Mitsubishi MOTORS Lancer Evolution VIII 2003 Technical Information Manual

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2003

MITSUBISHI

LANCER

EVOLUTION VIII

TECHNICAL

INFORMATION

MANUAL

FOREWORD

This manual has been prepared as an introduction to

the specifications, features, construction, functions,

and other areas of the new 2003 LANCER EVOLU-

TION VIII. It includes Technical Information and Body

Repair Service. The Body Repair sections immediate-

ly follow Group 55 - Heater, Air Conditioning and Ven-

tilation.

Please read this manual carefully so that it will be of

assistance for your service and sales activities. Please

note the following service manuals are also available

and should be used in conjunction with this manual.

SERVICE MANUAL

PARTS CATALOG

No part of this publication may be reproduced, stored in any retrieval

system of transmitted, in any form or by any means, including but not

limited to electronic, mechanical photocopying, recording or otherwise,

without the prior written permission of Mitsubishi Motors Corporation.

ã2003 Mitsubishi Motors Corporation

All Rights, Reserved

Printed in USA

MSSP-260B-2003

GROUP INDEX

General . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . . . .

Engine Electrical. . . . . . . . . . . . . . . .

Engine and Emission Control . . . . .

Clutch. . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transaxle . . . . . . . . . . . . . . .

Propeller Shaft . . . . . . . . . . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . .

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

MSSP-206B-2003

BUM6K103A

Wheel and Tire . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . .

Service Brakes . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . .

Body. . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . .

Interior and Supplemental

General . . . . . . . . . . . . . . . . . . . . . . .

Restraint System (SRS) . . . . . . . . . .

Chassis Electrical . . . . . . . . . . . . . . .

Heater, Air Conditioning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

and Ventilation . . . . . . . . . . . . . . . . .

Body Repair

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Summary of Contents for Mitsubishi MOTORS Lancer Evolution VIII 2003

