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Mitsubishi 1993 3000GT Technical Information Manual

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  • Page 2 This page intentionally left blank.
  • Page 3 All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation. © Mitsubishi Motors Corporation May 1992...

  • Page 4: Model Indications

    MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. Indicates the manual transmission, or models equipped with the manual transmission. MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection. 4WD: Indicates the 4 wheel-drive vehicles. DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an engine.

  • Page 5: Explanation Of Circuit Diagrams

    GENERAL - How to Use This Manual EXPLANATION OF CIRCUIT DIAGRAMS The symbols used in circuit diagrams are used as NOTE described below. For detailed information concerning the reading of circuit diagrams, refer to the separate manual of "ELECTRICAL WIRING".
  • Page 6 NOTES This electronic document was created from material published and copyrighted in 1992 by Mitsubishi Motor Corporation (MMC). All rights to the original material are reserved by them. This electronic document may be distributed freely, without financial charge. Note that this document is not an exact replica of the original manual.

  • Page 7: Table Of Contents

    GENERAL CONTENTS DESIGN STRATEGIES FOR Chassis ..............11 DEVELOPMENT ............2 Supplemental Restraint System (SRS) ....13 Basic Themes for Development ........2 Small Amount Refrigerant System (Air Conditioner) ............14 COMMODITY FEATURES ..........3 Theft-alarm System ..........15 TECHNICAL FEATURES ..........4 Serviceability ............

  • Page 8: Design Strategies For Development

    GENERAL - Design Strategies for Development DESIGN STRATEGIES FOR DEVELOPMENT BASIC THEMES FOR DEVELOPMENT New 4WD Sports Car drive in a sporty manner. A 4WD system that accurately transmits the power of the engine to the road surface, thus eliminating the The DOHC twin-turbochargers and twin-intercoolers danger that normally accompanies speed, has been coupled...

  • Page 9: Commodity Features

    GENERAL - Commodity Features COMMODITY FEATURES Dynamic real sports styling • Low and wide proportions • Capsule image due to glass with complex curves • Large-diameter wide tyres that symbolize super 4WD • Sports cockpit centered around the driver Interior with an abundantly sporty feel •...

  • Page 10: Technical Features

    GENERAL - Technical Features TECHNICAL FEATURES EXTERIOR Dynamic sports car proportions with wide tread and tight interior. Features The forward passenger compartment looks like a capsule, using glass with complex curves. Side air dam that provides improved aerodynamic characteristics for the side of the vehicle. 17"...

  • Page 11: Interior

    GENERAL - Technical Features INTERIOR Interior that creates a real feeling of a cockpit centering around the driver. Features An instrument panel that emphasizes a feeling of closeness. Round 3-meter arrangement with sporty imag.e. Easy-to-see goggle type meter cluster. Full round door trim that appears to be one with the instrument panel. Superior sports type front seat that gives support.

  • Page 12: Engine

    GENERAL - Technical Features ENGINE A 3.0L DOHC engine with twin-turbochargers and twin-intercoolers have been developed to provide even higher output and higher performance. SPECIFICATIONS Displacement Maximum output Maximum torque Items kW (PS)/rpm kgm (Nm)/rpm (cu. in.) 210 (285) / 6,000 41.5 (407) /3,000 2972 (181.4) Specifications...
  • Page 13 GENERAL - Technical Features Quiet operation • Noise and vibration have been decreased by the adoption of roller rocker arms. • Noise generated by the valve mechanism has been decreased by the hydraulic auto lash adjusters. • Both powerful exhaust sound fitting a high performance vehicle and quietness due to the active exhaust system. •...
  • Page 14 GENERAL - Technical Features...

  • Page 15: Transaxle

    GENERAL - Technical Features TRANSAXLE W5MG1 TYPE MANUAL TRANSAXLE The W5MG1 type manual transaxle is a full-time 4WD developed to match the high output and high torque of manual transaxle made by GETRAG * and newly the 6G72-DOHC (Turbo) engine. 1.

  • Page 16: Clutch Booster

    0-10 GENERAL - Technical Features CLUTCH BOOSTER A 4" single type clutch booster is used to reduce the force needed to depress the clutch pedal. Air intake plenum Release cylinder Clutch booster Vacuum tank Clutch pedal...

  • Page 17: Chassis

    0-11 GENERAL - Technical Features CHASSIS Steering • A compact lightweight integral type rack and pinion type power steering for outstanding steering response. • Tilt steering construction for ideal steering position. • SRS built into the steering wheel to protect the driver. •...
  • Page 18 0-12 GENERAL - Technical Features Brake 8+9 inch tandem brake X-arrangement of lines that Rear drum-in-ventilated disc booster to reduce the maintains balanced braking in brake with built-in parking force needed to depress front and rear even if the brake and featuring good the brake pedal.

  • Page 19: Supplemental Restraint System (Srs)

    0-13 GENERAL - Technical Features SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS is a system that works with the seat belt and is when a shock that is over the design value (deceleration designed as auxiliary equipment to the seat belt. G) is added to the entire vehicle from the front. It only functions to protect the upper body of the driver...

  • Page 20: Small Amount Refrigerant System

    GENERAL - Technical Features 0-14 SMALL AMOUNT REFRIGERANT SYSTEM (AIR CONDITIONER) In order to protect the ozone layer, the small amount the amount of chloro-fluoro carbon used as the refrigerant system was developed by improving the refrigerant in automobile air conditioners. structural parts of the air conditioner, making it more compact, etc.

  • Page 21: Theft-Alarm System

    0-15 GENERAL - Technical Features THEFT-ALARM SYSTEM To make the vehicle theftproof, this system is de- been forced open without using a key. Furthermore, the starter circuit is interrupted so that the engine signed to operate the horn intermittently for 30 se- conds when the locked door, hood or tailgate has may not be operated.

  • Page 22: Serviceability

    0-16 GENERAL - Technical Features SERVICEABILITY A series of investigations from a variety of angles are and a reduced need for maintenance, with carried out starting from the planning and design stages, improvements in reliability and durability. to produce a vehicle with complete diagnosis functions Items of improved serviceability •...

  • Page 23: Vehicle Identification

    Z1 6 A M N G F L 6 1. Development order (& Drive train) 7. Specified engine feature Z1 - MITSUBISHI 3000GT F - Turbocharger (with intercooler) (Full time 4WD) Steering wheel location 2. Engine type L - Left hand 6 - 2,972 cc (181.4 cu.

  • Page 24: Major Specifications

    0-18 GENERAL - Major Specifications MAJOR SPECIFICATIONS OOF0015 Items Z16AMNGFL6 Z16AMNGFL Z16AMNGFLW , Z16AMNGFR6 Z16AMNGFR Z16AMNGFR8 Dimensions mm(in.) Overall length 4,560 (179.5) Overall width 1,840 (72.4) Overall height (unladen) 1,285 (50.6) Wheelbase 2,470 (97.2) Track-Front 1,560 (61.4) Track-Rear 1,580 (62.2) Ground clearance (unladen) 145 (5.7) Overhang-Front...
  • Page 25 ENGINE CONTENTS - GENERAL INFORMATION ......... CONTROL SYSTEM …………………………………..14 System Block Diagram ……………………………….15 Specifications ............2 Engine Sectional View ..........2 Sensors ……………………………………………….. 16 Actuators ……………………………………………….18 BASE ENGINE .............. 4 Fuel Injection Control …………………………………19 Oil Jet .................4 Idle Speed Control (ISC) …………………………… 20 Main Bearing Cap ............4 Mechanical Dashpot ………………………....21 Crank Angle Sensor and...

  • Page 26: General Information

    ENGINE - General Information GENERAL INFORMATION NOTE The engine is a V-type 6-cylinder (bank angle 60°) 2,972 For details of the basic engine structure, refer to the (181.4 cu.in.) DOHC 24 valve design and is previously-issued '91 SIGMA Technical Information basically the same as the engine equipped in the Manual.

  • Page 27: Engine Sectional View

    ENGINE - General Information ENGINE SECTIONAL VIEW 7EN0477 7EN0478...

  • Page 28: Base Engine

    ENGINE - Base Engine BASE ENGINE OIL JET There is an oil jet for cooling the pistons. Main gallery Oil jet [opens valve at 2 kg/cm (28 psi) or more] Crankshaft Main bearing 7EN0479 MAIN BEARING CAP The main bearing caps are of a conventional integrated vibration from the main drive section has been type with beam.

  • Page 29: Crank Angle Sensor And Cam Position Sensor

    ENGINE - Base Engine CRANK ANGLE SENSOR AND CAM POSITION SENSOR An ultra-small crank angle sensor and cam position a large space saving and to provide improved sensor have been positioned inside the crankshaft crank angle detection precision. sprocket and camshaft sprocket respectively to realize Cam sprocket Crank sprocket Crankshaft...

