Mitsubishi LANCER EVOLUTION-VII 2001 Technical Information Manual
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Mitsubishi LANCER EVOLUTION-VII 2001 Technical Information Manual

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TECHNICAL INFORMATION MANUAL
EVOLUTION-VII
Pub. No. N0104CT9A

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Summary of Contents for Mitsubishi LANCER EVOLUTION-VII 2001

  • Page 1 www.TuningEvo.Club TECHNICAL INFORMATION MANUAL EVOLUTION-VII Pub. No. N0104CT9A...
  • Page 2 RALLIART Inc. Since the EVOLUTION-VII is a rally- based model, it will not be warranted and will not be homologated for general production. Therefore, any service matters on the EVOLUTION-VII should be inquired to RALLIART Inc. as usual. E Mitsubishi Motors Corporation April 2001...
  • Page 3 NOTES...

  • Page 4: Table Of Contents

    GENERAL CONTENTS HOW TO USE THIS MANUAL ....Active Center Differential (ACD), Active Yaw Control (AYC) ....... . Model Indications .

  • Page 5: How To Use This Manual

    Mitsubishi brand. Furthermore, enhancement of competitiveness as well as driving performance in various motor sport events has been sought.
  • Page 6 GENERAL - Product Features Further improve- (1) Mitsubishi original revolutionary technology with all wheel control ment in handling Newly developed active center differential system (ACD) (to be performance compatible with steering response to cornering and rising traction made performance) hancement of the...

  • Page 7: Technical Features

    GENERAL - Technical Features TECHNICAL FEATURES EXTERIOR DESIGN FEATURES The 7th generation EVOLUTION has acquired the (3) Exclusive blister fender to appeal good road image of “high performance sports sedan” equipped hanging (traction characteristics) and brisk with guaranteed quality and fearless determination driving capability as “high quality driving sedan”...

  • Page 8: Interior

    Technical Features INTERIOR DESIGN FEATURES High performance interior to provide an impression (2) The Mitsubishi original design made by MOMO of sports minded vehicle as the 7th generation used for the steering has the same design used EVOLUTION for horn pad as the shift lever to express...

  • Page 9: Body Dimensions And Spacious Cabin

    GENERAL - Technical Features BODY DIMENSIONS AND SPACIOUS CABIN Body Dimensions The dimensions of the EVOLUTION-VII except for the overall width have been altered in comparison with those of EVOLUTION-VI. Dimensions mm Dimensions mm Item Item Overall length 4 455 (+105) Rear overhang 935 ( - 15) 1 770 (±0)

  • Page 10: Active Center Differential (Acd), Active Yaw Control (Ayc)

    GENERAL - Technical Features ACTIVE CENTER DIFFERENTIAL (ACD), ACTIVE YAW CONTROL (AYC) ACD, which is designed for improving drive characteristics by electronically controlling center differential movement, and AYC, which has been adopted since EVOLUTION-IV are featured by combing two systems for integrated control so that further improvements in driving performance can be achieved.

  • Page 11: Engine

    GENERAL - Technical Features ENGINE The turbo charger specifications have been Since adoption of magnesium diecasting rocker optimized by reducing the size of the turbine nozzle cover and hollow camshaft is intended for light diameter to increase the engine torque at weight of the upper part of the engine, vibration low - middle speed range as well as high speed of engine - transmission at acceleration can be...
  • Page 12 GENERAL - Technical Features Strut insulator Lower arm bushing (Pillow ball bushing with rubber) Coil spring Stabilizer bar Crossmember Strut assembly (shock absorber) Stabilizer link Lower arm Crossmember bar <RS (option), RS-II> Coil spring Shock absorber Stabilizer bar Upper arm Crossmember Toe control arm Differential...

  • Page 13: Safety

    0-10 GENERAL - Technical Features SAFETY ACTIVE SAFETY BRAKING SYSTEM All models feature fade-resistant 14-inch ventilated New for the Lancer, EBD works with the ABS discs up front and rear 8-inch drums for sure, linear computer to evenly modulate each channel’s stopping power.
  • Page 14 0-11 GENERAL - Technical Features PASSIVE SAFETY SRS AIR BAGS Dual SRS (Supplemental Restraint System) front Seat belt with pretensioner featured for the driver’s airbags deploy only upon detection of frontal impact. and front passenger’s seats is designed for instantly When used in combination with the 3-point ELR taking up the slack in the seat belt at the time seatbelts, they significantly mitigate head and upper...
  • Page 15 0-12 GENERAL - Technical Features BODY CONSTRUCTION EVOLUTION-VII safety-enhanced body Adding to all-round occupant protection is a structure comprises front and rear crushable zones deformation-resistant, highly rigid cabin structure that effectively absorb the impact energy of front that features strategic reinforcements plus large and rear collisions.

  • Page 16: Equipments

    0-13 GENERAL - GENERAL - Technical Features Technical Features SAFETY-ENHANCED FRONT SEATS The front seats are designed to minimise the risk In-house tests show a roughly 40% improvement of whiplash in a collision from the rear. in occupant injury figures. The headrestraints have been ideally angled forward, while the seat frame was moved toward the rear.

  • Page 17: Vehicle Identification

    16 valves intercooler turbo) 16 valves-intercooler turbo) SNGFZL/R RS-II MODEL CODE Items Contents CT 9 A S N D F Development MITSUBISHI LANCER EVOLUTION-VII Engine type 1,997 mL petrol engine 2 3 4 5 6 7 8 9 Sort Passenger car Body style...

  • Page 18: Major Specifications

    0-15 GENERAL - Major Specifications MAJOR SPECIFICATIONS Items CT9A SNDFZL/R SNGFZL/R Vehicle Front track 1 1,500, 1,515 dimensions Overall width 2 1,770 Front overhang 3 855 Wheel base 4 2,625 Rear overhang 5 975 Overall length 6 4,455 Ground clearance 7 140 (unladen) Overall height (unladen)
  • Page 19 NOTES...

  • Page 20: Components

    ENGINE CONTENTS GENERAL INFORMATION ....System Block Diagram ....Control System Diagram .

  • Page 21: General Information

    ENGINE - General Information GENERAL INFORMATION This engine has the same basic structure as the previous 4G63-T/C engine, however, the following enhancements have been added in order to provide improved performance. The piston shape has been changed. The width of the piston rings has been reduced in order to reduce engine friction. The turbocharger type has been changed.

  • Page 22: Base Engine

    ENGINE - Base Engine BASE ENGINE PISTON The top land height has been changed from 5 mm to 6 mm, and the second land height has been changed from 4.5 mm to 5 mm. <NEW> <OLD> 6 mm 5 mm 5 mm 4.5 mm PISTON RING...

  • Page 23: Lubrication System

    ENGINE - Lubrication System LUBRICATION SYSTEM ENGINE OIL COOLER The drawn cup air-cooled type engine oil cooler has been adopted. The engine oil cooler is installed below the right head lamp assembly and brings in the air through the oil cooler duct of the front bumper to cool the engine oil.

  • Page 24: Cooling System

    ENGINE - Cooling System COOLING SYSTEM The cooling system is a water-cooled pressurized, forced circulation type which offers the following features. To improve the reliability of cavitation at a high engine speed and to increase the amount of engine coolant, output control system in which a thermostat is installed at the outlet of engine coolant from the engine to the radiator has been adopted.