Page 1 Chassis Electrical ....limited to electronic, mechanical photocopying, recording or otherwise, without the prior written permission of Mitsubishi Motors Corporation. Heater, Air Conditioning ã2003 Mitsubishi Motors Corporation .
Page 2 52B-1 GROUP 52B SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS GENERAL DESCRIPTION..52B-2 SRS-ECU ..... . 52B-10 SYSTEM OPERATION.
Page 3 52B-2 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) GENERAL DESCRIPTION GENERAL DESCRIPTION M2521000100132 CAUTION • Driver and front passenger air bags and seat belt pre-tensioners deploy and operate in all head-on collisions that exceed the threshold to activate the SRS system. • The specific value is the equivalent impact when a vehicle collides against a concrete (fixed) wall at approximately 25 km/h (16 mph) or more.
Page 4 52B-3 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) GENERAL DESCRIPTION CONSTRUCTION DIAGRAM VEHICLES IDENTIFICATION CODE CHART PLATE SRS WARNING LIGHT RADIATOR DRIVER'S AIR BAG MODULE PASSENGER'S (FRONT) AIR BAG MODULE FRONT IMPACT SENSOR CLOCK SPRING DATA LINK CONNECTOR SEAT BELT WITH (FOR SCAN PRE-TENSIONER SRS-ECU TOOL)
Page 5 52B-4 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) GENERAL DESCRIPTION SRS SYSTEM CIRCUIT DIAGRAM IGNITION SWITCH (IG1) No.3 No.2 POWER 7.5A 7.5A BACK UP SOURCE DC-DC CONVERTER CIRCUIT FOR CAPACITOR SIDE-AIRBAG COMBINATION METER (SRS WARNING LIGHT) WARNING LIGHT CONNECTOR LOCK FRONT AIR BAG DRIVE SCAN TOOL SAFING...
Page 6 52B-5 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) GENERAL DESCRIPTION CAUTION LABELS Labels to indicate cautions regarding the handling and the services of SRS air bag air attached on the position shown in the following illustration. COVER CLOCK SPRING SUN VISOR SRS-ECU PASSENGER'S (FRONT) AIR BAG MODULE SEAT BELT WITH PRE-TENSIONER...
Page 7 52B-6 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) GENERAL DESCRIPTION LABEL CONTENTS WARNING: SRS BEFORE REPLACING STEERING WHEEL, READ SERVICE MANUAL. THIS AIR BAG MODULE CANNOT BE REPAIRED. DO NOT DISASSEMBLE OR TAMPER. CAUTION: SRS CLOCK SPRING THIS IS NOT A REPAIRABLE PART. IF DEFECTIVE, REPLACE ENTIRE UNIT ACCORDING TO THE SERVICE MANUAL INSTRUCTIONS.
Page 8 52B-7 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SYSTEM OPERATION LABEL CONTENTS WARNING CHILDREN CAN BE KILLED OR INJURED BY PASSENGER AIR BAG. THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN 12 AND UNDER. MAKE SURE ALL CHILDREN USE SEAT BELTS OR CHILD SEAT. NOT TO BE REMOVED EXCEPT BY OWNER.
Page 9 52B-8 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SYSTEM OPERATION FRONT IMPACT SENSOR CAUTION Never disassemble the front impact sensor. The front impact sensor is installed in the radiator support SENSOR INTERNAL CIRCUIT panel. In a collision, the contact in the front impact sensor turns ON and an output signal is send to the SRS-ECU.
Page 10 52B-9 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SYSTEM OPERATION SRS AIR BAG SPECIAL CONNECTOR SEAT BELT WITH PRE-TENSIONER (DRIVER'S SIDE) CLOCK SPRING DRIVER'S AIR BAG MODULE SRS-ECU PASSENGER'S (FRONT) AIR BAG MODULE SEAT BELT WITH PRE-TENSIONER (FRONT PASSENGER'S SIDE) AC103223 To enhance the Systemís reliability, a connector lock switch is integrated into the SRS-ECU connector, the air bag module connectors, the clock spring connec- tor, the seat belt pretensioner connectors (black con-...
Page 11 52B-10 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS-ECU The switch is a mechanism that shorts the power CAUTION supply terminal to the ground terminal automatically When the connector is disconnected, there will in the air bag squib circuit when the connector is dis- be short circuit between the terminals.
Page 12 52B-11 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS-ECU DIAGNOSTIC TROUBLE CODE OUTPUT The SRS-ECU diagnoses the following items and stores a diagnostic trouble code in the non-volatile memory (EEPROM* ) when a problem is detected. Therefore, the memory is not deleted after a battery terminal is disconnected, (The diagnostic trouble code memory can be deleted by the scan tool.) CODE NO.
Page 13 52B-12 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS-ECU CODE NO. MAJOR CONTENTS OF DIAGNOSTICS Passenger's (front) air bag squib activating circuit short-circuited Passenger's (front) air bag squib activating circuit open-circuited Driverís seat belt pre-tensioner (squib ignition drive circuit) system detected short Driverís seat belt pre-tensioner (squib ignition drive circuit) system detected open Passengerís seat belt pre-tensioner (squib ignition drive circuit) system detected short Passengerís seat belt pre-tensioner (squib ignition drive circuit) system detected...
Page 14 36-1 GROUP 36 PARKING BRAKE CONTENTS GENERAL INFORMATION ..36-2...
Page 15 36-2 PARKING BRAKE GENERAL INFORMATION GENERAL INFORMATION M2360000100173 FEATURE The parking brakes are a mechanical rear wheel brake design and controlled by a lever. CONSTRUCTION DIAGRAM AC211553AB...
Page 16 35B-1 GROUP 35B FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) CONTENTS GENERAL DESCRIPTION..35B-2 BRAKE MODULATOR (ABS-ECU) . . 35B-9 SENSORS ..... 35B-6 SYSTEM OPERATION .
Page 17 35B-2 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) GENERAL DESCRIPTION GENERAL DESCRIPTION M2351000100186 Top components such as Bremboä brakes, EBD and sports ABS improve braking power and braking sta- bility. SPORTS ABS EBD (Electronic Brake-force Distribution • 4-wheel independent control optimizes the brake system) force to each wheel to achieve a balance of •...
Page 18 35B-3 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) GENERAL DESCRIPTION CONSTRUCTION DIAGRAM AC209828 7, 10 10067AU AC211546 NAME OF PART NO. OUTLINE OF FUNCTION Sensor ABS sensor Sends alternating current signals at frequencies which are proportional to the rotation speeds of each wheel to the ABS-ECU. Lateral G-sensor 2 Sends data on vehicleís rate of lateral acceleration to the ABS-ECU.
Page 19 35B-4 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) GENERAL DESCRIPTION SYSTEM CONFIGURATION DIAGRAM FR SOLENOID VALVE (OUT) ABS SENSOR (FL) ABS SENSOR (RL) FR SOLENOID VALVE (IN) ABS SENSOR (RR) FL SOLENOID VALVE (OUT) ABS SENSOR (FR) FL SOLENOID VALVE (IN) LONGITUDINAL G-SENSOR RR SOLENOID VALVE (OUT) RR SOLENOID VALVE (IN) LATERAL G-SENSOR...
Page 20 35B-5 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) GENERAL DESCRIPTION ABS ELECTRICAL CIRCUIT DIAGRAM IGNITION IGNITION FUSIBLE FUSIBLE SWITCH (IG2) SWITCH (IG1) LINK 3 BATTERY LINK 1 JUNCTION BLOCK 7.5A 7.5A 7.5A RELAY COMBINATION METER STOPLIGHT SWITCH ANTI LATERAL LONGITUDINAL LOCK G-SENSOR G-SENSOR STEERING ANGULAR...
Page 21 35B-6 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) SENSORS SENSORS M2351001000137 ABS SENSOR FRONT REAR ABS ROTOR DRIVESHAFT DRIVESHAFT ABS SPEED SENSOR ABS ROTOR ABS SPEED SENSOR AC211549AB • The ABS rotors (43 teeth) are installed to the The ABS sensors consist of fixed ABS speed sen- sors and the ABS rotors that rotate at the same drive shafts, and the ABS speed sensors are speed as the wheels, that output alternating current...
Page 22 35B-7 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) SENSORS STEERING ANGULAR VELOCITY SENSOR OUTPUT WAVEFORM OF EACH PHOTOINTERRUPTOR 2˚ 4˚ 4˚ 4˚ 4˚ STEERING ANGULAR ST-1 VELOCITY SENSOR θ 4˚ 4˚ ST-2 θ θ Y2057AU 11˚ ST-N SLIT θ SLIT PLATE SLIT PLATE NEUTRAL POSITION ZENER DIODE (FOR DETECTION SLIT...
Page 23 35B-8 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) ACTUATORS STOPLIGHT SWITCH PARKING BRAKE SWITCH This switch turns on when the brake pedal is This switch turns on when the parking brake lever is depressed, and turns off when the brake pedal is pulled, and turns off when the parking brake lever is released.
Page 24 35B-9 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) BRAKE MODULATOR (ABS-ECU) BRAKE MODULATOR (ABS-ECU) M2351003000144 The ABS-ECU is basically the same as that of the LANCER except the followings: DIAGNOSTIC FUNCTIONS DIAGNOSTIC TROUBLE CODE OUTPUT ITEM Open circuit or short-circuit in ABS sensor (FR) Open circuit or short-circuit in ABS sensor (FL) Open circuit or short-circuit in ABS sensor (RR) Open circuit or short-circuit in ABS sensor (RL)
Page 25 35B-10 FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) SYSTEM OPERATION SERVICE DATA OUTPUT SCAN TOOL ITEM NO. CHECK ITEM DISPLAY TEXT DISPLAY OR UNIT FR SNSR Front-right ABS sensor km/h or mph FL SNSR Front-left ABS sensor RR SNSR Rear-right ABS sensor RL SNSR Rear-left ABS sensor BATT.
Page 26 35-1 GROUP 35 SERVICE BRAKES CONTENTS SERVICE BRAKES ........FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) .
Page 27 NOTES...
Page 28 35A-1 GROUP 35A SERVICE BRAKES CONTENTS GENERAL DESCRIPTION..35A-2 FRONT DISC BRAKE... . . 35A-5 MASTER CYLINDER ... . . 35A-4 REAR DISC BRAKE .
Page 29 35A-2 SERVICE BRAKES GENERAL DESCRIPTION GENERAL DESCRIPTION M2350000100183 Top components such as Bremboä brakes, EBD and sports ABS improve braking power and braking sta- bility. FEATURES 2. Adoption of an electronic brake-force distribution (EBD) makes it possible to maintain the maxi- Improved braking performance mum amount of braking force even when the 1.
Page 30 35A-3 SERVICE BRAKES GENERAL DESCRIPTION SPECIFICATIONS ITEM SPECIFICATION Master Type Tandem type cylinder I.D. mm (in) 26.9 (1.06) Brake Type Vacuum type, tandem booster Effective dia. of power cylinder 205 + 230 (8.07 + 9.06) mm (in) Boosting ratio 4.5 <Brake pedal depressing force: 230 N (51.7 lb)> Rear wheel hydraulic control method Electronic brake-force distribution (EBD) Front brakes Type...
Page 31 35A-4 SERVICE BRAKES MASTER CYLINDER MASTER CYLINDER M2350001000145 BRAKE FLUID RESERVOIR MASTER CYLINDER BODY PRIMARY PISTON ASSEMBLY PISTON RETAINER SECONDARY PISTON ASSEMBLY AC005372AE The master cylinder is a tandem-type, with a struc- ture that emphasizes safety. BRAKE BOOSTER ASSEMBLY M2350002000148 FRONT DIAPHRAGM REAR DIAPHRAGM PUSH ROD...
Page 32 35A-5 SERVICE BRAKES FRONT DISC BRAKE FRONT DISC BRAKE M2350003000141 PADS FRONT OF VEHICLE AC211388AB • The brake pads are equipped with mechanical- Brakes with the following specifications have been adopted for the front brakes. type audible wear indicators to notify the driver •...
Page 33 35A-6 SERVICE BRAKES REAR DISC BRAKE REAR DISC BRAKE M2350004000155 PADS FRONT OF VEHICLE AC211389AB • The brake pads are equipped with mechanical- Brakes with the following specifications have been adopted for the rear brakes. type audible wear indicators to notify the driver •...
Page 34 34-1 GROUP 34 REAR SUSPENSION CONTENTS GENERAL DESCRIPTION..34-2...
Page 35 34-2 REAR SUSPENSION GENERAL DESCRIPTION GENERAL DESCRIPTION M2340000100137 COMPONENT CHARACTERISTICS A trailing arm type multi-link suspension is used for the rear suspension. In contrast to the trailing arm (COMPARED TO THE LANCER) multi-link system used on the Lancer, the Lancer 1.
Page 36 34-3 REAR SUSPENSION GENERAL DESCRIPTION CONSTRUCTION DIAGRAM COIL SPRING STABILIZER BAR SHOCK ABSORBER UPPER ARM ASSEMBLY CROSSMEMBER (FORGED ALUMINUM) (FORGED ALUMINUM) DIFFERENTIAL SUPPORT STABILIZER BAR LINK MEMBER ASSIST LINK DIFFERENTIAL (FORGED ALUMINUM) SUPPORT ARM ASSIST LINK CONTROL BAR TRAILING ARM ASSEMBLY LOWER ARM ASSEMBLY (FORGED ALUMINUM) (FORGED ALUMINUM)
Page 37 NOTES...
Page 38 33A-1 GROUP 33A FRONT SUSPENSION CONTENTS GENERAL DESCRIPTION..33A-2 STRUT ASSEMBLY ....33A-5 LOWER ARM ....33A-4...
Page 39 33A-2 FRONT SUSPENSION GENERAL DESCRIPTION GENERAL DESCRIPTION M2330000100147 A MacPherson strut independent suspension-type suspension is used for the front suspension. Aggres- sive use of special components that include Mitsubishi Motorís own inverted struts and forged aluminum parts reduces weight to create a suspen- sion that gives superior performance made with com- petition use in mind.
Page 40 33A-3 FRONT SUSPENSION GENERAL DESCRIPTION CONSTRUCTION DIAGRAM COIL SPRING STRUT INSULATOR STABILIZER LINK (PILLOW BALL JOINT) STABILIZER BAR LOWER ARM BUSHING (PILLOW BALL BUSHING) STRUT (INVERTED STRUT) B-POINT G-POINT A-POINT LOWER ARM ASSEMBLY (FORGED ALUMINUM) FRONT AXLE FRONT AXLE No.1 CROSSMEMBER BAR CROSSMEMBER A-POINT...
Page 41 33A-4 FRONT SUSPENSION LOWER ARM LOWER ARM M2330002000050 STOPPERS FRONT OF VEHICLE LOWER ARM ASSEMBLY PILLOW BALL BUSHING ENLARGED BALL DIAMETER AC211384 Use of forged aluminum reduces load on the coil springs and produces nimble suspension action. In addition, outer casings and stoppers on the front bushings and pillow ball bushings in the rear improves the feeling of stiffness and stroke.
Page 42 33A-5 FRONT SUSPENSION STRUT ASSEMBLY STRUT ASSEMBLY M2330001000079 SECTION A -A INVERTED STRUT KNUCKLE FRONT OF ECCENTRIC BOLT VEHICLE -1˚ CAMBER -2˚ CAMBER SELECTED SELECTED -1˚ CAMBER -2˚ CAMBER SELECTED SELECTED AC211392AB An inverted strut layout (with the cylinder at the top between the strut assembly and knuckle.
Page 43 NOTES...
Page 44 00-1 GROUP 00 GENERAL CONTENTS HOW TO USE THIS MANUAL..00-2 SUSPENSION ..... . . 00-7 ACTIVE SAFETY.
Page 45 00-2 GENERAL HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL M2000029000093 ABBREVIATIONS M/T: Indicates manual transaxle, or models equipped with the manual transaxle. The following abbreviations are used in this manual AWD: Indicates 4-wheel-drive vehicles. for classification of model types: A/C: Indicates air conditioning.
Page 46 00-3 GENERAL TECHNICAL FEATURES TECHNICAL FEATURES EXTERIOR M2000017000160 DESIGN FEATURES AC205386 AC205387 AC210723 6. Rear Spoiler 1. Large Three Diamond Mark Placing top priority on weight reduction, the rear spoiler made of carbon fiber is used as a standard. The vertical struts give the impression of speedy per- 2.
Page 47 00-4 GENERAL TECHNICAL FEATURES INTERIOR M2000018000152 DESIGN FEATURES AC211416 It is vertically angled toward the front. 1. Steering wheel A MOMO leather-wrapped 3-spoke steering 4. Separated center panel and floor console wheel is used. 5. Seats 2. Meter panel High-back sport type RECARO seats are used in The driver-oriented meter panel has been the front, and a high-back bench seat is used for designed for easy visibility.
Page 48 00-5 GENERAL TECHNICAL FEATURES BODY DIMENSIONS M2000019000133 AC102003AB NO. ITEM DIMENSION ITEM DIMENSION Overall length mm (in) 4,535 (178.5) Tread mm (in) Front 1,515 (59.6) Overall width mm (in) 1,770 (69.7) Rear 1,515 (59.6) Overall height mm (in) 1,450 (57.1) Front leg space mm (in) 930 (36.6) Rear leg space mm (in)
Page 49 00-6 GENERAL TECHNICAL FEATURES MINIMUM TURNING RADIUS NO. ITEM DIMENSION Effective turning radius mm (in) 5,900 (232.3) Minimum turning radius mm (in) 5,600 (220.5) Front overhang mm (in) 930 (36.6) Wheelbase mm (in) 2,625 (103.3) AC005234 ENGINE M2000020000104 2.0-litre 16-valve DOHC engine The 4G63 2.0-liter engine is available with MFI.