  • Page 30: Mounting

    ENGINE - Mounting MOUNTING The engine mounts use a principal axis inertia support Roll stoppers (front and rear) are installed on the system. crossmember that is elastically supported on the body to This support method on the principal axis inertia is a reduce transmission of engine vibration to the body.

  • Page 31: Lubrication System

    ENGINE - Lubrication System LUBRICATION SYSTEM An oil pressure gauge unit has been installed in all equipped in the oil pan (Vehicles for Europe). models. In addition, an oil level sensor has been Rocker arm Orifice Lash adjuster Oil pressure gauge unit Lash adjuster...

  • Page 32: Cooling System

    ENGINE - Cooling System COOLING SYSTEM • The cooling system uses a water cooling pressure The two step control system is used for the motor control circulation system and it has the following driven cooling fan and condenser fan for less fan features.
  • Page 33 ENGINE - Cooling System Items Specifications Radiator fan motor Maker Nippon Denso Type Direct flow ferrite type Rated load torque Nm (kgm, ft.lbs.) 53 (5.3, 39) Speed 2,080 ± 250 ·A Current 13.6 ± 1 Thermo sensor for radiator fan Operating temperature °C (ºF) OFF --+ ON...

  • Page 34: Intake/Exhaust System

    1-10 ENGINE - Intake/Exhaust System INTAKE/EXHAUST SYSTEM TWIN TURBOCHARGERS AND TWIN INTERCOOLERS Compact, lightweight, turbochargers with outstanding one is arranged on the front and rear banks just like the response are used in each bank, front and rear, for the turbocharger.

  • Page 35: Exhaust Pipe

    1-11 ENGINE - Intake/Exhaust System EXHAUST PIPE The exhaust pipe is divided into three sections, front pipe is used for the front pipe to improve exhaust pipe, centre pipe and main muffler. It is installed on the efficiency, and a dual tail pipe with muffler cutter is used body via a rubber hanger to reduce transmission of as the main muffler.

  • Page 36: Fuel System

    1-12 ENGINE - Fuel System FUEL SYSTEM al 4G63 engine. The fuel system consists of electromagnetic fuel in- The fuel tank is located under the luggage compart- jectors, delivery valves, a fuel pressure regulator for ment floor and the fuel filters are in the fuel tank and regulating fuel pressure, and an electromagnetic fuel in the engine compartment to filter the fuel.
  • Page 37 1-13 ENGINE - Fuel System Normally, the negative pressure in the intake manifold current flow to the fuel pressure control valve to activate acts upon the fuel pressure regulator to maintain the the fuel pressure regulator by means of atmospheric fuel pressure at a constant level with regard to the pressure.

  • Page 38: Control System

    1-14 ENGINE - Control System CONTROL SYSTEM some parts differ as shown below. The control system used is basically the same as that in the conventional 6G72 engine in the SIGMA. However, Main items changed or added Notes · Control relay and fuel pump power circuit have Simplified power circuit ·...

  • Page 39: System Block Diagram

    1-15 ENGINE - Control System SYSTEM BLOCK DIAGRAM Remarks The changed or added items with respect to the conventional engine are shown in bold letters.

  • Page 40: Sensors

    1-16 ENGINE - Control System SENSORS Carn position sensor and crank angle sensor 6AF0009 6AF0002 Crank angle sensor Carn position sensor The cam position sensor consists of a flux screening nals as shown in the illustration below, and input these plate fixed to the crankshaft sprocket on the rear bank pulse signals to the engine control unit.
  • Page 41 1-17 ENGINE - Control System The shapes of the flux screening plates used in the cam position Flux screening plate for Carn sensor and crank angle sensor are as shown in the illustration at left. position sensor Detection of the cam position and crank angle is the same as for the conventional 4G93-S0HC engine, where the magnetic flux passing through the Hall element inside the sensor unit is alternately screened and allowed through by the vanes on the flux screening...

  • Page 42: Actuators

    1-18 ENGINE - Control System ACTUATORS FUEL PUMP RELAY NO.2 Fuel pump relay No.2 is the relay that changes the supply voltage to the fuel pump in 2 steps, High/Low. The engine control unit controls the amount of fuel discharged from the fuel pump by changing the supply voltage.

  • Page 43: Fuel Injection Control

    1-19 ENGINE - Control System FUEL INJECTION CONTROL The fuel injection control method is basically the same as that used in the conventional 6G72 engine. SYSTEM CONFIGURATION DIAGRAM...

  • Page 44: Idle Speed Control (Isc)

    1-20 ENGINE - Control System IDLE SPEED CONTROL (ISC) (1) Stepper motor (STM) position control with the anti- (2) Other controls are basically the same control system lock braking system (ABS) function was added. as in the conventional 6G72 engine. SYSTEM CONFIGURATION DIAGRAM...

  • Page 45: Mechanical Dashpot

    1-21 ENGINE - Control System MECHANICAL DASHPOT There is a mechanical dashpot which gradually closes the throttle valve from a set opening during deceleration to improve deceleration feeling.

  • Page 46: Ignition Timing And On Time Control

    1-22 ENGINE - Control System IGNITION TIMING AND ON TIME CONTROL The ignition timing and on time control methods are basically the same as those used before. SYSTEM CONFIGURATION DIAGRAM...

  • Page 47: Power Supply And Fuel Pump Control

    1-23 ENGINE - Control System POWER SUPPLY AND FUEL PUMP CONTROL Fuel pump control for controlling power supply to the Power supply control to the injector, air flow sensor, ISC servo, etc. is the same as in the conventional 6G72 fuel pump is also the same as in the conventional 6G72 engine.

  • Page 48: Turbo Meter Control

    1-24 FUEL - Control System TURBO METER CONTROL The turbo meter is a current type meter. The engine Then, the unit determines the duty ratio according to the control unit receives the intake air volume signal from load and drives the turbo meter. the air flow sensor and the rpm signal from the crank Duty ratio ~= Load ~= angle sensor and calculates the engine load.

  • Page 49: Turbo Pressure Control

    1-25 FUEL - Control System TURBO PRESSURE CONTROL Turbo pressure used in the waste gate actuator is valve. As a result, turbo pressure corresponding to controlled by duty control of the waste gate solenoid driving conditions can be obtained. The engine control unit turns the power transistor in the unit on and, when normal current (duty 100%) flows in the waste gate solenoid valve coil, the waste gate solenoid valve does not open if turbo pressure does not rise above the set pressure of the waste gate...

  • Page 50: Fuel Pressure Control

    1-26 FUEL - Control System FUEL PRESSURE CONTROL FUEL SYSTEM-FUEL PRESSURE CONTROL VALVE (Refer to P. 1-12) AIR FLOW SENSOR (AFS) FILTER RESET CONTROL, AIR CONDITIONER RELAY CONTROL These controls are the same as those for the conventional 6G72 engine.

  • Page 51: Air Flow Sensor (Afs)

    1-27 ENGINE - Control System SELF DIAGNOSIS SYSTEM The following items have been made more complete. (3) Service data items to be transferred to multi-use (1) Check engine lamp ON items tester (2) Self diagnosis items (4) Actuator test items by multi-use tester CHECK ENGINE LAMP CONTROL The check engine lamp ON items are shown in the following table.
  • Page 52 1-28 ENGINE - Control System Code Diagnosis item Description DIAGNOSIS 2 Mode • Coolant temperature sensor Open or short circuit in sensor and allied circuit Valid • Increased connector contact resistance Crank angle sensor Abnormal sensor output Valid Cam position sensor Abnormal sensor output Valid Vehicle speed sensor (reed switch)
  • Page 53 1-29 ENGINE - Control System Item No. Service data item Unit Power steering fluid pressure switch ON - OFF Air conditioner switch ON - OFF Electric load switch ON - OFF Air flow sensor reset signal ON - OFF Ignition timing adjustment mode ON - OFF Volumetric efficiency Crank angle sensor output (readable at 2,000 rpm or less)

  • Page 54: Emission Control System

    1-30 ENGINE - Emission Control System EMISSION CONTROL SYSTEM that the amount of vapour that escapes to the The emission control system is basically the same as that used in the 6G72 engine fitted to the PAJERO/ atmosphere has been reduced. •...
  • Page 55 1-31 ENGINE - Emission Control System <Australia> <GCC and General Export>...

  • Page 56: Cruise Control System

    1-32 ENGINE - Cruise Control System CRUISE CONTROL SYSTEM NOTE The cruise control system makes constant-speed driving The cruise control system is basically the same as the possible at a speed designated by the driver [within a system equipped in the SIGMA. range of approx.
  • Page 57 POWER- TRANSMISSION COMPONENTS CONTENTS CLUTCH ………………………………………………….. FRONT AXLE ..............12 Specifications ………………………………....2 Specifications ............12 Clutch Booster ………………………………....3 REAR AXLE ..............13 MANUAL TRANSMISSION .......... 4 Specifications ............13 Specifications ............4 Axle Shaft ..............13 Sectional View ............5 Drive Shaft ...............13 W5MG1 4WD Transmission ........