  • Page 25: Intake And Exhaust

    ENGINE - Intake and Exhaust INTAKE AND EXHAUST AIR INTAKE SYSTEM AIR DUCT, AIR CLEANER By introducing fresh cool air from the top of the radiator efficiently, the engine performance has been enhanced and intake air noise has been reduced. Burnable used paper mixed with plastic materials have been adopted in consideration for reduction of industrial wastes and protection of global environment.
  • Page 26 ENGINE - Intake and Exhaust INTER COOLER WATER SPRAY To complement the intercooler efficiency in ranges where the cooling efficiency of the air cooled intercooler is insufficient, and attain high performance in various operating environments, a system which cools by spraying water from a special washer tank for the intercooler to the front of the intercooler has been adopted.
  • Page 27 ENGINE - Intake and Exhaust SYSTEM DIAGRAM Ignition switch (IG2) Ignition switch (IG1) Fuse 7.5A 7.5A Front-ECU (Tail lamp relay) Water spray relay Combination meter Fuse 7.5A Water spray motor Engine-ECU Water spray switch MANUAL AUTO...

  • Page 28: Exhaust System

    ENGINE - Exhaust System EXHAUST SYSTEM EXHAUST FITTING BRACKET An exhaust fitting bracket has been added in order to provide greater rigidity. Exhaust fitting Exhaust manifold heat protector Exhaust fitting bracket TURBOCHARGER The turbocharger type TD05HR-16G6-9.8T and TD05HRA-16G6-9.8T have been adopted. Compared to previous types of turbocharger, these new types have a smaller turbine housing nozzle area which improves response at medium to low speeds.
  • Page 29 1-10 ENGINE - Intake and Exhaust EXHAUST PIPE AND MUFFLER Exhaust pipe consisting of 3 separation system: front exhaust pipe, center exhaust pipe, and exhaust main muffler, has the following features: The adoption of a seal ring has reduced vibrations during idling and driving noise. A main muffler incorporating a back pressure variable valve is adopted.

  • Page 30: Fuel System

    1-11 ENGINE - Fuel System FUEL SYSTEM The fuel system consists of parts such as electromagnetic-type fuel injectors, a delivery pipe and a fuel pressure regulator. In addition, a fuel pressure control solenoid valve has been provided in order to maintain idling stability after the engine is re-started when it is hot.

  • Page 31: Fuel Tank

    1-12 ENGINE - Fuel System FUEL TANK A steel fuel tank is located under the floor of the For better serviceability, the fuel tank has been rear seats to provide increased safety and increase coupled with the main line by a one-touch joint the amount of luggage compartment space.

  • Page 32: Control System

    1-13 ENGINE - Control System CONTROL SYSTEM The control system is based on the system for 4G63-DOHC-Tubocharger which has been installed in the EVOLUTION-VI, with the following improvements added. Improvements/Additions Remarks Adoption of compact throttle position sensor Smaller size and light weight Higher resistance to vibration Idle position switch disused Basically the same as that used in the SPACE...

  • Page 33: System Block Diagram

    1-14 ENGINE - Control System SYSTEM BLOCK DIAGRAM No.1 injector Engine-ECU Air flow sensor No.2 injector Fuel injection control No.3 injector Intake air temperature sensor Idle speed control No.4 injector Barometric pressure sensor Idle speed control servo Ignition timing control (stepper motor) Engine coolant temperature sensor No.1, No.4 ignition coil...

  • Page 34: Control System Diagram

    1-15 ENGINE - Control System CONTROL SYSTEM DIAGRAM L1 Oxygen sensor (front) l1 Injector l2 Idle speed control servo L2 Oxygen sensor (rear) l3 Fuel pressure control solenoid valve L3 Air flow sensor l4 Waste gate solenoid valve L4 Intake air temperature sensor Engine-ECU L5 Throttle position sensor l5 EGR control solenoid valve...

  • Page 35: List Of Component Functions

    1-16 ENGINE - Control System LIST OF COMPONENT FUNCTIONS Name Function Engine-ECU Uses the signals input from the various sensors to control operation of actuators in accordance with the driving conditions. Sensors Ignition switch-IG Detects the ON/OFF position of the ignition switch. When this signal is input to the engine-ECU, power is supplied to components such as the injectors, air flow sensor, idle speed control servo and crank angle sensor.
  • Page 36 1-17 ENGINE - Control System Name Function Sensors A/C load signal Inputs the compressor drive state (low load/high load) to the engine-ECU. The engine-ECU controls the A/C idle-up revolution speed using this signal. Intercooler water spray switch Sprays water when certain driving conditions are satisfied. (automatic) Intercooler water spray switch Sprays water while the switch is being pressed by the driver.
  • Page 37 1-18 ENGINE - Control System Name Function Actuators Alternator G terminal Controls the current generated by the alternator in accordance with the signal from the engine-ECU. A/C relay Controls the A/C compressor operation. Engine warning lamp Illuminates when a sensor malfunction is detected to warn the driver (check engine lamp) of the problem.

  • Page 38: Fuel Injection Control

    1-19 ENGINE - Control System FUEL INJECTION CONTROL The fuel injection control system is basically the same as the control system for the 4G63-DOHC-Turbocharger engine installed in the Evolution-VI. SYSTEM CONFIGURATION DIAGRAM Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Throttle position sensor Fuel pressure control...

  • Page 39: Ignition Timing And Distribution Control

    1-20 ENGINE - Control System IGNITION TIMING AND DISTRIBUTION CONTROL The ignition timing and distribution control system is basically the same as the control system for the 4G63 - DOHC-Turbocharger engine installed in the Evolution-VI. SYSTEM CONFIGURATION DIAGRAM Ignition switch Battery Air flow sensor Barometric pressure sensor...

  • Page 40: Fuel Pump Relay Control

    1-21 ENGINE - Control System FUEL PUMP RELAY CONTROL The fuel injection amount is controlled by the fuel pump relay 3 in order to reduce the amount of return fuel when the engine is running at low speeds and fuel consumption is low, and also to reduce noise.

  • Page 41: Egr Control And Purge Control

    1-22 ENGINE - Control System EGR CONTROL AND PURGE CONTROL Refer to the EMISSION CONTROL SYSTEM. DIAGNOSIS SYSTEM The engine-ECU is prvided with the following functions to make system inspection easier. Engine warning lamp control Diagnosis function Service data output Actuator test NOTE Refer to the Workshop Manual for details on each item.

  • Page 42: Emission Control System

    1-23 ENGINE - Emission Control System EMISSION CONTROL SYSTEM The following improvements in the control details have been made to the system, which is basically the same as the previous system used in the 4G63-DOHC-Turbocharger engine for the EVOLUTION-VI. An electronically-controlled EGR system utilizing an EGR control solenoid valve has been adopted. An electronically-controlled purge control system utilizing purge control solenoid valve has been adopted.

  • Page 43: Mount

    1-24 ENGINE - Mount MOUNT The inertia axial system based on the past achievements in COLT/LANCER has been adopted for the engine mount system. Longitudinal installation type of cylindrical liquid-filled engine mount has been adopted for reduction of idle vibration and improvement of ride feeling. The liquid-filled mount system has been adopted for transmission mount to improve ride feeling by optimizing the insulator.
  • Page 44 1-25 ENGINE - ENGINE - Mount Mount <Engine roll stopper/Crossmember/Centermember : L.H. drive vehicles> Rear roll mount bracket Rear roll rod assembly Rear roll rod bracket Crossmember Front roll mount bracket Front roll stopper Crossmember bar Centermember <Engine roll stopper/Crossmember/Centermember : R.H. drive vehicles> Rear roll mount bracket Rear roll stopper Crossmember...