Page 50 00-7 GENERAL TECHNICAL FEATURES SUSPENSION M2000023000095 LOWER ARM BUSHING STABILIZER LINK (PILLOW BALL BUSHING) (PILLOW BALL JOINT) STRUT INSULATOR COIL SPRING STABILIZER BAR STRUT (INVERTED STRUT) LOWER ARM ASSEMBLY (FORGED ALUMINUM) FRONT AXLE No.1 CROSSMEMBER UPPER ARM ASSEMBLY FRONT AXLE (FORGED ALUMINUM) CROSSMEMBER BAR CROSSMEMBER...
Page 51 00-8 GENERAL TECHNICAL FEATURES ACTIVE SAFETY M2000031000090 BRAKING SYSTEM PARKING BRAKE SWITCH STEERING ANGULAR VELOCITY SENSOR HYDRAULIC UNIT {INTEGRATED IN BRAKE MODULATOR (ABS-ECU)} 10067AU ABS SENSOR LATERAL G-SENSOR DATA LINK LONGITUDINAL G-SENSOR CONNECTOR ABS SENSOR STOPLIGHT SWITCH AC211719 Top components such as Bremboä brakes, EBD and EBD (Electronic Brake-force Distribution sports ABS aim to improve braking power and brak- system)
Page 52 00-9 GENERAL TECHNICAL FEATURES PASSIVE SAFETY M2000032000093 SRS AIR BAGS DRIVER'S AIR BAG PASSENGER'S SEAT BELT PRE-TENSIONER (FRONT) AIR BAG AC211587AB Driverís and front passengerís air bags and seat SEAT BELT WITH PRE-TENSIONER belts with pre-tensioner are standard. The seat belts with pre-tensioner work simulta- neously with the SRS.
Page 53 00-10 GENERAL TECHNICAL FEATURES BODY CONSTRUCTION SIDE DOOR BEAM ENLARGED CROSS-SECTION OF ROOF BOW REINFORCED FRONT PILLAR ENLARGED CROSS- SECTION AND EXTENDED FRONT REINFORCED CENTER SIDE MEMBER PILLAR ENLARGED CROSS-SECTION OF SIDE SILL ENLARGED CROSS-SECTION AND MINIMIZED VERTICAL OFFSET OF FRONT FLOOR MEMBER ADDED DASH CROSSMEMBER AC211731AB...
Page 54 00-11 GENERAL TECHNICAL FEATURES Items Dealing with Environmental Protection PREVENTION OF PART NAME MAIN DETAIL ATMOSPHERIC POLLUTION Recycling Air cleaner case Application of recycled polypropylene material that contains recycled paper makes effective use of resources and reduces weight. Hood weatherstripping Use of a thermoplastic elastomer olefin material makes recycling easier.
Page 55 00-12 GENERAL VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION M2000001000280 VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number (VIN) is located on a plate attached to the left top side of the instrument panel. AC100836AB VEHICLE IDENTIFICATION CODE CHART PLATE All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.
Page 56 00-13 GENERAL GENERAL DATA AND SPECIFICATIONS GENERAL DATA AND SPECIFICATIONS M2000030000116 GENERAL SPECIFICATIONS AC211823 ITEM CT9A SNGFZL 2M Vehicle Overall length 1 4,535 (178.5) dimension mm (in) Overall width 2 1,770 (69.7) Overall height 3 1,450 (57.1) (unladen) Wheelbase 4 2,625 (103.3) Tread-front 5 1,515 (59.6) Tread-rear...
Page 57 NOTES...
Page 58 31-1 GROUP 31 WHEEL AND TIRE CONTENTS GENERAL INFORMATION ..31-2...
Page 59 31-2 WHEEL AND TIRE GENERAL INFORMATION GENERAL INFORMATION M2310000100178 The following wheel and tire specifications have been established. SPECIFICATIONS ITEM SPECIFICATION Wheel Type Aluminum type 17 × 8JJ Size Amount of wheel offset mm (in) 38 (1.5) Pitch circle diameter (PCD) mm 114.3 (4.50) (in) Tire...
Page 60 21-1 GROUP 21 CLUTCH CONTENTS GENERAL DESCRIPTION..21-2...
Page 61 21-2 CLUTCH GENERAL DESCRIPTION GENERAL DESCRIPTION M2210000100063 The clutch is a dry single-disc, diaphragm type using hydraulic controls. SPECIFICATIONS ITEM SPECIFICATION Engine model 4G63-DOHC-Intercooler Turbocharger Clutch disc type Dry single plate type 240 × 160 (9.4 × 6.3) Clutch disc facing diameter OD x ID mm (in) Clutch cover type Diaphragm spring type 9,320 ±...
Page 62: Table Of Contents
37-1 GROUP 37 POWER STEERING CONTENTS GENERAL DESCRIPTION..37-2 OIL PUMP ..... . 37-6 STEERING WHEEL .
Page 63: General Description
37-2 POWER STEERING GENERAL DESCRIPTION GENERAL DESCRIPTION M2370000100129 • A rack and pinion steering gear provides steering FEATURES that feels more direct and for ample handling per- Power steering has been adopted in all vehicles to formance. make the steering easier. •...
Page 64: Oil Pump
37-3 POWER STEERING STEERING WHEEL CONSTRUCTION DIAGRAM STEERING WHEEL STEERING COLUMN SHAFT ASSEMBLY RETURN OIL RESERVOIR HOSE PRESSURE HOSE SUCTION HOSE OIL PUMP ASSEMBLY STEERING GEAR COOLER TUBE ASSEMBLY ASSEMBLY AC211250 AB STEERING WHEEL M2370001000147 The steering wheel has the following features: •...
Page 65: Steering Shaft And Column
37-4 POWER STEERING STEERING SHAFT AND COLUMN STEERING SHAFT AND COLUMN M2370002000128 TILT BRACKET(A) TILT BRACKET(B) STEERING SHAFT ASSEMBLY TILT LEVER SECTION B-B SECTION A-A ONEWAY CAPSULE RIVET AC209414AC • A collapsible intermediary shaft prevents the The steering column allows drivers to sit in their pre- ferred driving position, and the tilt steering wheel steering column from entering the passenger offers easy access.
Page 66 37-5 POWER STEERING STEERING SHAFT AND COLUMN SHOCK ABSORBING MECHANISM PRIMARY IMPACT When the vehicle is in a collision and there is a force applied to BEFORE COLLISION the steering column assembly from the steering gear, the col- lapse device is contracted to absorb the shock load. This pre- vents the steering column from moving into the passenger compartment during the impact.
Page 67 37-6 POWER STEERING OIL PUMP 2. As the bracket breaks free, the rivet comes out of the U- BEFORE COLLISION section groove in the tilt plate, allowing the steering column U-SECTION GROOVE assembly to move towards the engine compartment. RIVET TILT PLATE TILT BRAKET (B) STEERING COLUMN...
Page 68 37-7 POWER STEERING STEERING GEAR STEERING GEAR M2370003000079 TIE-ROD END GEAR HOUSING VALVE HOUSING TIE-ROD BELLOWS HOLLOW GEAR HOUSING BUSHING CROSSMEMBER INNER PIPE CROSSMEMBER AC211252 AB • Using the following parts have contributed to • The installation accuracy, rigidity and steering reduce weight: aluminium steering gear and link- stability have been improved by using an eye age valve housing, plastic tie-rod bellows, and...
Page 69 37-8 POWER STEERING OIL RESERVOIR OIL RESERVOIR M2370005000064 An oil reservoir is rubber-mounted. RUBBER MOUNT VIEW A RUBBER MOUNT AC211259 AB...
Page 70 27-1 GROUP 27 REAR AXLE CONTENTS REAR AXLE ....27-2 DIFFERENTIAL....27-3...
Page 71 27-2 REAR AXLE REAR AXLE REAR AXLE M2270003000083 • The driveshaft on differential side incorporates a The rear axle consists of rear wheel hub assembly, knuckles and driveshafts, and has the following fea- TJ type constant velocity joint. • ABS rotors for detecting the wheel speed are tures: •...
Page 72 27-3 REAR AXLE DIFFERENTIAL DIFFERENTIAL M2270001000087 A mechanical-type Limited Slip Differential is used. The differential specifications are established as fol- lows. SPECIFICATIONS ITEM SPECIFICATION Reduction gear type Hypoid gear Reduction ratio 3.307 Differential gear type (Type × number of Straight bevel gear × 2 Side gear gears) Straight bevel gear ×...
Page 73 27-4 REAR AXLE DIFFERENTIAL DIFFERENTIAL MOUNT The front of differential carrier is supported with the differential support member via the differential mount bracket with insulator. The rear is supported with the differential support arm. CONSTRUCTION DIAGRAM TOE CONTROL DIFFERENTIAL SUPPORT MEMBER DIFFERENTIAL SUPPORT DIFFERENTIAL...
Page 74 54-1 GROUP 54 CHASSIS ELECTRICAL CONTENTS CHASSIS ELECTRICAL ....... SIMPLIFIED WIRING SYSTEM (SWS) ....
Page 75 NOTES...
Page 76 54A-1 GROUP 54A CHASSIS ELECTRICAL CONTENTS GENERAL DESCRIPTION..54A-2 LIGHTING ..... . 54A-5 DIAGNOSIS SYSTEM .
Page 77: General Description
54A-2 CHASSIS ELECTRICAL GENERAL DESCRIPTION GENERAL DESCRIPTION M2540000100142 FEATURES 6. A large combination meter with analog indicators is used. 1. Waterproof connectors are used in the engine 7. Position light indicator is used in the combination compartment. meter. 2. A relay box is used. 8.
Page 78: Battery
54A-3 CHASSIS ELECTRICAL BATTERY DATA LINK CONNECTOR DATA LINK CONNECTOR (BLACK) Diagnosis control 2, 3 − Grounding Grounding − MFI, ABS, SRS − ETACS-ECU − − − 12-PIN CONNECTOR 16-PIN CONNECTOR (WHITE) (BLACK) − Simulated vehicle speed signal AC005418AB − Battery DATA LINK CONNECTOR (WHITE) 21 −...
Page 79: Immobilizer System
54A-4 CHASSIS ELECTRICAL IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM M2540003000069 The engine immobilizer system prevents the engine 4. The immobilizer ECU compares the ID code that from starting and immobilizes the vehicle if a key was sent with pre-registered ID codes, and if it other than the key registered for that vehicle is used matches, a control signal approving ignition is in an attempt to start the engine after forced entry.
Page 80: Lighting
54A-5 CHASSIS ELECTRICAL LIGHTING LIGHTING M2540004000192 EXTERIOR LIGHTS REAR COMBINATION LIGHT • A rear combination light is exclusive for EVOLU- HEADLIGHT ASSEMBLY TION. • A high intensity discharge (HID) headlight is pro- HIGH MOUNT STOP LIGHT vided for low-beam headlight, so that visibility is •...
Page 81 54A-6 CHASSIS ELECTRICAL LIGHTING HIGH MOUNT STOP LIGHT LICENSE PLATE LIGHT BACK-UP LIGHT REAR COMBINATION LIGHT TAILLIGHT STOP/TAIL LIGHT TURN SIGNAL LIGHT AC210962 DESCRIPTION OF STRUCTURE AND OPERATION FOR HID HEADLIGHT INCEPTIVE GAS (XENON) ELECTRODE (TUNGSTEN) ELECTRODE (TUNGSTEN) DISCHARGE BULB METAL IODIDE MERCURY (SODIUM, SCANDIUM)
Page 82 54A-7 CHASSIS ELECTRICAL LIGHTING INTERIOR LIGHTS • A map light serving also as front dome light can • A rear dome light illuminates the back seat. A be used at both the driver's seat and passenger trunk light immuminates the trunk. seat..
Page 83: Combination Meter
54A-8 CHASSIS ELECTRICAL COMBINATION METER COMBINATION METER M2540005000151 • A large, clear LCD type odo-tripmeter is provided. The combination meter features large, clearly visible analog gauges. The gauges are arranged with the The odometer continuously displays values while tachometer in the middle, the speedometer at left, the tripmeter has a twin-trip (trip A, trip B) func- and the fuel and coolant temperature gauges and tion which is switched by a reset button.
Page 84 54A-9 CHASSIS ELECTRICAL RADIO, CD PLAYER, SPEAKER, ANTENNA CONSTRUCTION DIAGRAM ROOF ANTENNA TWEETER* FRONT SPEAKER* CD PLAYER CD CHANGER REAR SPEAKER* AC210965 NOTE: The * indicates equipped on the left and right sides. <RADIO AND CD CHANGER> P000 SCAN AUDIO PUSH SEEK TRACK...
Page 85 NOTES...
Page 86 51-1 GROUP 51 EXTERIOR CONTENTS GENERAL INFORMATION ..51-2 WINDSHIELD WIPER AND WASHER 51-5 GENERAL INFORMATION ... . . 51-5 BUMPER ..... . 51-3 REAR WIPER AND WASHER .
Page 87 51-2 EXTERIOR GENERAL INFORMATION GENERAL INFORMATION M2510000100547 The front mask carries on and further instills the new 4. Rear Spoiler Mitsubishi design identity while also achieving a bal- Two types of rear spoiler are available (i.e. Type A ance of cooling and aerodynamic performance. Con- and B).
Page 88 51-3 EXTERIOR BUMPER BUMPER GENERAL INFORMATION M2510000100592 A large front bumper integrated with radiator grill and a rear bumper integrated with rear under spoiler have been adopted for better aerodynamic perfor- mance. A cooling hole for the intercooler is in the center of the front bumper.
Page 89 51-4 EXTERIOR AERO PARTS AERO PARTS GENERAL INFORMATION M2510000100558 • An under cover, a side air dam and a rear spoiler • The rear spoiler has two types. Type A is stan- have been adopted for better aerodynamic per- dard, and type B is optional equipment. The formance and an appealing look.
Page 90 51-5 EXTERIOR WINDSHIELD WIPER AND WASHER WINDSHIELD WIPER AND WASHER GENERAL INFORMATION M2510000100569 CONSTRUCTION DIAGRAM WIPER BLADE WIPER ARM WIPER MOTOR WIPER LINK ASSEMBLY FRAME AC210201...
Page 91 51-6 EXTERIOR WINDSHIELD WIPER AND WASHER TANK LID HINGE WASHER TANK Y1893AU WASHER TANK FRONT WASHER MOTOR WASHER NOZZLE WASHER HOSE AC210194 • Two-speed type windshield wipers operate at low • The mist wiper function is activated by moving or high speed. the wiper switch in the opposite direction.
Page 92 51-7 EXTERIOR REAR WIPER AND WASHER REAR WIPER AND WASHER GENERAL INFORMATION M2510000100570 CONSTRUCTION DIAGRAM WASHER HOSE WIPER BLADE WIPER ARM WASHER NOZZLE WASHER TANK WIPER MOTOR FRONT WASHER MOTOR REAR WASHER MOTOR AC210174 • The fixed interval type intermittent wiper has •...
Page 93 51-8 EXTERIOR OUTSIDE MIRROR OUTSIDE MIRROR GENERAL INFORMATION M2510000100581 Electric remote control outside mirror have been adopted. CONSTRUCTION DIAGRAM OUTSIDE MIRROR REMOTE CONTROL MIRROR SWITCH Y1043AU MIRROR SURFACE Y0320AU AC210398...
Page 94 26-1 GROUP 26 FRONT AXLE CONTENTS GENERAL DESCRIPTION..26-2...
Page 95 26-2 FRONT AXLE GENERAL DESCRIPTION GENERAL DESCRIPTION M2260000100132 • The drive shaft on the differential side incorpo- The front axle consists of front wheel hub assembly, knuckles and drive shafts, and has the following fea- rates a TJ type constant velocity joint. •...
Page 96 54B-1 GROUP 54B SIMPLIFIED WIRING SYSTEM (SWS) CONTENTS GENERAL INFORMATION ..54B-2 DIAGNOSTIC TROUBLE CODE SET ......54B-5 COMMUNICATION METHOD .
Page 97: General Information
54B-2 SIMPLIFIED WIRING SYSTEM (SWS) GENERAL INFORMATION GENERAL INFORMATION M2541000100167 SWS is a minimal line system which transmits NOTE: : ETACS (Electronic Time and Alarm Con- numerous signals using one wiring system. trol System) To transmit numerous signals, the ETACS -ECU, col- umn switch and front-ECU incorporate multi-distribu- tion circuits to carry out communication between...
Page 98: Multi-Distribution Input/Output
54B-3 SIMPLIFIED WIRING SYSTEM (SWS) MULTI-DISTRIBUTION INPUT/OUTPUT BY CIRCUIT MULTI-DISTRIBUTION INPUT/OUTPUT BY CIRCUIT M2541002000144 Multi-distribution is employed by the following cir- cuits. The relation of the input switches, sensors, ECUs connected by multi-distribution lines, and out- puts are also shown below. TONE ALARM •...
Page 99 54B-4 SIMPLIFIED WIRING SYSTEM (SWS) MULTI-DISTRIBUTION INPUT/OUTPUT BY CIRCUIT REAR WIPER AND WASHER • Rear wiper • Rear washer ECU AND SWITCH INPUT SWITCH OUTPUT SIDE CONNECTED BY MULTI-DISTRIBUTION COLUMN SWITCH (REAR WIPER WASHER SWITCH) • IGNITION SWITCH (ACC) • REAR WIPER MOTOR ETACS-ECU •...
Page 100: Diagnostic Trouble Code Set
54B-5 SIMPLIFIED WIRING SYSTEM (SWS) DIAGNOSTIC FUNCTION DIAGNOSTIC FUNCTION M2541003000136 DIAGNOSTIC TROUBLE CODE SET The ETACS-ECU sends diagnostic trouble codes if NOTE: Refer to the Service Manual for details of the the communication line is faulty when the scan tool is diagnostic items.
Page 101: Tone Alarm
54B-6 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS FUNCTIONS AND CONTROL OF SWS ECUS M2541004000151 The following functions are controlled by the SWS ECUs: FUNCTION CONTROL ECU DESCRIPTION TONE ALARM Ignition key reminder tone alarm function ETACS-ECU P.54B-7 Light reminder tone alarm function ETACS-ECU, column switch...
Page 102 54B-7 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS TONE ALARM Ignition key reminder tone alarm function When the driverís door is opened with the ignition key inserted in the ignition key cylinder (ignition switch is in the OFF posi- IGNITION SWITCH (IG1) tion,) the tone alarm sounds intermittently to indicate that the...
Page 103 54B-8 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS CENTRAL DOOR LOCKING SYSTEM Door locking by operating the driverís or front passengerís door lock key cylinder When the key is inserted in the driverís or front passengerís DRIVER'S OR (LOCK) door lock key cylinder and turned counterclockwise to lock the PASSENGER'S...