  • Page 58: Clutch

    POWER-TRANSMISSION COMPONENTS - Clutch CLUTCH The clutch is the dry single-plate diaphragm type; Some models are equipped with a clutch damper in A hydraulic type with clutch booster is used for the the clutch tube to make changes in hydraulic pres- clutch control.
  • Page 59 A 4" single type clutch booster is used to reduce the of the clutch booster is basically the same as with the force to depress the pedal. The structural operation brake booster. Diaphragm Booster piston Valve plunger Poppet Operating rod Push rod Filter Valve plunger stopper key...

  • Page 60: Manual Transmission

    POWER-TRANSMISSION COMPONENTS - Manual Transmission MANUAL TRANSMISSION The manual transmission is a W5MG1 transmission. A cable type floor shift is used for transmission control. The W5MGI is a transmission that has been newly developed to respond to the high output and high torque of the 6G72-DOHC-Turbo engine.

  • Page 61: Sectional View

    POWER-TRANSMISSION COMPONENTS - Manual Transmission SECTIONAL VIEW W5MG1 Clutch housing 5th speed gear 1st speed gear Center shaft 1st-2nd synchronizer hub Viscous coupling 2nd speed gear Center differential Transaxle case Reverse idler gear 3rd speed gear Front differential 3rd-4th synchronizer hub Transfer driven bevel gear 4th speed gear Transfer drive bevel gear...

  • Page 62: W5Mg1 4Wd Transmission

    POWER-TRANSMISSION COMPONENTS - Manual Transmission W5MG1 4WD TRANSMISSION The W5MG1 is a 3-shaft, full time 4WD transmission. A double-mesh prevention device using an interlock It is not only a planetary gear type differential with the plate and a reverse mis-shift prevention device using center differential on the NO.3 shaft used, but also a a stopper plate are adopted in the shift control viscous coupling acting as a differential limiter that is...
  • Page 63 POWER-TRANSMISSION COMPONENTS - Manual Transmission The distribution of the drive force to the carrier and sun gear in a planetary gear type differential is determined by the number of teeth on the ring gear and sun gear. Here is the figure of the velocity diagram if the number of teeth on the ring gear is Zr and the number of teeth on the sun gear is Zs.
  • Page 64 POWER-TRANSMISSION COMPONENTS - Manual Transmission DOUBLE-CONE SYNCHRONIZER 1st speed gear Synchronizer sleeve Synchronizer 2nd speed gear Synchronizer cone Outer synchronizer ring Synchronizer hub 09F0123 The double-cone synchronizer used for 1st speed and outer surface liner respectively, and is coupled with the 2nd speed are made up, as shown in the figure above, clutch gear by the projections (6 locations) on the speed of the speed gear, clutch gear (welded to the speed...
  • Page 65 POWER-TRANSMISSION COMPONENTS - Manual Transmission Then the chamfer of the outer synchronizer ring spline and the chamfer of the synchronizer sleeve spline come in contact. As a result of this contact, a major pushing force is generated in the outer synchronizer ring, the friction torque between the synchronizer cone and outer synchronizer ring and inner synchronizer ring increases, and then the difference in rotational speed of the 1st speed gear and the synchronizer hub disappears.

  • Page 66: Transmission Control

    2-10 POWER-TRANSMISSION COMPONENTS - Manual Transmission TRANSMISSION CONTROL • • A combination of a wave washer and thrust There are vibration-prevention rubber pieces washer are used in the shift lever shaft of the shift mounted on the transaxle side of the shift cable lever assembly, and this not only reduces the and selector cable, and on the shift lever looseness in the direction of the lever shaft but...

  • Page 67: Propeller Shaft

    2-11 POWER-TRANSMISSION COMPONENTS - Propeller Shaft PROPELLER SHAFT has small friction in the direction of the shaft. This The propeller shaft is a 3-section 4-joint shaft with 2 structure helps reducing torque fluctuation, vibration center bearings. This division into 3 sections and noise.

  • Page 68: Front Axle

    2-12 POWER-TRANSMISSION COMPONENTS - Front Axle FRONT AXLE • The B.J. joint boot is made of highly-durable resin to The drive shaft is of the Birfield joint (B.J.)-tripod joint provide improved reliability (T.J.) type. This type features high power transmission efficiency and low vibration and noise.

  • Page 69: Rear Axle

    2-13 POWER-TRANSMISSION COMPONENTS - Rear Axle REAR AXLE The differential carrier and axle housing have been shaft with the companion flange in between. separated from each other, and T.J. and B.J. drive The front of the differential carrier is supported elastically shafts arranged in between.
  • Page 70 2-14 POWER-TRANSMISSION COMPONENTS - Rear Axle AXLE SHAFT To prevent mud that may be deposited around the The axle shaft is a semi-floating type supported by ball bearings (outer and inner) in the housing. bearing (outer), a dust shield has been provided. On models with the anti-lock braking system, there is a wheel speed sensing rotor on the axle shaft.

  • Page 71: Differential

    2-15 POWER-TRANSMISSION COMPONENTS - Rear Axle DIFFERENTIAL The differential uses lower friction torque bearings limited slip differential which provides outstanding and oil seals to improve power performance and fuel performance during operation on a muddy surface consumption. has been established. For faster differential cooling and higher reliability There is a 4-wheel steering (4WS) oil pump on the during high speed operation, a differential carrier with...

  • Page 72: Differential Support

    2-16 POWER-TRANSMISSION COMPONENTS - Rear Axle DIFFERENTIAL SUPPORT supports and differential support member. It is elastically The front and rear of the differential carrier are mounted mounted via a bushing. on the suspension crossmember by the differential Differential support (R.H.) Differential support member 11N0038...
  • Page 73 DRIVE-CONTROL COMPONENTS CONTENTS 4 WHEEL STEERING (4WS) SYSTEM ......27 SUSPENSION ............... 2 Specifications ............27 Features ..............2 System Construction ..........28 FRONT SUSPENSION ..........3 Rear Wheel Steering Oil Pump, ......29 Features ..............3 Control Valve ............29 Specifications ............3 Power Cylinder ............

  • Page 74: Suspension

    DRIVE CONTROL COMPONENTS - Suspension SUSPENSION wishbone type. In addition, 4WS is equipped in all A 4 wheel independent suspension system has been adopted, with the front suspension of a MacPherson models. strut type, and the rear suspension of a double FEATURES 1.

  • Page 75: Front Suspension

    DRIVE CONTROL COMPONENTS - Front Suspension FRONT SUSPENSION Perimeter type (crossed parallel) suspension mem- bers are used in the front suspension to improve driv- ing stability. FEATURES • Reduction of vibration and noise because the en- • Adoption of negative offset geometry for out- tire suspension system is elastically supported by standing braking stability.

  • Page 76: Camber Adjustment Mechanism

    DRIVE CONTROL COMPONENTS - Front Suspension Strut assembly Stabilizer bar No.2 crossmember Right member 12F0082 No.1 cross member Lower arm Left member CAMBER ADJUSTMENT MECHANISM It is possible to adjust the camber by turning the strut lower mounting bolt. Section A-A Adjusting cam (eccentric bolt) 12FOO26...

  • Page 77: Rear Suspension

    DRIVE CONTROL COMPONENTS - Rear Suspension REAR SUSPENSION FEATURES • Independent suspension for sure grip on the • Anti-lift geometry to control tail lifting when brak- ground. ing. • • Arm arrangement to minimized camber variations Improved quietness due to differential carrier against the ground.

  • Page 78: Crossmember And Crossmember Support Bushing

    DRIVE CONTROL COMPONENTS - Rear Suspension Shock absorber Crossmember Upper arm Differential support Trailing arm 12F0105 CROSSMEMBER AND CROSSMEMBER SUPPORT BUSHING The crossmember support bushing provides better The crossmember not only receives input from each isolation of high frequency noise such as noise from arm and link as a real suspension crossmember but the differential and gears by using inter-mass to shift also supports the rear differential.

  • Page 79: Electronic Control Suspension (Ecs)

    DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) ELECTRONIC CONTROL SUSPENSION (ECS) The electronic control suspension (ECS) is a system force is changed by commands from the ECS control that automatically switches the damping force char- unit; the actuator built into the shock absorbers is acteristics of the four shock absorbers, front and rear, in activated and the flow of oil inside the absorbers is three steps (SOFT, MEDIUM and HARD) in response to...
  • Page 80 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) REAR SUSPENSION Items Specifications Suspension system Double-wishbone type ° Camber 10' ± 30' Toe-in mm (in.) 0.5 ± 2.5 (0.02 ± 0.10) Coil spring Wire dia. x 0.D. x free length mm (in.). 12.2 x 117.2 x 379.3 (0.48 x 4.61 x 14.93) Coil spring identification colour Blue x 2...