  • Page 45: Accelerator System

    1-26 ENGINE - Accelerator System ACCELERATOR SYSTEM The accelerator system is a cable and suspended vent noise and vibration when the cable and accel- pedal combination. erator arm contact. Plastic bushing and rubber damper have been at- tached to the end of the accelerator cable, to pre- CONSTRUCTION DIAGRAM Plastic bushing Rubber...
  • Page 46 POWER TRAIN CONTENTS CLUTCH ....... . System Structure ......Oil Pressure Unit .

  • Page 47: Clutch

    POWER TRAIN - Clutch CLUTCH SPECIFICATIONS Items Specifications Engine model 4G63-DOHC-Intercooler Turbocharger Clutch disc type Dry single plate type Clutch disc facing diameter O.D.×I.D. mm 240×160 Clutch cover type Diaphragm spring pull type Clutch cover set load N 9,320 ± 750 Control system Hydraulic type Release cylinder I.D.

  • Page 48: Manual Transmission

    POWER TRAIN - Manual Transmission MANUAL TRANSMISSION The manual transmission is a W5M5 transmission. This transmission incorporates the following changes from the F5M4 type transmission mounted to GALANT. With the incorporation of 4WD, the center differential has been positioned at the front differential of the 2WD, and the front differential has been positioned inside the transfer.

  • Page 49: Sectional View

    POWER TRAIN - Manual Transmission SECTIONAL VIEW W5M51 <Vehicle with VCU> 1. 4th gear 11. Transfer cover 2. 3rd - 4th synchronizer 12. Hypoid pinion 3. 3rd gear 13. Center differential 4. Transmission case 14. 1st gear 5. Clutch housing 15.
  • Page 50 POWER TRAIN - Manual Transmission W5M51 <Vehicle with ACD> 1. 4th gear 12. Piston 2. 3rd - 4th synchronizer 13. Transfer hydraulic case 3. 3rd gear 14. Hypoid pinion 4. Transmission case 15. Center differential 5. Clutch housing 16. 1st gear 6.
  • Page 51 POWER TRAIN - Manual Transmission W5M51 <Vehicle with Helical Gear LSD and VCU> 1. 4th gear 11. Transfer cover 2. 3rd - 4th sychronizer 12. Hypoid pinion 3. 3rd gear 13. Center differential 4. Transmission case 14. 1st gear 5. Clutch housing 15.
  • Page 52 POWER TRAIN - Manual Transmission W5M51 <Vehicle with Helical Gear LSD and ACD> 1. 4th gear 12. Piston 2. 3rd - 4th sychronizer 13. Transfer hydraulic case 3. 3rd gear 14. Hypoid pinion 4. Transmission case 15. Center differential 5. Clutch housing 16.

  • Page 53: 4Wd System

    POWER TRAIN - Manual Transmission 4WD SYSTEM The 4WD system is a center differential full-time 4WD with limited slip differential. The center differential has been positioned at the front differential of the 2WD transmission, and the front differential has been positioned inside the transfer. The limited slip differential of the center differential has been positioned at the back of the front differential in the transfer.

  • Page 54: Power Train

    POWER TRAIN - Manual Transmission POWER TRAIN Helical Gear LSD The helical gear LSD is composed of four long pinions, four short pinions, three thrust washers, side gears A and B, and cases A and B. The long pinions are in contact with the side gear B and short pinions, while the short pinions are in contact with the side gear A and long pinions.
  • Page 55 2-10 POWER TRAIN - Manual Transmission Operations during differential (when there is rotational difference between the left and right wheels) When the frictional coefficient of the left and right wheels are more or less equal, and a slight rotational difference occurs at the left and right wheels (normal turning), rotational difference will also occur between side gears A and B.

  • Page 56: Transmission Control

    2-11 POWER TRAIN - Manual Transmission Driving power Forward direction Thrust washer Torque High speed side Low speed side Long pinion Thrust washer Differential case Short pinion Side gear A Side gear B TRANSMISSION CONTROL The shift lever construction adopted the The shift and select cable securing portions spherical rotary shaft fulcrum type to assure have been elastically supported to reduce...

  • Page 57: Active Center Differential (Acd) And Active Yaw Control (Ayc)

    2-12 POWER TRAIN - ACD and AYC ACTIVE CENTER DIFFERENTIAL (ACD) AND ACTIVE YAW CONTROL (AYC) The LANCER EVOLUTION-VII adopts the newly developed active center differential (ACD). The driving performance of the ACD has been improved by varying the center differential drive by electronic control.
  • Page 58 2-13 POWER TRAIN - ACD and AYC COMPONENT VIEW ACD mode indicator lamp AYC torque transfer differential Parking brake switch Steering wheel sensor Throttle position sensor (TPS) Reserve tank ABS-ECU Hydraulic unit assembly Lateral G sensor Wheel speed sensor Longitudinal ACD transfer G sensor Engine-ECU...
  • Page 59 2-14 POWER TRAIN - ACD and AYC LIST OF MAIN COMPONENTS Components Outline of function ACD transfer Controls the transmission torque of the hydraulic multi plate clutch by the hydraulic unit, and adjusts the center differential. 4WD-ECU Processes information of various sensors and switches, calculates the hydraulic multi plate clutch transmission torque and amount of AYC torque movement and direction, and controls the hydraulic unit on the basis of them.
  • Page 60 2-15 POWER TRAIN - ACD and AYC OUTLINE OF ACD AND AYC Idling information Engine-ECU <ACD and AYC Equipped Vehicle> ACD mode switch ABS monitor signal Parking brake switch Wheel speed sensor <FL> Wheel speed sensor <RL> ABS- ACD mode indicator lamp Wheel speed sensor <RR>...

  • Page 61: Description Of Structure And Operations

    2-16 POWER TRAIN - ACD and AYC DESCRIPTION OF STRUCTURE AND OPERATIONS The ACD system adopts a transfer limited slip differential as the hydraulic multi plate clutch, and electronically controls it using sensors, 4WD-ECU, and hydraulic unit. NOTE Refer to P.2-30 for details on the AYC structure and operations. SYSTEM STRUCTURE AYC torque transfer differential...
  • Page 62 2-17 POWER TRAIN - ACD and AYC TRANSFER LIMITED SLIP DIFFERENTIAL During acceleration and deceleration, the piston is moved in the right direction according to the oil pressure from the hydraulic unit to connect the hydraulic multi plate clutch (friction plate and disc) and set the center differential to the direct engagement state as much as possible.
  • Page 63 2-18 POWER TRAIN - ACD and AYC HYDRAULIC UNIT The hydreaulic unit is composed of the accumulator (electric pump, pressure sensor, accumulator) and pressure controller (proportional valve, directional valve). The pressure accumulator intermittently operates the pump, and accumulates the control pressure required in the accumulator.
  • Page 64 2-19 POWER TRAIN - ACD and AYC When the proportional valve is OFF, the oil pressure from the electric pump will be cut off by the proportional valve. Proportional From electric pump valve (OFF) For this reason, oil pressure will be supplied to the ACD or AYC and each system will be set into the non-operating state.

