Page 1 WORKSHOP MANUAL EVOLUTION-VI Pub. No. S9806CNCP9-A...
Page 2: Table Of Contents
RALLIART Inc. Since the EVOLUTION-VI 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-VI should be inquired to RALLIART Inc. as usual. Mitsubishi Motors Corporation March 1999...
Page 3 (3) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B – Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 4 00-1 GENERAL CONTENTS HOW TO USE THIS MANUAL ....Points to Note for Intermittent Malfunctions ..Scope of Maintenance, Repair and Servicing MODELS ....... . Explanations .
Page 5: How To Use This Manual
00-3 GENERAL – How to Use This Manual HOW TO USE THIS MANUAL SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS AND SERVICING EXPLANATIONS STANDARD VALUE This manual provides explanations, etc. concerning Indicates the value used as the standard for judging procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection and servicing of the subject model.
Page 6: General
00-4 GENERAL – How to Use This Manual EXPLANATION OF MANUAL CONTENTS Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Component Diagram A diagram of the component parts is provided near the front of each section in order to give a reader a better under-...
Page 7 00-5 GENERAL – How to Use This Manual Indicates the Indicates the Indicates the Indicates the group title. section title. group num- page number. ber. Denotes non-reus- able part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Tightening torque”.
Page 8: How To Use
00-6 GENERAL – How to Use Troubleshooting/Inspection Service Points HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems still follow this outline.
Page 9: Diagnosis Function
00-7 GENERAL – How to Use Troubleshooting/Inspection Service Points 4. INSPECTION CHART FOR DIAGNOSIS CODES 5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-10 for how to read the inspection procedures.) 6.
Page 10 00-8 GENERAL – How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP 1. Use the special tool to earth No.1 terminal (diagnosis Diagnosis connector control terminal) of the diagnosis connector. 2. To check ABS system, remove the valve relay. NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS...
Page 11 00-9 GENERAL – How to Use Troubleshooting/Inspection Service Points Diagnosis result display method when using a voltmeter Example of diagnosis code voltage wave pattern for Normal voltage wave pattern diagnosis code No. 24 0.5 sec. 0.5 sec. 1.5 secs. 0.5 sec. 12 V Tens Place...
Page 12: How To Use The Inspection Procedures
00-10 GENERAL – How to Use Troubleshooting/Inspection Service Points HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component.
Page 13: Connector Measurement Service Points
00-11 GENERAL – How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED Harness connector (WITH CIRCUIT IN A CONDITION OF CONTINUITY)
Page 14: Connector Inspection
00-12 GENERAL – How to Use Troubleshooting/Inspection Service Points CONNECTOR INSPECTION Connector disconnected or improperly connected VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out Due to harness tension at terminal section Low contact pressure between male and female terminals Low connection pressure due to rusted terminals or foreign matter lodged in terminals Defective connector contact...
Page 15: Inspection Service Points For A Blown Fuse
00-13 GENERAL – How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition of continuity.
Page 16: Models
4G63 (2,000-DOHC – W5M51 16 valves intercooler 16 valves-intercooler (4WD 5M/T) (4WD-5M/T) SNGF ’98 EVOLUTION-V turbo) Applicable serial numbers GF-CP9A: CP9A – 0000001 Y <LANCER EVOLUTION-VI> Model Class Model Grade Engine model Transmission Fuel supply code code year model system...
Page 17: Precautions Before Service
00-15 GENERAL – Precautions Before Service PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Always use the designated special tools and test equipment.
Page 18 00-16 GENERAL – Precautions Before Service SERVICING THE ELECTRICAL SYSTEM Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (–) cable from the battery in order to avoid damage caused by short-circuiting.
Page 19 00-17 GENERAL – Precautions Before Service MUT-II MUT-II sub-assembly Refer to the MUT-II INSTRUCTION MANUAL for instructions on handling the MUT-II. ROM pack Connect the MUT-II to the diagnosis connector as shown in the illustration. Caution Connection and disconnection of the MUT-II should always be made with the ignition switch in the OFF position.
Page 20: Support Locations For Lifting And Jacking
00-18 GENERAL – Support Locations for Lifting and Jacking SUPPORT LOCATIONS FOR LIFTING AND JACKING GARAGE JACK Caution Do not support the vehicles at locations other than specified supporting points. Neglecting this will cause damage, etc. Caution Never support the rear floor crossmember.
Page 21: Axle Stands
00-19 GENERAL – Support Locations for Lifting and Jacking AXLE STANDS Notch Notch Rubber Rubber SINGLE-POST AND DOUBLE-POST LIFT Notch Notch...
Page 22: Special Handling Instruments For Towing
00-20 GENERAL – Special Handling Instruments for Towing SPECIAL HANDLING INSTRUMENTS FOR TOWING Towing methods Remarks For 4WD models, the basic principle is that all If a tow truck is used four wheels are to be raised before towing. Lifting method for 4 wheels – Good The shift lever should be set to 1st gear and the parking brake should be applied.
Page 23: Brake Test
00-21 GENERAL – Brake Test BRAKE TEST In order to stabilize the viscous coupling’s dragging force, the brake test should always be conducted after the speedometer test. FRONT WHEEL MEASUREMENTS 1. Place the front wheels on the brake tester. 2. Perform the brake test. Brake tester Caution The rear wheels should remain on the ground.
Page 24: Tightening Torque
00-22 GENERAL – Tightening Torque TIGHTENING TORQUE Each torque value in the table is a standard value The values in the table are not applicable: for tightening under the following conditions. (1) If toothed washers are inserted. (1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
Page 25 11-1 ENGINE CONTENTS GENERAL INFORMATION ....EXHAUST MANIFOLD ....SPECIFICATIONS .
Page 26: General Information
11-2 ENGINE – General Information GENERAL INFORMATION Descriptions Specifications Type In-line OHV, SOHC Number of cylinders Combustion chamber Pentroof + curved top piston type Total displacement dm 1,997 Cylinder bore mm 85.0 Piston stroke mm 88.0 Compression ratio Valve timing Intake valve Opens (BTDC) Closes (ABDC)
Page 27: Specifications
11-3 ENGINE – Specifications SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard value Limit Timing belt Auto-tensioner rod projection length mm – Auto-tensioner rod pushed-in amount [when pushed with a force of 98 1.0 or less – – 196 N] mm Rocker arms and camshaft Camshaft cam height mm Intake 35.79...
Page 28 11-4 ENGINE – Specifications Items Standard value Limit Intake oversize rework dimensions of valve 0.3 O.S. 35.30 – 35.33 – guide hole mm guide hole mm 0.6 O.S. 35.60 – 35.63 – Exhaust oversize rework dimensions of 0.3 O.S. 33.30 – 33.33 –...
Page 29: Torque Specifications
11-5 ENGINE – Specifications Items Standard value Limit Alternator Rotor coil resistance Approx. 3 – 5 – Protrusion length of brush mm – Starter motor Commutator runout mm 0.05 Commutator outer diameter mm 32.0 31.4 Commutator undercut mm – TORQUE SPECIFICATIONS Items Alternator and ignition system Oil level gauge guide...
Page 30 11-6 ENGINE – Specifications Items Rocker cover Engine support bracket Camshaft sprocket bolt Timing belt rear right cover Timing belt rear left upper cover Fuel and emission control parts Throttle body Fuel pressure regulator Delivery pipe Vacuum tank bracket Solenoid valve bracket Solenoid valve Vacuum hose and vacuum pipe Secondary air intake manifold...
Page 31 11-7 ENGINE – Specifications Items OIl return pipe (Turbocharger side) Oil return pipe (Oil pan side – Head mark 7) Oil return pipe (Oil pan side – Head mark 10) Oil pipe Oil pipe eye bolt (Cylinder head side) Oil pipe eye bolt (Turbocharger side) Water pipe Water pipe eye bolt Exhaust manifold (M8)
Page 32 11-8 ENGINE – Specifications Items Front case and oil pan Drain plug Oil pan Oil screen Buffle plate Oil pressure switch Oil cooler by-pass valve Relief plug Plug Front case Oil pump cover (Screw) Oil pump cover (Bolt) Piston and connecting rods Connecting rod nut 20 + 90 to 94 Crankshaft and flywheel...
Page 33: New Tightening Method By Use Of Bolts To Be Tightened In Plastic Area
AAD Part No. 8672 or equivalent As required Oil return pipe gasket AAD Part No. 8731 or equivalent As required Thermostat housing Mitsubishi Genuine Part No. MD970389 or As required equivalent Water outlet fitting Mitsubishi Genuine Part No. MD970389 or As required...
Page 34: Form-In-Place Gasket
11-10 ENGINE – Specifications FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance.
Page 35: Special Tools
11-11 ENGINE – Special Tools SPECIAL TOOLS Tool Number Name MD998781 Flywheel stopper Holding of flywheel and drive plate MD998778 Crankshaft Removal of crankshaft sprocket sprocket puller MD998719 Pulley holder pin Holding camshaft sprocket MB990767 Crankshaft pulley holder MD998785 Sprocket stopper Holding silent shaft sprocket MD998767 Tensioner puller...
Page 36 11-12 ENGINE – Special Tools Tool Number Name MB991654 Cylinder head bolt Removal and installation of cylinder head bolt wrench (12) MD998772 Valve spring Removal and installation of valve and related compressor parts MD998735 Valve spring compressor MD998737 Valve stem seal Installation of valve stem seal installer MD998727...