Page 104 54B-9 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS Door locking or unlocking by operating the driverís or front passengerís door lock switch When the door is locked by the driverís or front passengerís door lock switch, the ETACS-ECU operates its door lock relay DRIVER'S OR (LOCK) and passes a current through the door lock actuators of all...
Page 105 54B-10 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS Timed locking mechanism After unlocking the doors with the keyless entry transmitter, if no doors are opened, if the key is not inserted or if the locking function is not operated, the ETACS-ECU automatically locks the doors in 30 seconds.
Page 106 54B-11 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS The front-ECU determines the intermittent time TI from the input SWS data signal, and turns ON the windshield wiper drive signal. When the wiper is at the STOP position, the windshield WINDSHIELD WIPER DRIVE wiper auto-stop signal goes OFF to turn OFF the windshield...
Page 107 54B-12 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS Low speed wiper and high speed wiper control WINDSHIELD LOW-SPEED WIPER SWITCH WINDSHIELD HIGH-SPEED WIPER SWITCH WINDSHIELD WIPER AUTO-STOP SIGNAL WINDSHIELD WIPER DRIVE SIGNAL ON (HIGH) WINDSHIELD WIPER SPEED SWITCHING OFF (LOW) RELAY LOW SPEED OPERATIONS...
Page 108 54B-13 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS REAR WIPER AND WASHER Rear wiper control REAR WIPER SWITCH BACKUP LIGHT SWITCH REAR WIPER DRIVE SIGNAL t: 1 SECOND T1: 7.4 SECONDS T3: 3 SECONDS T2: 8 SECONDS T4: 0.6 SECOND AC101553 If the rear wiper switch of the column switch assem-...
Page 109 54B-14 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS HEADLIGHT Headlight automatic-shutdown function If the lighting switch (taillight switch or headlight switch) is ON, IGNITION SWITCH the headlights (including the taillights) will automatically go off (IG1) in the following conditions to prevent the battery from discharg- DRIVER'S DOOR ing.
Page 110 54B-15 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS FLASHER TIMER FUNCTION Turn signal light The turn signal light output (flashing signal) is turned ON when the turn signal light ignition switch is ON and the turn signal IGNITION SWITCH light switch is ON (LH or RH.) If the front turn signal light or rear TURN SIGNAL...
Page 111 54B-16 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS • When a door is opened with the ignition switch • When the ignition key is removed with all doors off, the dome light lights up at a luminance of 100 closed, the dome light lights up at a luminance of percent.
Page 112 54B-17 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS Door-ajar indicator light function This indicator light warns the driver that door(s) are not closed. If a door switch is on, the ETACS-ECU operates the door-ajar indicator light on the combina- tion meter.
Page 113 54B-18 SIMPLIFIED WIRING SYSTEM (SWS) FUNCTIONS AND CONTROL OF SWS ECUS FUNCTION CONFIGURATION PROCEDURE Headlight automatic-shutdown When the passing switch is turned ON for more than two seconds with the function auto-light switch ON and the turn signal light switch turned to RH, the headlight automatic-shutdown function is switched between available and unavailable.
Page 114 11A-1 GROUP 11A ENGINE CONTENTS GENERAL SPECIFICATIONS ..11A-2 BASE ENGINE ....11A-3...
Page 115 11A-2 ENGINE GENERAL DESCRIPTION GENERAL DESCRIPTION M2112000100233 The model 4G63-DOHC engine, based on the 4G63 single-overhead-camshaft engine has four valves per cylinder and two camshafts in the cylinder head (double-overhead-camshaft configuration). GENERAL SPECIFICATIONS ITEM 4G63-DOHC-T/C 1,997 Total displacement 　 cc Combustion chamber Pent roof type Bore ×...
Page 116 11A-3 ENGINE BASE ENGINE BASE ENGINE M2112001000176 CYLINDER HEAD The cylinder head is made of an aluminum alloy that The spark plugs are located at the center of the com- is lightweight and offers outstanding cooling effi- bustion cambers. ciency. The camshaft bearings are placed at six locations on The combustion chamber is of the pent-roof type.
Page 117 11A-4 ENGINE BASE ENGINE TIMING BELT TRAIN The intake camshaft, exhaust, and the oil pump are All sprockets are made of a sintered alloy. driven by a single timing belt. Timing belt tension varies at different engine temper- atures and ages of the belt. The auto tensioner absorbs changes in belt tension to prevent the noise problem from getting worse and to improve durability.
Page 118 11A-5 ENGINE BASE ENGINE VALVE The change to natrium-filled exhaust valves reduces weight and assists in cooling the bell section. NATRIUM-FILLED AK204065AB...
Page 119 NOTES...
Page 120 15-1 GROUP 15 INTAKE AND EXHAUST CONTENTS AIR INTAKE SYSTEM ... . 15-2 EXHAUST SYSTEM ....15-5 AIR DUCT AND AIR CLEANER .
Page 121: Air Intake System
15-2 INTAKE AND EXHAUST AIR INTAKE SYSTEM AIR INTAKE SYSTEM AIR DUCT AND AIR CLEANER M2150004000032 • The air cleaner is made from recycled paper • Unrestricted fresh ambient air enters from above mixed with plastic to reduce industrial wastes and the radiator, engine performance has been protect the environment.
Page 122: Charge Air Cooler Water Spray
15-3 INTAKE AND EXHAUST AIR INTAKE SYSTEM CHARGE AIR COOLER WATER SPRAY M2150008000012 • Sprays water when the water spray switch on the To complement the charge air cooler efficiency in floor console is operated. ranges where the cooling efficiency of the air cooled •...
Page 123 15-4 INTAKE AND EXHAUST AIR INTAKE SYSTEM SYSTEM DIAGRAM FRONT-ECU IGNITION IGNITION TAILLIGHT SWITCH (IG1) SWITCH (IG2) RELAY RELAY JUNCTION BLOCK JOINT JOINT CONNECTOR (2) CONNECTOR (4) JUNCTION BLOCK CHARGE AIR COOLER COMBINATION WATER SPRAY METER RELAY JOINT CONNECTOR (1) ENGINE CONTROL MODULE...
Page 124: Exhaust System
15-5 INTAKE AND EXHAUST EXHAUST SYSTEM EXHAUST SYSTEM TURBOCHARGER M2150009000015 Dual exhaust passages from the engine to the tur- bine housing prevents obstruction of the flow and guides the exhaust gas smoothly to the turbine to improve low and mid-range torque and engine response.
Page 125: Exhaust Pipe And Muffler
15-6 INTAKE AND EXHAUST EXHAUST SYSTEM EXHAUST PIPE AND MUFFLER M2150003000039 • All stainless exhaust piping reduces corrosion The exhaust system consists of 3 separate sections: and heat. front exhaust pipe, center exhaust pipe, and main • Thermal insulating cover and materials on front muffler.
Page 126 13B-1 GROUP 13B FUEL SUPPLY CONTENTS GENERAL DESCRIPTION..13B-2 FUEL TANK ....13B-3...
Page 127 13B-2 FUEL SUPPLY GENERAL DESCRIPTION GENERAL DESCRIPTION M2134000100123 The fuel tank assembly consists of the following The fuel system consists of the following compo- • Fuel pump module nents: • Fuel level sensor (sub) • Fuel injector • Fuel tank leveling valve assembly •...
Page 128 13B-3 FUEL SUPPLY FUEL TANK FUEL TANK M2134001000163 • Fuel tank shut-off valve A steel fuel tank is located under the floor of the rear • Fuel tank differential pressure sensor seats to provide increased safety and increase the • Fuel tank temperature sensor amount of luggage compartment space.
Page 129 NOTES...
Page 130 25-1 GROUP 25 PROPELLER SHAFT CONTENTS GENERAL DESCRIPTION..25-2...
Page 131 25-2 PROPELLER SHAFT GENERAL DESCRIPTION GENERAL DESCRIPTION M2250000100089 • For environmental protection, a lead-free grease A 3 way split, 4-joint type propeller shaft with center bearing, with the following features is utilized: is used on the LJ and the center bearing. •...
Page 132 16-1 GROUP 16 ENGINE ELECTRICAL CONTENTS CAMSHAFT POSITION SENSOR . . . 16-2...
Page 133 16-2 ENGINE ELECTRICAL CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR M2163002000069 The camshaft position sensor detects the camshaft position using a sensing cylinder which is mounted at the rear end the exhaust camshaft. CAMSHAFT SENSING CYLINDER CAMSHAFT POSITION SENSOR AK204160...
Page 134 12-1 GROUP 12 ENGINE LUBRICATION CONTENTS GENERAL DESCRIPTION..12-2...
Page 135 12-2 ENGINE LUBRICATION GENERAL DESCRIPTION GENERAL DESCRIPTION M2120000100012 The drawn cup air-cooled type engine oil cooler has been adopted. The engine oil cooler is installed below the right headlight assembly and brings in the air through the oil cooler duct of the front bumper to cool the engine oil.
Page 136 55-1 GROUP 55 HEATER, AIR CONDITIONING AND VENTILATION CONTENTS GENERAL INFORMATION ..55-2 VENTILATION SYSTEM... 55-6 HEATER AND AIR CONDITIONER SYSTEM ..... . . 55-4...
Page 137 55-2 HEATER, AIR CONDITIONING AND VENTILATION GENERAL INFORMATION GENERAL INFORMATION M2551000100191 The heater and air conditioner system incorporating Reliable visual field (improvement in safety) the heater and cooling unit has reduced ventilation 1. Achievement of ventilation system to defog win- resistance to increase air volume and reduce noise.
Page 138 55-3 HEATER, AIR CONDITIONING AND VENTILATION GENERAL INFORMATION CONSTRUCTION DIAGRAM BLOWER ASSEMBLY LIQUID PIPE B LIQUID PIPE A FLEXIBLE SUCTION HOSE HEATER UNIT A/C COMPRESSOR FLEXIBLE SUCTION PIPE CONDENSOR FAN CONDENSOR DISCHARGE FLEXIBLE HOSE AC210187 HEATER UNIT MOTOR FOR INSIDE/OUTSIDE AIR SELECTION DAMPER AIR THERMOMETER SENSOR...
Page 139 55-4 HEATER, AIR CONDITIONING AND VENTILATION HEATER AND AIR CONDITIONER SYSTEM HEATER AND AIR CONDITIONER SYSTEM M2551001000197 BLOWER ASSEMBLY AND HEATER UNIT OUTLET AIR CHANGEOVER DAMPER INTAKE DUCT HEATER UNIT HEATER CORE AIR MIX DOOR EVAPORATOR (COOLING UNIT) INSIDE AND OUTSIDE AIR CHANGEOVER DAMPER BLOWER ASSEMBLY AC211013...
Page 140 55-5 HEATER, AIR CONDITIONING AND VENTILATION HEATER AND AIR CONDITIONER SYSTEM HEATER AND AIR CONDITIONER CONTROL OUTLET CHANGEOVER TEMPERATURE SWITCH ADJUSTMENT SWITCH BLOWER SWITCH REAR WINDOW INSIDE/OUTSIDE AIR DEFOGGER SWITCH AC006080 CHANGEOVER SWITCH AIR-CONDITIONER SWITCH • Rear window defogger switch with timer The following are heater and air conditioner control •...
Page 141 55-6 HEATER, AIR CONDITIONING AND VENTILATION VENTILATION SYSTEM VENTILATION SYSTEM M2551002000145 DESCRIPTION OF STRUCTURE AND OPERATION TO WINDSHIELD (DEFROSTER) TO FRONT DOOR WINDOW (SIDE DEFROSTER) CENTER TO FRONT DOOR WINDOW SIDE VENTILATOR VENTILATOR (SIDE DEFROSTER) SIDE VENTILATOR TO DRIVER SEAT FOOTWELL TO PASSENGER SEAT FOOTWELL AC210428 AIR OUTLET...
Page 142 32-1 GROUP 32 POWER PLANT MOUNT CONTENTS GENERAL DESCRIPTION..32-2...
Page 143 32-2 POWER PLANT MOUNT GENERAL DESCRIPTION GENERAL DESCRIPTION M2320000100113 • Installation of roll stopper in the upper area has The inertia axial system based the LANCER system has been adopted for the engine mount system. reduced engine rolling. Furthermore, enlarge- •...
Page 144 14-1 GROUP 14 ENGINE COOLING CONTENTS GENERAL DESCRIPTION ..14-2...
Page 145 14-2 ENGINE COOLING GENERAL DESCRIPTION GENERAL DESCRIPTION M2140000100122 • To improve engine cooling performance and The cooling system is a water-cooled pressurized, forced circulation type which offers the following fea- reduce weight, a plastic tank and aluminum radia- tures. tor fins are used. •...
Page 146 52-1 GROUP 52 INTERIOR AND SUPPLEMENTAL SYSTEM (SRS) CONTENTS INTERIOR ......... . SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .
Page 147 NOTES...
Page 148 52A-1 GROUP 52A INTERIOR CONTENTS GENERAL INFORMATION ..52A-2 SEAT BELT..... 52A-7 INSTRUMENT PANEL AND FLOOR TRIMS .
Page 149: General Information
52A-2 INTERIOR GENERAL INFORMATION GENERAL INFORMATION M2520000100247 FEATURES 7. Folding assist grip 8. Nonflammable materials are used for instrumen- Improvements in quality tal panel, floor console, and trims. 1. Fully trim-covered interior Usability 2. Formed type door trims with cloth inserts 1.
Page 150: Instrument Panel And Floor Console
52A-3 INTERIOR INSTRUMENT PANEL AND FLOOR CONSOLE INSTRUMENT PANEL AND FLOOR CONSOLE M2520001000124 TITANIUM COLOR PAINT AIR BAG DOOR CENTER PANEL BOX FLOOR CONSOLE BOX WITH LID GLOVE BOX REAR SEAT ASHTRAY FRONT SEAT ASHTRAY CUP HOLDER AC210431AB • A pad incorporating the front passengerís air bag The instrument panel and the floor console have the following features.
Page 151: Accessories
52A-4 INTERIOR ACCESSORIES ACCESSORIES M2520002000105 SUNGLASSES POCKET MAP LAMP TICKET HOLDER, VANITY MIRROR WITH LID FOLDING ASSIST GRIP VANITY MIRROR WITH LID AC211396 • A push-opening sunglasses pocket (incorporating • A ticket holder is on the driverís side. • A folding assist grip has been installed to improve a map lamp) has been installed to improve con- venience <Vehicles without sunroof>.
Page 152: Seat
52A-5 INTERIOR SEAT SEAT FRONT SEAT M2520004000134 RECLINING ADJUSTMENT AC210102AB SLIDING ADJUSTMENT • Adjustments for both reclining and sliding are High-back sport type RECARO seat is used for the front seat. The front seats offer the following advan- step-free to allow occupants to adjust the seats to tages: achieve the best posture for driving.
Page 153: Rear Seat
52A-6 INTERIOR SEAT REAR SEAT M2520007000111 <ISO-FIX CHILD SEAT FIXING BAR> <UPPER TETHER ANCHOR> CUP HOLDER ARMREST AC209729 • An upper tether anchor has been installed on the A high-back bench seat is used for rear seat. The rear seat offer the following advantages: rear shelf trim, and an ISO-FIX child seat fixing •...
Page 154: Seat Belt
52A-7 INTERIOR SEAT BELT SEAT BELT M2520010000111 SEAT BELT WARNING LIGHT 3-POINT SEAT BELT WITH ELR/ALR CHANGEOVER MECHANISM ELR 3-POINT SEAT BELT SEAT BELT RETRACTOR ONE-TOUCH PUSH BUTTON STYLE ADJUSTABLE SEAT BELT ANCHOR SEAT RETRACTABLE BUCKLE 3-POINT SEAT BELT WITH ELR/ALR CHANGEOVER MECHANISM SEAT BELT RETRACTOR AC209722...
Page 155 52A-8 INTERIOR SEAT BELT SEAT BELT RETRACTOR WITH FORCE LIMITER The driverís/front passengerís seat belt retractor has been equipped with a force limiter. The force limiter is a device which operates when a predetermined force is applied, and limits the force.
Page 156: Trims
52A-9 INTERIOR TRIMS TRIMS INTERIOR TRIMS M2520012000098 REAR PILLAR TRIM (BACK SIDE) ENERGY ABSORPTION RIB FRONT PILLAR TRIM (BACK SIDE) ENERGY ABSORPTION RIB REAR PILLAR TRIM UPPER CENTER PILLAR TRIM REAR SHELF TRIM FRONT PILLAR TRIM COWL SIDE TRIM REAR SCUFF PLATE LOWER CENTER PILLAR TRIM FRONT SCUFF PLATE AC209732...
Page 157: Door Trim
52A-10 INTERIOR TRIMS DOOR TRIM M2520012300077 <REAR DOOR TRIM> <FRONT DOOR TRIM> CLOTH COVERED PART CLOTH COVERED PART DOOR POCKET AC210219 • A hard resin material is used for door trim to pro- • Cloth covers part of door trim. •...
Page 158 17-1 GROUP 17 ENGINE AND EMISSION CONTROL CONTENTS ACCELERATOR SYSTEM ..17-2 EMISSION CONTROL ... . 17-3 GENERAL DESCRIPTION ... . . 17-2 GENERAL DESCRIPTION .
Page 159 17-2 ENGINE AND EMISSION CONTROL ACCELERATOR SYSTEM ACCELERATOR SYSTEM GENERAL DESCRIPTION M2170001000091 The accelerator system is a cable and suspended pedal combination. Plastic bushing and rubber damper have been attached to the end of the accel- erator cable, to prevent noise and vibration when the cable and accelerator pedal arm contact.