  • Page 81: Main Parts And Their Functions

    DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) MAIN PARTS AND THEIR FUNCTIONS Parts Function Mounting position Sensor ECS switch Control mode selection switch Meter bezel Steering wheel angular velocity sensor Detects turning direction and Column switch angular velocity of steering wheel Under front seat (LH) G-sensor Detects up/down vibration of vehicle...

  • Page 82: Features Of Each Mode

    3-10 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) FEATURES OF EACH MODE Mode ECS indicator Damping force Features light TOUR Automatic selection • Normal damping force with emphasis on a comfortable ride depending on driving (SOFT) conditions • Safe operation control when making sudden turns or during high SOFT speed.

  • Page 83: Structure And Operation

    3-11 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) STRUCTURE AND OPERATION SENSOR ECS Switch The ECS switch is a return type switch mounted on the meter bezel. When the battery is connected and the ignition switch turned ON, it starts in the TOUR mode. Then, it changes between the TOUR and SPORT mode each time the mode changeover switch is pressed.
  • Page 84 3-12 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) Vehicle Speed Sensor The vehicle speed sensor is mounted directly onto the transmission. For the structure of the vehicle speed sensor, refer to GROUP 7 - Meters and Gauges. Position Detection Switch The position detection switches are combined with the damping force changeover actuator built into each shock absorber.
  • Page 85 3-13 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) ACTUATOR ECS Indicator Lamp There is an indicator lamp (green) to indicate the mode in the combination meter. When a breakdown is detected, it flashes at intervals of 0.5 second to warn the driver. Mode TOUR SPORT...
  • Page 86 3-14 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) SHOCK ABSORBER The shock absorber comes with a built in damping force Furthermore, the piston valve has a double seat and the base valve is made of 2 valves; accurate control is changeover actuator (including a, position detection switch) and the damping force can be changed in 3 possible at any damping force step for achieving both...
  • Page 87 3-15 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) Internal Operation of Shock Absorber SOFT (low damping force) When bounding The damping force is determined mainly by the flow resistance on the base valve side and a low damping force is obtained by passing oil in the lower part of the piston through the check valve built into the check nut and the orifice (large dia.) with no resistance.
  • Page 88 3-16 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) ECS CONTROL UNIT The ECS control unit is mounted on the inside of the change the damping force of the 4 shock absorbers. rear side trim. The ECS control unit sends a signal to the damping force changeover actuator to simultaneously Structure ECS control unit...
  • Page 89 3-17 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) Function Chart S: SOFT M: MEDIUM H: HARD Anti-Rolling Control CONTROL START Change to a higher damping force according to the control map for the vehicle speed and steering wheel angular velocity which depends on the operation of the steering wheel.
  • Page 90 3-18 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) Anti-Diving Control CONTROL START of deceleration exceeds 0.4G there will be a change to When the stop light switch goes ON, the ECS control HARD. unit calculates deceleration from the change in vehicle CONTROL HOLD speed.
  • Page 91 3-19 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) FAIL-SAFE AND DIAGNOSIS CODE TABLE NOTE 1. An "X" indicates normal operation and a "---" indicates stop of control. 2. Control stop, warning display and fixing of damping force return to normal operation when the ignition switch is turned OFF.
  • Page 92 3-20 DRIVE-CONTROL COMPONENTS - Electronic Control Suspension (ECS) Service data output function The ECS control unit receives the data input for control and outputs it to the diagnosis connector as a serial signal. SERVICE DATA CHART Item No. Service data items G-sensor output Throttle position sensor output Steering wheel angular velocity sensor output...

  • Page 93: Wheel And Type

    3-21 DRIVE-CONTROL COMPONENTS - Wheel and Tyre WHEEL AND TYRE SPECIFICATIONS Items Specifications Tyre size 225/50R17 Wheel type Aluminum type Wheel size 17 x 7 1/2 JJ Amount of wheel offset mm (in.) 46 (1.8) Tyre inflation pressure kPa (kg/cm , psi) Front 220 (2.2, 32)

  • Page 94: Power Steering

    3-22 DRIVE-CONTROL COMPONENTS - Power Steering POWER STEERING • • The steering wheel comes with SRS (Supplemental The oil pump is a vane type oil pump with a fluid Restraint System). (Refer to GROUP 6-SRS for flow control system so the steering force varies SRS.) according to engine speed.

  • Page 95: Steering Wheel And Column

    3-23 DRIVE-CONTROL COMPONENTS - Power Steering STEERING WHEEL AND COLUMN The steering whee and column have the following features that make maneuverability and safety really outstanding. • The steering wheel has an outstanding design • The steering shaft and column absorb shock that promotes maneuverability and a good view of energy when there is a collision with its shock the meters.
  • Page 96 3-24 DRIVE-CONTROL COMPONENTS - Power Steering TILT STEERING CONSTRUCTION The tilt steering consists of the tilt lever, tilt bolts (A, has right threads and tilt bolt B has left threads, and B), tilt bracket and column plate, etc. The tilt bolts (A, the tilt bracket is pressed and fixed to the column B) are attached to the end of the tilt lever;...
  • Page 97 3-25 DRIVE-CONTROL COMPONENTS - Power Steering SHOCK ABSORBING STRUCTURE (1) When the vehicle collides with something and there is a load added to the steering shaft from the gear box (primary shock), the lower shaft of steering shaft assembly crushes polyacetal resin, absorbing the shock load using the friction of the steering column (lower) and steering column bush as it slides into the lower...

  • Page 98: Oil Pump

    3-26 DRIVE-CONTROL COMPONENTS - Power Steering OIL PUMP engine speed and ideal harder steering at high The oil pump is a vane type oil pump with fluid flow speed. control system that provides light steering at low OIL PUMP PERFORMANCE 13F0042 NOTE (1) P-Qf characteristic: Pump pressure and pump delivery rate...

  • Page 99: Wheel Steering (4Ws) System

    3-27 DRIVE-CONTROL COMPONENTS - 4 Wheel Steering (4WS) System 4 WHEEL STEERING (4WS) SYSTEM By adding steering to the rear wheels, a 4 wheel NOTE steering system has been established which improves The 4WS vehicles are basically identical to Galant 4WD controllability and stability in the medium and high speed in the construction and operation of the 4WS.

  • Page 100: System Construction

    3-28 DRIVE-CONTROL COMPONENTS - 4 Wheel Steering (4WS) System SYSTEM CONSTRUCTION • The oil pump for the rear wheel steering delivers the amount of oil proportional to the rear wheel speed. • The hydraulic power cylinder is connected to the This allows rear wheel steering angle control middle joint of the rear trailing arms.

  • Page 101: Rear Wheel Steering Oil Pump

    3-29 DRIVE-CONTROL COMPONENTS - 4 Wheel Steering (4WS) System REAR WHEEL STEERING OIL PUMP The rear wheel steering oil pump driven by a dedicated The basic construction of the pump is the same as the power steering oil pump. drive gear in the rear differential carrier delivers the amount of oil corresponding to the rear wheel speed.

  • Page 102: Brakes

    3-30 DRIVE-CONTROL COMPONENTS - Brakes BRAKES The service brakes use a brake system featuring ex- cellent braking force and a high level of reliability and durability. FEATURES Improved braking 1. Four-wheel anti-lock braking system (4ABS) to prevent slipping performance due to locking of the wheels and for applying the ideal braking force is used.

  • Page 103: Service Brakes

    3-31 DRIVE-CONTROL COMPONENTS - Service Brakes SERVICE BRAKES SPECIFICATIONS Items Vehicles for Europe Vehicles for General Export, GCC and Australia Master cylinder Type Tandem (with level sensor) Tandem (with level sensor) 1.0. mm (in.) 26.9 (1 1/16)) 26.9 (1 1/16) Brake booster Type Vacuum type, tandem...

  • Page 104: Front Disc Brake

    3-32 DRIVE-CONTROL COMPONENTS - Service Brakes FRONT DISC BRAKE A face-to-face and different diameter 4-piston type made braking feeling. from aluminium has been adopted for the front disc For safety, there is an audible wear indicator on the brakes. inner side of the pad to warn when the limit of pad use Not only is braking force well balanced with pressure has been reached.

  • Page 105: Rear Disc Brake

    3-33 DRIVE-CONTROL COMPONENTS - Service Brakes REAR DISC BRAKE A face-to-face 2-piston type made from aluminium has brake built into the brake disc. been adopted for the rear disc brakes in vehicles for For safety, there is an audible wear indicator in the inner Europe, and floating caliper single piston type has been side of the pad to warn when the limit of pad use has adopted in vehicles for General Export, GCC and...
  • Page 106 3-34 DRIVE-CONTROL COMPONENTS - Anti-lock Braking System (ABS) ANTI-LOCK BRAKING SYSTEM (ABS) performance on dry roads to better performance under With the use of ABS in 4WD models, not only is the all conditions such as slippery road surfaces, etc. The “driving"...

