicle Service RADIATOR FAN MOTOR CHECK Radiator fan motor 1. Remove the center under cover. (Refer to GROUP 51 - Front Bumper.) 2. Disconnect the radiator fan motor connector. 3. Check that the motor rotates when energizing battery voltage between the terminals of connectors of the radiator fan motor side.Check that there is abonormal noise from the radiator fan motor then.
Page 871: Thermostat
14-11 ENGINE COOLING - ENGINE COOLING - Thermostat Thermostat THERMOSTAT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-6.) Air Duct Assembly Removal and Installation (Refer to GROUP 15 - Air Cleaner.) Vacuum Pipe, Secondary Air Pipe Assembly Removal and Installation (Refer to GROUP 15 - Secondary Air Supply System.) 10 ±...
Page 872 14-12 ENGINE COOLING - Thermostat INSTALLATION SERVICE POINTS "AA THERMOSTAT INSTALLATION Install the thermostat being careful not to fold over or scratch the rubber ring. Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat. In addition, be careful not to fold over or scratch the rubber ring when inserting.
Page 873: Water Pump
14-13 ENGINE COOLING - Water Pump WATER PUMP Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. REMOVAL AND INSTALLATION Pre-remobal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-6.)
Page 874: Water Hose And Water Pipe
14-14 ENGINE COOLING - Water Hose and Water Pipe WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION Pre-remobal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-6.) Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 - Air Cleaner.) Air Bypass Valve Assembly, Air Bypass Hose, Air Hose E and Air Pipe C, Air Hose D Removal and Installation (Refer to GROUP 15 - Intercooler.) Secondary Air Control Valve Bracket Removal and Installation...
Page 875: Radiator
14-15 ENGINE COOLING - Water Hose and Water Pipe/Radiator REMOVAL SERVICE POINT AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the hose and the hose clamp, disconnect the hose. INSTALLATION SERVICE POINTS Water pump or thermostat case "AA O-RING INSTALLATION Fit an O-ring into the groove of the water inlet pipe and apply water to the circumference of the O-ring or the...
Page 876 14-16 ENGINE COOLING - Radiator 5.0 ± 1.0 N·m 12 ± 2 N·m 12 ± 2 N·m 3.5 ± 0.4 N·m 4.0 ± 0.4 N·m 4.5 ± 0.4 N·m 12 ± 1 N·m Radiator removal steps Radiator fun controller and radiator fun motor removal steps 1.
Page 877 14-17 ENGINE COOLING - ENGINE COOLING - Radiator Radiator REMOVAL SERVICE POINTS AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE REMOVAL After making mating marks on the radiator hose and the hose clamp,disconnect the radiator hose. AB" AIR PIPE B MOUNTING BOLT REMOVAL After removing the bolt, position air pipe B out of the way so that the pipe does not interfere with the radiator assembly or the radiator fan motor, the fan and shroud assembly.
Page 878 NOTES...
Page 879 15-1 INTAKE AND EXHAUST CONTENTS GENERAL INFORMATION ....Vacuum Tank Check ......AIR CLEANER .
Page 880: General Information
15-2 INTAKE AND EXHAUST - General Information GENERAL INFORMATION SUPERCHARGING PRESSURE CONTROL By controlling the duty of the waste gate solenoid valve, the waste gate actuator functions to control the supercharging pressure. This allows a supercharged pressure matching the engine operation state to be attained. Control is carried out to prevent excessive supercharging and thereby prevent engine damage.
Page 881: Service Specification
15-3 INTAKE AND EXHAUST - Service Specifications/Special Tool/On-vehicle Service SERVICE SPECIFICATIONS Item Standard value Limit Turbocharger supercharging pressure (waste gate solenoid 59 - 84 valve not operating) kPa Initial activation pressure of waste gate actuator (at the stroke Approximately 100 of approximately 1 mm) kPa Waste gate solenoid valve coil resistance (at 20_C) Ω...
Page 882: Supercharging Pressure Control System Check
15-4 INTAKE AND EXHAUST - On-vehicle Service 4. When the indicated supercharging is more than standard value, supercharging control may be faulty, therefore check the followings. Malfunction of the waste gate actuator Malfunction of waste gate valve Disconnection or cracks of the waste gate actuator rubber hose SUPERCHARGING PRESSURE CONTROL Throttle body...
Page 883: Waste Gate Solenoid Valve Check
15-5 INTAKE AND EXHAUST - On-vehicle Service 3. If there is a significant deviation from the standard value, check the actuator or the waste gate valve: replace actuator or turbocharger assembly if necessary. WASTE GATE SOLENOID VALVE CHECK OPERATION CHECK 1.
Page 884: Intake Manifold Pressure Check
15-6 INTAKE AND EXHAUST - On-vehicle Service INTAKE MANIFOLD PRESSURE CHECK Refer to GROUP 11A – On-vehicle Service. SECONDARY AIR CONTROL SYSTEM CHECK 1. Start the engine and carry out idling. 2. Confirm that the secondary air valve lifts up when the engine-ECU connector No.
Page 885: Secondary Air Valve Check
15-7 INTAKE AND EXHAUST - On-vehicle Service COIL RESISTANCE CHECK Measure the resistance between the solenoid valve terminals. Standard value: 29 – 35 Ω (at 20_C) SECONDARY AIR VALVE CHECK 1. Disconnect the secondary air valve. 2. Connect the hand vacuum pump to the secondary air valve’s nipple.
Page 886: Air Cleaner
15-8 INTAKE AND EXHAUST - Air Cleaner AIR CLEANER REMOVAL AND INSTALLATION Caution Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions. 1. Avoid any shock or load to these parts when removing and installing them. 2.
Page 887: Intercooler
15-9 INTAKE AND EXHAUST - Intercooler INTERCOOLER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner Removal and Installation (Refer to P.15-8.) Front Bumper Removal and Installation (Refer to Water Spray Hose Connection removal GROUP 51.) Installation (Refer to P.15-10.) 12 ±...