Page 160 17-3 ENGINE AND EMISSION CONTROL EMISSION CONTROL EMISSION CONTROL GENERAL DESCRIPTION M2171000100195 The emission control system is basically the same as The EGR system does not contain a vacuum control that for the 2.4L engine installed in the ECLIPSE. valve. The evaporative emission system has a check valve between the intake manifold and the evapora- tive emission purge solenoid to prevent reverse flow during boost.
Page 161 NOTES...
Page 162 13-1 GROUP 13 FUEL CONTENTS MULTIPORT FUEL SYSTEM (MFI) ..... . FUEL SUPPLY ........
Page 163 NOTES...
Page 164 13A-1 GROUP 13A MULTIPORT FUEL SYSTEM (MFI) CONTENTS GENERAL DESCRIPTION..13A-2 FAN MOTOR CONTROL ..13A-9 SENSOR..... . . 13A-4 FUEL PRESSURE CONTROL, INTAKE CHARGE PRESSURE CONTROL .
Page 165: General Description
13A-2 MULTIPORT FUEL SYSTEM (MFI) GENERAL DESCRIPTION GENERAL DESCRIPTION M2132000100172 The control functions are basically the same as those for the 2.0-liter turbocharged engine of the previous ECLIPSE (D32A, D33A). In addition to the improve- ments already adopted on the 2.4-liter engine of the ECLIPSE (D52A), the following improvements have been made: IMPROVEMENT/ADDITION...
Page 166 13A-3 MULTIPORT FUEL SYSTEM (MFI) GENERAL DESCRIPTION SYSTEM BLOCK DIAGRAM SENSOR, SWITCH ACTUATOR ENGINE CONTROL MODULE(ECM) Volume airflow sensor No.1 injector No.2 injector Intake air temperature sensor [1] Fuel injection control No.3 injector Barometric pressure sensor No.4 injector Engine coolant temperature sensor Idle air control motor [2] Idle speed control...
Page 167: Sensor
13A-4 MULTIPORT FUEL SYSTEM (MFI) SENSOR SENSOR M2132001000101 CLUTCH PEDAL POSITION SWITCH The clutch pedal position switch is a contact type switch that is mounted on the clutch pedal assembly to detect the pressing of CLUTCH PEDAL POSITION SWITCH the clutch pedal. When the driver presses the clutch pedal while shifting gears, the contacts of the clutch pedal position switch close.
Page 168: Fuel Injection Control
13A-5 MULTIPORT FUEL SYSTEM (MFI) FUEL INJECTION CONTROL FUEL INJECTION CONTROL M2132003000130 The fuel injection control is basically the same as When the driver presses the clutch pedal while shift- that for the 2.0-liter turbocharged engine installed on ing gears, this control changes the fuel injection vol- the previous ECLIPSE.
Page 169: Idle Air Control (Iac)
13A-6 MULTIPORT FUEL SYSTEM (MFI) IDLE AIR CONTROL (IAC) IDLE AIR CONTROL (IAC) M2132004000133 The idle air control is basically the same as that for the 2.4L engine installed in the ECLIPSE. System Configuration Diagram VOLUME AIRFLOW SENSOR BAROMETRIC PRESSURE SENSOR INTAKE AIR TEMPERATURE SENSOR IDEL AIR CONTROL BIMETAL...
Page 170: Ignition Timing And Distribution Control
13A-7 MULTIPORT FUEL SYSTEM (MFI) IGNITION TIMING AND DISTRIBUTION CONTROL IGNITION TIMING AND DISTRIBUTION CONTROL M2132005000136 The ignition timing and distribution control is basi- cally the same as that for the 2.4L engine installed in the ECLIPSE. System Configuration Diagram IGNITION SWITCH BATTERY VOLUME AIRFLOW SENSOR...
Page 171: Fuel Pump Control
13A-8 MULTIPORT FUEL SYSTEM (MFI) FUEL PUMP CONTROL FUEL PUMP CONTROL M2132017500019 • A relay circuit has been added in order to supply • A control function has been added to change the the power for actuating the fuel pump directly fuel discharge volume of the fuel pump in two from the battery.
Page 172: Fan Motor Control
13A-9 MULTIPORT FUEL SYSTEM (MFI) FAN MOTOR CONTROL FAN MOTOR CONTROL M2132008000061 To control the radiator fan motor, the same stepless To control the condenser fan motor, the same two- control system with pulse wide modulation (PWM) stage control system with two relays that is used on that is used on the 2.4-liter engine of the ECLIPSE the 2.0-liter turbocharged engine of the previous (D52A), has been adopted.
Page 173: On-Board Diagnostics
13A-10 MULTIPORT FUEL SYSTEM (MFI) ON-BOARD DIAGNOSTICS ON-BOARD DIAGNOSTICS M2132009000138 The powertrain control module (PCM) has been pro- vided with the following functions for easier system inspection. Diagnostic Trouble Code (DTC) and Service Engine Soon/Malfunction Indicator Lamp (MIL) Function The diagnostic trouble code (DTC) and service engine soon/malfunction indicator lamp MIL items are shown in the following table.
Page 174 13A-11 MULTIPORT FUEL SYSTEM (MFI) ON-BOARD DIAGNOSTICS DIAGNOSTIC ITEM MIL ITEM P0172 System too rich × P0181 Fuel tank temperature sensor circuit range/performance × P0182 Fuel tank temperature sensor circuit low input × P0183 Fuel tank temperature sensor circuit high input ×...
Page 175 13A-12 MULTIPORT FUEL SYSTEM (MFI) ON-BOARD DIAGNOSTICS DIAGNOSTIC ITEM MIL ITEM P0830 Clutch pedal position switch circuit range/ performance − P1400 Manifold differential pressure sensor circuit malfunction × P1603 Battery backup circuit malfunction × P2066 Fuel level sensor circuit range/performance (sensor 2) ×...
Page 176 13A-13 MULTIPORT FUEL SYSTEM (MFI) ON-BOARD DIAGNOSTICS MUT-II/III SCAN TOOL ITEM NO. INSPECTION ITEM UNIT DISPLAY HO2S BANK1 S2 Heated oxygen sensor (rear) IAT SENSOR Intake air temperature sensor °C (°F) IG. TIMING ADV Ignition coils and ignition power transistor °...
Page 177 NOTES...
Page 178 22A-1 GROUP 22A MANUAL TRANSAXLE CONTENTS GENERAL DESCRIPTION..22A-2 TRANSMISSION CONTROL ..22A-5 AWD SYSTEM ....22A-4...
Page 179 22A-2 MANUAL TRANSAXLE GENERAL DESCRIPTION GENERAL DESCRIPTION M2220000100086 The W5M5 manual transaxle has been adopted. This W5M5 transaxle is an AWD unit. In structure and operation, the transaxle is very similar to FWD model, however the gear ratio is appropriate for high torque engine with turbocharger and AWD.
Page 180 22A-3 MANUAL TRANSAXLE GENERAL DESCRIPTION 19 18 17 16 15 14 AC207467AB HYPOID PINION 4TH SPEED GEAR CENTER DIFFERENTIAL 3RD − 4TH SPEED 1ST SPEED GEAR SYNCHRONIZER HUB 1ST − 2ND SPEED 3RD SPEED GEAR SYNCHRONIZER HUB TRANSAXLE CASE 2ND SPEED GEAR CLUTCH HOUSING 5TH SPEED GEAR REVERSE BEARING RETAINER...
Page 181 22A-4 MANUAL TRANSAXLE AWD SYSTEM AWD SYSTEM M2220000300013 TRANSAXLE ENGINE TARNSFER VISCOUS CENTER DIFFERENTIAL COUPLING UNIT (VCU) FRONT DIFFERENTIAL REAR DIFFERENTIAL AC207584 • The AWD system uses the center differential with • A viscous coupling unit (VCU) is used for the cen- limited slip device.
Page 182 22A-5 MANUAL TRANSAXLE TRANSMISSION CONTROL TRANSMISSION CONTROL M2220002000096 CONSTRUCTION DIAGRAM SELECT CABLE TRANSAXLE CONTROL CABLE ASSEMBLY SHIFT KNOB SHIFT CABLE SHIFT LEVER ASSEMBLY AC207487 • The shift lever is the spherical rotary shaft fulcrum • The shift and select cable securing portions have type.
Page 183 NOTES...
Page 184 42-1 GROUP 42 BODY CONTENTS GENERAL DESCRIPTION..42-2 BODY COLOR CHARTS ....42-9 DOOR ......42-10 HOOD AND FENDER .
Page 185: General Description
42-2 BODY GENERAL DESCRIPTION GENERAL DESCRIPTION M2420000100109 The main body (monocoque body) is highly rigid and 5. Impact safety body RISE (Realized Impact Safety has excellent noise and vibration reduction charac- Evolution) is adopted for the main body (mono- teristics. It also contributes reduced vehicle weight. coque body).
Page 186: Hood And Fender
42-3 BODY HOOD AND FENDER HOOD AND FENDER HOOD AND FENDER M2420001400039 Aluminum hood and fender are used to reduce the weight of the body. A hood air outlet garnish is used to prevent overheating of the engine compartment. CONSTRUCTION DIAGRAM HOOD AIR OUTLET GARNISH HOOD...
Page 187: Main Body
42-4 BODY MAIN BODY MAIN BODY BODY PANELING M2420002000090 : Anti-corrosion steel panels : High-tensile steel panels AB201073 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.
Page 188: Body Shell
42-5 BODY MAIN BODY BODY SHELL M2420003000093 Impact safety body AB201008 The following structure ensures survival space dur- 4. Enlarged cross section of front floor side member ing impact and facility to rescue passengers. 5. Enlarged cross section of side sill outer reinforce- 1.
Page 189 42-6 BODY MAIN BODY Steel plate with uneven thickness FRONT SIDEMEMBER INNER CENTER PILLAR REINFORCEMENT THE THICKNESS OF THE CENTER PILLAR REINFORCEMENT LOCATED ABOVE THIS PART IS INCREASED. THE THICKNESS OF THE FRONT SIDEMEMBER INNER PLATE LOCATED BEHIND THIS PART IS INCREASED. ( WITHOUT THE SIDE OUTER PANEL ) FRONT END CROSSMEMBER OUTER THE THICKNESS OF THE FRONT END CROSSMEMBER...
Page 190 42-7 BODY MAIN BODY Operational stability SECTION A - A SECTION B - B FRONT PILLAR REINFORCEMENT UPPER COWL TOP LOWER PANEL ROOF RAIL FRONT SIDE OUTER PANEL SPRING HOUSE BRACKET SECTION C - C REAR SHELF PANEL REAR SHELF EXTENSION UPPER FRAME TO FRONT PILLAR BRACE REAR PILLAR...
Page 191: Quietness
42-8 BODY MAIN BODY QUIETNESS M2420004000085 SECTION A - A DASH SILENCER DASH PANEL AB201074 AB AB201074 The following items improve quietness. 3. Filling high rigid foam materials into the side sill 1. Sound absorption foam materials have been filled and the roof side rail to suppress panel vibration into the front pillar, the roof side rail, the center reduces road noise.
Page 192: Body Color Charts
42-9 BODY MAIN BODY BODY COLOR CHARTS M2420005000129 OUTER PANEL- COLOR INNER PANEL- COLOR COLOR COLOR COLOR COLOR COMPOSITION COLOR COLOR CODE NUMBER NAME OF FILM NUMBER NAME SILVER CMA10031 Cool Silver Metallic AC10595 GRAY BRIGHT CMT10010 French Blue Solid CMB17004 BRIGHT BLUE BLUE...
Page 193: Door
42-10 BODY DOOR DOOR DOOR LOCK M2420009000091 CONSTRUCTION DIAGRAM <FRONT> <REAR> OUTSIDE HANDLE OUTSIDE HANDLE INSIDE LOCK ROD INSIDE HANDLE INSIDE LOCK CABLE INSIDE HANDLE DOOR LATCH ASSEMBLY DOOR LATCH DOOR LOCK ASSEMBLY ACTUATOR DOOR LOCK ACTUATOR INSIDE HANDLE ROD INSIDE HANDLE ROD DRIVER'S SIDE PASSENGER'S SIDE...
Page 194 42-11 BODY DOOR CENTRAL DOOR LOCKING SYSTEM Door lock operation table OPERATION OPERATION DRIVERíS SIDE PASSENGERíS REAR DOOR DOOR SIDE DOOR Key cylinder Driverís side Lock Lock Lock Lock door Unlock Unlock Unlock* Unlock* Inside lock knob Lock Lock Lock Lock Unlock Unlock...
Page 195: Keyless Entry System
42-12 BODY DOOR KEYLESS ENTRY SYSTEM M2420010000095 CONSTRUCTION DIAGRAM ETACS-ECU (RECEIVER AND ANTENNA INCORPORATED) Y0232AU RADIO SIGNAL ELECTRIC SIGNAL TRANSMITTER LOCK BUTTON • The signal causes the dome light to flash twice when the door is locked, or come on for 15 seconds when the door is unlocked. •...
Page 196 42-13 BODY DOOR OPERATION OF TRANSMITTER OPERATION OF KEYLESS ENTRY SYSTEM Lock button Press once Lock all doors Unlock button Press once Unlock the driverís door Press once more Unlocks all doors CIPHER CODE The left figure shows a code which is sent from the RKE trans- TRANSMITTER UNLOCK SWITCH mitter.
Page 197: Window Glass Regulator
42-14 BODY DOOR WINDOW GLASS REGULATOR M2420011000098 CONSTRUCTION DIAGRAM <REAR> <FRONT> STATIONARY WINDOW GLASS DOOR WINDOW GLASS DOOR WINDOW GLASS POWER WINDOW GLASS REGULATOR ASSEMBLY POWER WINDOW GLASS REGULATOR ASSEMBLY POWER WINDOW MAIN SWITCH (DRIVER'S SIDE) DOOR LOCK SWITCH (FOR CENTRAL DOOR LOCKING SYSTEM) POWER WINDOW LOCK SWITCH...
Page 198: Lid
42-15 BODY TRUNK LID M2420013000050 TRUNK LID LATCH LOCK CYLINDER TRUNK LID RELEASE HANDLE AC101145 TRUNK LID RELEASE CABLE EMERGENCY TRUNK LID RELEASE HANDLE HANDLE HOLDER AC101168 TRUNK LID LATCH ASSEMBLY AC101169AB • A trunk lid latch, which prevents a person from •...
Page 199: Window Glass
42-16 BODY WINDOW GLASS WINDOW GLASS M2420015000090 AC005392 NO. NAME TYPE THICKNESS COLORING VISIBLE LIGHT {mm (in)} PERMEATION RATE Windshield Laminated 4.3 (0.2) Green glass Front door window glass Tempered 3.1 (0.1) Green glass Rear door window glass 3.1 (0.1) Green Rear stationary window glass 3.1 (0.1)
Page 200: Sunroof
42-17 BODY SUNROOF SUNROOF M2420016000082 Construction diagram DRAIN HOSE SUNSHADE SUNROOF MOTOR ASSEMBLY (BUILT-IN SUNROOF ECU) ROOF LID GLASS DRAIN HOSE DRAIN HOSE DRAIN HOSE OPENING SWITCH TILT-UP SWITCH CLOSE/DOWN SWITCH AC210365AB • Due to the elimination of manual operation in the The power sliding glass sunroof with the tilt-up func- tion to provide sufficient ventilation by tilting up event of a malfunction, a new function of moving...
Page 201 42-18 BODY SUNROOF • Fully closing operation as a transmitter adjust- The motor is installed at the front of the housing. It ment function can be done with the lock switch. consists of the motor body, drive gear and sunroof- (Refer to GROUP 54B, SIMPLIFIED WIRING ECU.
Page 202 Mitsubishi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.
Page 203 GROUP 7 WIRING AND PIPING DIAGRAM CONTENTS PIPING DIAGRAM ....
Page 204 WIRING AND PIPING DIAGRAM PIPING DIAGRAM PIPING DIAGRAM M4070002000026 Drain hose is equipped routed in some parts of These drain hose must be removed before body pan- closed-section structures of the body construction. els in these areas can be replaced. DRAIN HOSE (VHICLES WITH SUNROOF) DRAIN HOSE...
Page 205 GROUP 9 BASE OF BODY REPAIR CONTENTS WELDING..... . STANDARD PROCEDURES FOR SHEET METAL WORK ..... . 9-25 WELDING .
Page 206: Welding
BASE OF BODY REPAIR WELDING WELDING WELDING M4090001000025 Welding is the partial joining of two or more metals by deposition; the welding methods used for body maintenance and repair can be classified into the fol- lowing methods. Fusion methods Shielded arc welding Temperature: 1,130˚C - 1,550˚C gas arc welding (2,066˚F - 2,822˚F)
Page 207 BASE OF BODY REPAIR WELDING PROCEDURE There are three basic stages in electric resistance spot weld- ing. 1. Initial pressure application stage This stage precedes the current application. Applying pressure to the steel panels through the electrode tips ensures a uniform contact resistance and a smoother current flow.
Page 208 BASE OF BODY REPAIR WELDING NUGGET FORMATION COOLING WATER MORE THAN ELECT- 1.6 mm RODE (0.06 in) MELTING POINT STEEL PANEL 1.6 mm (0.06 in) OR LESS NUGGET ELECT- C IS THE SCATTER POINT RODE SMALL ← WELDING CURRENT → LARGE WATER 1,095 1,650˚C...
Page 209 BASE OF BODY REPAIR WELDING NOTES REGARDING WELDING 90˚ - 120˚ DIAMETER OF THE ELECTRODE TIP THICKNESS OF THE PANEL AB200030AB • The overall strength will increase as the pitch 1. Selection of the electrode tips decreases; however, if the pitch decreases •...
Page 210 BASE OF BODY REPAIR WELDING WELDING REQUIREMENTS Example • Center pillar (outer): plate thickness 1.4 mm (0.06 Standard steel plate (SPCC, etc.) inch), material SPCC CAUTION • Center pillar (inner): plate thickness 1.5 mm (0.06 If the total thickness of the plates at the weld inch), material SPCC places is 3 mm (0.12 inch) or more, use plug The number of weld points are as below when the...
Page 211 BASE OF BODY REPAIR WELDING Galvanized steel plate (SECC) CAUTION If the total thickness of the plates at the weld places is 3 mm (0.1 inch) or more, use plug weld- ing, because spot welding will not provide suffi- cient welded strength. PANEL NUMBER OF REPAIR WELD (PERCENTAGE OF FACTORY WELD) THICKNESS*...
Page 212: Gas Shield Arc Welding