  • Page 107: System Drawing

    3-35 DRIVE-CONTROL COMPONENTS - Anti-lock Braking System (ABS) SYSTEM DRAWING Front left wheel (FL) Rear left wheel (RL) 14F0063...

  • Page 108: Abs Electric Diagram

    3-36 DRIVE-CONTROL COMPONENTS - Anti-lock Braking System (ABS) ABS ELECTRIC DIAGRAM 14F0062...

  • Page 109: Abs Hydraulic Function Drawing

    3-37 DRIVE-CONTROL COMPONENTS - Anti-lock Braking System (ABS) ABS HYDRAULIC FUNCTION DRAWING rear right and left wheels - are controlled hydraulically at The ABS uses 2 channels (2 hydraulic systems) with the the same time. hydraulic control method being as follows. Also, if vehicle speed exceeds approximately 8 km/h It controls the front and rear wheels on the same side (5.0 mph), the brake hydraulic pressure control is ap-...

  • Page 110: Sensor

    3-38 DRIVE-CONTROL COMPONENTS - Anti-lock Braking System (ABS) SENSOR WHEEL SPEED SENSOR • • By improving the mounting precision of the sensor, it The sensors for the front wheel consist of a speed is possible to make the speed sensor and rotor gap sensor mounted on the knuckle and a rotor (47 unadjustable types.

  • Page 111: Electronic Control Unit (Ecu)

    3-39 DRIVE-CONTROL COMPONENTS - Anti-lock Braking System (ABS) ELECTRONIC CONTROL UNIT (ECU) The ECU is mounted on the quarter inner lower panel compared by both CPUs and, if the data do not match, (RH). The ECU is made up of 2 microprocessors, in- ABS control is stopped.
  • Page 112 3-40 DRIVE-CONTROL COMPONENTS - Anti-lock Brake System DIAGNOSIS FUNCTIONS SELF DIAGNOSIS CODE OUTPUT FUNCTION There are 13 diagnosis items, and the diagnosis result is The ECU has the following functions to facilitate in- spection of the system. recorded even if the battery terminals are disconnected. •...

  • Page 113: Parking Brake

    3-41 DRIVE-CONTROL COMPONENTS - Parking Brake PARKING BRAKE The parking brake is of the mechanical rear wheel The parking brake cable is of the V-type and is acces- braking type. sible for adjustment through the service hole provided in The parking brake is offset toward the driver's seat from the floor console.
  • Page 114 NOTES...
  • Page 115 BODY CONTENTS GENERAL DESCRIPTION ........... 2 DOORS ………………………………………………….. Features ..............2 Door Panel .............. 10 Door Lock ..............11 MAIN BODY ..............3 Window Glass Regulator ......... 12 Body Panelling ......: ......3 Body Shell ..............4 LID ................

  • Page 116: General Description

    BODY - General Description GENERAL DESCRIPTION FEATURES 1. Ample use of high strength steel sheets Light weight 2. Improvement in rigidity of outer door panels by use of effective reinforcements Added rigidity Ample use of anti-corrosion steel sheets Corrosion control 1.

  • Page 117: Main Body

    BODY - Main Body...

  • Page 118: Body Shell

    BODY - Main Body BODY SHELL HEADLAMP SUPPORT Furthermore, the hood latch bracket has a closed A structure as shown below is used with the large soft cross section to improve strength. fascia which consists of the front bumper, skirt panel and (2) A large headlamp housing is used to improve header panel moulded into one unit.
  • Page 119 BODY - Main Body FRONT FLOOR (2) There is Iarge, integrated backbone reinforcement A double-floor structure is adopted, this not only im- on the upper surface of the front floor to improve proves rigidity but also reduces air resistance be- rigidity.

  • Page 120: Interference Panel Coating

    BODY - Main Body INTERFERENCE PEARL COATING Powder mica used in interference pearl coating has its In interference pearl coating, the thickness of titanium surface coated with titanium dioxide in the same way as dioxide coating on powder mica is increased to make the powder mica used in conventional white pearl the phase lag longer so that colours may be developed coating.

  • Page 121: 3C1B Pearl Coating

    Main BODY - Body 3C1B PEARL COATING The 3-coat pearl coating so far effected by 3C38 (3-coating and- 2-baking method) has been made possible by 3C1B (3-coating- and-1-baking method). COLOURED PEARL COATING The powder mica surface coated with titanium dioxide is further coated with coloured inorganic compound for its colouring.
  • Page 122 BODY - Main Body...

  • Page 123: Air Pressure Noise Reduction

    BODY - Air Pressure Noise Reduction AIR PRESSURE NOISE REDUCTION FLUSH SURFACE Measures were taken to improve the feeling of quality drastically reduced to improve the air pressure effect and to reduce air resistance and air noise by making by regulating the flow under the floor. all parts matched with flush surface.

  • Page 124: Full Glass Catch

    4-10 BODY - Air Pressure Noise Reduction Doors Since the door glass is sucked out by the vacuum good seal between the drip line weather-strip and the caused by air flow when driving at high speed, a full door glass is assured and the sucking noise when glass catch is mounted to the weather-strip holder in driving at high speed is shut down.

  • Page 125: Door Lock

    4-11 BODY - Doors DOOR LOCK A roller type 2-step door check is used on all models Central door locking with a key reminder system has which improves the operational feel when opening and been adopted so that all doors can be locked and un- closing the door and it holds the door securely at the locked by means of the driver's side inside lock knob or midway position.

  • Page 126: Window Glass Regulator

    4-12 BODY - Doors WINDOW GLASS REGULATOR A wire winding system is used in the window glass order to prevent the glass from getting scratched, a regulator. Power windows which use a wire winding glass striker is mounted on the outside of the door system in the window glass regulator are equipped on glass so the beltline weather-strip outer stabilizer is all models.

  • Page 127: Lid

    4-13 BODY - Lid/Window Glass HOOD Since the hood has been enlarged, a gas type spring is used to reduce the force needed for opening and closing it. TAILGATE The tailgate uses an inner hinge system with inverted gas springs. Furthermore, a cable type tailgate opener is used for all models.

  • Page 128: Sunroof

    4-14 BODY - Sunroof SUNROOF A tilt-up and detachable sunroof with excellent lighting This sunroof has the following features. ability and a feeling of space and made from • Adoption of a sunroof regulator which enables the strengthened glass has been adopted, thereby pro- sunroof tilt to be adjusted to any desired angle viding improved comfort.
  • Page 129 EXTERIOR CONTENTS SUMMARY OF EXTERIOR PARTS ......2 ACTIVE AERO SYSTEM ..........6 Construction Diagram ..........7 BUMPERS ..............3 Construction and Operation ........8 DOOR MIRRORS ............4 AERO PARTS ............... 5...

  • Page 130: Summary Of Exterior Parts

    EXTERIOR - Summary of Exterior Parts SUMMARY OF EXTERIOR PARTS Large resin bumpers have been adopted on both the In addition, an active aero system that operates at front and rear in all vehicles to emphasize the sporty vehicle speeds of 80 km/h (50 mph) or more has also look.

  • Page 131: Bumpers

    EXTERIOR - Bumpers BUMPERS • Bumpers that seem to be an integral part of the body TPO (Thermo Plastic Olefin elastomer) is used as are installed. the material for the bumper face and, by improving • To improve safety, both front and rear bumpers molding precision, it seems to be one unit with the have built-in bumper absorbers to absorb shock.

  • Page 132: Door Mirrors

    EXTERIOR - Door Mirrors DOOR MIRRORS • The door mirrors are collapsible types with a sporty and All models are equipped with the electric remote control mirror. The electric remote control switch is aerodynamic design. • installed on the left side of the instrument panel. The door mirror is installed a little away from the •...
  • Page 133 EXTERIOR - Aero Parts AERO PARTS <Except vehicles for Australia> The following aero parts are used to improve aerody- • A side air dam is installed to improve the aerody- namic characteristics and marketability. namic characteristics of the side of the vehicle. •.
  • Page 134 EXTERIOR - Aero Parts ACTIVE AERO SYSTEM <Vehicles for Europe and General Export> lifting force has been reduced by means of the In order to improve aerodynamic characteristics when driving at high speed, a variable front venturi skirt and rear spoiler. •...

  • Page 135: Construction Diagram

    EXTERIOR - Aero Parts CONSTRUCTION DIAGRAM Motor Variable front Crank arm venturi skirt Linkage Motor 18F0247 Cable Variable rear spoiler 18F0248 Key reminder switch Active aero warning lamp Vehicle speed sensor 18F0301 Active aero control unit...