Page 888: Intercooler Water Spray
15-10 INTAKE AND EXHAUST - Intercooler Water Spray INTERCOOLER WATER SPRAY Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to Front Bumper Removal and Installation (Refer to GROUP 51 - Front Bumper.) GROUP 51.) REMOVAL AND INSTALLATION <WATER SPRAY SWITCH> Water spray switch removal steps 1.
Page 889: Intercooler Water Spray
15-11 INTAKE AND EXHAUST - Intercooler Water Spray <WATER SPRAY NOZZLE/WATER SPRAY HOSE/WASHER TANK> 11 ± 2 N·m 11 ± 2 N·m Water spray nozzle/Water spray Washer tank removal steps hose removal steps 2. Water spray hose connection 2. Water spray hose connection 8.
Page 890 15-12 INTAKE AND EXHAUST - Intercooler Water Spray INSTALLATION SERVICE POINTS WATER SPRAY HOSE/TAPE INSTALLATION "AA Attach the water spray hose to the front bumper with a tape as shown in the illustration. <Tape attachment position> Tape Tape Tape Tape 65 mm 30 mm 0 mm...
Page 891 15-13 INTAKE AND EXHAUST - Intercooler Water Spray INSPECTION <Water spray switch> 1. WATER SPRAY SWITCH CONTINUITY CHECK Switch position Switch position Terminal No Terminal No. AUTO MANUAL EARTH ILL (+) ILL ( - ) AUTO NEUTRAL 2. WATER SPRAY MOTOR CHECK <Water spray motor>...
Page 892: Secondary Air Supply System
15-14 INTAKE AND EXHAUST - Secondary Air Supply System SECONDARY AIR SUPPLY SYSTEM REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Duct Removal and Installation (Refer to P.15-8.) Strut Tower Bar Removal and Installation (Refer to GROUP 42.) 5.9 ± 1.0 N·m Air pipe C 23 ±...
Page 893 15-15 INTAKE AND EXHAUST - Secondary Air Supply System INSTALLATION SERVICE POINTS "AA GASKET INSTALLATION Install the gasket so that its salient can face towards the direction as shown in the illustration. Salient Secondary air pipe assembly "BA GASKET INSTALLATION Install the gasket so that its protrusion can face towards the Protrusion direction as shown in the illustration.
Page 894: Intake And Exhaust
15-16 INTAKE AND EXHAUST - Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Duct Removal and Installation (Refer to P.15-8.) Crossmember Bar Removal and Installation (Refer Strut Tower Bar Removal and Installation to GROUP 32 - Engine Roll Stopper, Centermember.) (Refer to GROUP 42.) Front Exhaust Pipe Removal and Installation (Refer Under Cover Removal and Installation...
Page 895 15-17 INTAKE AND EXHAUST - INTAKE AND EXHAUST - Intake Manifold Intake Manifold 5.0 ± 1.0 N·m 20 ± 2 N·m 20 ± 2 N·m 20 ± 2 N·m 11 ± 1 N·m 9.0 ± 1.0 N·m 36 ± 6 N·m 20 ±...
Page 896 15-18 INTAKE AND EXHAUST - Intake Manifold INSTALLATION SERVICE POINTS "AA FUEL HIGH-PRESSURE HOSE CONNECTION 1. Apply a drop of new engine oil to the O-ring. Caution Be sure not to let engine oil enter the delivery pipe. 2. While turning the injector, high-pressure fuel hose and fuel pressure regulator to the right and left, install the delivery pipe, while being careful not to damage the O-ring.
Page 897: Exhaust Manifold
15-19 INTAKE AND EXHAUST - Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Air Pipe A, Air Pipe C, Air Hose D, Air Pipe B Removal (Refer to GROUP 51 - Front bumper.) and Installation (Refer to P.15-9.) Radiator Removal and Installation Crossmember Bar Removal and Installation (Refer...
Page 898 15-20 INTAKE AND EXHAUST - INTAKE AND EXHAUST - Exhaust Manifold Exhaust Manifold REMOVAL SERVICE POINT AA" OXYGEN SENSOR REMOVAL Use special tool to remove the oxygen sensor. MD998770 Oxygen sensor AB" OIL FEED PIPE REMOVAL Take care not to let foreign objects get into the oil passage hole of the turbocharger after the oil feed pipe is removed.
Page 899 15-21 INTAKE AND EXHAUST - Exhaust Manifold "CA OIL RETURN PIPE GASKET INSTALLATION Print Install the gasket so that its print part can face towards the oil pan side. Gasket INSPECTION Check the following points; replace the part if a problem is found.
Page 900: Turbocharger
15-22 INTAKE AND EXHAUST - Turbocharger TURBOCHARGER DISASSEMBLY AND REASSEMBLY 11.3 ± 1.5 Nm Disassembly steps D Inspection of turbocharger waste gate "DA 4. Turbine housing "FA actuator operation AA" "CA 5. Snap ring 1. E-ring AB" "BA 6. Turbine wheel assembly 2.
Page 901 15-23 INTAKE AND EXHAUST - Turbocharger DISASSEMBLY SERVICE POINTS AA" SNAP RING REMOVAL Lay the unit with the compressor cover side facing down and using snap ring pliers, remove the compressor cover attaching snap ring. Caution When removing the snap ring, hold it with fingers to prevent it from springing away.
Page 902 15-24 INTAKE AND EXHAUST - Turbocharger "CA SNAP RING INSTALLATION Chamfered edge Lay the assembly with the compressor cover facing down Snap ring and fit the snap ring. Caution Fit the snap ring with its chamfered side facing up. Turbine wheel assembly Compressor cover...
Page 903 15-25 INTAKE AND EXHAUST - Turbocharger COMPRESSOR COVER Oil passage Check the compressor cover for traces of contact with the Turbine wheel compressor wheel and other damage. TURBINE WHEEL ASSEMBLY 1. Check the turbine and compressor wheel blades for bend, burr, damage, corrosion and traces of contact on the back side and replace if defective.
Page 904: Exhaust Pipe And Main Muffler
15-26 INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) Crossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.) 13 ±...
Page 905 16-1 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM ....IGNITION SYSTEM ....GENERAL INFORMATION .
Page 906: Charging System