BASE OF BODY REPAIR WELDING GAS SHIELD ARC WELDING M4090003000010 WIRE NOZZLE CONTACT TIP METAL VAPOR SHIELD GAS AB200035 Gas shielded arc welding is one method of arc weld- fuse the area. There are two types of gas shielded ing. In this method, while the area to be welded is arc welding, classified according to the gas they use shielded from the air by a layer of inert gas (such as as the shield gas: carbon dioxide (CO2) gas shielded...
Page 213 BASE OF BODY REPAIR WELDING FEATURES OF MIG SPOT WELDING In comparison to resistance spot welding, MIG spot welding has the following advantages and disadvan- tages. ITEM MIG SPOT WELDING ELECTRIC RESISTANCE SPOT WELDING • Light weight • Although the torch with separate Working •...
Page 214 9-10 BASE OF BODY REPAIR WELDING The MIG welding done around the doors, wheelhouse arches, etc., to prevent the flanges from coming undone after hemming work is also called MIG spot welding. AB200038 AB PLUG WELDING CAUTION In order to prevent the formation of blowholes, fill in each 5 TO 6 mm hole completely in one pass.Be sure that the two panels (0.2 in)
Page 215: Other Types Of Welding
9-11 BASE OF BODY REPAIR WELDING The angle of the torch should be 15 degree angle to 30 degree angle for either technique, and the tip should be maintained at a distance of 6 to 10 mm (0.2 to 0.4 inch) from the surface 15˚...
Page 216 9-12 BASE OF BODY REPAIR WELDING This filler metal is most applicable for the brazing 2. Silver alloy filler metal (silver solder) of steel and non-ferrous alloy other than alumin- Silver alloy filler metal consists of silver, copper, ium, magnesium, and others with low melting zinc or cadmium, nickel, and tin, or other metals.
Page 217 9-13 BASE OF BODY REPAIR WELDING 1. Carburizing flame (acetylene-rich flame) Notes with regard to gas welding This flame has an excess of acetylene or a defi- 1. Handle the oxygen and acetylene tanks carefully. ciency of oxygen. The incomplete combustion 2.
Page 218: Body Repair
9-14 BASE OF BODY REPAIR BODY REPAIR BODY REPAIR STANDARD BODY REPAIR PROCEDURES M4090006000031 STANDARD PROCEDURES FOR The following is an explanation of the standard repair procedures for the monocoque body and the frame- REPLACEMENT OF WELDED PANELS type body. Furthermore, please refer to the replace- In order to maintain the proper levels of strength, ment of welded panels for the applicable model for rigidity, and precision when making welded panel...
Page 219 9-15 BASE OF BODY REPAIR BODY REPAIR NOTE: If a replacement panel is to be mounted by doing plug welding from the side of the panel remaining on the body, either a hole can be made in the panel on the body, or a hole can be made right through both the panel which is to remain on the body and the panel to be replaced.
Page 220 9-16 BASE OF BODY REPAIR BODY REPAIR 7. Flange correction for spot weld traces Correct any flanges that become bent or deformed when spot welds are broken or during other work. AB200058 CAUTION Do not use a flame for paint coat removal because doing so might damage the paint coat of panels which are not to be replaced, thus causing corrosion.
Page 221 9-17 BASE OF BODY REPAIR BODY REPAIR CAUTION Perform the operations carefully so that the cut ends fit TWO-LAYER together properly. CONSTRUCTION 11.Cutting of new parts by using a measurement marking If overlap cutting is not possible in a place where butt OUTER PANEL welding is to be done, make a measurement marking on the APPROX.
Page 222 9-18 BASE OF BODY REPAIR BODY REPAIR CAUTION During temporary mounting, it is extremely important to obtain accurate measurements for each component. The mounting positions for the front and rear suspensions are especially crucial with regard to safety; therefore, it is nec- essary that all work concerning these areas be done care- fully and correctly.
Page 223 9-19 BASE OF BODY REPAIR BODY REPAIR 15.Spot welding When doing spot welding, it is not only important to correctly position the electrode tips, but also to hold the two panels securely together with vise-grip pliers or some other type of clamps, being sure that they are in perfect contact with each other.
Page 224 9-20 BASE OF BODY REPAIR BODY REPAIR (2) After completing the hemming work, make MIG spot welds at 50 to 60 mm (2.0 to 2.4 inches) intervals on the inside. AB200073 CAUTION Be sure not to grind the panel down too much. Before welding the outer panel, be sure to apply an anticorrosion agent.
Page 225 9-21 BASE OF BODY REPAIR BODY REPAIR CAUTION Wipe off any anticorrosion agent which oozes out onto surfaces to be painted later; the presence of such anticor- rosion agent would prevent correct adhesion of the paint coat. 20.Application of an anticorrosion agent Apply an ample amount of anticorrosion agent to any welded areas and to all surfaces from which the paint coat was removed.
Page 226: Theft Protection
9-22 BASE OF BODY REPAIR BODY REPAIR • At the outer and inner side of any place sub- SAFETY jected to heat. 1. Procedures related to the installation of any com- ponent related to safety must be done with partic- 3.
Page 227 9-23 BASE OF BODY REPAIR BODY REPAIR PANEL REPAIR CAUTION 1. Take care when respraying the original part to cover the theft protection label with masking tape prior to respraying. In addition, remember to peel off the masking tape after completion of the respray.
Page 228: Attachment Of Silencers
9-24 BASE OF BODY REPAIR BODY REPAIR ATTACHMENT OF SILENCERS M4090009000018 DASH PANEL INTERIOR SIDE Thickness: 1.6 mm (0.06 in) AB200097 Thickness: 3.2 mm (0.13 in) (two 1.6 mm (0.06 in) silencers overlapped) Silencers (petroleum-asphalt sheets) are attached to welded panel, cut and attach replacement material the upper surface of the floor and at the interior side (in the shape shown in the figure).
Page 229: Positioning Dimensions For Openings
9-25 BASE OF BODY REPAIR BODY REPAIR POSITIONING DIMENSIONS FOR OPENINGS M4090010000012 PORTA POWER AB200100 When replacing the panel of the opening of the front pillar, center pillar and other openings, make a point to securely bite the poltapower, etc. so the position of the opening is not off-center.
Page 230 9-26 BASE OF BODY REPAIR BODY REPAIR 3. Use the hammer and dolly to repair the dents and other uneven surfaces of the panel. (1) First repair the larger areas of damage so that they are as close as possible to the original condition before the damage occurred.
Page 231: Using A Frame Straightener
9-27 BASE OF BODY REPAIR BODY REPAIR USING A FRAME STRAIGHTENER M4090013000011 For serious and extensive damage, when for exam- 3. Finally, determine what repair methods should be ple the damage extends to the frame of members, it used. is necessary to first use a frame straightener to make •...
Page 232: Frame Repair Procedures
9-28 BASE OF BODY REPAIR BODY REPAIR FRAME REPAIR PROCEDURES M4090014000014 The frame is subjected to the following types of These various types of loads are compounded under loads. various conditions, and are applied to the frame. • Vertical loads... Vertical loads may occur either As a result, it is important, before attempting to repair while stopped or during travel.
Page 233 9-29 BASE OF BODY REPAIR BODY REPAIR 4. Use a chisel or gouging tool to open up the crack and holes, and then fill the crack and holes by MIG welding. CRACK CRACK-STOP HOLE APPROX. APPROX. APPROX. 8 mm (0.3 in) 1 mm 90˚...
Page 234: Notes Regarding Repair Work
9-30 BASE OF BODY REPAIR BODY REPAIR NOTE: If the crack is at the upper side of the frame, attach the reinforcement plate facing downward, as shown in (1). If the crack is at the lower side, attach the reinforcement plate to face upward, as shown in (2).
Page 235 9-31 BASE OF BODY REPAIR BODY REPAIR • SRS-ECU, air bag module, clock spring, front (2) If heat damage may occur during paint work, impact sensor, the side impact sensor: 93 °C remove the SRS-ECU, the air bag module, (200 °F) or more clock spring, the front impact sensor, the side •...
Page 236: Heat-Withstand Temperatures Of Resin-Plastic Parts
9-32 BASE OF BODY REPAIR BODY REPAIR Only the amounts of paint to be used for the day's work should be in the work area; do not keep excessive amounts of paint, or paint which is not going to be used, in the work area. HEALTH AND SANITATION PROCEDURES The following points should be noted for employee health and sanitation.
Page 237 9-33 BASE OF BODY REPAIR BODY REPAIR MATERIAL NAME ABBREVIATION HEAT-DEFORMATION WHERE MAINLY USED TEMPERATURE °C (°F) Cellulose acetate 60 to 100 (140 to 212) Door trim molding butyrate Polyamide 140 to 160 (284 to 320) Harness connector, Wheel cover, Cooling fan, Fuel strainer Talc filled PA-TD...
Page 238 9-34 BASE OF BODY REPAIR BODY REPAIR MATERIAL NAME ABBREVIATION HEAT-DEFORMATION WHERE MAINLY USED TEMPERATURE °C (°F) Thermoplastic TPO (TEO) 80 (176) Mud guard, Side airdam elastomer (olefine) Urea formaldehyde UF 120 to 145 (248 to 293) Glass fiber UP-(GT + TD) 200 (392) Rear air spoiler reinforced...
Page 239: How To Distinguish Types Of Plastics
9-35 BASE OF BODY REPAIR BODY REPAIR HOW TO DISTINGUISH TYPES OF PLASTICS M4090017000013 There are various methods that can be employed to determine types of plastics, among them (1) using a chemical solvent, etc., to check it chemically, (2) scratching the material to determine its make-up, (3) cutting of a small piece (where the scar can't be seen) and burning it to judge by the way it burns, etc.
Page 240: Corrosion Protection
9-36 BASE OF BODY REPAIR CORROSION PROTECTION CORROSION PROTECTION ANTICORROSION TREATMENT AT THE FACTORY M4090019000019 Anticorrosion treatment at the time of production includes the following measures. THE USE OF GALVANIZED STEEL PLATE : locations where galvanized steel plate is used. AB200136 AB Because galvanized steel plate has excellent corro- sion resistance, it is used in areas which have a high...
Page 241 9-37 BASE OF BODY REPAIR CORROSION PROTECTION CATIONIC ELECTRODEPOSITION UNDERCOATING CATIONIC ANIONIC COATING COATING ALKALI COUNTERAGENT COUNTERAGENT SOLUTION ANIONIC ELECTRODEPOSITION CATIONIC ELECTRODEPOSITION AB200110AB In the cationic electrodeposition method, the car body is the negative pole, thus preventing damage to the zinc plating of the galvanized body panels or to the chemically formed phosphate crystals.
Page 242 9-38 BASE OF BODY REPAIR CORROSION PROTECTION WAX INJECTION Wax injection is used at the lower part of the frame, side sill and hollow panels, etc., in order to obtain a better anticorrosion effect. AB200113 ANTICORROSION PRIMER 1. ROCKER PANEL PRIMER APPLICATION AB200114 AB200114 Anticorrosion primer is used at the side sill outer pan-...
Page 243: Anticorrosion Treatment At The Time Of Body Repair Work
9-39 BASE OF BODY REPAIR CORROSION PROTECTION ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK M4090020000013 The following procedures should be followed for anticorrosion protection when making repairs. AB200116 CORROSION PROTECTION FOR HOLLOW PARTS CAUTION • Wipe away any excess anticorrosion agent on the coated surface, because it can adversely affect the coating.
Page 244 9-40 BASE OF BODY REPAIR CORROSION PROTECTION 2. Use a brush to apply spot sealer to the contact surfaces of the panels (both the new panel and the panel remaining on the body) to be spot welded. AB200119 3. Do not spot welding. NOTE: The spot welding can be done as the spot sealer is dry to the touch.
Page 245 9-41 BASE OF BODY REPAIR CORROSION PROTECTION • After applying sealant to the door-stop, etc., clean away any excess so as to be sure that there is no interference with installed parts, etc. AB200123 UNDERCOATING : Undercoating application locations AB200124 •...
Page 246 NOTES...
Page 247 GROUP 8 REFERENCE MATERIAL CONTENTS BOLTED PANEL FIT AND ADJUSTMENT ADJUSTMENT OF OTHER PARTS ........
Page 248 REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT BOLTED PANEL FIT AND ADJUSTMENT HOOD M4080005000060 ADJUSTMENT OF HOOD FIT 1. If the clearance between the hood and body is uneven, loosen the hood hinge assembling nut and hood hinge assembling bolt, move the hood to and fro, and left and right to adjust the hood so the clearance around the hood is even.
Page 249 REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT DOOR M4080006000085 ADJUSMENT OF DOOR FIT CAUTION • Attach protection tape to the fender and door edges where the hinge is installed. • Do not rotate special tool MB991164 with a torque of over 98 N⋅m (72 ft-lb) 1.
Page 250: Trunk Lid
REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT (3) Adjustment by using shims (forward and rearward) Increase or decrease the number of shims so that the SHIM striker engages with the door latch properly. STRIKER Door striker assembling bolt tightening torque: 11 ±...
Page 251: Installation And Removal Of Adhesive Components
REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS AERO PARTS M4080015000038 SIDE AIR DAM REAR SPOILER <TYPE A> REAR SPOILER <TYPE B> AB202317...
Page 252 REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS ADHESIVE TAPE POSITION DOUBLE-SIDED TAPE SIDE AIR DAM AB202318AB ADHESIVE TAPE: DOUBLE-SIDED TAPE [ 5 mm (0.20 in) WIDTH AND 1.2 mm (0.05 in) THICKNESS ] DOUBLE-SIDED TAPE REAR SPOILER <TYPE A> AB202335AB ADHESIVE TAPE: DOUBLE-SIDED TAPE A: [5 mm ( 0.2 in ) WIDTH AND 0.8 mm ( 0.03 in ) THICKNESS ]...
Page 253 REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS 1. Attach protection tape all the way along the edges of the double-sided tape which is still adhering to the body. DOUBLE-SIDED TAPE PROTECTION TAPE AC200049 2. Scrape off the double-sided tape with a resin spatura as possible.
Page 254: Adjustment Of Other Parts
REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS ADJUSTMENT OF OTHER PARTS FRONT WHEEL ALIGNMENT M4080009000062 Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, wheels, and tires should be serviced to normal condition before measuring wheel alignment.
Page 255: Rear Wheel Alignment
REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS REAR WHEEL ALIGNMENT M4080010000066 1. The rear suspension, wheels and tyres should be serviced to normal condition prior to measurement of wheel alignment. 2. Measure the wheel alignment with the vehicle parked on a level surface.
Page 256: Headlight Aiming
8-10 REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS HEADLIGHT AIMING M4080011000069 PRE-AIMING INSTRUCTIONS 1. Inspect for badly rusted or faulty headlight assemblies. 2. These conditions must be corrected before a satisfactory adjustment can be made. 3. Inspect tire inflation, and adjust if it is necessary. 4.
Page 257: Fog Light Aiming
8-11 REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS HEADLIGHT ADJUSTMENT 1. The low beam headlight should project on the screen upper edge of the beam (cut-off). 2. If not the case, turn the adjusting screws to achieve the specified low-beam cut-off location on the aiming screen. VERTICAL ADJUSTING VERTICAL...