Page 37 11-13 ENGINE – Special Tools Tool Number Name MB991603 Silent shaft bearing Guide stopper for removal and installation of puller stopper counterbalance shaft rear bearing Use with MD998372. MD998705 Silent shaft bearing Installation of counterbalance shaft front and installer rear bearing MD998375 Crankshaft front...
Page 38: Alternator And Ignition System
11-14 ENGINE – Alternator and Ignition System ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 3 Nm 10 Nm 25 Nm 13 Nm 44 Nm 21 Nm 23 Nm 9 Nm 25 Nm Removal steps 1. Oil level gauge 9. Center cover 2.
Page 39: Timing Belt
11-15 ENGINE – Timing Belt TIMING BELT REMOVAL AND INSTALLATION 11 Nm 49 Nm 3.5 Nm 24 Nm 24 Nm 11 Nm 11 Nm 118 Nm 9 Nm 49 Nm 30 Nm 18 19 45 Nm 19 Nm 88 Nm 49 Nm 9 Nm 48 Nm...
Page 40 11-16 ENGINE – Timing Belt REMOVAL SERVICE POINTS AA" TIMING BELT REMOVAL (1) If the timing belt is to be reused, chalk an arrow mark on the back surface of the belt so that the belt can be reinstalled in the same direction. (2) Place the exhaust camshaft sprocket in a position where the timing mark for No.
Page 41 11-17 ENGINE – ENGINE – Timing Belt Timing Belt AE" TIMING BELT “B” REMOVAL Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must...
Page 42 11-18 ENGINE – Timing Belt "BA ENGINE SUPPORT BRACKET INSTALLATION Coat the bolts illustrated with sealant before tightening. Specified sealant: 3M AAD Part No. 8672 or equivalent "CA SEALANT APPLICATION TO SEMI-CIRCULAR PACKING Specified sealant: 3M AAD Part No. 8672 or equivalent 10 mm 10 mm Semi-...
Page 43 11-19 ENGINE – Timing Belt "DA SEALANT APPLICATION TO ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: 3M AAD Part No. 8672 or equivalent Apply sealant 10 mm 10 mm 10 mm Apply sealant 10 mm Apply sealant Apply sealant "EA SPACER INSTALLATION...
Page 44 11-20 ENGINE – Timing Belt "GA TIMING BELT “B” INSTALLATION (1) Align timing marks on the crankshaft sprocket “B” and Timing counterbalance shaft sprocket with the marks on the front marks Timing case respectively. (on front marks case) (2) Install the timing belt “B” on the crankshaft sprocket “B” and counterbalance shaft sprocket.
Page 45 11-21 ENGINE – Timing Belt "IA OIL PUMP SPROCKET INSTALLATION (1) Insert a Phillips screwdriver (shank diameter 8 mm shaft) through the plug hole on the left side of the cylinder block to block the left counterbalance shaft. (2) Install the oil pump sprocket. (3) Apply a proper amount of engine oil to the bearing surfaces of the nuts.
Page 46 11-22 ENGINE – Timing Belt "LA TIMING BELT INSTALLATION Timing mark (1) Place the exhaust side camshaft sprocket in a position where its timing mark is one tooth offset from the timing mark on the rocker cover in the counterclockwise direction. NOTE Even if the timing marks on the sprocket and the rocker cover are brought into alignment, the exhaust camshaft...
Page 47 11-23 ENGINE – Timing Belt (6) Remove the Phillips screwdriver. Place the oil pump sprocket in a position where its timing mark is one tooth offset from the mated timing mark in the counterclockwise Timing mark direction. 6EN1327 (7) Fit the timing belt over the exhaust side camshaft sprocket, and secure it at the illustrated position using a paper clip.
Page 48 11-24 ENGINE – Timing Belt (11)Fit the timing belt over the tensioner pulley. NOTE When fitting the timing belt over the tensioner pulley, turn intake side camshaft sprocket little counterclockwise, as this will facilitate the work. (12)Turn the crankshaft pulley a little in the illustrated direction Crankshaft to pull up the timing belt at the idler pulley side.
Page 49 11-25 ENGINE – Timing Belt (17)Loosen the retaining bolt of the tensioner pulley. Caution Loosening the retaining bolt can cause the intake and exhaust camshafts to turn, resulting in slackened timing belt. Use care that the timing belt does not come off the sprockets at this time.
Page 50 11-26 ENGINE – Timing Belt (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear on teeth. (8) Missing tooth. AUTO TENSIONER (1) Check the auto tensioner for possible leaks and replace as necessary.
Page 51: Fuel And Emission Control Parts
11-27 ENGINE – Fuel and Emission Control Parts FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION 11 Nm 11 Nm 18 Nm 9 Nm 9 Nm Removal steps 1. Throttle body 9. O-ring "CA 2. Throttle body gasket 10. Grommet 3.
Page 52 11-28 ENGINE – Fuel and Emission Control Parts INSTALLATION SERVICE POINTS "AA INJECTORS INSTALLATION (1) Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector top end. Be careful not to damage O-ring during installation.
Page 53: Secondary Air System And Intake Manifold
11-29 ENGINE – Secondary Air System and Intake Manifold SECONDARY AIR SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION 21 Nm 24 Nm 21 Nm 11 Nm 35 Nm 24 Nm 49 Nm 11 Nm 13 Nm 35 Nm 35 Nm 19 Nm 30 Nm Removal steps...
Page 54 11-30 ENGINE – Secondary Air System and Intake Manifold INSTALLATION SERVICE POINTS "AA AIR CONTROL VALVE BRACKET INSTALLATION (1) Attach the air control valve bracket and the engine hanger to the intake manifold using bolts and nuts with which the intake manifold is also installed to the engine. (2) Tighten the bolts and nuts to the specified torque in the sequence given in the illustration.
Page 55: Exhaust Manifold
11-31 ENGINE – Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION 16 Nm 59 Nm 12 Nm 11 Nm 29 Nm 30 Nm 49 Nm 10 Nm 41 Nm 10 Nm 59 Nm 41 Nm 14 Nm 59 Nm 19 Nm 54 Nm 9 Nm Head mark 7: 9 Nm...
Page 56 11-32 ENGINE – Exhaust Manifold INSTALLATION SERVICE POINTS "AA EXHAUST MANIFOLD INSTALLATION Tighten the exhaust manifold mounting nuts to the specified torque in the sequence given in the illustration. "BA GASKET / OIL RETURN GASKET INSTALLATION Timing belt side EVOLUTION IV AND V Oil pan Install the gasket with the silicon-printed side toward the oil pan and with the tabbed end directed as shown.
Page 57 11-33 ENGINE – Exhaust Manifold "CA GASKET INSTALLATION Position the projection as shown in the illustration. Projection...
Page 58: Water Pump And Water Hose
11-34 ENGINE – Water Pump and Water Hose WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION <EVOLUTION VI> 10 Nm 13 Nm 9.8 Nm 24 Nm 11 Nm 24 Nm 29 Nm 11 Nm 22 Nm 14 Nm Removal steps 1.
Page 59 11-35 ENGINE – Water Pump and Water Hose REMOVAL AND INSTALLATION <EVOLUTION IV or V> 24 Nm 13 Nm 13 Nm 24 Nm 11 Nm 29 Nm 22 Nm 14 Nm Removal steps "CA 9. Water outlet fitting 1. Water hose "BA 10.
Page 60 Apply 3 mm diameter of form-in-place gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent "CA WATER OUTLET FITTING INSTALLATION Apply 3 mm diameter of form-in-place gasket (FIPG) to the location shown in the illustration.
Page 61: Rocker Arms And Camshaft
11-37 ENGINE – Rocker Arms and Camshaft ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 21 Nm 20 Nm 10 Nm 13 Nm 9 Nm 11 Nm Apply engine oil to all moving parts before installation. Removal steps "CA 10. Camshaft bearing cap front 1.
Page 62 11-38 ENGINE – Rocker Arms and Camshaft INSTALLATION SERVICE POINTS "AA LASH ADJUSTER INSTALLATION Caution If the lash adjuster is re-used, clean the lash adjuster. Fit the lash adjuster onto rocker arm without allowing diesel fuel to spill out. "BA CAMSHAFT INSTALLATION Camshaft sprocket side (1) Apply engine oil to the journals and cams of the camshafts.
Page 63 INSTALLATION Apply 3 mm diameter of form-in-place gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent "FA CAMSHAFT POSITION SENSING CYLINDER Paint mark INSTALLATION (1) Set the No. 1 cylinder to the compression top dead center position (so that dowel pin of the exhaust camshaft is at the top).
Page 64 11-40 ENGINE – Rocker Arms and Camshaft LASH ADJUSTER Caution (1) The lash adjusters precision-engineered mechanisms. allow them become contaminated by dirt or other foreign substances. (2) Do not attempt to disassemble the lash adjusters. (3) Use only fresh diesel fuel to clean the lash adjusters. (1) Prepare three containers and approximately five liters of diesel fuel.
Page 65 11-41 ENGINE – Rocker Arms and Camshaft (4) Removal the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. Caution Make sure the oil hole in the side of the body is pointing toward container A.
Page 66 11-42 ENGINE – Rocker Arms and Camshaft (9) Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster’s height matches that of a new lash adjuster.
Page 67: Cylinder Head And Valves
11-43 ENGINE – Cylinder Head and Valves CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION Apply engine oil to all 78 Nm Loosen completely 20 Nm + 90_ + 90_ moving parts before installation. Removal steps AA" "DA 1. Cylinder head bolt AC"...
Page 68 11-44 ENGINE – Cylinder Head and Valves REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS Keep removed parts in order according to the cylinder number and intake/exhaust. MB991654 AA" CYLINDER HEAD BOLTS REMOVAL Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little.