16-2 ENGINE ELECTRICAL - Charging System CHARGING SYSTEM GENERAL INFORMATION The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads. OPERATION Voltage Rotation of the excited field coil generates AC voltage in the stator.
Page 907: Service Specifications
16-3 ENGINE ELECTRICAL - Charging System ALTERNATOR SPECIFICATIONS Items Specifications Type Battery voltage sensing Rated output V/A 12/90 Voltage regulator Electronic built-in type SERVICE SPECIFICATIONS Items Standard value Limit Alternator output line voltage drop (at 30 A) V max. 0.3 Regulated voltage ambient - 20_C 14.2 - 15.4...
Page 908: On-Vehicle Service
16-4 ENGINE ELECTRICAL - Charging System ON-VEHICLE SERVICE ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST Ammeter Alternator Voltmeter Battery Terminal B This test determines whether the wiring from the between the “B” terminal and the disconnected alternator “B” terminal to the battery (+) terminal output wire.
Page 909: Output Current Test
16-5 ENGINE ELECTRICAL - Charging System (6) Reconnect the negative battery cable. (11)If the value displayed on the voltmeter is above (7) Connect a tachometer or the MUT-II. the limit value, there is probably a malfunction (Refer to GROUP 11 - On-vehicle Service.) in the alternator output wire, so check the wiring (8) Leave the hood open.
Page 910 16-6 ENGINE ELECTRICAL - Charging System This test determines whether the alternator output (10)Turn the light switch on to turn on headlamps current is normal. and then start the engine. (1) Before the test, always be sure to check the (11)Immediately after setting the headlamps to high following.
Page 911: Regulated Voltage Test
16-7 ENGINE ELECTRICAL - Charging System REGULATED VOLTAGE TEST Load Ammeter Ignition MB991519 switch Black Alternator Voltmeter Blue Yellow Battery Engine-ECU This test determines whether the voltage regulator (6) Connect a DC test ammeter with a range of is correctly controlling the alternator output voltage. 0 - 100 A in series between the “B”...
Page 912: Waveform Check Using An Analyzer
16-8 ENGINE ELECTRICAL - Charging System (14)If the voltage reading conforms to the value (17)Remove the tachometer or the MUT-II. in the voltage regulation, then the voltage (18)Disconnect the negative battery cable. regulator is operating normally. (19)Disconnect the ammeter and voltmeter. If the voltage is not within the standard value, (20)Connect the alternator output wire to the there is a malfunction of the voltage regulator...
Page 913 16-9 ENGINE ELECTRICAL - Charging System Voltage at alternator B terminal - 0.2 - 0.4 Time NOTE The voltage waveform of the alternator B terminal can undulate as shown at left. This waveform is produced when the regulator operates according to fluctuations in the alternator load (current), and is normal for the alternator.
Page 914: Alternator
16-10 ENGINE ELECTRICAL - Charging System EXAMPLES OF ABNORMAL WAVEFORMS NOTE 1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the analyzer. 2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating).
Page 915 16-11 ENGINE ELECTRICAL - Charging System 5.0 ± 1.0 N·m 11 ± 1 N·m 9.0 ± 1.0 N·m 13 ± 1 N·m 36 ± 6 N·m 9.0 ± 1.0 N·m 14 ± 3 N·m 20 ± 2 N·m (Engine oil) 22 ±...
Page 916 16-12 ENGINE ELECTRICAL - Charging System REMOVAL SERVICE POINTS AA" DELIVERY PIPE, INJECTOR, AND FUEL PRESSURE REGULATOR ASSEMBLY REMOVAL After loosening the installed parts, set the related parts aside to make some space for removing the alternator. AB" DRIVE BELT REMOVAL Due to the adoption of the Serpentine drive system with the auto-tensioner, the following operation is required: 1.
Page 917 16-13 ENGINE ELECTRICAL - Charging System DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Front bracket assembly 8. Stator AA" AC" 2. Alternator pulley 9. Plate AB" "BA 3. Rotor AC" "AA 10. Regulator assembly 4. Rear bearing 11. Brush 5. Bearing retainer 12.
Page 918 16-14 ENGINE ELECTRICAL - Charging System DISASSEMBLY SERVICE POINTS AA" FRONT BRACKET ASSEMBLY REMOVAL Insert a flat tip screwdrivers or the like in the clearance between the front bracket assembly and stator core, to pry open and separate the stator and front bracket. Caution Do not insert a screwdriver too far, or the stator coil gets damaged.
Page 919 16-15 ENGINE ELECTRICAL - Charging System "BA ROTOR INSTALLATION Wire After installing the rotor, remove the wire used to fix the brush. INSPECTION ROTOR CHECK 1. Check the continuity between the rotor coil slip rings, and replace the rotor if the resistance value is not at the standard value.
Page 920 16-16 ENGINE ELECTRICAL - Charging System RECTIFIERS CHECK 1. Inspect the (+) heat sink by checking the continuity between the (+) heat sink and stator coil lead wire connection terminal using a tester probe. If there is a continuity at both, the diode is short circuited, so replace the rectifier.
Page 921: Starting System
16-17 ENGINE ELECTRICAL - Starting System STARTING SYSTEM GENERAL INFORMATION If the ignition switch is turned to the “START” and M terminal to conduct. Thus, current flows to position, current flows in the pull-in and holding engage the starter motor. coils provided inside magnetic switch, attracting When the ignition switch is returned to the “ON”...
Page 922: Starter
16-18 ENGINE ELECTRICAL - Starting System STARTER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP51 - Front Bumper.) Crossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.) Front Exhaust Pipe Assembly Removal and Installation (Refer to GROUP 15.) 13 ±...
Page 923 16-19 ENGINE ELECTRICAL - Starting System 5. If pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket. MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2.