  • Page 136: Construction And Operation

    EXTERIOR - Aero Parts CONSTRUCTION AND OPERATION VARIABLE FRONT VENTURI SKIRT The motor is mounted on the front end crossmember, switch inside the motor turns OFF and the motor and the motor and the front venturi skirt are con- stops operating. nected via a crank arm and a linkage.
  • Page 137 EXTERIOR - Aero Parts DEFLECTOR The deflector that is located on the rear spoiler pre- ing the air flow speed over the rear surface of the ve- vents dust from being drawn up from underneath the hicle. vehicle and dirtying the rear of the vehicle by increas- Section A-A Deflector Deflector...
  • Page 138 5-10 EXTERIOR - Aero Parts ACTIVE AERO SWITCH The active aero switch has three contact positions: AUT01, AUT02 and OFF. The front venturi skirt and rear spoiler move to the operated position and the standard position in accordance with the position of this switch and the vehicle speed.

  • Page 139: Aero Parts

    5-11 EXTERIOR - Aero Parts Operation circuits Moving from standard position to operated position When the front venturi skirt and rear spoiler are in the able signal in cases 1 and 2 for the following order of standard position, each drive circuit outputs a vari· conditions 1 and 2.
  • Page 140 5-12 EXTERIOR - Aero Parts <Operation chart for front venturi skirt limit <Operation chart for rear spoiler limit switches> switches> Active aero switch To rheostat Active aero control unit Front venturi skirt...
  • Page 141 5-13 EXTERIOR - Aero Parts Moving from operated position to standard position When the front venturi skirt and rear spoiler are in the signal in any of the cases 1 - 4 for the following order of operated position, each drive circuit outputs a standard conditions 1, 2 and 3.
  • Page 142 5-14 Parts EXTERIOR - Aero <Operation chart for rear spoiler limit switches> <Operation chart for front venturi skirt limit switches> 18F0238...
  • Page 143 INTERIOR CONTENTS SUMMARY OF INTERIOR PARTS ......SEAT BELT ..............9 Construction and Operation of the INSTRUMENT PANEL AND CONSOLE Energy-absorbing Belt and the Buckle ..... 9 BOX ................3 Electric Type Low Tension Seat Belt ...... 10 <Vehicles for General Export and GCC> SHELF COVER ............

  • Page 144: Summary Of Interior Parts

    INTERIOR - Summary of Interior Parts SUMMARY OF INTERIOR PARTS create a high-quality sports car atmosphere. In addition to being easier to use, the interior parts improve the feeling of fitness and solidity and FEATURES 1. Full trim interior 2. Round and one-unit instrument panel Improvement of quality feeling 3.

  • Page 145: Instrument Panel And Console Box

    INTERIOR - Instrument Panel and Console Box/Shelf Cover INSTRUMENT PANEL AND CONSOLE BOX A round instrument panel is used, creating the feeling of The console box is divided into two sections, front and being in a cockpit. The panel surface is covered with rear.

  • Page 146: Seats

    INTERIOR - Seats SEATS A sports type of front seat that emphasizes the feeling to the conventional reclining adjustment, there is a of being supported has been provided, and also real special function in this seat; when the seatback is leather seats have been provided as an option.

  • Page 147: Construction And Operation

    INTERIOR - Seats CONSTRUCTION AND OPERATION POWER SEAT Lumbar Support Structure If the switch on the front console is pushed to the front support plate to the front. This is a stepless, continuous as shown in the figure, the lumbar support motor stroke adjustment.
  • Page 148 INTERIOR - Seats Front Height and Rear Height Adjusting Structure As the seat cushion continues to rise, the claw on the The front and rear portions of the seat cushion can be raised and lowered independently. If the front height and shaft turns the limit switch from ON to OFF, cutting off rear height switch is pushed to the UP side, motor power to the motor and stopping it.
  • Page 149 INTERIOR - Seats Slide Adjustment Structure The motor and support are fixed to the upper rail, and the nut housing is attached to the lower rail. When the motor rotates, the worm gear drives the screw to shift the upper rail forward or backward. This controls the forward/backward seat sliding.

  • Page 150: Headrestraint (Horizontal Adjustment Mechanism)

    INTERIOR - Seats HEADRESTRAINT (HORIZONTAL ADJUSTMENT MECHANISM) backward without changing the angle at which the head There is a, link mechanism in the headrestraint that can touches its surface. adjust the headrestraint in four steps forward and CONSTRUCTION lock spring. The plate mounted on the shaft is pressed to The stay and right/left bracket are one unit.

  • Page 151: Seat Belt

    INTERIOR - Seat Belt SEAT BELT The seat belt has the following mechanisms. FRONT SEAT BELT REAR SEAT BELT • 3-point belt with ELR (electric type low tension seat • 3- point belt with ELR belt)<Vehicies for General Export and GCC> •...

  • Page 152: Electric Type Low Tension Seat Belt

    6-10 INTERIOR - Seat Belt ELECTRIC TYPE LOW TENSION SEAT BELT <Vehicles for General Export and GCC> key is turned OFF, and the belt winding force does not There is an electric type low tension mechanism in the return to its original condition immediately after the front seat belt retractor to reduce belt tension and the ignition key is turned OFF so the passenger does not feeling of pressure when the seat belt is buckled.
  • Page 153 6-11 INTERIOR - Seat Belt OPERATIONAL DESCRIPTION Seat Belt Stored Condition-7When Pulling Out Since the memory tape is wound up, the bushing spring that are wound up, moves in the winding shaft and tape holder turn as one unit. The torque of direction by the rotation of the bushing shaft and tape the two springs, the reducing spring and normal holder.
  • Page 154 6-12 INTERIOR - Seat Belt Buckle Switch ON When Seat Belt is Initially Wound Up memory tape and, while the memory tape is loose, When the tongue is released from the buckle with the torque is not transferred to the bushing shaft. When ignition switch ON, the switch inside the buckle is the memory tape is wound completely tight, the turned OFF, current to the solenoid is cut off and the...

  • Page 155: Supplemental Restraint System (Srs)

    6-13 INTERIOR - Supplemental Restraint System (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) • The SRS is designed for use as a supplemental system Has a double detection circuit to allow the air bag to for the seat belt, proving effective only when the seat deploy only when either of the right and left front belt is worn.

  • Page 156: Srs Schematic

    6-14 INTERIOR - Supplemental Restraint System (SRS) SRS SCHEMATIC...

  • Page 157: Warning/Caution Labels

    6-15 INTERIOR - Supplemental Restraint System (SRS) WARNING/CAUTION LABELS A number of caution labels relating to the SRS can be The language written in the label is principally English, found in the vehicle, as shown in the following but some of the labels are written in German or French. illustration.
  • Page 158 MITSUBISHI dealer. inoperative, risking serious driver Injury. E. CAUTION: SRS diagnosis unit This unit cannot be repaired. CAUTION: SRS If defective, remove and replace entire unit per Before removal of steering gearbox, read service service manual instructions.

  • Page 159: Construction And Operation

    6-17 INTERIOR - Supplemental Restraint System (SRS) CONSTRUCTION AND OPERATION IMPACT SENSORS There are 2 different types of sensors used; 2 front a metallic case, etc. If an impact greater than preset is impact sensors and safing impact sensor. One front applied in the direction of the arrow shown in the impact sensor is provided in each of the right and left illustration, the inertial force causes the roller to rotate...
  • Page 160 6-18 INTERIOR - Supplemental Restraint System (SRS) Front impact sensor Safing impact sensor Bracket G sensor Wire G sensor Connector Case Bracket 13R0662 Sealant Connector 19N0234 G sensor Roller Fixed contact Moving contact Inactive gas Impact Metallic case Base 13R0664 Moving contact Roller Roll spring...