Page 69 11-45 ENGINE – Cylinder Head and Valves (3) How to Neutralize Sodium Place a container filled with more than 10 liters of water in a well ventilated large space. Wear rubber gloves and goggles, and carefully take out broken valves from the cylinder head. Put a broken valve in the water-filled container and quickly get away from the container at least 2 or 3 m.
Page 70 11-46 ENGINE – Cylinder Head and Valves "BA VALVE SPRING INSTALLATION Direct the valve spring end with identification color toward the spring retainer. "CA RETAINER LOCK INSTALLATION The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal.
Page 71 11-47 ENGINE – Cylinder Head and Valves (6) Make paint marks on the cylinder head bolt heads and cylinder head. (7) Give a 90 turn to the cylinder head bolts in the specified tightening sequence. (8) Give another 90 turn to the cylinder head bolts and make sure that the paint mark on the head of each cylinder head bolt and that on the cylinder head are on the same straight line.
Page 72 11-48 ENGINE – Cylinder Head and Valves VALVE (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve seat contact should be maintained uniform at the center of valve face. (2) If the margin exceeds the service limit, replace the valve. Item Standard value mm Limit mm...
Page 73 11-49 ENGINE – Cylinder Head and Valves VALVE SEAT Valve stem end Assemble the valve, then measure the valve stem projection between the end of the valve stem and the spring seating Valve stem surface. If the measurement exceeds the specified limit, projection replace the valve seat.
Page 74 11-50 ENGINE – Cylinder Head and Valves VALVE GUIDE REPLACEMENT PROCEDURE (1) Force the valve guide out toward the cylinder block using a press. (2) Machine the valve guide hole in the cylinder head to the size of the oversize valve guide to be installed. Caution Do not use the valve guide of the same size as the removed one.
Page 75: Front Case, Counterbalance Shaft And Oil Pan
11-51 ENGINE – Front Case, Counterbalance Shaft and Oil Pan FRONT CASE, COUNTERBALANCE SHAFT AND OIL PAN REMOVAL AND INSTALLATION 10 Nm Apply engine oil to all moving parts before installation. 24 Nm 10 Nm 54 Nm 22 Nm 16 Nm 19 Nm 36 Nm 19 Nm...
Page 76 11-52 ENGINE – Front Case, Counterbalance Shaft and Oil Pan REMOVAL SERVICE POINTS MD998727 AA" OIL PAN REMOVAL (1) Remove all oil pan bolts. (2) Drive in the special tool between the cylinder block and oil pan. NOTE Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage.
Page 77 11-53 ENGINE – Front Case, Counterbalance Shaft and Oil Pan AE" COUNTERBALANCE SHAFT REAR BEARING REMOVAL MB991603 Using the special tool, remove the left counterbalance shaft rear bearing from the cylinder block. NOTE When removing the left counterbalance shaft rear bearing, install the special tool (MB991603) in front of the cylinder block.
Page 78 11-54 ENGINE – Front Case, Counterbalance Shaft and Oil Pan "CA COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION Using special tools, install front bearing. MD998705 MD998705 Bearing Cylinder block 6EN1035 "DA COUNTERBALANCE SHAFT OIL SEAL INSTALLATION Using a suitable socket wrench, install the counterbalance shaft oil seal into the front case.
Page 79 11-55 ENGINE – Front Case, Counterbalance Shaft and Oil Pan "GA OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION Apply engine oil amply to the gears and line up the alignment marks. "HA FRONT CASE ASSEMBLY INSTALLATION (1) Set the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
Page 80 "LA OIL PAN INSTALLATION (1) Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: Mitsubishi Genuine Part MD970389 equivalent...
Page 81 11-57 ENGINE – Front Case, Counterbalance Shaft and Oil Pan "MAOIL FILTER INSTALLATION Bracket side (1) Clean the installation surfaces of the filter bracket. (2) Apply engine oil to the O-ring of the oil filter. (3) Screw the oil filter in until the O-ring contacts the bracket. Then tighten 3/4 turn (tightening torque: 16 Nm).
Page 82 11-58 ENGINE – Front Case, Counterbalance Shaft and Oil Pan COUNTERBALANCE SHAFT (1) Check oil holes for clogging. (2) Check journals for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace the counterbalance shaft, bearing or front case assembly. OIL COOLER BY-PASS VALVE (ENGINE WITH AIR COOLING TYPE OIL COOLER) (1) Make sure that the valve moves smoothly.
Page 83: Piston And Connecting Rod
11-59 ENGINE – Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 20 Nm + 90_ to 94_ Removal steps "GA 1. Connecting rod nut "CA 7. Piston ring No. 2 AA"...
Page 84 11-60 ENGINE – Piston and Connecting Rod REMOVAL SERVICE POINTS AA" CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
Page 85 11-61 ENGINE – Piston and Connecting Rod INSTALLATION SERVICE POINTS "AA PISTON PIN INSTALLATION (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width (2) Obtain dimension L (to be used later) from the above measurements by using by following formula.
Page 86 11-62 ENGINE – Piston and Connecting Rod (10)Check that the piston moves smoothly "BA OIL RING INSTALLATION Upper (1) Fit the oil ring spacer into the piston ring groove. side rail NOTE 1. The side rails and spacer may be installed in either direction.
Page 87 11-63 ENGINE – Piston and Connecting Rod "CA PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION (1) Using piston ring expander, fit No. 2 and then No. 1 piston ring into position. NOTE 1. The ring end is provided with identification mark. Item Identification mark No.
Page 88 11-64 ENGINE – Piston and Connecting Rod (2) The connecting rod bearing identification mark is stamped at the position shown in the illustration. Crankshaft pin Connecting rod bearing Classi- Identifica- Identifi- O. D. mm Identi- Thickness mm fication tion mark cation fication color...
Page 89 11-65 ENGINE – Piston and Connecting Rod "GA CONNECTING ROD CAP NUT INSTALLATION Caution If the cylinder head has been installed before installing the connecting rod cap nut, be sure to remove the spark plugs. (1) Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method, the bolts should be examined BEFORE reuse.
Page 90 11-66 ENGINE – Piston and Connecting Rod (3) Install the piston ring into the cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge.
Page 91: Crankshaft And Flywheel
11-67 ENGINE – Crankshaft and Flywheel CRANKSHAFT AND FLYWHEEL REMOVAL AND INSTALLATION 132 Nm 11 Nm 9 Nm 11 Nm 11 Nm 32 Nm Apply engine oil to all moving parts before installation. 25 Nm + 90_ Removal steps "BA 9. Crankshaft bearing lower 1.
Page 92 11-68 ENGINE – Crankshaft and Flywheel INSTALLATION SERVICE POINTS "AA CRANKSHAFT THRUST BEARING INSTALLATION (1) Install the two thrust bearing in the number 3 bearing bore in the cylinder block. For easier installation, apply engine oil to the bearings; this will help hold them in position.
Page 93 11-69 ENGINE – Crankshaft and Flywheel Crankshaft journal outside diameter Cylinder block bearing bore Crankshaft bearing Identification color Size mm Identification mark Identification mark or color Yellow 56.994 – 57.000 0 or Black 1 or Green 2 or Yellow None 56.988 –...
Page 94 11-70 ENGINE – Crankshaft and Flywheel (4) Tighten the bolts to 25 Nm in the specified tightening sequence. Arrow mark (5) Make a paint mark on the head of each bolt. (6) Make a paint mark on the bearing cap at the position Paint mark Paint mark 90 from the paint mark made on the bolt in the direction...
Page 95 ENGINE – Crankshaft and Flywheel "EA SEALANT APPLICATION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent NOTE (1) Be sure to install the case quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx.
Page 96 11-72 ENGINE – Crankshaft and Flywheel (5) Using cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct cylinder to an oversize and replace piston and piston rings. Measure at the points shown in illustration. Standard value: Cylinder I.D. 85.00 – 85.03 mm Cylindricity 0.01 mm or less BORING CYLINDER (1) Oversize pistons to be used should be determined on...
Page 97: Throttle Body
11-73 ENGINE – Throttle Body THROTTLE BODY DISASSEMBLY AND REASSEMBLY 3.5 Nm 3.5 Nm Disassembly steps AA" "AA 1. Throttle position sensor (with built- NOTE in closed throttle position switch) The fixed SAS and the speed adjusting screw are 2. Idle speed control body assembly correctly adjusted at the factory and should not be 3.
Page 98 11-74 ENGINE – Throttle Body DISASSEMBLY SERVICE POINTS AA" THROTTLE POSITION SENSOR AND IDLE AIR CONTROL MOTOR REMOVAL (1) Do not disassemble the sensor and motor. (2) Do not immerse solvent to clean the sensor and motor. Clean then with shop towel. AB"...
Page 99: Turbocharger
11-75 ENGINE – Turbocharger TURBOCHARGER DISASSEMBLY AND REASSEMBLY 11 Nm Disassembly steps "FA D Inspection of turbocharger waste gate "DA 4. Turbine housing AA" "CA 5. Snap ring actuator operation AB" "BA 6. Turbine wheel assembly 1. Snap pin 2. Waste gate actuator 7.
Page 100 11-76 ENGINE – Turbocharger DISASSEMBLY SERVICE POINTS AA" SNAP RING REMOVAL Lay the unit with the compressor cover side facing down and using snap ring pliers, remove the compressor cover attaching snap ring. Caution When removing the snap ring, hold it with fingers to prevent it from springing away.