Page 924 16-20 ENGINE ELECTRICAL - Starting System MAGNETIC SWITCH RETURN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12 V battery between M-terminal and body. Battery Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.
Page 925 16-21 ENGINE ELECTRICAL - Starting System DISASSEMBLY AND REASSEMBLY 16 14 Disassembly steps 12. Packing A 13. Packing B 1. Cover 14. Plate 2. Screw 15. Planetary gear 3. Magnetic switch AA" 16. Lever 4. Screw AC" "AA 17. Snap ring 5.
Page 926 16-22 ENGINE ELECTRICAL - Starting System DISASSEMBLY SERVICE POINTS “S” terminal “B” terminal AA" MAGNETIC SWITCH REMOVAL Disconnect field coil wire from “M” terminal of magnetic switch. Field coil “M” terminal wire AB" ARMATURE/BALL REMOVAL Caution When removing the armature, take care not to lose the ball (which is used as a bearing) in the armature end.
Page 927 16-23 ENGINE ELECTRICAL - Starting System REASSEMBLY SERVICE POINT "AA STOP RING/SNAP RING INSTALLATION Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring. Stop ring Overrunning Stop ring clutch Snap ring INSPECTION COMMUTATOR CHECK 1. Place the armature in a pair of “V” blocks and check the runout with a dial indicator.
Page 928 16-24 ENGINE ELECTRICAL - Starting System OVERRUNNING CLUTCH CHECK 1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch assembly. Free 2.
Page 929 16-25 ENGINE ELECTRICAL - Starting System ARMATURE COIL OPEN-CIRCUIT INSPECTION Check the continuity between segments. If there is continuity, the coil is in order. MAGNETIC SWITCH COIL DISCONNECTION TEST Confirm that there is continuity between the “M” terminal and body A. If there is no continuity, replace the magnetic switch.
Page 930: Ignition System
16-26 ENGINE ELECTRICAL - Ignition System IGNITION SYSTEM GENERAL INFORMATION This system is equipped with two ignition coils (A causes the primary currents in the ignition coils and B) with built-in power transistors for the No. to be alternately interrupted and allowed to flow 1 and No.
Page 931: Service Specifications
16-27 ENGINE ELECTRICAL - Ignition System IGNITION COIL SPECIFICATIONS Items Specifications Type Molded 2-coil SPARK PLUG SPECIFICATIONS Items Specifications IGR7A-G DENSO VW22PR-DA7 SERVICE SPECIFICATIONS IGNITION COIL Items Standard value Secondary coil resistance kΩ 8.5 - 11.5 SPARK PLUG Items Standard value Limit Spark plug gap mm 0.6 - 0.7...
Page 932: On-Vehicle Service
16-28 ENGINE ELECTRICAL - Ignition System ON-VEHICLE SERVICE IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK Check by the following procedure, and replace if there is a malfunction. SECONDARY COIL RESISTANCE CHECK Measure the resistance between the high-voltage terminals of the ignition coil. Standard value: 8.5 - 11.5 kΩ...
Page 933: Spark Plug Check, Cleaning And Replacement
16-29 ENGINE ELECTRICAL - Ignition System SPARK PLUG CHECK, CLEANING AND REPLACEMENT SPARK PLUG GAP CHECK Caution 1. Do not adjust the gap of the iridium plug. 2. Cleaning of the iridium plug could damage the tip of the electrode. Thus, if the plug must be cleaned because of soot, etc., use a plug cleaner and clean within a short time of 20 seconds or less to protect the electrode.
Page 934: Waveform Check Using An Analyzer
16-30 ENGINE ELECTRICAL - Ignition System WAVEFORM CHECK USING AN ANALYZER Ignition Secondary Voltage Waveform Check MEASUREMENT METHOD 1. Clamp the secondary pickup around the spark plug cable. NOTE (1) The peak ignition voltage will be reversed when the spark cables No. 2 and No. 4, or No. 1 and No. 3 cylinders are clamped.
Page 935 16-31 ENGINE ELECTRICAL - Ignition System STANDARD WAVEFORM Observation Conditions Function Secondary Pattern height High (or Low) Pattern selector Raster Engine revolutions Curb idle speed Spark line (point A) Ignition voltage (point D) Wave damping reduction section (point B) Dwell section Secondary ignition...
Page 936 16-32 ENGINE ELECTRICAL - Ignition System WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal waveform examples, 1, 2, 3 and 4). Spark line Plug gap Condition of Compression Concentration of Ignition timing...
Page 937 16-33 ENGINE ELECTRICAL - Ignition System EXAMPLES OF ABNORMAL WAVEFORMS Abnormal waveform Wave characteristics Cause of problem Example 1 Spark line is high and short. Spark plug gap is too large. 01P0215 Example 2 Spark line is low and long, and is Spark plug gap is too small.
Page 938: Ignition Coil
16-34 ENGINE ELECTRICAL - Ignition System IGNITION COIL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Center Cover Removal and Installation (Refer to GROUP 11A - Camshaft and Camshaft Oil Seal.) 10 ± 2 N·m 10 ± 2 N·m 25 ± 4 N·m Removal steps 1.
Page 939: Camshaft Position Sensor
16-35 ENGINE ELECTRICAL - Ignition System CAMSHAFT POSITION SENSOR REMOVAL AND INSTALLATION 8.8 ± 1.0 N·m Removal steps 1. Camshaft position sensor connector 2. Camshaft position sensor 3. O-ring CRANK ANGLE SENSOR REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
Page 940 16-36 ENGINE ELECTRICAL - Ignition System 8.8 ± 1.0 N·m 12 ± 2 N·m 22 ± 4 N·m 22 ± 4 N·m 12 ± 2 N·m 22 ± 4 N·m 40 ± 5 N·m 49 ± 9 N·m 49 ± 9 N·m 8.8 ±...
Page 941: Detonation Sensor
16-37 ENGINE ELECTRICAL - Ignition System DETONATION SENSOR REMOVAL AND INSTALLATION Caution Do not give any impact during removal and installation of detonation sensor. Pre-removal and Post-installation Operation Intake Manifold Stay Removal and Installation (Refer to GROUP 15 - Intake Manifold.) 23 ±...
Page 942 NOTES...
Page 943 17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM ..EVAPORATIVE EMISSION CONTROL SYSTEM ....... GENERAL INFORMATION .