  • Page 161: Air Bag Module

    6-19 INTERIOR - Supplemental Restraint System (SRS) AIR BAG MODULE The air bag module is an assembly part comprising of an air bag, pad cover, inflator, and parts for securing them. It is provided at the centre of the steering wheel. Caution Make sure that the air bag is never disassembled.
  • Page 162 6-20 INTERIOR - Supplemental Restraint System (SRS) Inflator gas which is forced through the diffuser screen into the The inflator consists of a squib, igniter, gas generants, air bag. The diffuser screen serves as a filter to remove diffuser screen, etc. contained in an aluminum container. cinders and also helps cool down the gas temperature It is mounted in the air bag module housing.
  • Page 163 6-21 INTERIOR - Supplemental Restraint System (SRS) (2) In approximately 20 milliseconds after the collision, the air bag folded in the pad cover will begin to inflate, the pad cover will break at its crease, and the air bag will expand outward. (3) In approximately 35 milliseconds after the collision, the inflated air bag will touch the chest of the driver.
  • Page 164 6-22 INTERIOR - Supplemental Restraint System (SRS) SRS DIAGNOSIS UNIT The SRS diagnosis unit monitors the impact sensors, ignition switch is ON to supply the squib ignition ,current, squib, wiring harness, condensers, battery voltage etc. It even if the power cable from the battery is broken by the detects a problem, it and illuminates the "SRS"...
  • Page 165 6-23 INTERIOR - Supplemental Restraint System (SRS) Component Main Monitoring Point Diagnosis Code No. Double lock connector Unlock or lock switch open-circuited IG1 voltage low (Multi-purpose fuse No. 11 is blown) Battery IG 1 voltage low (Multi-purpose fuse No. 18 is blown) External circuit open-circuited or short-circuited SRS warning lamp...
  • Page 166 6-24 INTERIOR - Supplemental Restraint System (SRS) Supplying squib ignition energy The energy for ignition of the squib is supplied by two circuits; the battery of the vehicle and the condensers. Even if the power voltage of the SRS diagnosis unit is lost, the ignition capability is retained by the condensers for more than 0.5 seconds.
  • Page 167 6-25 INTERIOR - Supplemental Restraint System (SRS) 3. Diagnosis function Fault diagnosis continues to be performed during the period the ignition switch is ON except during cranking. If a fault is detected, the SRS warning lamp is lit. The microcomputer determines a diagnosis code on the basis of the results of measurements by various measuring circuits and stores it in "EEPROM".
  • Page 168 6-26 INTERIOR - Supplemental Restraint System (SRS) SRS CONNECTOR The connector of the SRS diagnosis unit has a double lock mechanism, fit verification mechanism and connector shorting mechanism. DOUBLE LOCK MECHANISM The mechanism is composed of two mechanisms: each connector of the SRS diagnosis unit is locked to the connector of the harness, then these connectors (of the four harnesses) are locked with the secondary lock lever mounted on the connector of the SRS diagnosis unit side.
  • Page 169 6-27 INTERIOR - Supplemental Restraint System (SRS) FIT VERIFICATION MECHANISM The mechanism is used to electrically check the engagement of the connector between the SRS diagnosis unit and the body wiring harness. The operating principle is described below. (1) Securely connect the SRS diagnosis unit and harness side connectors and press the secondary lock lever down to lock the connectors.
  • Page 170 6-28 INTERIOR - Supplemental Restraint System (SRS) CLOCK SPRING the rotor and the other end mounted to the upper case. The clock spring is provided between the steering wheel The upper and lower cases are mounted to the steering (air bag module) and column switch body (steering column.
  • Page 171 6-29 INTERIOR - Supplemental Restraint System (SRS) Neutral position indication mechanism The system comprises of a ring gear (number of teeth: rotating direction of the rotor by the difference in the 90) provided in the upper case, a transparent cover number of teeth between the gear and ring gear or by mounted on the rotor with screws, and a gear (number of 10 teeth.
  • Page 172 6-30 INTERIOR - Supplemental Restraint System (SRS) SRS WARNING LAMP The SRS warning lamp is provided at the lower right corner of the combination meter. When the SRS is in good order, the lamp should illuminate for approximately 7 seconds after the ignition key has been turned ON, or the engine has been started, and will then go out.
  • Page 173 EQUIPMENT CONTENTS GENERAL INFORMATION ON ACCESSORY SOCKET ..........20 EQUIPMENT ..............ETACS (ELECTRONIC TIME AND ALARM Features ..............2 CONTROL SYSTEM) ..........21 Summary of Functions ........... 21 WIRING HARNESS ............3 Construction Diagram ..........3 Operation ..............23 Central Door Locking Preventing Doors DIAGNOSIS SYSTEM ..........

  • Page 174: Equipment

    EQUIPMENT - General Information GENERAL INFORMATION New equipment and new functions have been added to make the equipment better. FEATURES 1. Gold plating of electronic control system terminals. Improved reliability 2. MWP (Multipole Water Proof type) connector. 3. Adoption of small amount refrigerant air conditioner system. 1.

  • Page 175: Wiring Harness

    EQUIPMENT - Wiring Harness WIRING HARNESS The wiring harness is divided into the main wiring • CAVS (Compressed Conductor Automobile Vinyl harnesses [front wiring harness, body wiring harness Semi-rigid Wire) is used for the electrical wiring (LH, RH), control wiring harness, instrument panel wiring harness to make it lighter.

  • Page 176: Diagnosis System

    EQUIPMENT - Diagnosis System DIAGNOSIS SYSTEM Diagnosis system is designed to improve serviceability and has the following functions NOTE Saved in memory as long as the data is not electrically canceled. DIAGNOSIS CONNECTOR The diagnosis connector for the following systems is located on the right side of the junction block.

  • Page 177: Battery

    ELECTRICAL - Battery / Lighting BATTERY The battery of the following specifications has been established. SPECIFICATIONS Items STANDARD OPTIONAL <Except vehicles for Australia> Type 55D23R-MF 75D26R-MF Capacity (5H R) Reserve capacity min. Cold cranking current LIGHTING GENERAL INFORMATION There is also a convenient engine compartment in- Parallel link type pop-up headlamp that go up and down spection lamp for inspecting at night and for service to vertically are used.

  • Page 178: Structural Diagram

    ELECTRICAL - Lighting STRUCTURAL DIAGRAM <Vehicles for General Export and GCC> <Vehicles for Europe> Room lamp Room lamp Engine compartment Engine compartment Spot lamp Spot lamp inspection lamp inspection lamp Door lamp Door lamp 16F0421 16F0419 Fog lamp Side turn-signal lamp Driving lamp Front combination lamp Headlamp...
  • Page 179 ELECTRICAL - L ighting EXPLANATION OF STRUCTURE Pop-up Headlamp The pop-up head lamp consists of the pop-up motor, link assembly, rod connecting the pop-up motor and link assembly, and head lamp to raise and lower the headlamp. When the pop-up switch or lighting switch is turned ON, the popup motor rotates, the rod connected to the pop-up motor moves the link assembly to raise the headlamp.
  • Page 180 7- 8 ELECTRICAL - Lighting Driving Lamp <Vehicles for Europe and Australia> The driving lamps come on when the head lamps are flashed for passing or when the headlamp switch is turned to the high beam. OPTICAL HORN LENS (FOR PASSING LAMP IN VEHICLES FOR AUSTRALIA) Since the head lamp faces the front even when retracted, the head lamp, if used when passing, lamps up and shines in retracted...
  • Page 181 ELECTRICAL - Lighting <Vehicles for General Export and GCC> NOTE ”o” indicates the head lamp operation or position resulting from switch operation. Lighting switch ON means that the head- lamps are in the illumination position.
  • Page 182 7 -10 ELECTRICAL - Lighting Raising Headlamp When the Pop-up Switch is Turned From OFF to (contact side) goes ON, current flows in the pop-up ON and the Lighting Switch is OFF or at TAIL motor and the headlamp starts to go up. When the crank arm rotates approximately 180 When the pop-up switch is turned ON, the judgment reaches the UP position where it stops automatically,...
  • Page 183 7 -11 ELECTRICAL - Lighting the head lamp relay (contact side) goes ON, current When the Pop-up Switch is OFF and the Lighting Switch is Turned OFF or From TAIL to HEAD flows in the headlamp, the judgment circuit in the ETACS control unit senses the ON signal at the same When the lighting switch is turned to HEAD (on mod- time as the headlamp lights up, and just as in the...
  • Page 184 7 -12 ELECTRICAL - Lighting Lowering Headlamp When the Pop-up Switch is Turned From ON to matically stopping the down movement, current to the OFF and the Lighting Switch is OFF or at TAIL pop-up motor is cut off, the pop-up motor stops and the When the pop-up switch is turned OFF, the judgment headlamp stays in the down position.

  • Page 185: Headlamp Leveling System

    7-13 ELECTRICAL - Lighting HEADLAMP LEVELING SYSTEM The headlamps leveling system is a system that the driver can, if desired, use to change the head lamps illumination angle in the vertical direction so as to prevent approaching vehicles from being subjected to excessive brightness due to a change in the attitude of this vehicles because of the number of people or the amount of load carried.

  • Page 186: Meters And Gauges

    7-14 ELECTRICAL - Meters and Gauges METERS AND GAUGES COMBINATION GAUGE COMBINATION METER The combination gauge used is a 3-set gauge type with The combination meter uses analogue meters that are sporty feeling. large, and easy-to-read, indicator lights and warning lights.

  • Page 187: Vehicle Speed Sensor

    7-15 ELECTRICAL - Meters and Gauges VEHICLE SPEED SENSOR STRUCTURE The rotating shaft of the vehicle speed sensor is Magneto Resistive Element (MRE) in the top of the mounted directly on the transmission speedometer magnet detects the rotation of the magnet and driven gear.