  • Page 65: Electronic Control System

    2-20 POWER TRAIN - ACD and AYC ELECTRONIC CONTROL SYSTEM THROTTLE POSITION SENSOR For detecting the throttle valve opening angle. Also used as throttle position sensor for engine control. LONGITUDINAL G SENSOR/LATERAL G SENSOR The longitudinal G sensor are sensors detecting the acceleration in the longitudinal directions of the vehicle, and are basically the same as those used conventionally.
  • Page 66 2-21 POWER TRAIN - ACD and AYC Output waveform of each sensor N (Neutral point) 2° Steering wheel sensor 4° 4° ST-1 θ 4° 4° ST-2 θ Slit 11° ST-N θ Slit plate Slit plate Neutral position Photointerruptor detection slit (ST-2) Zener diode for disconnec-...
  • Page 67 2-22 POWER TRAIN - ACD and AYC ACD MODE SWITCH When the ACD mode switch is pressed, the mode switches to TARMAC, GRAVEL, or SNOW. ACD mode TARMAC GRAVEL SNOW Good condi- paved roads, Snowy roads tion roads roads gravel roads ACD mode switch ACD MODE INDICATOR LAMP ACD mode indicator lamp...
  • Page 68 2-23 POWER TRAIN - ACD and AYC The terminals of the 4WD-ECU are arranged as follows. 1. Proportional valve <ACD> 25. - 2. - 26. ECU earth 3. Proportional valve <AYC>* 31. ECU backup power supply 4. - 32. Pressure sensor 5.
  • Page 69 2-24 POWER TRAIN - ACD and AYC Code Diagnosis Item Mode indica- Main diagnosis details tor lamp (f: all lit, – : normally displayed) Steering wheel sensor <ST-N> system short-circuit Steering wheel sensor <ST-N> ST N Fixing of steering wheel sensor <ST-N> system Steering wheel sensor Short-circuit or fixing of output of steering wheel sensor <ST-1, <ST-1, ST-2>...
  • Page 70 2-25 POWER TRAIN - ACD and AYC SERVICE DATA Item No. Item Unit Wheel speed sensor <FR> km/h (Displayed for every 1 km/h) Wheel speed sensor <FL> km/h (Displayed for every 1 km/h) Wheel speed sensor <RR> km/h (Displayed for every 1 km/h) Wheel speed sensor <RL>...
  • Page 71 2-26 POWER TRAIN - ACD and AYC ACTUATOR TEST Item No. Content Drive Specifications Driving Check time Bleeding Outputs current to the 5 minutes Check that no air is discharged from the <ACD> proportional valve accord- bleeder screw installed on the ACD ing to the steering angle.

  • Page 72: Propeller Shaft

    2-27 POWER TRAIN - POWER TRAIN - Propeller Shaft Propeller Shaft PROPELLER SHAFT 3 way split 4-joint type propeller shaft with center bearing is adopted. SPECIFICATIONS Item Vehicles without AYC Vehicles with AYC 3 way split 4-joint type propeller shaft Propeller Type shaft...

  • Page 73: Front Axle

    2-28 DRIVETRAIN - Front Axle FRONT AXLE The front axle consists of front hubs, knuckles, The drive shaft incorporates B.J.-T.J. type wheel bearings and drive shafts, and it has the constant velocity joints with high transmission following features. efficiency and low vibration and noise. The wheel bearing is unit bearing (Double-row ABS rotors for detecting the wheel speeds are angular contact ball bearing) which is integrated...

  • Page 74: Rear Axle

    2-29 DRIVETRAIN - Rear Axle REAR AXLE The rear axle consists of rear hubs, wheel bearings, The drive shaft incorporates B.J.-T.J. type drive shafts, and rear differentialand, it has the constant velocity joints with high transmission following features. efficiency and low vibration and noise. The wheel bearing is a unit bearing (double-row ABS rotors for detecting the wheel speeds are angular contact ball bearing).

  • Page 75: Differential

    2-30 DRIVETRAIN - Differential DIFFERENTIAL Mechanical type Limited Slip Differential <Vehicles without AYC> or Torque transfer differential <Vehicles with AYC> is adopted. About the structure of AYC, refer to P.2-3, manual transmission. MECHANICAL LIMITED SLIP DIFFERENTIAL SPECIFICATIONS Item Mechanical LSD Reduction gear type Hypoid gear Reduction ratio...
  • Page 76 2-31 DRIVETRAIN - Differential TORQUE TRANSFER DIFFERENTIAL The torque transfer differential consists of differential mechanism,acceleration/decelation gear and two pairs of wet multi-plate clutch. The hipoid gear oil is used to lublicate differential part, ATF-SP III is used to lublicate torque movement part (acceleration/decelation gear and clutch). L.H.
  • Page 77 2-32 DRIVETRAIN - Differential TORQUE TRANSFER DIFFERENTIAL MECHANISM High When high speed clutch is pushed, the driving power always speed speed side side moves from high speed side to low speed side, and controls the driving power with the aid of the property which the movement of driving power is proportional to the pushing force of clutch.

  • Page 78: Differential Mount

    2-33 DRIVETRAIN - Differential Mount DIFFERENTIAL MOUNT The front of differential carrier is suported with the The front of torque transfer differential is supported differential support member via the differential with the differential support member with insulator mount bracket with insulator,and the rear is via the differential mount bracket,and the rear is suported with the differential support arm.
  • Page 79 NOTES...
  • Page 80 DRIVE-CONTROL COMPONENTS CONTENTS SUSPENSION ......Steering Gear ......Features .
  • Page 81 DRIVE-CONTROL COMPONENTS - Suspension/Front Suspension SUSPENSION The suspension which has been adjusted to new A McPherson strut-type suspension has been used body dimension with the optimal tuning has im- at the front, and a multi-link suspension has been proved its cornering ability. used at the rear.

  • Page 82: Front Suspension

    DRIVE-CONTROL COMPONENTS - Front Suspension CONSTRUCTION DIAGRAM Strut insulator Lower arm bushing (Pillow ball bushing with rubber) Coil spring Stabilizer bar Crossmember Strut assembly (shock absorber) Stabilizer link Lower arm Crossmember bar <RS (option), RS-II> SPECIFICATIONS SUSPENSION SYSTEM Items Lancer EVOLUTION-VII Lancer EVOLUTION-VI Tommi Makinen Edition Suspension method...
  • Page 83 DRIVE-CONTROL COMPONENTS - Front Suspension COIL SPRING Item Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi Makinen Edition RS (standard), RS-II RS (option) Tarmac suspension Normal suspension Wire diameter mm Average diameter mm Free length mm LOWER ARM Like Lancer EVOLUTION-VI Tommi Makinen Improved the reliability and steering feeling by Edition, an aluminium forged lower arm has been reducing friction as well as making the ball size...

  • Page 84: Stabilizer Bar

    DRIVE-CONTROL COMPONENTS - Front Suspension/Rear Suspension STABILIZER BAR Following modifications have been made to Lancer Prevents the occurance of unusual noise EVOLUTION-VI Tommi Makinen Edition. caused by lateral sliding of brackets with Prevents the occurance of unusual noise by installation of two mounting bolts to the increasing the volume of stabilizer bushing.

  • Page 85: Specifications

    DRIVE-CONTROL COMPONENTS - Rear Suspension SPECIFICATIONS SUSPENSION SYSTEM Item Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi Makinen Edition Suspension method Multi-link Multi-link WHEEL ALIGNMENT Items Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ Tommi Makinen Edition - 1_00’ - 1_00’ Camber Toe-in COIL SPRING Items Lancer EVOLUTION-Ⅶ Lancer EVOLUTION-Ⅵ...