Page 101 11-77 ENGINE – Turbocharger "CA SNAP RING INSTALLATION Chamfered edge Snap ring Lay the assembly with the compressor cover facing down and fit the snap ring. Caution Fit the snap ring with its chamfered side facing up. Turbine wheel assembly Compressor cover "DA TURBINE HOUSING INSTALLATION...
Page 102 11-78 ENGINE – Turbocharger COMPRESSOR COVER Oil passage Check the compressor cover for traces of contact with the Turbine wheel compressor wheel and other damage. TURBINE WHEEL ASSEMBLY (1) Check the turbine and compressor wheel blades for bend, burr, damage, corrosion and traces of contact on the back side and replace if defective.
Page 103: Alternator
11-79 ENGINE – Alternator ALTERNATOR DISASSEMBLY AND REASSEMBLY Disassembly steps AA" AC" 1. Front bracket assembly 8. Stator AB" 2. Alternator pulley 9. Plate "BA 3. Rotor AC" "AA 10. Regulator assembly 4. Rear bearing 11. Brush 5. Bearing retainer 12.
Page 104 11-80 ENGINE – Alternator DISASSEMBLY SERVICE POINTS AA" FRONT BRACKET ASSEMBLY REMOVAL Insert a flat tip screwdrivers or the like in the clearance between the front bracket assembly and stator core, to pry open and separate the stator and front bracket. Caution Do not insert the screwdriver too far, or the stator coil gets damaged.
Page 105 11-81 ENGINE – Alternator "BA ROTOR INSTALLATION Wire After installing the rotor, remove the wire used to fix the brush. INSPECTION ROTOR CHECK (1) Check the continuity between the rotor coil slip rings, and replace the rotor if the resistance value is not at the standard value.
Page 106 11-82 ENGINE – Alternator RECTIFIERS CHECK (1) Inspect the (+) heat sink by checking the continuity between the (+) heat sink and stator coil lead wire connection terminal using a tester probe. If there is a continuity at both, the diode is short circuited, so replace the rectifier.
Page 107: Starter Motor
11-83 ENGINE – Starter Motor STARTER MOTOR DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Cover 13. Packing A 2. Screw 14. Packing B AA" 3. Magnetic switch 15. Plate 4. Screw 16. Planetary gear 5. Through 17. Lever AC" "AA 18. Snap ring 6.
Page 108 11-84 ENGINE – Starter Motor DISASSEMBLY SERVICE POINTS “S” terminal Magnetic switch AA" MAGNETIC SWITCH REMOVAL Disconnect field coil wire from “M” terminal of magnetic switch. “B” terminal “M” terminal Field coil wire AB" ARMATURE / BALL REMOVAL Caution When removing the armature, take care not to lose the ball (which is used as a bearing) in the armature end.
Page 109 11-85 ENGINE – Starter Motor REASSEMBLY SERVICE POINTS "AA STOP RING / SNAP RING INSTALLATION Using a suitable pulling tool, pull overrunnig clutch stop ring over snap ring. Stop ring Overrunning clutch Stop ring Snap ring INSPECTION COMMUTATOR CHECK (1) Place the armature in a pair of “V” blocks and check the runout with a dial indicator.
Page 110 11-86 ENGINE – Starter Motor OVERRUNING CLUTCH CHECK (1) While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If clutch does not function Free properly, replace overrunnig clutch assembly. (2) Inspect pinion for wear or burrs.
Page 111 11-87 ENGINE – Starter Motor ARMATURE COIL OPEN-CIRCUIT INSPECTION Check the continuity between segments. If there is continuity, the coil is in order.
Page 112 13-1 FUEL CONTENTS MULTIPOINT INJECTION (MPI) ..ON-VEHICLE SERVICE ....Fuel Pump Resistor Check ....GENERAL .
Page 113: Multipoint Injection (Mpi)
13-2 MPI – General MULTIPOINT INJECTION (MPI) GENERAL OUTLINE OF CHANGE The descriptions of the troubleshooting using an MUT-II tester have been added. The fuel system and its management of EVOLUTION-VI are different from those of EVOLUTION-V in the following items. Accordingly, the service procedures for these items are described herein. The service procedures for the remaining item are the same as those for EVOLUTION-V.
Page 114 13-3 MPI – General MPI System Diagram L1 Oxygen sensor l1 Injector Engine ECU L2 Air flow sensor l2 ISC servo L3 Intake air temperature sensor l3 Fuel pressure control valve L4 Throttle position sensor l4 Waste gate solenoid valve L5 Idle switch l5 Secondary air control solenoid valve L6 Camshaft position sensor...
Page 115: Service Specifications
13-4 MPI – Service Specifications / Sealant SERVICE SPECIFICATIONS Items Specifications Basic ignition timing _BTDC Basic idle speed rpm Throttle position sensor adjusting voltage mV 400 – 1,000 Throttle position sensor resistance k 3.5 – 6.5 ISC servo coil resistance (at 20_C) 28 –...
Page 116: Special Tools
13-5 MPI – Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub MPI system inspection assembly MB991348 Test harness set Measurement of voltage during trouble- shooting Inspection using an oscilloscope MB991519 Alternator harness Measurement of voltage during connector troubleshooting MD998478 Test harness Measurement of voltage during trouble-...
Page 117: Troubleshooting
13-6 MPI – Troubleshooting TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the Multipoint Fuel Injection (MPI) system, the engine warning lamp will illuminate.
Page 118 13-7 MPI – Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item Control contents during malfunction Air flow sensor Uses the throttle position sensor signal and engine speed signal (crank angle sensor signal) to take reading of the basic injector drive time and basic ignition timing from...
Page 119 13-8 MPI – Troubleshooting 3. INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Air flow sensor system 13-8 Intake air temperature sensor system 13-9 Throttle position sensor system 13-9 Engine coolant temperature sensor system 13-10 Crank angle sensor system 13-11 Camshaft position sensor system 13-12...
Page 120 13-9 MPI – Troubleshooting Code No. 13 Intake air temperature sensor system Probable cause D Malfunction of the intake air temperature sensor Range of Check D Ignition switch: ON D Improper connector contact, open or short-circuited D Excluding 60 seconds after the ignition switch is turned to ON or immediately harness wire of the intake air temperature sensor circuit D Malfunction of the engine-ECU after the engine starts.
Page 121 13-10 MPI – Troubleshooting Code No. 21 Engine coolant temperature sensor system Probable cause D Malfunction of the engine coolant temperature sensor Range of Check D Ignition switch: ON D Improper connector contact, open or short-circuited D Excluding 60 seconds after the ignition switch is turned to ON or immediately harness wire of the engine coolant temperature sensor after the engine starts.
Page 122 13-11 MPI – Troubleshooting Code No. 22 Crank angle sensor system Probable cause D Malfunction of the crank angle sensor Range of Check D Engine is cranking. D Improper connector contact, open or short-circuited Set conditions harness wire of the crank angle sensor D Sensor output voltage does not change for 4 seconds (no pulse signal input.) D Malfunction of the engine-ECU Measure at the crank angle sensor connector A-51.
Page 123 13-12 MPI – Troubleshooting Code No. 23 Camshaft position sensor system Probable cause D Malfunction of the camshaft position sensor Range of Check D Ignition switch: ON D Improper connector contact, open or short-circuited D Engine speed is approx. 50 r/min or more. harness wire of the camshaft position sensor circuit D Malfunction of the engine-ECU Set conditions...
Page 124 13-13 MPI – Troubleshooting Code No. 24 Vehicles speed sensor system Probable cause D Malfunction of the vehicle speed sensor Range of check D Ignition switch: ON D Improper connector contact, open or short-circuited D Excluding 60 seconds after the ignition switch is turned to ON or immediately harness wire of the vehicle speed sensor circuit D Malfunction of the engine-ECU after the engine starts.
Page 125 13-14 MPI – Troubleshooting Code No. 25 Barometric pressure sensor system Probable cause D Malfunction of the barometric pressure sensor Range of Check D Ignition switch: ON D Improper connector contact, open or short-circuited D Excluding 60 seconds after the ignition switch is turned to ON or immediately harness wire of the barometric pressure sensor circuit D Malfunction of the engine-ECU after the engine starts.
Page 126 13-15 MPI – Troubleshooting Code No. 31 Detonation sensor system Probable cause D Malfunction of the detonation sensor Range of Check D Ignition switch: ON D Improper connector contact, open or short-circuited D Excluding 60 seconds after the ignition switch is turned to ON or immediately harness wire of the detonation sensor circuit D Malfunction of the engine-ECU after the engine starts.
Page 127 13-16 MPI – Troubleshooting Code No. 44 Ignition coil and power transistor unit system Probable cause D Malfunction of the ignition coil Range of Check D Engine speed is approx. 50 – 4,000 r/min D Improper connector contact, open or short-circuited D Engine is not cranking.
Page 128 13-17 MPI – Troubleshooting Code No. 64 Alternator FR terminal system Probable cause D Open circuit in alternator FR terminal circuit Range of Check D Engine speed is approx. 50 r/min or more D Malfunction of the engine-ECU Set Conditions D The input voltage from the alternator FR terminal is higher than 4.5 V for 20 seconds.
Page 129 13-18 MPI – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference page procedure Communication Communication with all systems is impossible. 13-20 with MUT-II is with MUT-II is impossible. Communication with engine-ECU only is impossible. 13-20 Engine warning The engine warning lamp does not illuminate right after the 13-21 lamp and ignition switch is turned to the ON position.