Page 944: Engine And Emission Control
17-2 ENGINE AND EMISSION CONTROL - Engine Control System ENGINE CONTROL SYSTEM GENERAL INFORMATION A cable-type accelerator mechanism and a suspended-type pedal have been adopted. SERVICE SPECIFICATIONS Items Standard value Accelerator cable play mm 1 - 2 Engine idle speed r/min Engine idle speed r/min 850 ±...
Page 945: Accelerator Cable And Pedal
17-3 ENGINE AND EMISSION CONTROL - Engine Control System ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION Post-installation Operation Accelerator Cable Adjustment (Refer to P.17-2.) <L.H. drive vehicles> 5.0 ± 1.0 N·m 10 ± 2 N·m 12 ± 2 N·m <R.H. drive vehicles> 5.0 ±...
Page 946: Emission Control System
17-4 ENGINE AND EMISSION CONTROL - Emission Control System EMISSION CONTROL SYSTEM GENERAL INFORMATION The emission control system consists of the following subsystems: Crankcase emission control system Evaporative emission control system Exhaust emission control system Items Name Specification Crankcase emission Positive crankcase ventilation (PCV) valve Variable flow type control system...
Page 947: Service Specifications
17-5 ENGINE AND EMISSION CONTROL - Emission Control System SERVICE SPECIFICATIONS Items Standard value Purge control solenoid valve coil resistance (at 20_C) Ω 30 - 34 EGR control solenoid valve coil resistance (at 20_C) Ω 29 - 35 VACUUM HOSE VACUUM HOSE PIPING DIAGRAM From fuel tank...
Page 948: Vacuum Circuit Diagram
17-6 ENGINE AND EMISSION CONTROL - Emission Control System VACUUM CIRCUIT DIAGRAM Intake manifold Throttle body combustion From air chamber cleaner Vacuum Purge control tank solenoid valve Fuel pressure solenoid valve Air by-pass valve Fuel pressure EGR control regulator solenoid valve Secondary air control solenoid valve Check valve...
Page 949: Vacuum Hose Check
17-7 ENGINE AND EMISSION CONTROL - Emission Control System VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected. 2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage.
Page 950: Crankcase Emission Control System
17-8 ENGINE AND EMISSION CONTROL - Emission Control System CRANKCASE EMISSION CONTROL SYSTEM GENERAL INFORMATION The crankcase emission control system prevents crankcase ventilation (PCV) valve. blow-by gases from escaping inside the crankcase The PCV valve lifts the plunger according to the into the atmosphere.
Page 951: Component Location
17-9 ENGINE AND EMISSION CONTROL - Emission Control System COMPONENT LOCATION PCV valve POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 1. Remove the ventilation hose from the PCV valve. 2. Remove the PCV valve from the rocker cover. 3. Reinstall the PCV valve at the ventilation hose. 4.
Page 952: Evaporative Emission Control System
17-10 ENGINE AND EMISSION CONTROL - Emission Control System EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents When the engine coolant temperature is low or fuel vapours generated in the fuel tank from when the intake air quantity is small (when the escaping into the atmosphere.
Page 953: Purge Control System Check
17-11 ENGINE AND EMISSION CONTROL - Emission Control System PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (red stripe) from throttle Throttle body body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3.
Page 954: Purge Control Solenoid Valve Check
17-12 ENGINE AND EMISSION CONTROL - Emission Control System PURGE CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose from the solenoid valve. 2.
Page 955: Exhaust Gas Recirculation (Egr) System
17-13 ENGINE AND EMISSION CONTROL - Emission Control System EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers the exhaust port of the cylinder head to the the nitrogen oxide (NOx) emission level. When the combustion chamber through the intake manifold air/fuel mixture combustion temperature is high, to decrease the air/fuel mixture combustion...
Page 956: Component Location
17-14 ENGINE AND EMISSION CONTROL - Emission Control System COMPONENT LOCATION EGR valve EGR control solenoid valve Throttle body Vacuum tank Alternator EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (green stripe) from the EGR control solenoid valve, and then connect a hand vacuum pump via the three-way terminal.
Page 957: Egr Valve Check
17-15 ENGINE AND EMISSION CONTROL - Emission Control System EGR VALVE CHECK 1. Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly. 2. Connect a hand vacuum pump to the EGR valve. 3.
Page 958: Egr Control Solenoid Valve Check
17-16 ENGINE AND EMISSION CONTROL - Emission Control System EGR CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (yellow stripe, green stripe, white stripe) from the solenoid valve.
Page 959: Egr Valve
17-17 ENGINE AND EMISSION CONTROL - Emission Control System EGR VALVE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Hose E Removal and Installation (Refer to GROUP 15 - Inter Cooler.) 21 ± 4 N·m Removal steps 1. Vacuum hose connection 2.
Page 960: Canister
17-18 ENGINE AND EMISSION CONTROL - Emission Control System CANISTER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Pipe C, Air Hose D Removal and Installation (Refer to GROUP 15 - Inter Cooler.) Battery and Battery Tray Removal and Installation Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 - Air Cleaner.) Canister removal steps 1.
Page 961: Catalytic Converter
17-19 ENGINE AND EMISSION CONTROL - Emission Control System CATALYTIC CONVERTER GENERAL INFORMATION The three-way catalytic converter, together with When the mixture is controlled at stoichiometric the closed loop air-fuel ratio control based on the air-fuel ratio, the three-way catalytic converter oxygen sensor signal, oxidizes carbon monoxides provides the highest purification against the three (CO) and hydrocarbons (HC) and reduces nitrogen...