Page 258 8-12 REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS 6. Thoroughly clean fog light lenses. 7. Place the vehicle on a level floor, perpendicular to a flat screen 7.62m (25.0 feet) away from the bulb center-marks on the fog light lens. 8. Rock vehicle sideways to allow vehicle to assume its normal position.
Page 259: Supplemental Restraint
8-13 REFERENCE MATERIAL SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG 2. If it is not within the standard value range, adjust by turning the adjusting screw. VERTICAL ADJUSTING Standard value: (Vertical direction): Top of the hot zone should be 101 mm (4.0 inches) (0.76°) downward from the height of the fog light center.
Page 260 NOTES...
Page 261 GROUP 6 BODY COLOR CONTENTS BODY COLOR CODE ... . BODY COLORING ....HEADLAMP SUPPORT ....BODY COLOR CHARTS .
Page 262 BODY COLOR BODY COLOR CODE BODY COLOR CODE M4060001000118 1. The body color code is imprinted on the vehicle information code plate, which is mounted on the front deck. VEHICLE INFORMATION CODE PLATE AC211608AB 2. The information is contained in the body color charts. BODY COLOR CODE AB202021AD BODY COLOR CHARTS...
Page 263 BODY COLOR BODY COLORING BODY COLORING HEADLAMP SUPPORT M4060009000071 (Except color code X42) :BLACK (AC10657) AB202124 DOOR SASH, WHEELHOUSE M4060000100048 (Except color code X42) 1 LUSTROUS BLACK (AC10790) 2 BLACK (AC10657) AB202125...
Page 264 NOTES...
Page 265 GROUP 5 SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS ......
Page 266 SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS M4050001000117 The location and material of each of the principal synthetic-resin parts are shown below. 2, 5 AB202186AB AB202187AB NO PART NAME NAME OF RESIN ABBREVIATION HEAT- WITHSTAND TEMP [°C (°F)] Door mirror Acrylonitrile butadiene styrene 80 (176)
Page 267 SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS NO PART NAME NAME OF RESIN ABBREVIATION HEAT- WITHSTAND TEMP [°C (°F)] Splash shield Polyethylene 100 (212) 10 Front bumper side cover Polypropylene 80 (176) 11 Oil cooler duct 12 Front bumper side core 13 Front bumper center core 14 Rear bumper core 15 Instrument panel...
Page 268 NOTES...
Page 269 GROUP 4 CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS ..UNDERBODY ANTICORROSION AGENT LOCATIONS ... . . UNDERCOAT APPLICATION LOCATIONS ....
Page 270 CORROSION PROTECTION BODY SEALING LOCATIONS BODY SEALING LOCATIONS M4040001000138 If the sealant application is directly visible on the NOTE: The bold dotted line indicates the application outer plate and requires appearance quality of the area on the rear. application in areas such as the drip rail, pillar, clinch and so on, then apply the sealant so that it is flat, or wipe off any excess mounding after the application.
Page 271 CORROSION PROTECTION BODY SEALING LOCATIONS SIDE BODY AB202134 AB202136AB AB202135 AB202138AB AB202137 TSB Revision...
Page 272 CORROSION PROTECTION BODY SEALING LOCATIONS AB202139AB AB202140AB AB202141AB AB202142AB AB202143AB AB202144 AB202145AB AB202146AB TSB Revision...
Page 273 CORROSION PROTECTION BODY SEALING LOCATIONS HOOD FRONT DOOR AB202131 AB202147 REAR DOOR TRUNK LID AB202148 AB202149AB TSB Revision...
Page 274 CORROSION PROTECTION UNDERCOAT APPLICATION LOCATIONS UNDERCOAT APPLICATION LOCATIONS M4040003000112 The under parts of the body is undercoated for anti- Tape the areas marked with an asterisks to protect corrosive, anti-rust, anti-chipping, and anti-vibration those areas from getting any undercoating on those performance.
Page 275 CORROSION PROTECTION UNDERBODY ANTICORROSION AGENT LOCATIONS UNDERBODY ANTICORROSION AGENT LOCATIONS M4040009000024 In order to provide a greater corrosion resistance, NOTE: • underbody corrosion prevention treatment should be Take care not to permit the anticorrosion agent to performed after undercoat application. After complet- come in contact with body painting, brake parts, ing body repairs, restore this underbody corrosion exhaust pipes, bearing seals for rear axle and...
Page 276 NOTES...
Page 277 GROUP 3 WELDED PANEL REPLACEMENT CONTENTS HEADLAMP SUPPORT ... ROOF ......3-28 FENDER SHIELD.
Page 278: Headlamp Support
WELDED PANEL REPLACEMENT HEADLAMP SUPPORT HEADLAMP SUPPORT M4030003000100 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.) AB201903...
Page 279 WELDED PANEL REPLACEMENT HEADLAMP SUPPORT NOTE: Partial replacement is okay depending on the range of damage. : CUTTABLE RANGE AB201968...
Page 280: Fender Shield
WELDED PANEL REPLACEMENT FENDER SHIELD FENDER SHIELD M4030004000095 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.) AB201904...
Page 281 WELDED PANEL REPLACEMENT FENDER SHIELD (WITH THE UPPER FRAME EXTENSION OUTER REMOVED) AB202219...
Page 282 WELDED PANEL REPLACEMENT FENDER SHIELD 17 POINTS, LEFT SIDE ONLY 6 POINTS, LEFT SIDE ONLY 9 POINTS, LEFT SIDE ONLY 5 POINTS, LEFT SIDE ONLY AB202220...
Page 283 WELDED PANEL REPLACEMENT FENDER SHIELD NOTES...
Page 284: Front Sidemember (Partial Replacement)
WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT) FRONT SIDEMEMBER (PARTIAL REPLACEMENT) M4030000100045 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 285 WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT) LEFT SIDE 45 mm (1.77 in) 83 mm (3.27 in) CENTER OF SPLASH CENTER OF FRONT SHIELD MOUNTING SIDEMEMBER INNER HOLE POSITIONING HOLE AB202222AB NOTE: Refer to the Headlamp Support Section on P.3-2 for the welding point with headlamp support.
Page 286: Front Pillar
3-10 WELDED PANEL REPLACEMENT FRONT PILLAR FRONT PILLAR M4030005000139 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.) AB201906...
Page 287 3-11 WELDED PANEL REPLACEMENT FRONT PILLAR RIGHT SIDE <VEHICLES WITH STANDARD ROOF> <VEHICLES WITH SUNROOF> AB202203 NOTE ON REPAIR WORK INSTALLATION <Vehicles with standard roof> 1. To reinforce the strength of the front pillar cut area, cut the FRONT PILLAR side outer panel 160 mm (6.3 in) above the front pillar cut REINFORCEMENT UPPER B...
Page 288 3-12 WELDED PANEL REPLACEMENT FRONT PILLAR 3. Divide the new front pillar inner upper parts into A (front pillar inner reinforcement and front pillar inner upper) and B (front pillar reinforcement upper and front pillar reinforcement upper B). AB200369AB 4. When assembling Part A, weld the areas shown in the figure of the instructions from the outside and inside.
Page 289 3-13 WELDED PANEL REPLACEMENT FRONT PILLAR 8. When assembling a new front pillar outer parts, apply a front pillar silencer protector in advance, bury the clearance with butyl tape then apply structural adhesives in the areas shown in the figure of the instructions. ADHESIVE TYPE BRAND Epoxyayresin...
Page 290 3-14 WELDED PANEL REPLACEMENT FRONT PILLAR 12.Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with foam materials. AB100787 INSTALLATION <Vehicles with sunroof>...
Page 291 3-15 WELDED PANEL REPLACEMENT FRONT PILLAR CAUTION Weld and repair if the side sill reinforcement support is SIDE SILL REINFORCEMENT damaged. SUPPORT 4. Remove the side outer panel from the new front pillar outer parts. Cut the front pillar outer by aligning it with the side sill outer reinforcement center on the body-side.
Page 292 3-16 WELDED PANEL REPLACEMENT FRONT PILLAR 7. Apply in advance body sealant in the areas shown in the figure of the instructions when assembling the side outer panel. : BODY SEALANT AB200475 AB 8. Assemble the side outer panel, then bolt and tape the hole and flange with aluminum tape and fill the hole with foam materials as shown in the figure of the instructions.
Page 293: Center Pillar
3-17 WELDED PANEL REPLACEMENT CENTER PILLAR CENTER PILLAR M4030006000091 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.) AB201907...
Page 294 3-18 WELDED PANEL REPLACEMENT CENTER PILLAR NOTE ON REPAIR WORK REMOVAL 1. Since the center pillar reinforcement and side sill outer CENTER PILLAR reinforcement center of the side sill is adhered together, cut REINFORCEMENT the side outer panel in a place where the reinforcement joint is visible, as shown in the figure of the instructions, to remove the center pillar reinforcement.
Page 295 3-19 WELDED PANEL REPLACEMENT CENTER PILLAR 4. When assembling the center pillar reinforcement, apply adhesives in the areas shown in the figure of the instructions. ADHESIVE TYPE BRAND Epoxyayresin 3Mä Part No.8115 or adhesive equivalent : ADHESIVE AB100796AC 5. When attaching the center pillar inner, attach the center pillar silencer protector to the center pillar inner, and seal the holes of the center pillar silencer protector with butyl tape.
Page 296: Side Sill
3-20 WELDED PANEL REPLACEMENT SIDE SILL SIDE SILL M4030007000102 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.) AB201908...
Page 297 3-21 WELDED PANEL REPLACEMENT SIDE SILL AB202327AB NOTE ON REPAIR WORK REMOVAL To remove the side sill outer reinforcement, cut it 60mm (2.36 in) behind the cut-out part. 60 mm (2.36 in) SIDE SILL OUTER REINFORCEMENT CENTER AB200598AC INSTALLATION 1. Cut only the side sill outer reinforcement center on the body- 50 mm (1.97 in) side, 50mm (1.97 in) forward of the cut area and then remove.
Page 298 3-22 WELDED PANEL REPLACEMENT SIDE SILL 3. Cut the side sill reinforcement support 50mm (1.97 in) forward of the cut area of the side sill outer reinforcement 50 mm (1.97 in) center. SIDE SILL REINFORCEMENT SUPPORT AB200601AB 4. Adhere in advance adhesives in the areas shown in the figure of the instructions when assembling the side sill outer reinforcement.
Page 299 3-23 WELDED PANEL REPLACEMENT SIDE SILL 8. Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with foam materials.
Page 300: Quarter Outer
3-24 WELDED PANEL REPLACEMENT QUARTER OUTER QUARTER OUTER M4030008000097 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.) AB201912...
Page 301 3-25 WELDED PANEL REPLACEMENT QUARTER OUTER AB202224 CAUTION Avoid the fuel filler bracket (left side). NOTE: Parts replacement is advised.Depending on the dam- aged range. : CUTTABLE RANGE AB201967AB...
Page 302 3-26 WELDED PANEL REPLACEMENT QUARTER OUTER NOTE ON REPAIR WORK INSTALLATION 1. Attach the rear pillar silencer protector, and fill the gaps with Y0249AV REAR PILLAR butyl tape. When attaching the quarter outer, apply sealant SILENCER PROTECTER to the areas indicated in the illustration. LEFT SIDE ONLY : BODY SEALANT AB202225AB...
Page 303 3-27 WELDED PANEL REPLACEMENT QUARTER OUTER 3. Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape. Then melt the foam materials with a soldering gun so a clip, etc. can thoroughly be inserted in the hole that was clogged with foam materials, to bore open the hole.
Page 304 3-28 WELDED PANEL REPLACEMENT ROOF ROOF M4030011000097 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.) AB201909 REPAIR WELDS...
Page 305: Rear End Panel
3-29 WELDED PANEL REPLACEMENT REAR END PANEL REAR END PANEL M4030009000067 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 306: Rear Floor
3-30 WELDED PANEL REPLACEMENT REAR FLOOR REAR FLOOR M4030010000094 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.) AB201915...
Page 307 3-31 WELDED PANEL REPLACEMENT REAR FLOOR LEFT SIDE ONLY RIGHT SIDE ONLY AB202229AB NOTE ON REPAIR WORK REMOVAL Cut the rear floor pan 200 ± 50 mm (7.9 ± 1.97 in) from the REAR SEAT BACK back of the rear seat back reinforcement as shown in the illus- REINFORCEMENT tration.
Page 308: Quarter Inner
3-32 WELDED PANEL REPLACEMENT QUARTER INNER QUARTER INNER M4030012000090 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.) AB201913...
Page 309 3-33 WELDED PANEL REPLACEMENT QUARTER INNER LEFT SIDE ONLY (WITH THE SIDE SILL OUTER REINFORCEMENT REAR REMOVED) AB202231AB...
Page 310 3-34 WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) QUARTER INNER (PARTIAL REPLACEMENT) M4030000200031 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 311 3-35 WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) NOTE ON REPAIR WORK REMOVAL 1. Since there is a rear pillar reinforcement in the quarter inner panel cut area, remove the rear pillar reinforcement. REAR PILLAR REINFORCE- MENT AB202008 2. Adhere tape along the wheel arch of the quarter inner panel as shown in the figure of the instructions, use the tape as a guide so about 20mm (0.79 in) of the flange remains, then cut and remove.
Page 312 3-36 WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) 3. Weld the quarter inner panel then apply a body sealing in the area shown in the figure of the instructions. BODY SEALING AB202293AC...
Page 313: Front Door Outer Panel
3-37 WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL FRONT DOOR OUTER PANEL M4030013000093 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 AB201894...
Page 314: Rear Door Outer Panel
3-38 WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL REAR DOOR OUTER PANEL M4030014000096 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 AB201893...
Page 315: Aluminum Panel
3-39 WELDED PANEL REPLACEMENT ALUMINUM PANEL ALUMINUM PANEL ALUMINUM PANEL CHARACTERISTICS M4030000500010 Description of aluminum panel 2. More durable: Aluminum has the property of creating oxide coating on its surface when it A new aluminum panel with higher strength and bet- contacts with the air.
Page 316: Aluminum Panel Repair
3-40 WELDED PANEL REPLACEMENT ALUMINUM PANEL ALUMINUM PANEL REPAIR M4030000700014 Items to be noted when working on sheet metal 1. Main differences of sheet metal work WORK ALUMINUM STEEL SHEET DESCRIPTION PANEL Hammering Mallet or plastic Sheet metal hammer hammer Washer welding Not possible Possible...
Page 317 3-41 WELDED PANEL REPLACEMENT ALUMINUM PANEL Correction of uneven surface Basically, the same as the steel panel. Work with consideration of characteristics of the aluminum panel. 1. Correction of metal sheet: CAUTION • Heat-up the panel until you feel heat with a keplar work glove on the reverse side of the panel.
Page 318 3-42 WELDED PANEL REPLACEMENT ALUMINUM PANEL CAUTION Aluminum plates are softer than steel sheets, therefore select an appropriate abrasive to prevent the surface from deep scratch. 4. Sanding: Grind the surface by a disk sander or a double- action sander. •...
Page 319 3-43 WELDED PANEL REPLACEMENT ALUMINUM PANEL 4. Check for distortion: Grind the surface with 80 to 120-grit sandpaper and then check for distortion. AB202113 CAUTION • The surface shall be heated to approximately 250°C (482°F) when correcting distortion. • Care must be taken when heating the panel because it can melt without discoloration.
Page 320: Aluminum Panel Paint
3-44 WELDED PANEL REPLACEMENT ALUMINUM PANEL Finish with putty 1. Grind the putty applied area with a 150 to 180-grit double- action sander. 2. Degrease and clean the putty applied area. 3. Apply 2-liquid type epoxy primer or a pretreatment agent for aluminum.
Page 321 GROUP 2 BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND MEASUREMENT TYPE B (ACTUAL-MEASUREMENT METHODS ..... DIMENSIONS)....UNDER BODY.
Page 322 BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS BODY DIMENSIONS AND MEASUREMENT METHODS M4020001000095 1. Type A (projected dimensions) PROJECTED DIMENSION Indicates the dimension when a measurement location is projected onto the plane. The difference in height of the measurement points should HEIGHT be taken into consideration when measuring.