Page 130 13-19 MPI – Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Symptom Starting Won’t start The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won’t start. Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Page 131: Communication With All Systems Is Impossible
13-20 MPI – Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is impossible. Probable cause (Communication with all systems is impossible.) D Malfunction of the diagnosis connector The cause is probably a defect in the power supply system (including earth) for the D Malfunction of the harness wire diagnosis line.
Page 132: Inspection Procedure
13-21 MPI – Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after Probable cause the ignition switch is turned to the ON position. D Burnt-out bulb of the engine warning lamp For checking for burnt-out bulb, the engine-ECU causes the engine warning lamp D Defective engine warning lamp circuit to illuminate for five seconds immediately after the ignition switch is turned to ON.
Page 133: No Initial Combustion (Starting Impossible)
13-22 MPI – Troubleshooting INSPECTION PROCEDURE 5 No initial combustion (starting impossible) Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that a spark plug is defective, D Malfunction of the fuel pump system or that the supply of fuel to the combustion chamber is defective.
Page 134: Initial Combustion But No Complete Combustion
13-23 MPI – Troubleshooting INSPECTION PROCEDURE 6 Initial combustion but no complete combustion Probable cause (starting impossible) D Malfunction of the ignition system In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the injector system sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
Page 135: Long Time To Start (Improper Starting)
13-24 MPI – Troubleshooting INSPECTION PROCEDURE 7 Long time to start (Improper starting) Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that the spark is weak and ignition D Malfunction of the injector system is difficult, the initial mixture for starting is not appropriate, or sufficient compression D Inappropriate gasoline use pressure is not being obtained.
Page 136: Unstable Idling (Rough Idling, Hunting)
13-25 MPI – Troubleshooting INSPECTION PROCEDURE 8 Unstable idling (Rough idling, hunting) Probable cause D Malfunction of the ignition system In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of air-fuel ratio control system idle speed control (ISC) or compression pressure is defective.
Page 137: Engine
13-26 MPI – Troubleshooting INSPECTION PROCEDURE 9 Idling speed is high. (Improper idling speed) Probable cause D Malfunction of the ISC servo system In such cases as the above, the cause is probably that the intake air volume during D Malfunction of the throttle body idling is too great.
Page 138: Idling Speed Is Low. (Improper Idling Speed)
13-27 MPI – Troubleshooting INSPECTION PROCEDURE 10 Idling speed is low. (Improper idling speed) Probable cause D Malfunction of the ISC servo system In cases such as the above, the cause is probably that the intake air volume during D Malfunction of the throttle body idling is too small.
Page 139: When The Engine Is Cold, It Stalls At Idling. (Die Out)
13-28 MPI – Troubleshooting INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idling. (Die out) Probable cause D Malfunction of the ISC servo system In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate D Malfunction of the throttle body when the engine is cold, or that the intake air volume is insufficient.
Page 140: When The Engine Is Hot, It Stalls At Idling. (Die Out)
13-29 MPI – Troubleshooting INSPECTION PROCEDURE 12 When the engine is hot, it stalls at idling. (Die out) Probable cause D Malfunction of the ignition system In such cases as the above, the cause is probably that ignition system, air/fuel mixture, D Malfunction of air-fuel ratio control system idle speed control (ISC) or compression pressure is defective.
Page 141: The Engine Stalls When Starting The Car. (Pass Out)
13-30 MPI – Troubleshooting INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out) Probable cause D Drawing air into intake system In cases such as the above, the cause is probably misfiring due to a weak spark, D Malfunction of the ignition system or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
Page 142: Hesitation, Sag Or Stumble
13-31 MPI – Troubleshooting INSPECTION PROCEDURE 15 Hesitation, sag or stumble Probable cause D Malfunction of the ignition system In cases such as the above, the cause is probably that ignition system, air/fuel mixture D Malfunction of air-fuel ratio control system or compression pressure is defective.
Page 143: The Feeling Of Impact Or Vibration When Decelerating
13-32 MPI – Troubleshooting INSPECTION PROCEDURE 17 The feeling of impact or vibration when decelerating Probable cause D Malfunction of the ISC servo system Malfunction of the ISC servo system is suspected. MUT-II Self-Diag code Refer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES. Are diagnosis codes displayed? Check the ISC servo system.
Page 144 13-33 MPI – Troubleshooting INSPECTION PROCEDURE 19 Surge Probable cause D Malfunction of the ignition system Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of air-fuel ratio control system MUT-II Self-Diag code Refer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES. Are diagnosis codes displayed? Check the injector system.
Page 145: Too High Co And Hc Concentration When Idling
13-34 MPI – Troubleshooting INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling Probable cause D Malfunction of the air-fuel ratio control system Abnormal air-fuel ratio is suspected. D Deteriorated catalyst MUT-II Self-Diag code Refer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES. Are diagnosis codes displayed? Check that the crank angle sensor and the timing belt cover are Check the ignition timing.
Page 146: Low Alternator Output Voltage (Approx. 12.3 V)
13-35 MPI – Troubleshooting INSPECTION PROCEDURE 23 Low alternator output voltage (approx. 12.3 V) Probable cause D Malfunction of charging system The alternator may be defective, or malfunctions, which are listed in the right column, D Short circuit in harness between alternator G terminal may be suspected.
Page 147: Fuel Pump System
13-36 MPI – Troubleshooting INSPECTION PROCEDURE 25 <EVOLUTION-IV, EVOLUTION-V> Fuel pump system Probable cause D Malfunction of the fuel pump relay The engine-ECU turns the control relay ON when the engine is cranking or running, D Malfunction of the fuel pump and this supplies power to drive the fuel pump.
Page 148 13-37 MPI – Troubleshooting INSPECTION PROCEDURE 25 <EVOLUTION-VI> Fuel pump system Probable cause D The engine-ECU turns the fuel pump relay ON when the engine is cranking or D Malfunction of the fuel pump relay D Malfunction of the fuel pump relay No.2 running, and this supplies power to drive the fuel pump.
Page 149 13-38 MPI – Troubleshooting INSPECTION PROCEDURE 26 Idle position switch system Probable cause D Maladjustment of the accelerator cable The idle position switch inputs the condition of the accelerator pedal, i.e. whether D Maladjustment of the fixed SAS it is depressed or released (HIGH/LOW), to the engine-ECU. D Maladjustment of the idle position switch and throttle The engine-ECU controls the idle speed control servo based on this input.
Page 150 13-39 MPI – Troubleshooting INSPECTION PROCEDURE 28 Power steering fluid pressure switch system Probable cause D Malfunction of power steering fluid pressure switch The presence or absence of power steering load is input to the engine-ECU. D Improper connector contact, open or short-circuited The engine-ECU controls the idle speed control (ISC) servo based on this input.
Page 151 13-40 MPI – Troubleshooting INSPECTION PROCEDURE 30 <EVOLUTION-IV, EVOLUTION-V> Fan motor relay system (Radiator fan, A/C condenser fan) Probable cause D Malfunction of the fan motor relay The engine-ECU turns on/off the built-in power transistor to control the fan motor D Malfunction of the fan motor relay.
Page 152 13-41 MPI – Troubleshooting INSPECTION PROCEDURE 30 <EVOLUTION-VI> Fan motor relay system (Radiator fan, A/C condenser fan) Probable cause D Malfunction of the fan motor relay The engine-ECU turns on/off the built-in power transistor to control the fan motor D Malfunction of the fan motor relay.
Page 153 13-42 MPI – Troubleshooting INSPECTION PROCEDURE 31 <EVOLUTION-IV> Oxygen sensor system Probable cause D Malfunction of oxygen sensor When CO or HC concentration is too high, the malfunction of the parts shown at D Improper connector contact, open or short-circuited right may be the cause.
Page 154 13-43 MPI – Troubleshooting INSPECTION PROCEDURE 31 <EVOLUTION-V, EVOLUTION-VI> Oxygen sensor system Probable cause D Malfunction of oxygen sensor When CO or HC concentration is too high, the malfunction of the parts shown at D Improper connector contact, open or short-circuited right may be the cause.
Page 155 13-44 MPI – Troubleshooting INSPECTION PROCEDURE 32 Ignition circuit system Probable cause D Malfunction of ignition switch. The engine-ECU interrupts the ignition coil primary current by turning the power transistor D Improper connector contact, open or short-circuited inside the engine-ECU ON and OFF. harness wire D Malfunction of the engine-ECU 1.
Page 156 13-45 MPI – Troubleshooting INSPECTION PROCEDURE 34 Fuel pressure control valve system Probable cause D Malfunction of solenoid valve The fuel pressure control valve switches the pressure introduction into the fuel pressure D Improper connector contact, open or short-circuited regulator between the intake manifold and atmosphere. harness wire D Malfunction of engine-ECU Check the fuel pressure control valve.
Page 157 13-46 MPI – Troubleshooting INSPECTION PROCEDURE 36 Secondary air control solenoid valve system Probable cause D Malfunction of solenoid valve The secondary air control solenoid valve switches the pressure introduction into the D Improper connector contact, open or short-circuited secondary air valve between the intake manifold and atmosphere. harness wire D Malfunction of engine-ECU Check the secondary air control solenoid valve.
Page 158 13-47 MPI – Troubleshooting INSPECTION PROCEDURE 37 MUT-II: Inspection of no initial combustion MUT-II Data list Check the power supply and ignition switch-IG system. 16 engine-ECU power supply voltage (Refer to P.13-57.) (Refer to P.13-35, INSPECTION PROCEDURE 24.) Check timing belt for breakage. Does the camshaft rotate at the engine cranking? (When oil filler cap is removed.) Refer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
Page 159 13-48 MPI – Troubleshooting INSPECTION PROCEDURE 39 MUT-II: Check if uncomplete combustion occurs. MUT-II Self-Diag code Refer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES. Are diagnosis codes displayed? Check the fuel pump system. MUT-II Actuator test (Refer to P.13-36, INSPECTION PROCEDURE 25.) 07 Fuel pump (Refer to P.13-61.) Check the engine coolant temperature sensor system.