Page 962 NOTES...
Page 963: Clutch
21A-1 CLUTCH CONTENTS CLUTCH ............CLUTCH OVERHAUL .
Page 964 21A-2 CLUTCH CONTENTS GENERAL INFORMATION ....Bleeding ........Clutch Pedal Position Switch Adjustment .
Page 965: General Information
Clutch fluid Brake fluid DOT3 or DOT4 As required Push rod assembly Rubber grease Boot Release cylinder push rod MITSUBISHI genuine grease Part No. 0101011 ON-VEHICLE SERVICE Clutch pedal height <L.H. drive Vehicles> <R.H. drive Vehicles> CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1.
Page 966: Bleeding
21A-4 CLUTCH - On-Vehicle Service 3. If the height of the clutch pedal is outside the standard value, loosen the setting nut to adjust the pedal height Setting nut to the standard value. Caution Do not push in the master cylinder push rod at this time, otherwise the clutch will not operate properly.
Page 967: Clutch Pedal
21A-5 CLUTCH - On-Vehicle Service/Clutch Pedal 5. Fix the clutch pedal position switch by rotating approx. quarter turn to clockwise in the position as shown in the illustration. 6. Connect the connector to the clutch pedal position switch. Full stroke 7.
Page 968 21A-6 CLUTCH - Clutch Pedal Removal steps D Column cover, under cover, lower 7. Clevis pin frame (Refer to GROUP 52A.) 8. Clutch master cylinder mounting nut 1. Connector connection 9. Master cylinder member mounting bolt 2. Clutch pedal position switch 10.
Page 969: Clutch Control
<L.H. drive vehicles> Release fork 15 ± 1 N·m Release cylinder push rod Specified grease: MITSUBISHI genuine grease Part No. 0101011 12 ± 2 N·m 30 ± 4 N·m 18 ± 3 N·m 13 ± 2 N·m Clutch master cylinder removal...
Page 970 Clutch Control <R.H. drive vehicles> Release fork Release cylinder push rod 13 ± 2 N·m Specified grease: MITSUBISHI genuine grease Part No. 0101011 15 ± 1 N·m 18 ± 3 N·m 6, 8 Clutch master cylinder removal Clutch release cylinder removal...
Page 971: Clutch Master Cylinder
21A-9 CLUTCH - Clutch Control DISASSEMBLY AND REASSEMBLY CLUTCH MASTER CYLINDER Caution Do not disassemble piston assembly. 13 ± 2 N·m <L.H. drive vehicles> <R.H. drive vehicles> Clutch fluid: Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease Disassembly steps 1.
Page 972 NOTES...
Page 973 21B-1 CLUTCH OVERHAUL CONTENTS GENERAL DESCRIPTION ....LUBRICANTS ......SPECIFICATIONS .
Page 974 22 ± 2 LUBRICANTS Items Specified lubricants Release fork and release cylinder push rod contact section MITSUBISHI genuine grease Part No.0101011 or equivalent or equivalent Release fork and release fork shaft sliding section Release fork and release bearing contact section...
Page 975 21B-3 CLUTCH OVERHAUL - Clutch CLUTCH REMOVAL AND INSTALLATION 18 ± 3 N•m 9.8 ± 2 N•m 18 ± 3 N•m 15 ± 2 N•m 18 ± 3 N•m 22 ± 2 N•m Removal steps 1. Clutch fluid line bracket "CA 11.
Page 976 Apply grease on the release fork at the position shown in the illustration. Grease Specified grease: MITSUBISHI genuine grease Part No.0101011 or equivalent "CA SEALING CAP INSTALLATION Press the sealing cap into the position shown in the illustration 2 mm while taking care so that it is not tilted.
Page 977 21B-5 CLUTCH OVERHAUL - Clutch INSPECTION CLUTCH COVER (1) Check the pressure plate surface for wear, cracks or discoloration. (2) Check the strap plate rivet for looseness. If loose, replace the clutch cover. CLUTCH DISC Caution Do not wash the clutch disc with cleaning oil. (1) Check the facing for decomposition caused by rivet looseness, single-side contact or seizure, and check for the presence of grease.
Page 978 21B-6 CLUTCH OVERHAUL - Clutch Release Cylinder CLUTCH RELEASE CYLINDER DISASSEMBLY AND REASSEMBLY 11 ± 1 N•m Disassembly step 1. Cap "AA 5. Piston cup 2. Air breather "AA 6. Piston 3. Push rod 7. Conical spring 4. Boot 8. Release cylinder...
Page 979 After applying brake fluid on the inner surface of the release cylinder and circumference of the piston and piston cup, insert the piston and piston cup into the release cylinder. Brake fluid Specified fluid: MITSUBISHI genuine brake fluid “DIA-QUEEN Piston Piston cup BRAKE FLUID SUPER 4” or equivalent INSEPCTION...
Page 980 NOTES...
Page 981: Manual Transmission
22A-1 MANUAL TRANSMISSION CONTENTS MANUAL TRANSMISSION ........MANUAL TRANSMISSION OVERHAUL .
Page 982 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 983: General
Transmission oil Gear oil SAE 75W-90 or 75W-85W conforming to API GL-4 Transfer Vehicles without ACD or ve- MITSUBISHI Genuine Gear Oil Part No.8149630 EX, 0.55 hicles without ACD and AYC CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD (GL 5 SAE 80W...
Page 984: Special Tools
22A-4 MANUAL TRANSMISSION - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II Sub as- Diagnosis code checking sembly MB991529 Diagnosis code checking harness G sensor check MB991348 Test harness set MD998330 Oil pressure gauge Hydraulic pressure measurement <ACD> (including (3.0 MPa) MD998331) MB991705...
Page 985: Troubleshooting
22A-5 MANUAL TRANSMISSION - Troubleshooting <ACD> TROUBLESHOOTING <ACD> BASIC TROUBLESHOOTING CONDITIONS Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. NOTE Before starting the troubleshooting procedure, make sure that the following items have been checked okay. Is the appropriate steering wheel installed at the center of the steering column shaft correctly? Are the tire, wheel size, specifications, air pressure, balance, and wear state normal? Is the wheel alignment normal? Has the engine, suspension, etc.