Page 323 BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS 6. When measuring the suspension mounting arm, or link BOLT mounting position, use the suspension mounting bolt, etc. (Type B only) 7. The body center points are shown for the purpose of check- ing the position of the left and right symmetry location.
Page 324: Dimensions)
BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) TYPE A (PROJECTED DIMENSIONS) UNDER BODY M4020005000150 mm (in) Y0620AV 1,239 (48.8) (38.7) (13.4) 1,010 (39.8) (28.1) (31.9) (6.0) 1,232 (29.5) (28.1) (48.5) (37.0) (6.3) (13.3) (30.9) (21.4) (28.4) (9.7) AB201748AB Y0620AV (29.8) 1,157 1,232 (45.6) (48.5)
Page 325 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) mm (in) (13.4) (19.6) (10.0) (13.3) (8.0) (13.6) (13 .0) (7.3) (8.0) (7.1) (6.4) (5.6) (3.9) (4.5) (22.2) (9.8) (19.8) (27.2) 1,335 1,230 (52.6) (48.4) (13.3) 1,545 (60.8) AB201750AB AB201728 AC AB202159 AB201817AB 5, 6, 7, 8 AB201808AB AB202160AB AB201809...
Page 326 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) SUSPENSION INSTALLATION DIMENSIONS M4020013000133 mm (in) (28.4) (14.6) (32.6) (11.4) (18.5) (7.5) 1,110 1,186 (18.9) (43.7) (28.1) (46.7) (27.6) (33.8) (39.3) (31.9) (35.7) (28.1) (33.5) (35.5) (3.9) (16.4) (3.4) (14.8) (11.3) 18 19 (12.7) (14.6) AB201751AB (30.1)
Page 327 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) mm (in) VEHICLE CENTER VEHICLE CENTER 11˚36´ 4˚24´ (20.8) (34.0) (17.3) (14.1) 3 12´ (13.2) 14 15 (29.6) (24.7) (13.0) (9.4) (13.3) (13.7) (8.5) (6.4) (4.1) (3.9) (6.9) (7.5) (7.8) (13.6) 1,257 (49.5) (18.8) (15.8) (22.2) (20.6)
Page 328: Under Body
BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY M4020005000161 AB201748 mm (in) 1,250 (49.2) (13.4) (38.7) 1,010 (39.8) 1,232 (7.0) (28.1) (28.1) (48.5) (31.9) (37.0) (29.5) (6.8) (31.7) (21.4) (13.4) (29.0) (11.5) AB201754AB 1,170 (29.8) 1,241 (46.1) (34.4) (48.9)
Page 329 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB202159 AB201728 AC AB201817AB 5, 6, 7, 8 AB201808AB AB201809 AB202160AB AB201818AB AB201811AB...
Page 330: Suspension Installation
2-10 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) SUSPENSION INSTALLATION DIMENSIONS M4020013000144 mm (in) (15.3) (29.2) (7.5) (11.6) (18.5) (19.6) 1,186 (35.7) (28.1) (28.1) (46.7) (27.6) (31.9) (35.5) (4.4) (33.5) (17.2) (4.1) (11.5) (15.2) (15.0) (14.1) AB201756AB 1,137 1,075 (35.0) (33.8) (44.8) (42.3) (30.6)
Page 331 2-11 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) 3, 16 10, 22 AB201820 AB201821AB AB201819AB 18, 20 AB201822AB AB201824 AB201823AB AB201825...
Page 332: Front Body
2-12 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) FRONT BODY M4020006000078 mm (in) 1,091 (43.0) (34.3) 1,508 (59.4) BODY CENTER POINT 1,390 1,437 (54.7) (56.6) (26.2) 1,558 (61.3) (28.7) (21.4) (34.8) (12.9) (34.4) (34.3) 1,382 1,040 (29.5) (54.4) (40.9) (29.6) (27.2) (35.2) AB201758AB (28.8)
Page 333 2-13 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) STANDARD HOLE SHAPE− STANDARD HOLE SHAPE− MEASUREMENT POINT SIZE mm (in) MEASUREMENT POINT SIZE mm (in) Center of hood hinge Round−9 (0.4) Center of front bumper Round−9 (0.4) mounting hole reinforcement mounting hole Corner of roof panel −...
Page 334: Side Body
2-14 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) SIDE BODY M4020007000071 mm (in) (32.6) (27.1) (34.4) (31.8) (18.2) (28.2) (22.9) 1,127 (44.4) 1,084 1,174 (35.5) (42.7) (46.2) (34.0) (37.8) AB201760AB 1,100 (43.3) (28.8) 1,067 (42.0) (33.0) 1,124 1,094 (44.3) (43.1) (14.0) (13.3) (35.5) 1,041...
Page 335 2-15 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) 38, 48 42, 50 46, 51 AB201836 AB202191 AB201838...
Page 336: Rear Body
2-16 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) REAR BODY M4020008000085 mm (in.) (39.0) (25.7) 1,271 (50.0) BODY CENTER POINT 1,200 (47.2) 1,269 (21.0) (50.0) (22.3) (27.9) 1,104 (43.5) (18.0) 1,562 1,018 (61.5) (40.1) (29.5) AB201762 AB STANDARD HOLE SHAPE− STANDARD HOLE SHAPE−...
Page 337 2-17 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB201840AB AB201841AB AB201839AB 55, 56 AB201842 AB201843AB AB201844AB...
Page 338: Interior
2-18 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) INTERIOR M4020009000088 mm (in) 1,112 1,145 (43.8) (45.1) 1,235 1,297 (48.6) 1,289 (51.1) (50.7) 1,379 1,395 (54.3) (54.9) 1,407 1,368 (55.4) (53.9) 1,388 (54.6) AB201763AB 1,072 1,100 (42.2) (43.3) 1,016 1,085 (40.0) (42.7) 1,136 (44.7) (33.4)
Page 339 2-19 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) mm (in) (38.8) (31.8) 1,106 (43.5) (22.8) (37.0) AB201765AB STANDARD HOLE SHAPE− STANDARD HOLE SHAPE− MEASUREMENT POINT SIZE mm (in) MEASUREMENT POINT SIZE mm (in) Center of rear end trim Round−8.5 (0.3) Front pillar positioning −...
Page 340 2-20 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB202195 AB202195 AB201843AB AB201845AB AB201846AB AB201849AB 62, 63 AB201848AB AB201850AB AB201847AB...
Page 341 GROUP 1 BODY CONSTRUCTION CONTENTS BODY COMPONENTS... . UNDER BODY..... . . 1-17 DOOR .
Page 342: Body Components
BODY CONSTRUCTION BODY COMPONENTS BODY COMPONENTS M4010001000102 52 53 54 76 77 : Anti-corrosion steel panels : High-tensile steel panels AB202151AB...
Page 343 BODY CONSTRUCTION BODY COMPONENTS 43. REAR COMBINATION LAMP HOUSING HEADLAMP SUPPORT PANEL 44. SIDE ROOF RAIL INNER HOOD LOCK STAY 45. ROOF SIDE RAIL REINFORCEMENT CENTER FRONT END CROSSMEMBER 46. FRONT PILLAR INNER UPPER FRONT END UPPER BAR 47. FRONT PILLAR INNER LOWER HEADLAMP SUPPORT PANEL SIDE 48.
Page 344: Body Main Cross-Sectional Views
BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS BODY MAIN CROSS-SECTIONAL VIEWS M4010002000105 AB201974 FRONT PILLAR ROOF REINFORCEMENT UPPER ROOF PANEL PANEL SIDE OUTER PANEL FRONT MAP LAMP PILLAR SIDE ROOF BRACKET REINFORCE- FRONT ROOF RAIL RAIL INNER MENT UPPER (B) FRONT PILLAR INNER AB201984 REINFORCEMENT AB201886AB...
Page 345 BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS AB201911AB (SUNROOF) (STANDARD ROOF) FRONT FRONT PILLAR PILLAR INNER UPPER FRONT PILLAR INNER UPPER INNER FRONT PILLAR REINFORCEMENT UPPER REINFORCEMENT UPPER FRONT PILLAR SIDE OUTER REINFORCE- PANEL MENT UPPER FRONT PILLAR FRONT PILLAR REINFORCEMENT INNER REINFORCEMENT UPPER SIDE OUTER PANEL...
Page 346: Maintenance, Serviceability
BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY MAINTENANCE, SERVICEABILITY M4010003000120 FENDER SHIELD A positioning hole, marking and cut-out has been added on the front fender shield, front upper frame inner, front side member gusset rear and dash panel to improve assembling workability when replacing the panel.
Page 347 BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY SIDE STRUCTURE A panel positioning cut-out has been added on the door opening to improve assembling workability when replacing the panel. PANEL POSITIONING NOTCH AB200202AB AB202025AB SIDE OUTER PANEL The extra parts are supplied in 4 different cut forms as a result of employing the integrated side-frame side outer panel.
Page 348: Body Construction Characteristics
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS BODY CONSTRUCTION CHARACTERISTICS FRONT BODY M4010010000092 HEADLAMP SUPPORT NOTE: *: Steel sheets with different thickness welded to form one steel sheet. 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 349 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS FENDER SHIELD NOTE: *: Steel sheets with different thickness welded to form one steel sheet. 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 real- ize lightweight.
Page 350 1-10 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS FRONT SIDEMEMBER REINFORCEMENT RIGHT SIDE AB201018AB AB202015AC 10. PIPE SUPPORT REAR FRONT SIDEMEMBER INNER 11. PIPE NUT FRONT SIDEMEMBER BULKHEAD A 12. FRONT SIDEMEMBER REAR FRONT SIDEMEMBER OUTER 13. DASH CROSSMEMBER EXTENSION ENGINE MOUNT BRACKET 14.
Page 351 1-11 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS LEFT SIDE AB201019AB AB202017AC 13. FRONT SIDEMEMBER INNER REINFORCEMENT SUSPENSION CROSSMEMBER SUPPORT 14. FRONT SIDEMEMBER REINFORCEMENT OUTER BRACKET 15. FRONT SIDEMEMBER BULKHEAD (A) DASH CROSSMEMBER EXTENSION 16. FRONT SIDEMEMBER INNER FRONT SIDEMEMBER REAR 17. PIPE SUPPORT FRONT PIPE NUT 18.
Page 352 1-12 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS FRONT DECK Strut house gusset and upper frame to front pillar brace have been added to improve body rigidity. AB201020AB CLUTCH PEDAL SUPPORT BRACKET STRUT TOWER BAR BRACKET UPPER FRAME EXTENSION INNER COWL TOP LOWER PANEL 10.
Page 353: Roof
1-13 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS ROOF M4010013000091 The cross section of the roof bow has been made large to improve safety in collision. STANDARD ROOF AB202150AB SUN ROOF AB201928AB FRONT ROOF BOW ROOF PANEL MAP LAMP BRACKET REAR ROOF RAIL FRONT ROOF RAIL REAR ROOF BOW ROOF PANEL REINFORCEMENT...
Page 354: Side Body
1-14 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS SIDE BODY M4010011000095 SIDE STRUCTURE 23 24 AB201022AB 21. REAR FLOOR SIDE BRACE FRONT PILLAR REINFORCEMENT LOWER 22. REAR FLOOR BRACE REINFORCEMENT EXTENSION 23. FUEL FILLER NECK BRACKET (LH only) FRONT PILLAR INNER LOWER EXTENSION 24.
Page 355 1-15 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 43. REAR DOOR HINGE REINFORCEMENT UPPER 44. CENTER PILLAR SEATBELT REINFORCEMENT 45. CENTER PILLAR INNER 46. FRONT PILLAR REINFORCEMENT UPPER (B) (VEHICLES WITH STANDARD ROOF) 47. FRONT PILLAR INNER REINFORCEMENT (VEHICLES WITH STANDARD ROOF) 48.
Page 356: Rear Body
1-16 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS REAR BODY M4010012000087 REAR END CROSSMEMBER A rear shelf extension has been added to form closed structure. Then, the rear shelf and the rear floor have been joined to improve the torsion rigidity of the seat back plate. AB201022AB REAR SHELF CHILD SEAT BELT SEAT BACK PLATE...
Page 357: Under Body
1-17 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS UNDER BODY M4010014000094 FRONT FLOOR The cross section of the front floor sidemember has been made large to improve safety in collision. AB202031AB FRONT FLOOR SIDEMEMBER INSTRUMENT PANEL CENTER BRACKET FRONT FLOOR SIDEMEMBER REINFORCEMENT REINFORCEMENT FRONT FRONT FLOOR CROSSMEMBER FRONT...
Page 358 1-18 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS REAR FLOOR AB201025AB 10. DIFFERENTIAL / FUEL SUPPORT BRACKET REAR FLOOR PAN REAR SEAT BACK PLATE EXTENSION 11. REAR FLOOR SIDEMEMBER JACK BRACKET 12. DIFFERENTIAL / FUEL SUPPORT BRACKET SPARE TIRE BRACKET FRONT REAR SEAT BACK REINFORCEMENT 13.
Page 359 1-19 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS REAR FLOOR SIDEMEMBER REINFORCEMENT AB202032AB AB202033AB 13. REAR FLOOR SIDEMEMBER REINFORCEMENT TRAILING ARM OUTER BRACKET FRONT REAR FLOOR SIDEMEMBER SUPPORT 14. MUFFLER HANGER REAR TRAILING ARM INNER BRACKET 15. REAR FLOOR SIDEMEMBER REINFORCEMENT REAR FLOOR SIDEMEMBER REAR REAR FLOOR CROSSMEMBER EXTENSION 16.
Page 360: Door
1-20 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS DOOR M4010015000086 The front and back of side door beam has been made large to cope with the force from the front and sides during collision. RONT DOOR AB201026AB 15 16 EAR DOOR AB201027AB 11.
Page 361: Silencer Application Locations
1-21 BODY CONSTRUCTION SILENCER APPLICATION LOCATIONS SILENCER APPLICATION LOCATIONS M4010005000115 A silencer (MD-12 and melting sheet) has been NOTE: • MD-12 is a high performance sheet composed of adhered on the top part of the floor to improve anti- vibration performance and to shut-out exhaust gas asphalt applied with mica and thermosetting resin heat.
Page 362: Locations Using Urethane Foam And Foam Material
1-22 BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL M4010007000092 • Introduction of noise was prevented by inserting • Never use a gas burner or burn the areas urethane foam inside the center pillar. using foam materials.
Page 363 1-23 BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL AB201918 AB100698 FOAM ACOUSTIC MATERIAL HIGH RIGIDITY FOAM MATERIAL FRONT PILLAR REINFORCEMENT SIDE ROOF SIDE OUTER PANEL RAIL INNER UPPER SIDE OUTER PANEL AB201980AB AB201977AB FOAM ACOUSTIC MATERIAL CENTER PILLAR REAR PILLAR INNER INNER SIDE OUTER...
Page 364: Stiffener And Damp Sheet Application Locations
1-24 BODY CONSTRUCTION STIFFENER AND DAMP SHEET APPLICATION LOCATIONS STIFFENER AND DAMP SHEET APPLICATION LOCATIONS M4010008000103 Sound insulation was improved with anti-vibration NOTE: The main contents of a stiffener are epoxy effects and heightening surface rigidity with a stiff- resin. It comes in a sheet form and contains a mix- ener on the inner side of the side outer panel, and ture of glass fiber and filler, and cures (stiffens) when roof panel, as well as a damping sheet adhered to...
Page 365: Theft Protection
1-25 BODY CONSTRUCTION THEFT PROTECTION THEFT PROTECTION M4010017000037 In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts THEFT PROTECTION LABEL of the engine and transaxle, as well as main outer panels: Engine cylinder block, Transaxle housing, Fender, Doors, Trunk lid, Quarter panel, Hood, Bumpers In addition, a theft-protection label is attached to replacement...
Page 366 1-26 BODY CONSTRUCTION THEFT PROTECTION LOCATIONS LABEL AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS) ENGINE MANUAL TRANSAXLE AC211574 AB AC211575 QUARTER PANEL OUTER FENDER AC101605 AB THE ILLUSTRATION INDICATES LEFT OUTER SIDE. AC101606 AB RIGHT SIDE IS SYMMETRICALLY OPPOSITE. THE ILLUSTRATION INDICATES LEFT OUTER SIDE.
Page 367 1-27 BODY CONSTRUCTION THEFT PROTECTION LABEL AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS) FRONT DOOR REAR DOOR THE ILLUSTRATION INDICATES LEFT INNER SIDE. THE ILLUSTRATION INDICATES LEFT INNER SIDE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE. AC101607AB AC101608 AB HOOD...
Page 368 NOTES...

Mitsubishi MOTORS Lancer Evolution VIII 2003 Technical Information Manual

37-1 Group 37 Power Steering

Electrical

Group 54B Simplified Wiring System (Sws)

Exhaust

52A-1 Group 52A Interior

General Information

Instrument Panel and Floor Console

Accessories

Seat

Seat Belt

Trims

System (Mfi)

Control

Control

Charge Pressure Control

42-1 Group 42 Body

General Description

Strut Tower Bar

Hood and Fender

Main Body

Door

Lid

Window Glass

Sunroof

Repair

Welding

Body Repair

Corrosion Protection

Material

Installation and Removal of Adhesive Components

Adjustment of Other Parts

Front Wheel Alignment

Supplemental Restraint

Replacement

2-1 Group 2 Body Dimensions

Construction

Body Components

Body Main Cross-Sectional Views

Maintenance, Serviceability

Body Construction Characteristics

Silencer Application Locations

Locations Using Urethane Foam and Foam Material

Stiffener and Damp Sheet Application Locations

Theft Protection

Quick Links

Chapters

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Summary of Contents for Mitsubishi MOTORS Lancer Evolution VIII 2003