Page 160 13-49 MPI – Troubleshooting INSPECTION PROCEDURE 41 MUT-II: Check if idling speed is unstable. MUT-II Data list Check the idle position switch system. 26 Idle position switch (Refer to P.13-58.) (Refer to P.13-38, INSPECTION PROCEDURE 26.) Check the intake air temperature sensor system. (Refer to P.13-9, MUT-II Data list INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.) 13 Intake air temperature sensor (Refer to P.13-56.)
Page 161 13-50 MPI – Troubleshooting INSPECTION PROCEDURE 42 MUT-II: Engine stalling inspection when the engine is warmed up and idling. MUT-II Data list Check the idle position switch system. 26 Idle position switch (Refer to P.13-58.) (Refer to P.13-38, INSPECTION PROCEDURE 26.) Check the intake air temperature sensor system.
Page 162 13-51 MPI – Troubleshooting INSPECTION PROCEDURE 43 MUT-II: Check if hesitation, sag, stumble or poor acceleration occurs. MUT-II Data list Check the idle position switch system. 26 Idle position switch (Refer to P.13-58.) (Refer to P.13-38, INSPECTION PROCEDURE 26.) Check the intake air temperature sensor system. (Refer to P.13-9, MUT-II Data list 13 Intake air temperature sensor (Refer to P.13-56.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
Page 163 13-52 MPI – Troubleshooting INSPECTION PROCEDURE 44 MUT-II: Check if surge occurs. MUT-II Data list Check the idle position switch system. 26 Idle position switch (Refer to P.13-58.) (Refer to P.13-38, INSPECTION PROCEDURE 26.) Check the intake air temperature sensor system. (Refer to P.13-9, MUT-II Data list 13 Intake air temperature sensor (Refer to P.13-56.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
Page 164 13-53 MPI – Troubleshooting INSPECTION PROCEDURE 45 Check the engine-ECU power supply and earth circuit. 1. NG Check following Measure at the engine-ECU connectors, B-59, B-60, B-62. Repair D Disconnect the connector and measure at the harness side connectors: B-65, B-76 1.
Page 165 13-54 MPI – Troubleshooting INSPECTION PROCEDURE 46 <EVOLUTION-VI> Check fuel pump circuit. Check the following connector: Repair Measure at the fuel pump relay connector D-18. D Disconnect the connector and measure at the harness side. D-04 D Continuity between 1 and earth OK: Continuity Check trouble symptom.
Page 166 13-55 MPI – MPI – Troubleshooting Troubleshooting INSPECTION PROCEDURE 48 Check air flow sensor control circuit. 1. NG Measure at the air flow sensor connector A-25. Check the harness wire between the air flow sensor and control D Disconnect the connector and measure at the harness side. relay connector, and repair if necessary.
Page 167 13-56 MPI – Troubleshooting DATA LIST REFERENCE TABLE Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Oxygen Engine:After having When at 4,000 r/min, 200 mV or less Procedure 13-42 sensor warmed up engine is suddenly No. 31 decelerated Air/fuel mixture is made leaner when de-...
Page 168 13-57 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Throttle Ignition switch: ON Set to idle position 300 – 1,000 mV Code No. 13-9 position position Gradually open Increases in sensor proportion to throttle opening angle Open fully 4,500 –...
Page 169 13-58 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Crank angle Engine: Cranking Compare the engine Accord – – sensor Tachometer: speed readings on Connected the tachometer and the MUT-II. Engine: Idling When engine 1,300 –...
Page 170 13-59 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Injectors* Engine: Cranking When engine 27 – 41 ms – – <EVOLU- coolant temperature TION-IV> is 0_C (injection is carried out for all cylinders simultaneously) When engine 14 –...
Page 171 13-60 MPI – Troubleshooting Item Inspection Inspection contents Normal condition Inspection Reference item procedure page Ignition coils Engine: After Engine is idling 3_ATDC – – – and power having warmed up 13_BTDC transistors Timing lamp is set. <EVOLU- (The timing lamp TION-IV>...
Page 172: Fuel
13-61 MPI – Troubleshooting 8. ACTUATOR TEST REFERENCE TABLE Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Injectors Cut fuel to No. Engine: Idling condition Code No. 13-15 1 injector After having warmed becomes different up/Engine is idling up/Engine is idling (becomes unsta...
Page 173 13-62 MPI – Troubleshooting Item Inspection Drive contents Inspection contents Normal condition Inspection Reference item procedure page Radiator Drive the fan Ignition switch: ON Fan motors Procedure 13-40 motors (for A/C switch: ON* operate at high No. 30 (HIGH), radiator and speed.
Page 174 13-63 MPI – Troubleshooting ENGINE-ECU INSPECTION TERMINAL VOLTAGES Engine ECU connector Terminal Check item Check condition (Engine condition) Normal condition No.1 injector While engine is idling after having been warmed up, Momentarily drops suddenly depress the accelerator pedal suddenly depress the accelerator pedal. slightly from 11 slightly from 11 –...
Page 175 13-64 MPI – Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Radiator fan motor Radiator fan not operating (coolant temperature: System voltage relay (HI) 95_C or below) <EVOLUTION VI> <EVOLUTION-VI> Radiator fan at high speed (coolant temperature: 0 – 3 V 105_C or above) Fan motor relay (LOW) Fan not operating (coolant temperature: 95_C or...
Page 176 13-65 MPI – Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Alternator FR terminal Engine: Warm, idle (radiator fan: OFF) Voltage drops by 0.2 – Headlamp: OFF to ON 3.5 V. Brake lamp: OFF to ON Rear defogger switch: OFF to ON A/C switch Engine: Idle speed Turn the A/C switch OFF...
Page 177 13-66 MPI – Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Idle position switch Ignition switch: ON Set throttle valve to idle 0 – 1 V position Slightly open throttle 4 V or more valve Camshaft position Engine: Cranking 0.4 –...
Page 178 13-67 MPI – Troubleshooting RESISTANCE AND CONTINUITY BETWEEN HARNESS SIDE CONNECTORS AND TERMINALS Engine-ECU Harness Side Connector Terminal Arrangement Terminal No. Inspection item Normal condition (Check condition) 1 – 12 No.1 injector 2 – 3 (At 20_C) 14 – 12 No.2 injector 2 –...
Page 179: On-Vehicle Service
13-68 MPI – On-vehicle Service ON-VEHICLE SERVICE FUEL PUMP RESISTOR CHECK <EVOLUTION-VI> Standard value: 0.45 – 0.65 The inspection procedures are the same as for the preceding year-models. FUEL PUMP RELAY No.2 CONTINUITY CHECK <EVOLUTION-VI> Battery voltage Terminal No. Not supplied Supplied ENGINE CONTROL RELAY AND FUEL PUMP Equipment side connector for engine...
Page 180: Fuel Supply
13-69 FUEL SUPPLY – General / Fuel Tank FUEL SUPPLY GENERAL OUTLINE OF CHANGE The service procedures have been revised as shown below because of change in the fuel pump & gauge assembly and the fuel gauge unit. <EVOLUTION-VI> FUEL TANK <EVOLUTION-VI> REMOVAL AND INSTALLATION Removal steps 1.
Page 181 21A-1 CLUTCH CONTENTS GENERAL ....... ON-VEHICLE SERVICE ....Outline of Change .
Page 182: General
Clutch fluid Brake fluid DOT 3 or DOT 4 As required Push rod assembly Rubber grease Boot Release cylinder push rod MITSUBISHI genuine grease Part No. 0101011 ON-VEHICLE SERVICE Clutch pedal height <L.H. DRIVE VEHICLES> CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1.
Page 183: Bleeding
21A-3 CLUTCH – On-vehicle Service 4. Measure the clutch pedal play. Clutch pedal clevis pin play Standard value (B): 1 – 3 mm 5. If the clutch pedal play is not within the standard value, loosen the setting nut and move the push rod to adjust. Caution Do not push in the master cylinder push rod at this time.
Page 184: Clutch Pedal
21A-4 CLUTCH – Clutch Pedal CLUTCH PEDAL <L.H. DRIVE VEHICLES> REMOVAL AND INSTALLATION Post-installation Operation Clutch Pedal Adjustment (Refer to P. 21A-2.) 13 Nm 12 Nm 29 Nm 13 Nm Removal steps 1. Clutch master cylinder installation 9. Rod B 10.
Page 185: Clutch Control
15 Nm 13 Nm 15 Nm 15 Nm Release fork 15 Nm Specified grease: MITSUBISHI genuine grease Part No. 0101011 19 Nm Clutch master cylinder removal Clutch line removal steps steps 6. Clutch pipe 1. Clevis pin 7. Hose clip 2.
Page 186: Clutch Master Cylinder
21A-6 CLUTCH – Clutch Control DISASSEMBLY AND REASSEMBLY CLUTCH MASTER CYLINDER 13 Nm Clutch fluid: Brake fluid DOT3 or DOT4 Piston repair kit Grease: Rubber grease Disassembly steps 1. Piston stopper ring "AA 2. Push rod assembly 3. Boot 4. Piston assembly 5.
Page 187: Manual Transmission
22B-1 MANUAL TRANSMISSION OVERHAUL CONTENTS GENERAL ....... TRANSMISSION ......Outline of Change .