Page 986 22A-6 MANUAL TRANSMISSION - Troubleshooting <ACD> INSPECTION CHART FOR DIAGNOSIS CODES Diagnosis Diagnosis items Reference page code No. Power supply voltage (valve power supply) system open circuit or short-circuit 22A-8 Fail-safe relay system <inside 4WD-ECU> open circuit or short-circuit 22A-8 Wheel speed sensor <FR>...
Page 987 22A-7 MANUAL TRANSMISSION - Troubleshooting <ACD> Diagnosis Diagnosis items Reference page code No. Electric pump relay system open circuit or short-circuit 22A-29 electric pump malfunction 22A-30 or pressure sensor defect AYC control error Refer to GROUP 27B. ACD control error NOTE Code No.85 is not a code number output due to malfunction, but a code number output when control for the 4WD-ECU to protect the ACD is stopped in excessive driving.
Page 988 22A-8 MANUAL TRANSMISSION - Troubleshooting <ACD> INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No.12 Power supply voltage (valve power supply) Probable cause system The power supply circuit opens or short-circuits if the power supply voltage of the D Defective harness or connector 4WD-ECU is below 9 V or above 18 V.
Page 989 22A-9 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.21 Wheel speed sensor <FR> system Probable cause Code No.22 Wheel speed sensor <FL> system Code No.23 Wheel speed sensor <RR> system Code No.24 Wheel speed sensor <RL> system A diagnosis code corresponding to the open circuit or short circuit of the wheel D Wheel speed sensor fault speed sensor is output when one wheel speed sensor has detected a vehicle D Rotor fault...
Page 990 22A-10 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
Page 991 22A-11 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.25 Wrong-diameter tire Probable cause Code No.25 is output as wrong-diameter tire when one of the four vehicle D Tire fault speeds is outside the range of specified values in respect to the average of the D Wheel speed sensor fault four vehicle speed sensors, when the vehicle speed is above 20 km/h with the D Rotor fault...
Page 992 22A-12 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
Page 993 22A-13 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.26 Wheel speed sensor system (faulty output Probable cause signal) Code No.26 is output as output signal error of the wheel speed sensor when D Tire fault one wheel speed is outside the specified range at the vehicle speed of above D Wheel speed sensor fault 20 km/h.
Page 994 22A-14 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
Page 995 22A-15 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.31 Steering wheel sensor <ST-1, ST-2, ST-N> Probable cause system Code No.31 is output when open circuit or short circuit of the steering wheel D Steering wheel sensor fault sensor output line (ST-1, ST-2, or ST-N) occurs. D Harness or connector fault D 4WD-ECU fault MUT-II Diagnosis Code...
Page 996 22A-16 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.32, 33 Steering wheel sensor <ST-N> system Probable cause Code No.32 is output when the steering wheel sensor ST-N has been detected D Harness or connector fault at the neutral position in a state where the steering wheel has been determined D Steering wheel sensor fault to have changed above 40_C from steering wheel sensor ST-1 and ST-2.
Page 997 22A-17 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.34 Steering wheel sensor <ST-1, ST-2> system Probable cause Code No.34 is output when no change in the steering wheel sensor signal at a D Harness or connector fault vehicle speed of above 15 km/h is detected for a total of more than 15 minutes D Steering wheel sensor fault <ST-1, ST-2>, and turning is detected during this time.
Page 998 22A-18 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.41, 42 TPS system Probable cause Code No.41 is output as excessively small output when the TPS output is below D TPS fault 0.2 V In the idling state. D Harness or connector fault Code No.42 is output as excessively large output when the TPS output is more D 4WD-ECU fault than 4.8 V for more than 2 minutes continuously below a vehicle speed of 10...
Page 999 22A-19 MANUAL TRANSMISSION - Troubleshooting <ACD> MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.45 Pressure sensor system (Open circuit or Probable cause ground) Code No.45 is output when the output signal from the pressure sensor is below D Harness or connector fault 0.2 V.
Page 1000 22A-20 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.47 Pressure sensor system (Abnormal power Probable cause supply) Code No.47 is output when the pressure sensor power supply voltage is above D Harness or connector fault 4.0V during pressure sensor power OFF or less than 4.0V during pressure D Pressure sensor fault sensor power ON.