  • Page 86: Wheel And Tyre

    DRIVE-CONTROL COMPONENTS - Wheel and Tyre WHEEL AND TYRE FEATURES Following modifications have been made to Lancer Equipped with 205/65R15 94H tyre <RS EVOLUTION-VI Tommi Makinen Edition to improve (standard)> the vehicle performance. Exclusively EVOLUTION-VII 17-inch Exclusively to EVOLUTION-VII 17 - inch tyre aluminium wheel has been newly deeveloped has been newly developed by widening the by widening rim width from 7 1/2JJ to 8JJ <RS...

  • Page 87: Power Steering

    DRIVE CONTROL COMPONENTS - Power Steering POWER STEERING FEATURES To improve steering feeling and response of the A variable capacity pump has been adopted to steering system, the following steering system has reduce power losses improve fuel been adopted. consumption. When the engine speed increases, The system has been equipped with the MOMO pump chamber...

  • Page 88: Construction Diagram

    DRIVE CONTROL COMPONENTS - Power Steering CONSTRUCTION DIAGRAM <L.H. drive vehicles> Steering wheel Steering column and shaft Reservoir tank Return hose Suction hose Pressure hose Oil pump Assembly Steering gear Cooler tube and linkage <R.H. drive vehicles> Steering wheel Steering column and shaft Reservoir tank Return hose Suction hose...

  • Page 89: Steering Wheel

    3-10 DRIVE CONTROL COMPONENTS - Power Steering STEERING WHEEL There are two types of MOMO leather 3-spoke-type steering wheels (built-in SRS air bag) with different desigins. <RS (standard)> <RS(option), RS-II> STEERING SHAFT AND COLUMN For the steering column, an impact absorbing mechanism which absorbs impact energy in the event of a collision as well as a tilt steering mechanism which enables the driver to obtain an...
  • Page 90 3-11 DRIVE CONTROL COMPONENTS - DRIVE CONTROL COMPONENTS - Power Steering Power Steering SHOCK ABSORBING MECHANISM BEFORE COLLISION 1. Primary impact When the vehicle collides with something and there is a load added to the shaft sub assembly from the gearbox, the shaft sub assembly slides above the pipe sub assembly to absorb the shock load.

  • Page 91: Oil Pump

    3-12 DRIVE CONTROL COMPONENTS - Power Steering (2) At the same time that tilt bracket (A) separates, the clevis BEFORE COLLISION U - section pin comes out of the U - section groove in the tilt plate, groove allowing the steering column assembly to move forward. Clevis pin Tilt plate Tilt bracket (B)

  • Page 92: Steering Gear

    3-13 DRIVE CONTROL COMPONENTS - Power Steering STEERING GEAR Using the following parts have contributed to The installation accuracy, rigidity and steering save weight; an aluminium steering gear and stability have been improved by using an eye linkage valve housing, a plastic tie-rod bellows, bushing, which secures the steering gear to and the hollow-type tie-rod stud.

  • Page 93: Brakes

    3-14 DRIVE-CONTROL COMPONENTS - Brakes BRAKES The brake system has been designed to give greater reliability and durability and to provide excellent braking performance. FEATURES Improved braking perfor- 1. A 8+9-inch brake booster has been adopted to provide mance large braking force with a small pedal depression force. 2.

  • Page 94: Construction Diagram

    3-15 DRIVE-CONTROL COMPONENTS - Brakes CONSTRUCTION DIAGRAM <Vehicles with ABS> Brake booster* Hydraulic unit* Rear disc brake Parking brake Master cylinder* Front disc brake <Vehicles without ABS> Brake booster* Master cylinder and proportioning valves* Rear disc brake Parking brake Front disc brake NOTE For R.H.

  • Page 95: Specifications

    3-16 DRIVE-CONTROL COMPONENTS - Service Brakes SERVICE BRAKES SPECIFICATIONS Lancer EVOLUTION-VI Tommi Items Lancer EVOLUTION-VII Makinen Edition Master Type Tandem type Tandem type cylinder cylinder I.D. mm 26.9 26.9 Brake Type Vacuum type, tandem Vacuum type, tandem booster booster Effective dia. of power 205 + 230 180 + 205 cylinder mm...

  • Page 96: Master Cylinder

    3-17 DRIVE-CONTROL COMPONENTS - Service Brakes MASTER CYLINDER The master cylinder is a tandem-type, with a structure that emphasises safety. Reserve tank Master cylinder body Primary piston assembly Piston retainer Secondary piston assembly BRAKE BOOSTER A 8+9-inch tandem-type brake booster has been adopted.

  • Page 97: Disc Brakes

    3-18 DRIVE-CONTROL COMPONENTS - Service Brakes DISC BRAKES Brakes with the following specifications have been brake pads equipped with adopted. mechanical-type audible wear indicators V5-W43 2-piston ventilate discs for front brakes notify the driver when the usage limit (2 mm) <RS (standard)>...

  • Page 98: Brake Line

    3-19 DRIVE-CONTROL COMPONENTS - Service Brakes DISC BRAKE NOMENCLATURE Item Contents V 7 – Z 40 46 Brake disc type V: Ventilated Brake size 5: 15-inch (Minimum applicable 6: 16-inch disc wheel) 7: 17-inch No. of pistons S: 1 piston (floating type) W: 2 piston (floating type) X: 2 piston (opposed type) Z: 4 piston (opposed type)

  • Page 99: 4-Wheel Anti-Skid Braking System

    3-20 DRIVE-CONTROL COMPONENTS - 4ABS 4-WHEEL ANTI-SKID BRAKING SYSTEM (4ABS) FEATURES ABS has been adopted as optional equipment in By adding lateral G sensor, longitudinal G RS - II to maintain directional stability and steering sensor and steering wheel sensor, optimized performance during sudden braking or braking on ABS control at the time of cornering.

  • Page 100: 4Abs

    3-21 DRIVE-CONTROL COMPONENTS - 4ABS CONSTRUCTION DIAGRAM 7*, 10* NOTE For R.H. drive vehicles, only the position indicated by the * is symmetrical. Name of part Number Outline of functions Wheel speed sensor Send alternating current signals at frequencies which are Sensor proportional to the rotation speeds of each wheel to the ABS-ECU...

  • Page 101: Lateral G Sensor

    3-22 DRIVE-CONTROL COMPONENTS - 4ABS SYSTEM CONFIGURATION DIAGRAM Motor FR solenoid valve (OUT) Wheel speed sensor (FL) FR solenoid valve (IN) Wheel speed sensor (RL) FL solenoid valve (OUT) Wheel speed sensor (RR) FL solenoid valve (IN) Wheel speed sensor (FR) RR solenoid valve (OUT) Longitudinal G sensor RR solenoid valve (IN)

  • Page 102: Abs Electrical Circuit Diagram

    3-23 DRIVE-CONTROL COMPONENTS - 4ABS ABS ELECTRICAL CIRCUIT DIAGRAM Ignition Switch Ignition Switch Fusible link Fusible link Battery (IG2) (IG1) No. 1 No. 3 Junction block (Multi- purpose fuse) Dedicated fuse 7.5A 7.5A 7.5A Stop lamp switch Combination meter (ABS warning lamp) Longitudinal Lateral G sensor G sensor...