  • Page 188: Electric Type Speedometer

    7-16 ELECTRICAL - Meters and Gauges ELECTRIC TYPE SPEEDOMETER CONSTRUCTION The electric type speedometer uses an electronic that pass directly through it. Furthermore, the odometer and trip meter are directly driven by the circuit to control the electric signal from the vehicle speed sensor and a cross coil type speedometer that stepping motor with built-in gear.
  • Page 189 7-17 ELECTRICAL - Meters and Gauges Cross Coil When current flows in the cross coil, a magnetic field is generated in coil 1 and coil 2. Since the two magnetic fields pass directly through, the actual magnetic field is a combination of the two magnetic fields. Since the magnet is fixed to the pointer shaft, the magnet rotates to try to align the magnetic axis of the magnet in the direction of the combined magnetic field and thus rotates the speedometer pointer.

  • Page 190: Wiper And Washer

    7-18 ELECTRICAL - Meters and Gauges WIPER AND WASHER The front wiper is a semi-concealed type with the visibility when it rains, etc. It has the following additional features. following features. • • It uses a fixed time intermittent wiper. A variable time intermittent wiper under ETACS •...

  • Page 191: Radio And Tape Player

    7-19 ELECTRICAL - Meters and Gauges RADIO AND TAPE PLAYER • There are two types of AM/FM multi-electronic tuning 7 stop retractable motor driven antenna with a total length of 900mm (35.4 in.). radios for the radio and stereo . •...

  • Page 192: Accessory Socket

    7-20 ELECTRICAL - Radio and Tape Player Accessory Socket Type 2 Vehicles for General Export, GCC and Australia Vehicles for Europe AM/FM electronic tuning radio with LW/MW/FM electronic tuning radio tape player (1 DIN) with tape player (1 DIN) 16N0597 16N0598 ACCESSORY SOCKET There is a convenient accessory socket for use when using plug-in...

  • Page 193: Etacs (Electronic Time And Alarm Control System)

    7-21 ELECTRICAL - ETACS ETACS (ELECTRONIC TIME AND ALARM CONTROL SYSTEM) This control unit has an input check function to check ETACS (Electronic Time and Alarm Control System) is normality or abnormality of the circuit from the input adopted and uses a micro-computer for centralized switch to micro-computer in the control unit.
  • Page 194 7-22 ELECTRICAL - ETACS...

  • Page 195: Operation

    7-23 ELECTRICAL - ETACS OPERATION CENTRAL DOOR LOCKING judgement circuit, and when the key cylinder switch (1) When the inside lock knob on the driver's side is ON signal is input, an H signal is input to the lock locked, AND1 outputs an H signal which causes Tr2 output side of timer circuit I.

  • Page 196: Defogger Timer

    7-24 ELECTRICAL - ETACS DEFOGGER TIMER (1) When the ignition switch is ON, if the defogger After 11 minutes, the signal output by the timer switch is turned ON, the signal input to the NOT circuit becomes an L signal, and the defogger op- becomes an L signal, and the converted H signal eration is stopped.

  • Page 197: Seatbelt Tension Reducer Timer

    7-25 ELECTRICAL - ETACS SEAT BELT TENSION REDUCER TIMER (1) Because an H signal is input to the OR1 when the (3) When the ignition switch is turned from ON to OFF, ignition switch is turned to ON, OR2 outputs an H an H signal is output from timer I for 30 seconds, signal, and transistor Tr turns ON, enabling the front but if the driver's side door is opened during this...

  • Page 198: Dimmer Type Lamp

    7-26 ELECTRICAL - ETACS DIMMER TYPE LAMP and activates the timer circuit. (1) If the room lamp switch is the DOOR position and The timer circuit outputs to the Tr base a signal that the door is opened (door switch ON), current from gradually varies for 6 seconds due to duty control, the battery flows from lamps (room lamp, 'foot lamp and the voltage for the lams is gradually reduced to...

  • Page 199: Seatbelt Warning Lamp

    7-27 ELECTRICAL - ETACS SEAT BELT WARNING LAMP (4) After flashing for 6 second, the lamp goes out. (1) Voltage is applied from the battery via the seat belt (5) If the ignition switch is turned OFF during the 6 warning lamp to the Tr collector.

  • Page 200: And Washer Linked Wiper

    7-28 ELECTRICAL - ETACS INTERMITTENT WIPER (washer switch On time) delay, and the Tr is (1) If the wiper switch is turned to the INT position turned on via OR for one wiper cycle (mist wiper). when the ignition switch is in the ON or ACC (2) When the washer switch ON time is 0.6 second or position, the voltage value from the intermittent more, washer switch timer circuit I I is activated,...
  • Page 201 7-29 ELECTRICAL - ETACS INPUT INSPECTION FUNCTIONS OF ETACS The ETACS control unit has an input inspection function that can check everything from each switch to the ETACS control unit by using a multi-use tester to measure the voltage variations at the ETACS terminals on the diagnosis connector.

  • Page 202: Parts And Functions Related With Etacs

    7-30 ELECTRICAL - ETACS PARTS AND FUNCTIONS RELATED WITH ETACS NOTE (1) *mark indicates a switch or sensor that can be used for input inspection with the multi-use tester. mark indicates a part relevant for each function.

  • Page 203: Theft Alarm System

    7-31 ELECTRICAL - ETACS THEFT-ALARM SYSTEM Note that this system is controlled by the Electronic When the theft-alarm system has been armed by a fixed Control Unit (ECU) as one function of the ETACS sequence for locking the doors without the key, if (Electronic Time and Alarm Control System).
  • Page 204 7-32 ELECTRICAL - Theft-alarm System DEACTIVATING THE ALARM ARMING THE SYSTEM (1) To deactivate the alarm, insert the key into the After the following procedures have been completed, the door's key cylinder and turn the key. SECURITY lamp illuminates for about 20 seconds, and (2) The alarm is deactivated and the system is disarmed when illumination stops, the system is armed.

  • Page 205: Heaters And Air Conditioning

    7-33 ELECTRICAL - Heater and Air Conditioning HEATER AND AIR CONDITIONING GENERAL INFORMATION The heater and air conditioning have outstanding cooling and heating performance and use a small amount refrigerant system. FEATURES Improvement of Adoption of air conditioner colour monitor visual recognition Improvement of 1.

  • Page 206: Components

    7-34 ELECTRICAL - Heater and Air Conditioning COMPONENTS <AIR CONDITIONER> Air conditioner colour monitor Interior temperature sensor Photo sensor Engine coolant temperature switch (for air conditioner cut-off) 20F0053...
  • Page 207 7-35 ELECTRICAL - Heater and Air Conditioning <HEATER> To door window (side defroster) To front window (defroster) To driver's FACE (side ventilator) To driver's feet and knees Centre ventilator To passenger's feet and knees To door window (side defroster) To passengers FACE (side ventilator) Centre ventilator 20F0046...

  • Page 208: Small Amount Refrigerant System

    7-36 ELECTRICAL - Heater and Air Conditioning SMALL AMOUNT REFRIGERANT SYSTEM chlorofluorocarbon used as much as possible. The small From July 1989, the consumption and production of amount refrigerant system has been developed to specially designated chlorofluorocarbon have been improve the performance of the structural parts of the air regulated world-wide to protect the ozone layer.

  • Page 209: Heater Unit

    7-37 ELECTRICAL - Heater and Air Conditioning HEATER UNIT directly to the air outlet (FACE). As a result, noise is The heater unit is a 3-layer flow type full air mix heater with outstanding heating characteristics. reduced by reducing air flow resistance inside the heater and by controlling the generation of air There is a by-pass passage to increase the amount of air at maximum cooling.

  • Page 210: Compressor Control

    7-38 ELECTRICAL - Heater and Air Conditioning COMPRESSOR CONTROL If anyone of the following switches and sensors is turned off, the magnet clutch of the compressor is turned off. Switch and sensor Operating condition of compressor Blower switch } Automatic when in AUTO Air conditioner switch Dual-pressure switch High pressure switchkPa (kg cm...
  • Page 211 7-39 ELECTRICAL - Heater and Air Conditioning Air conditioner control panel Revolution pick-up sensor Dual-pressure switch Thermostat Engine coolant temperature switch MPI control unit 20F0044...
  • Page 212 7-40 ELECTRICAL - Heater and Air Conditioning CONDENSER FAN AND RADIATOR FAN CONTROL is designed to improve cooling efficiency and to reduce The rotational speed of the condenser fan and radiator fan noise. fan is controlled by the engine coolant temperature and FAN REVOLVING OPERATION MODE Belt lock controller...

  • Page 213: Refrigerant Line

    7-41 ·ELECTRICAL - Heater and Air Conditioning REFRIGERANT LINE The receiver piping joints have flange fittings and the O-ring from dropping out and to improve workability. pipe ends are flared (pipe expanded) to prevent the High pressure pipe A High pressure pipe B Flange O-ring...
  • Page 214 NOTES...
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