Page 188 22B-2 MANUAL TRANSMISSION OVERHAUL – General GENERAL OUTLINE OF CHANGE Of the newly introduced transmission model, the service procedures for the following unit sections are described. Transmission Clutch housing Reverse idler gear...
Page 189 22B-3 MANUAL TRANSMISSION OVERHAUL – Specifications SPECIFICATIONS TRANSMISSION MODEL TABLE <EVOLUTION-IV> Transmission model Gear ratio Speedometer gear ratio Final gear ratio Front LSD W5M51-1-X6A 29/36 4.529 Not available W5M51-1-X6A1 29/36 4.529 Available W5M51-1-X7A 30/36 4.529 Not available W5M51-1-X7A1 30/36 4.529 Available W5M51-1-Z6A 29/36...
Page 190 22B-4 MANUAL TRANSMISSION OVERHAUL – Transmission TRANSMISSION DISASSEMBLY AND REASSEMBLY 18 Nm 18 Nm 32 Nm 32 Nm 69 Nm 3.9 Nm 69 Nm 69 Nm Disassembly steps "IA 1. Transfer 6. Select lever "JA "HA 7. Speedometer gear 2. O-ring 3.
Page 191: Clutch Housing
22B-5 MANUAL TRANSMISSION OVERHAUL – Clutch Housing CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY 9.8 Nm Disassembly steps "BA 5. Bushing* 1. Clutch release bearing retainer "EA 2. Oil seal "AA 6. Cover-A AA" "DA 3. Outer race "AA 7. Cover-B AB" "CA 4. Outer race 8.
Page 192: Reverse Idler Gear
22B-6 MANUAL TRANSMISSION OVERHAUL – Reverse Idler Gear REVERSE IDLER GEAR DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation. Disassembly steps 1. Snap ring 2. Cone spring (except EVOLUTION-IV) 3. Thrust washer 4. Steel ball (except EVOLUTION-IV) 5.
Page 193: Front Axle
26-1 FRONT AXLE – General / Axle Hub and Knuckle <EVOLUTION-VI> GROUP 26 FRONT AXLE GENERAL OUTLINE OF CHANGE The installation method of the ball joint between the knuckle and the lower arm has been changed, and accordingly the removal and installation procedures of the axle hub and the knuckle have been revised.
Page 194 26-2 FRONT AXLE – Axle Hub and Knuckle <EVOLUTION-VI> INSPECTION MB990326 LOWER ARM BALL JOINT ROTATION STARTING TORQUE CHECK (1) After shaking the ball joint stud several times, install the nut to the stud and use the special tool to measure the rotation starting torque of the ball joint.
Page 195: Lubricants
27-1 REAR AXLE CONTENTS GENERAL ....... Bleeding ....... . . AYC Operation Check .
Page 196: General
Hypoid gear oil API classification GL-5 or higher 0.41 0.02 transfer SAE viscosity No. 90, 80W differential differential Torque transfer MITSUBISHI GENUINE DIA QUEEN AYC FLUID 0.70 *0.05 mechanism Hydraulic piping fluid Dia Queen ATF SPII or equivalent Torque transfer mechanism oil seal lips Vaseline...
Page 197: Special Tools
27-3 REAR AXLE – Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub- Inspection of AYC assembly (diagnosis display by MUT-II) MB991529 Diagnosis code Inspection of AYC check harness (diagnosis display by AYC warning lamp) MD998330 Oil pressure Hydraulic pressure measurement (MD998331) gauge <vehicles with AYC>...
Page 198 27-4 REAR AXLE – Special Tools / Troubleshooting <AYC> MB990925 Brass bar Toolbox Bar (one-touch type) Installer adapter Tool number (MB990925) O.D. mm Tool number (MB990925) O.D. mm MB990926 39.0 MB990933 63.5 MB990927 45.0 MB990934 67.5 MB990928 49.5 MB990935 71.5 MB990929 51.0 MB990936...
Page 199 27-5 REAR AXLE – Troubleshooting <AYC> 3. INSPECTION CHART FOR DIAGNOSIS CODE Diagnosis Diagnosis items Ref. page code No. Power supply voltage (valve power supply) system (open- or short-circuit) 27-6 FR wheel speed sensor system (open- or short-circuit) 27-6 FL wheel speed sensor system (open- or short-circuit) 27-6 RR wheel speed sensor system (open- or short-circuit) 27-6...
Page 200 27-6 REAR AXLE – Troubleshooting <AYC> 4. INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 12: Power supply voltage (valve power supply) Probable cause system D Defective harness or connector This code is output when the AYC-ECU power supply voltage drops below, goes D Defective battery beyond, a specified level.
Page 201 27-7 REAR AXLE – Troubleshooting <AYC> <Vehicles without ABS> Check the installation of wheel speed Repair sensor. Replace Measure at B-95 AYC-ECU connector. Check the wheel speed sensor. (Refer D Disconnect the connector and to Group 35B.) measure at the harness side. D Resistance across 7-20 (front, LH), 6-19 (front, RH), 9-22 (rear, LH), Check the following connectors:...
Page 202 27-8 REAR AXLE – Troubleshooting <AYC> Code No. 25: Wrong-diameter tire Probable cause D Defective harness or connector This code is output if the speed of any one of the four wheels exceeds a specified D Defective AYC-ECU level with respect to the average of the four wheel speed sensor outputs when the D Defective ABS-ECU steering wheel is in the straight-ahead position and the vehicle speed exceeds 20 km/h.
Page 203 27-9 REAR AXLE – Troubleshooting <AYC> Code No. 26: Wheel speed sensor system (faulty output Probable cause signal) D Defective harness or connector This code is output if the speed of one of the four wheels exceeds a specified level D Defective AYC-ECU when the vehicle speed is 20 km/h or more.
Page 204 27-10 REAR AXLE – Troubleshooting <AYC> Code No. 31: Steer sensor (ST-1, ST-2, ST-N) system Probable cause D Defective steer sensor This code is output when any of the steer sensors ST-1, ST-2, and ST-N is open-circuited D Defective harness or connector or the steer sensor ground wire is open-circuited.
Page 205 27-11 REAR AXLE – Troubleshooting <AYC> Code No. 33: Steer sensor (ST-N) system Probable cause D Defective steer sensor This code is output when the steering wheel is turned 400_ or more in the same D Defective harness or connector direction with ST-N OFF (HIGH voltage).
Page 206 27-12 REAR AXLE – Troubleshooting <AYC> Code No. 41: TPS system Probable cause D Defective TPS This code is output when the input from the throttle position sensor falls short of D Defective harness or connector 0.2 V. D Defective AYC-ECU Is the MPI diagnosis code No.
Page 207 27-13 REAR AXLE – Troubleshooting <AYC> Code No. 52: Longitudinal acceleration sensor system Probable cause D Defective longitudinal acceleration sensor This code is output when the longitudinal acceleration exceeds a predetermined value D Defective harness or connector while the vehicle is running with both ABS and brakes being inactive. D Defective AYC-ECU Check the acceleration sensor.
Page 208 27-14 REAR AXLE – Troubleshooting <AYC> Code No. 65: ABS monitor system Probable cause D Defective harness or connector This code is output when ABS is considered to remain activated (motor relay remains D Defective AYC-ECU ON) for a continuous 1-min.-or-more period. It is output also when there is an open-circuit in the harness between ABS motor relay and AYC-ECU.
Page 209 27-15 REAR AXLE – Troubleshooting <AYC> Code No. 72: Directional control valve (right) system Probable cause D Defective directional control valve (right) This code is output when the directional control valve (right) control circuit is open- D Defective harness or connector or short-circuited.
Page 210 27-16 REAR AXLE – Troubleshooting <AYC> Code No. 73: Directional control valve (left) system Probable cause D Defective directional control valve (left) This code is output when the directional control valve (left) control circuit is open- D Defective harness or connector or short-circuited.
Page 211 27-17 REAR AXLE – Troubleshooting <AYC> Code No. 81: AYC relay system Probable cause D Defective AYC relay This code is output when the coil circuit of the AYC relay is open- or short-circuited. D Defective harness or connector D Defective AYC-ECU Check the AYC relay.
Page 212 27-18 REAR AXLE – Troubleshooting <AYC> Code No. 82: Electric pump system Probable cause D Low hydraulic oil level This code is output if the pressure switch is not set to high-pressure position despite D Oil leak the AYC-ECU’s command to drive the AYC relay for a given period of time. D Defective fusible link D Defective AYC relay D Defective harness or connector...
Page 213 27-19 REAR AXLE – Troubleshooting <AYC> Code No. 83: Electric pump system Probable cause D Defective accumulator pressure switch This code is output if the pressure switch is not set to low-pressure position despite D Defective harness or connector the AYC-ECU’s command to change the driving force. Does the AYC motor continue turning Check the AYC relay for continuity.
Page 214 27-20 REAR AXLE – Troubleshooting <AYC> 5. INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Ref. page procedure No. Communication between MUT-II and the whole system is not possible. 27-20 Communicatio between MUT-II and AYC-ECU is not possible. 27-21 AYC warning lamp does not light up when the ignition key is turned to “ON” (engine 27-22 stationary).
Page 215 27-21 REAR AXLE – Troubleshooting <AYC> INSPECTION PROCEDURE 2 Communication between MUT-II and the AYC-ECU is not Probable cause possible. D Blown fuse The cause may be a malfunction of the AYC-ECU power supply circuit or an open D Defective harness or connector circuit in the diagnosis output circuit.