  • Page 103: Sensors

    3-24 DRIVE-CONTROL COMPONENTS - 4ABS SENSORS WHEEL SPEED SENSOR The wheel speed sensors consist of fixed ABS The ABS rotors (43 teeth) are installed to the speed sensors and the ABS rotors that rotate at drive shafts, and the ABS speed sensors are the same speed as the wheels, and output installed to knuckles.

  • Page 104: Actuators

    3-25 DRIVE-CONTROL COMPONENTS - 4ABS STOP LAMP SWITCH This switch turns on when the brake pedal is stop lamp switch is on or off by means of fluctuations depressed, and turns off when the brake pedal in voltage (ON: system voltage; OFF: Approximately is released.

  • Page 105: Abs-Ecu

    3-26 DRIVE-CONTROL COMPONENTS - DRIVE-CONTROL COMPONENTS - 4ABS 4ABS ABS-ECU The ABS-ECU is basically the same as that of the PININ <Europe> except for the followings: 1999 PAJERO io <General Export>/2000 PAJERO FAIL-SAFE FUNCTION Diagnosis code No Diagnosis code No. Item Item Open circuit or short-circuit in wheel speed sensor (FR)

  • Page 106: System Operation

    3-27 DRIVE-CONTROL COMPONENTS - 4ABS/Parking Brake Item No. Check item Display unit or words Lateral G sensor Steering wheel sensor (ST-N) ON/OFF Steering wheel sensor (ST-1) Steering wheel sensor (ST-2) Steering angle _ or OFF (When the steering angle is straight ahead position) SYSTEM OPERATION In terms of operation, the system is basically the...

  • Page 107: Abs Warning Lamp

    NOTES...

  • Page 108: Diagnosis Connector

    BODY CONTENTS GENERAL DESCRIPTION ....STRUT TOWER BAR ..... . . Features .

  • Page 109: Abs Control Unit (Abs-Ecu)

    BODY - General Description GENERAL DESCRIPTION FEATURES Weight reduction 1. Use of high-tensile steel panels and steel plate with uneven thickness 2. Use of aluminum for fender and hood High rigidity 1. Use of high-tensile steel panels and steel plate with uneven thickness 2.

  • Page 110: Main Body

    BODY - Main Body MAIN BODY BODY PANELING The body has been given enhanced impact safety performance. It has been made lighter by adopting aluminum alloy panels for the hood panel and front fender. : Anti-corrosion steel panels : High-tensile steel panels...

  • Page 111: Body Shell

    BODY - Main Body BODY SHELL IMPACT SAFETY BODY The following structure ensures survival space during impact and facilitaty to rescue passengers. 1. Application of enlarged and linear cross section of front side member 2. Addition of dash panel cross member 3.
  • Page 112 BODY - Main Body STEEL PLATE WITH UNEVEN THICKNESS Due to the adoption of steel plate with uneven thickness* for the following parts, the incorporate structure of uneven thickness has improved impact safety and has reduced weight. 1. The thickness of the front end crossmember outer applied at the right side of the vehicle has been increased.
  • Page 113 BODY - Main Body OPERATIONAL STABILITY The adoption of the following structure to increase rigidity of the suspension mounting part has improved driving stability and has reduced noise from the road. 1. By directly joining a spring house bracket with increased thickness to the cowl top lower panel, and adding an upper frame to the front pillar brace, the rigidity of the top, bottom, left, and right sides of the front suspension has been improved.
  • Page 114 BODY - Main Body QUIETNESS The adoption of the following items has improved quietness. 1. Foaming sound absorption materials have been filled into the front pillar, the roof side rail, the center pillar, the rear pillar, and the inside the wheel house arch to prevent noise getting inside the vehicle. 2.

  • Page 115: Body Colour Charts

    BODY - Main Body BODY COLOUR CHARTS Engine compartment and Colour Body Colour number Body colour name Composition luggage compartment colour colour of film code Colour number Colour name SILVER AC11169 Satellite Silver Metallic AC10595 GRAY BRIGHT CMT10010 French Blue Solid CMB17004 BRIGHT...

  • Page 116: Hood And Fender

    BODY - Hood and Fender/Strut Tower Bar HOOD AND FENDER The body has been made lightweight with the use of aluminum hood and fender. The hood has also been equipped with the air outlet and air inlet garnish. Hood Air inlet garnish Air outlet garnish Fender STRUT TOWER BAR...

  • Page 117: Rear End Cross Bar

    4-10 BODY - Rear End Cross Bar <RS> REAR END CROSS BAR <RS> The rear floor pan has been equipped with a rear end cross bar to improve body rigidity. Rear end cross bar...

  • Page 118: Door

    4-11 BODY - Door DOOR DOOR LOCK The central door lock to lock/unlock all doors with a key cylinder at the driver’s door has been installed. <RS: option, RS - II: standard> CONSTRUCTION DIAGRAM <Front> Section A – A Inside lock cable Clip Inside lock cable Inside handle...

  • Page 119: Window Glass Regulator

    4-12 BODY - Door WINDOW GLASS REGULATOR 1. Small-size and lightweight wire winding style has been adopted for the window glass regulator. 2. The power window with the safety function to activate the descending movement of the door window glass for 150 mm when jammed hand or neck is detected during the ascending movement of the door window glass has been adopted to increase safety.
  • Page 120 4-13 BODY - Trunk Lid/Window Glass TRUNK LID Downsizing of the trunk lid hinge and reduction of the hinge protrusion has increased practicality. Trunk lid hinge Approximately 128 mm Trunk lid hinge (the previous LANCER EVOLUTION-VII) WINDOW GLASS Laminated glasses for the windshield and tempered glasses for other areas have been used. Name Type Thickness...
  • Page 121 NOTES...
  • Page 122 EXTERIOR CONTENTS SUMMARY OF EXTERIOR PARTS ..WIPER AND WASHER ....Feature ....... . . Windshield Wiper .

  • Page 123: Summary Of Exterior Parts

    EXTERIOR - Summary of Exterior Parts SUMMARY OF EXTERIOR PARTS Sophisticated and bold exterior designs have been given to every detail. FEATURE 1. A radiator grill integrated front bumper has been Improvements in equipped. appearance 2. An air dam integrated rear bumper has been equipped. 3.

  • Page 124: Aero Parts

    EXTERIOR - Aero Parts AERO PARTS Installation of airdams and elevation adjustable large rear spoilers have improved aerodynamic characteris- tics and appearance. CONSTRUCTION DIAGRAM Front air dam Rear spoiler Side air dam...
  • Page 125 EXTERIOR - Aero Parts ELEVATION-ADJUSTABLE LARGE REAR SPOILER Remove the cap of the rear spoiler, loosen the elevation fulcrum nut, and change the four installing holes of the adjustment bolts to adjust the elevation of the spoiler wing according to the driving conditions. Rear spoiler Wing View A <Adjustment Bolt Installing Hole...

  • Page 126: Outside Mirror

    EXTERIOR - Outside Mirror OUTSIDE MIRROR A power remote control type <RS-II>, or manual type <RS> outside mirror has been installed. CONSTRUCTION DIAGRAM Power remote control mirror switch...

  • Page 127: Wiper And Washer

    EXTERIOR - Wiper and Washer WIPER AND WASHER WINDSHIELD WIPER Two-speed type windshield wipers to be operable in a low or high speed have been adopted. Intermittent wipers with the variable intermittent time have been adopted. Due to the installation of wiper link assembly with frames, higher rigidity of link assembly has achieved reduction of incomplete cleaning by smoother wiper operation and improvements in quiet wiper operation.