Mitsubishi Lancer Evolution-VII Workshop Manual

Manual

Engine

Base Engine

Lubrication System

Intake and Exhaust

Control System

Mount

Accelerator System

Drive-Control Components

Front Suspension

Rear Suspension

Parking Brake

Body

Main Body

Hood and Fender

Rear End Cross Bar <Rs

Table of Contents

Ignition System

Charging System

ENGINE CONTROL SYSTEM L.H. Drive Vehicles

Cooling System

HEADLAMP L.H. Drive Vehicles

TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP and LIGHTING MONITOR BUZZER L.H. Drive Vehicles

ROOM LAMP and LUGGAGE COMPARTMENT LAMP L.H. Drive Vehicles

REAR FOG LAMP L.H. Drive Vehicles

Headlamp Leveling System

TURN-SIGNAL LAMP and HAZARD WARNING LAMP L.H. Drive Vehicles

Back-Up Lamp

Stop Lamp

Horn

METER and GAUGE L.H. Drive Vehicles

Fuel Warning Lamp

Brake Warning Lamp

Oil Pressure Warning Lamp

POWER WINDOWS L.H. Drive Vehicles

Central Door Locking System

HEATER and MANUAL AIR CONDITIONER L.H. Drive Vehicles

Defogger

WINDSHIELD WIPER and WASHER L.H. Drive Vehicles

Remote Controlled Mirror

Clock

Cigarette Lighter and Ashtray Illumination Lamp

Audio System

Acd

ACD and AYC L.H. Drive Vehicles

Supplemental Restraint System (Srs) and Seat Belt Pretensioner

Immobilizer System

Intercooler Water Splay

Spare Connector

Workshop

Engine

Engine Overhaul

Engine Lubrication

Multipoint Fuel Injection (Mpi)

Inspection Chart for Trouble Symptoms

(How Toreduce the Fuel Pressure) 125

Fuel Pump Connectordisconnection

Cleaning

Check

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Mitsubishi Lancer Evolution-VII