  • Page 128: Windshield Washer

    EXTERIOR - Wiper and Washer WINDSHIELD WASHER 2-nozzle and 4-jet type indoor shield washers have been installed. Furthermore, the wiper related to washers function has been adopted. A washer tank has been installed in the trunk room. CONSTRUCTION DIAGRAM Trunk lid hinge Washer tank Washer tank Washer nozzle...
  • Page 129 NOTES...
  • Page 130 INTERIOR CONTENTS GENERAL INFORMATION ....INTERIOR TRIMS ..... . Features .

  • Page 131: General Information

    INTERIOR – General Information GENERAL INFORMATION The interiors to value functionality, habitation, and safety brings a new sense of good quality and security. Furthermore, it is also intended for getting actively involved with global environmental protection and natural resource recycling. FEATURES Improvements in quality Fully trim-covered interior...

  • Page 132: Instrument Panel And Floor Console

    INTERIOR – Instrument Panel and Floor Console INSTRUMENT PANEL AND FLOOR CONSOLE The instrument panel and the floor console have the A pad incorporating the front passenger’s air following features: bag door has improved appearance. The center panel with a new sense of design glove compartment convenient...

  • Page 133: Accessories

    INTERIOR – Accessories ACCESSORIES A vanity mirror has been installed to improve A folding assistant grip has been installed to usability. <RS-II> improve safety. Vanity mirror Folding assistant grip...

  • Page 134: Seat

    INTERIOR – INTERIOR – Seat Seat SEAT FRONT SEAT The most suitable driving position can be set RECARO seat adopting non-step adjustment by the sliding and reclining mechanism. <RS> slide and reclining mechanism have been Height adjustment function to secure the most equipped.

  • Page 135: Seat Belt

    INTERIOR – Seat Belt SEAT BELT FRONT SEAT BELT The adoption of 3-point seat belt with ELR which The seat belt retractor with the pre-tensioner has belt adjustment device for height and the and the force limiter for the driver’s seat and buckle fixed at the seat have secured the most the front passenger’s seat has been adopted suitable fitting for the wearer.

  • Page 136: Seat Belt Retractor With Force Limiter

    INTERIOR – Seat Belt SEAT BELT RETRACTOR WITH FORCE LIMITER The driver’s/front passenger’s seat belt retractor has been equipped with a force limiter. The force lim- iter is a device which operates when a predeter- mined force is applied, and limits the force. Seat belt retractor with force limiter OPERATION...

  • Page 137: Interior Trims

    INTERIOR – Interior Trims INTERIOR TRIMS The interiors are fully covered by trims to Use of inflammable materials for the trims has enhance product value. increased safety as outstanding interiors. Also, The adoption of the energy absorption rib mold material codes are indicated to deal with located in the rear of the front pillar trim and recycling easily.

  • Page 138: Supplemental Restraint System

    INTERIOR – Supplemental Restraint System (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS air bag is a system to be effective once Seat belt with pre - tensioner featured for the the seat belt is worn. The system is designed driver’s and front passenger’s seats is designed to be a supplemental system of the seat belt.

  • Page 139: Srs System Circuit Diagram

    6-10 INTERIOR – Supplemental Restraint System (SRS) SRS SYSTEM CIRCUIT DIAGRAM Ignition switch (IG SRS-ECU N_23 (multi-purpose fuse) 7.5A 7.5A Combination meter Connector lock switch* Connector short-circuit system* Connector short-circuit system* Driver’s side air bag module (squib) C-207 C-22 Clock spring C-204 Connector short-circuit system* Diagnosis connector...

  • Page 140: Caution Labels

    6-11 INTERIOR – Supplemental Restraint System (SRS) CAUTION LABELS Labels to indicate cautions regarding the handling and the services of SRS air bag are attached on the position shown in the following illustration. <TYPE 2> <TYPE 1> Steering wheel Driver’s side bag module Cover Clock spring Front passenger’s side air bag module...
  • Page 141 6-12 INTERIOR – Supplemental Restraint System (SRS) A. CAUTION: SRS G. WARNING: SRS BEFORE REPLACING STEERING WHEEL, FIX STRG. WHEEL AT TIRES STRAIGHT READ SERVICE MANUAL,THIS AIR BAG AHEAD BEFORE GEARBOX REMOVAL. MODULE CANNOT BE REPAIRED. DO NOT OTHER WISE, MAY DAMAGE SRS CLOCK DISASSEMBLE OR TAMPER.

  • Page 142: Construction And Operation

    6-13 INTERIOR – Supplemental Restraint System (SRS) CONSTRUCTION AND OPERATION NOTE for more information regarding the inflator and the Refer to ’99 PAJERO in Technical Information clock spring of the front passenger’s side air bag Manual (Pub. No. PYJE9805) or ’00 PAJERO PININ module.
  • Page 143 6-14 INTERIOR – Supplemental Restraint System (SRS) FRONT PASSENGER’S SIDE AIR BAG MODULE The front passenger’s side air bag module consists gas from two bores at the rear of the air bag to re- of air bag, inflator, module cover (incorporating the duce the shock from the impact.

  • Page 144: Srs-Ecu

    6-15 INTERIOR – Supplemental Restraint System (SRS) SRS-ECU The SRS-ECU incorporates an analog G sensor Backup power supply in case of power failure and safing G sensor for frontal collisions. in collisions In frontal collisions, the driver’s and front passen- Boosting function in case of battery voltage ger’s air bags deploy only when both the analog drop...
  • Page 145 6-16 INTERIOR – Supplemental Restraint System (SRS) Code Major Contents of Diagnosis Driver’s side front air bag squib activating circuit open-circuited Front passenger’s side front air bag squib activating circuit short-circuited Front passenger’s side front air bag squib activating circuit open-circuited Driver’s side front seat belt pretensioner activating circuit short-circuited Driver’s side front seat belt pretensioner activating circuit open-circuited Front passenger’s side front seat belt pretensioner activating circuit short-circuited...
  • Page 146 EQUIPMENT CONTENTS GENERAL DESCRIPTION ....COMBINATION METER ..... Features .

  • Page 147: General Description

    EQUIPMENT – General Description GENERAL DESCRIPTION The adoption of new accessories and functions has enhanced a lineup of equipment. FEATURES 1. Adoption of waterproof connector in the engine compartment Enhanced reliability 2. Installation of fuse box and relay box Enhanced visibility and 1.

  • Page 148: Diagnostic System

    EQUIPMENT – Diagnostic System DIAGNOSTIC SYSTEM Service quality has been improved by fitting diagnostic connectors for MUT-II inspection near the left knee area of the driver’s seat on the instrument panel. Diagnostic function Immobilizer air bag ETACS Column Front switch Diagnosis code output –...

  • Page 149: Battery

    EQUIPMENT – Diagnostic System/Battery/Immobilizer Diagnosis connector (Black) Battery Diagnostic connector (White) 21 - 25 – 27 - 32 – BATTERY Light and compact batteries have been adopted. Item Specifications 44B20L Voltage V Capacity (5-hour rate Ah) Electrolytic fluid specific gravity 1.280 (fully charged state at 20_C) IMMOBILIZER SYSTEM...
  • Page 150 EQUIPMENT – Immobilizer System DISPOSITION WHEN REPLACING IMMOBILIZER SYSTEM RELATED PARTS To replace immobilizer related parts, observe the table below. When the ignition key is re-registered with the MUT-II, the originally registered ignition key registration information will be lost. Engine-ECU Immobilizer-ECU Ignition key When replacing engine-ECU –...

  • Page 151: Lighting

    EQUIPMENT – Lighting LIGHTING EXTERIOR LAMPS The large lens adjusted to the exclusive body has been equipped with model specific 4 bulb type headlamp incorporating front turn signal lamp, position lamp. The low beam is a projector type used as a compact but efficient wide light distributor. The front turn signal lamp adopts an aluminum metal evaporated reflector to improve visibility.
  • Page 152 EQUIPMENT – Lighting CONSTRUCTION DIAGRAM Headlamp (High beam) Headlamp assembly Headlamp (Low beam) Side turn signal lamp Position lamp Front turn signal lamp Back up lamp or rear fog lamp ∗ Tail lamp Rear combination lamp Tail / stop lamp Rear turn signal lamp High mount stop lamp NOTE...

  • Page 153: Interior Lamps

    EQUIPMENT – Lighting INTERIOR LAMPS A map lamp serving also as front room lamp which can be used at both the driver’s seat and passenger sea is provided. A rear room lamp to light the backseat and trunk lamp to light the trunk are provided. SPECIFICATIONS Item Specifications...

  • Page 154: Combination Meter

    EQUIPMENT – Combination Meter COMBINATION METER The combination meter is an easy-to-read pointer type meter. At the center is a tachometer, on the left side a speedometer, on the right side a fuel meter, engine coolant thermometer, and indicator lamp. It has a sport and efficient design to allow the driver to read the meters clearly.

  • Page 155: Smart Wiring System (Sws)

    7-10 EQUIPMENT – Smart Wiring System (SWS) SMART WIRING SYSTEM (SWS) SWS is a minimal line system which transmits numerous signals using one wiring to control against increased weight and complication of harnesses which result from the increase in electronic accessories. Basically the same as the new SPACE RUNNER.

  • Page 156: Communication Method

    7-11 EQUIPMENT – Smart Wiring System (SWS) COMMUNICATION METHOD The exclusive signal lines for transmitting the multi-distribution data are connected as follows between the ETACS-ECU, column switch (incorporated inside the column ECU), front ECU, power window main switch (incorporated inside the power window ECU) and power window motor assemblies (incorporated inside the power window motor ECU) for internal communication.
  • Page 157 7-12 EQUIPMENT – Smart Wiring System (SWS) Circuit and input switch and sensor ECUs and switches con- Output side nected by multi-distribution 3. Windshield wiper washer D Windshield mist wiper D Windshield low speed wiper D Windshield high speed wiper D Windshield washer ETACS-ECU Column switch...

  • Page 158: Diagnostic Function

    7-13 EQUIPMENT – EQUIPMENT – Smart Wiring System (SWS) Smart Wiring System (SWS) DIAGNOSTIC FUNCTION DIAGNOSIS CODE SET The ETACS-ECU sends diagnosis codes if the communication line is faulty when the MUT-ll is connected. NOTE Refer to the Workshop Manual for details of the diagnostic items.

  • Page 159: Functions And Control Of Sws Ecus

    7-14 EQUIPMENT – Smart Wiring System (SWS) FUNCTIONS AND CONTROL OF SWS ECUS The following functions are controlled by the SWS ECUs: Functions Control ECU Lamp still ON reminder warning function ETACS-ECU, column switch Central door lock control function ETACS-ECU Power window timer function ETACS-ECU, power window main switch Windshield wiper washer control function...
  • Page 160 7-15 EQUIPMENT – EQUIPMENT – Smart Wiring System (SWS) Smart Wiring System (SWS) POWER WINDOW TIMER FUNCTION Ignition switch (IG) When the ignition switch is turned to the ON position, the power window relay and power window switch reception (Open) ON Driver’s seat door (Closed) OFF...
  • Page 161 7-16 EQUIPMENT – Smart Wiring System (SWS) 2. Low Speed Wiper, High Speed Wiper Control When the ignition switch is at the ACC or ON position, if the windshield low speed wiper switch of the column switch is turned ON, the front ECU turns ON the windshield wiper drive signal, turns OFF (LO) the windshield wiper speed relay, and operates the windshield wiper at low speed.
  • Page 162 7-17 EQUIPMENT – Smart Wiring System (SWS) HEADLAMP AUTO-CUT FUNCTION Even if the headlamp switch is ON, the head lamp will automatically go off in the following conditions to prevent the battery from discharging as a result of forgetting to turn off lights. (1) When the ignition key is turned from ON to OFF with the headlamp switch turned ON, and this state continues for 3 minutes, the headlamp will automatically be turned off.
  • Page 163 7-18 EQUIPMENT – Smart Wiring System (SWS) (2) Detects the signal where the hazard warning lamp switch input changes from OFF to ON, and reverse the flashing state according to this signal. (Flashes when the hazard Hazard warn- ing lamp lamp is not flashing and turns off when flashing.) switch NOTE...
  • Page 164 7-19 EQUIPMENT – Smart Wiring System (SWS) DIMMER TYPE ROOM LAMP CONTROL FUNCTION When the room lamp switch is at the door position, the ETACS-ECU controls the lighting of the room lamp as follows. (1) When a door is opened to get on or get off the vehicle (when the ignition switch is OFF), the lamp lights up (100%), when closed, the lamp dims (65%), and goes off 15 seconds later.

  • Page 165: Heater And Air Conditioner

    7-20 EQUIPMENT – Heater and Air Conditioner HEATER AND AIR CONDITIONER The heater and air conditioner system incorporating the heater and cleaning unit has reduced ventilation resistance to increase air volume and reduce noise. FEATURES 1. Installation of two-ray blow full air mix heater Improvements in comfort 2.
  • Page 166 7-21 EQUIPMENT – Heater and Air Conditioner CONSTRUCTION DIAGRAM Blower assembly Liquid pipe B Liquid pipe A Suction flexible hose Heater unit Compressor Suction pipe Condenser fun Condenser Discharge flexible hose...

  • Page 167: Heater And Air Conditoner System

    7-22 EQUIPMENT – Heater And Air Conditioner HEATER AND AIR CONDITIONER SYSTEM CONSTRUCTION AND DESCRIPTION BLOWER ASSEMBLY AND HEATER UNIT The following blower assembly and heater unit has been adopted to increase air volume, reduce noise, improve air-conditioning performance, as well as improve the car interior air environment. Installation of two-ray blow full air mix heater Incorporation of heater and cleaning unit Increase in the outside air intake duct area size of the blower assembly and optimization of the...
  • Page 168 7-23 EQUIPMENT – Heater And Air Conditioner Two-Ray Blow Full Air Mix Heater Air flow passing In the heater unit, there are two rays of air;one which passes through heater Air flow not core through the heater core, and air which does not pass through passing the core.

  • Page 169: Ventilation System

    7-24 EQUIPMENT – Heater And Air Conditioner HEATER AND AIR CONDITIONER CONTROL Adoption of the following heater and air conditioner control has improved operation performance and visual observation. Installation of dial type switch Incorporation of rear window defogger switch with timer Improved appearance by incorporating the center panel Temperature Blower switch...
  • Page 170 7-25 EQUIPMENT – Heater And Air Conditioner Air outlet RJST104003 - 170...
  • Page 171 NOTES...

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