Page 216 27-22 REAR AXLE – Troubleshooting <AYC> INSPECTION PROCEDURE 3 AYC warning lamp does not light up when the ignition key Probable cause is turned to “ON” (engine stationary). D Blown fuse The lamp power supply circuit is probably open-circuited, lamp bulb is out, or the D AYC warning lamp out circuit between AYC warning lamp and AYC-ECU or AYC-ECU itself is defective.
Page 217 27-23 REAR AXLE – Troubleshooting <AYC> INSPECTION PROCEDURE 4 AYC warning lamp remains lit up after the engine has Probable cause started. D Defective combination meter The AYC warning lamp ON circuit is probably short-circuited. D Defective harness (short-circuit) D Defective AYC-ECU NOTE This symptom is limited only when the communication with MUT-II is possible with AYC-ECU power supply in normal condition and the diagnosis code is correct.
Page 218 27-24 REAR AXLE – Troubleshooting <AYC> INSPECTION PROCEDURE 6 Rear tires are noisy during low-speed cornering. Probable cause Vehicle skews. D Defective hydraulic unit The hydraulic unit or torque transfer differential is probably defective. D Defective torque transfer differential NOTE This symptom is limited only when the diagnosis code is correct.
Page 219 27-25 REAR AXLE – Troubleshooting <AYC> DATA LIST REFERENCE TABLE The following items can be read by t01he MUT-II from the ECU input data. Item No. Check item Checking requirements Normal value Front-right wheel speed Perform a test run. Vehicle speeds displayed on the displayed on the Front-left wheel speed...
Page 220 27-26 REAR AXLE – Troubleshooting <AYC> Item No. Check item Checking requirements Normal value Steer sensor (ST-N) Steering wheel position Neutral position Ignition switch: ON Ignition switch: ON 90 deg. turned from neutral position Steer sensor (ST-1) Steering wheel position: Turn slowly counterclock- ON and OFF are wise.
Page 221 27-27 REAR AXLE – Troubleshooting <AYC> ACTUATOR TEST REFERENCE TABLE The following items can be tested by driving the corresponding actuator forcibly using the MUT-II. Item No. Check item Checking requirements Normal value Air bleeding Supply current to proportioning No air is to be bled from the valve in accordance with steering bleeder plug on the torque transfer angle to operate directional valve.
Page 222 27-28 REAR AXLE – Troubleshooting <AYC> CHECK AT AYC-ECU TERMINALS TERMINAL VOLTAGE LISTING The voltage is to be measured across each terminal and ground terminal. Fig. below shows the arrangement of the terminals. Terminal Check item Check requirement Normally Lateral acceleration sensor Ignition switch: ON 2.4 –...
Page 223 27-29 REAR AXLE – Troubleshooting <AYC> Terminal Check item Check requirement Normally Steer sensor (ST-N) Engine: Steering wheel: Neutral position 0.5 V or less Idle speed Idle speed Steering wheel: Turned 90_ from 2.5 – 3.5 V neutral position Ignition switch: Accelerator pedal: Fully closed 0.3 –...
Page 224 27-30 REAR AXLE – Troubleshooting <AYC> LISTING OF RESISTANCE AND CONTINUITY ACROSS CONNECTOR TERMINALS ON HARNESS SIDE Measure the resistance and check for continuity with the ignition switch in the “OFF” position and AYC-ECU connector disconnected. Measure the resistance and check for continuity across terminals listed below. Fig.
Page 225: On-Vehicle Service
27-31 REAR AXLE – On-vehicle Service <Vehicles with AYC> ON-VEHICLE SERVICE Alignment marks <VEHICLES WITH AYC> REAR AXLE TOTAL BACKLASH CHECK If the drive system roars or the vehicle vibrates, use the following procedure to measure total backlash in the rear axle.
Page 226: Gear Oil Change
Specified gear oil: MITSUBISHI GENUINE DIA QUEEN SUPER AYC FLUID 4. Fit the filler plug and tighten it to the specified torque.
Page 227: Fluid Level Check
(recommended tool) through the gap between the body and the differential support arm. Drain plug 49 Nm Specified gear oil: MITSUBISHI GENUINE DIA QUEEN SUPER AYC FLUID Oil syringe Quantity used: 0.70 (Recommended tool) *0.05 5.
Page 228: Bleeding
27-34 REAR AXLE REAR AXLE – On-vehicle Service <Vehicles with AYC> – On-vehicle Service <Vehicles with AYC> BLEEDING 1. Lift up the vehicle. 2. Connect the MUT-II to the 16-pin diagnosis connector. Caution Before connecting or disconnecting the MUT-II, always turn off the ignition switch. 3.
Page 229: Hydraulic Pressure Check
27-35 REAR AXLE – On-vehicle Service <Vehicles with AYC> NOTE (1) Hold the steering wheel in the neutral position. (2) If the steering wheel is turned, it may happen that the AYC system continues to operate (operation sounds are heard from the torque transfer differential). However, it does not mean a system failure.
Page 230: Differential Carrier Oil Seal Replacement
27-36 REAR AXLE – On-vehicle Service <Vehicles with AYC> (2) While this function is being disabled by the fail-safe function, the forced activation of the hydraulic unit can not be executed. 6. Check to ensure that the hydraulic pressure generated by the hydraulic unit conforms to the standard value.
Page 231: Wheel Speed Sensor Output Voltage Measurement
27-37 REAR AXLE – On-vehicle Service <Vehicles with AYC> WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT <VEHICLES WITHOUT ABS> 1. Lift up the vehicle and release the parking brake. 2. Disconnect the AYC-ECU harness connector and take measurements on the harness side connector. Caution Insert the probe from the harness side with the double lock of the connector unlocked.

Page 232: Action When Battery Runs Out
27-38 REAR AXLE – On-vehicle Service <Vehicles with AYC> Waveform Observation Points Symptom Probable cause Action Waveform amplitude is too small, or no Defective wheel speed sensor Replace sensor. waveform. Waveform amplitude varies greatly. (No Excessive axle hub lateral and radial runout Replace hub.
Page 233: Hydraulic Unit
27-39 REAR AXLE – Hydraulic Unit <Vehicles with AYC> HYDRAULIC UNIT <VEHICLES WITH AYC> REMOVAL AND INSTALLATION Caution (1) When connecting the return hose and suction hose, do not apply lubricant. (2) No foreign matter should be allowed in the hydraulic piping and joints. Pre-removal Operation Post-installation Operation Trunk Side Trim Removal...
Page 234 27-40 REAR AXLE – Hydraulic Unit <Vehicles with AYC> REMOVAL SERVICE POINTS AA" HYDRAULIC UNIT REMOVAL Should the hydraulic unit be discarded, drill a hole in the accumulator at the illustrated position beforehand in order to release the inside gas. Caution (1) The hydraulic unit has its accumulator filled with a high pressure gas.
Page 235: Sensor Relay
27-41 REAR AXLE – Sensor Relay <Vehicles with AYC> SENSOR RELAY <VEHICLES WITH AYC> REMOVAL AND INSTALLATION Caution: SRS For vehicles with SRS, before removal of air bag module and clock spring, refer to GROUP 52B – Service Precautions and Air Bag Module and Clock Spring. Steer sensor removal steps Acceleration sensor and AYC relay removal...

Page 236: Ayc-Ecu
27-42 REAR AXLE – Sensor Relay <Vehicles with AYC> / AYC-ECU INSPECTION 1. LONGITUDINAL AND LATERAL ACCELERATION SENSOR CHECK Refer to GROUP 35B – Acceleration Sensor. 2. AYC RELAY CONTINUITY CHECK Battery voltage Terminal No. When not energized When energized AYC-ECU REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation...
Page 237: Front Suspension
33A-1 FRONT SUSPENSION – General / Lower Arm <EVOLUTION-VI> GROUP 33A FRONT SUSPENSION GENERAL OUTLINE OF CHANGE The installation method of the ball joint between the knuckle and the lower arm has been changed, and accordingly the removal and installation procedures of the lower arm have been revised. <EVOLUTION-VI>...
Page 238 35A-1 BASIC BRAKE SYSTEM CONTENTS GENERAL ....... MASTER CYLINDER AND BRAKE BOOSTER .
Page 239: General
35A-2 BASIC BRAKE SYSTEM – General / On-vehicle Service GENERAL OUTLINE OF CHANGE The service procedures for left-hand drive vehicles have been established as described below. The service procedures for the front and rear disc brakes have been changed since they had been replaced by a different type.
Page 240 35A-3 BASIC BRAKE SYSTEM – On-vehicle Service If the free play exceeds the standard value, it is probably due to excessive play between the retaining ring bolt and brake pedal arm. Check for excessive clearance and replace faulty parts as required. 4.
Page 241: Brake Pedal
35A-4 BASIC BRAKE SYSTEM – Brake Pedal BRAKE PEDAL <L.H. DRIVE VEHICLES> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Instrument Under Cover Removal Accelerator Pedal Installation Steering Column Assembly Removal Steering Column Assembly Installation (Refer to GROUP 37A – Steering Wheel and Shaft.) (Refer to GROUP 37A –...
Page 242: Master Cylinder And Brake Booster
35A-5 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER <L.H. DRIVE VEHICLES> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining Brake Fluid Supplying Air Intake Hose Removal Brake Line Bleeding Brake Pedal Adjustment (Refer to P.35A-2.) Air Intake Hose Installation 14 Nm 15 Nm...
Page 243 35A-6 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster INSTALLATION SERVICE POINTS "AA VACUUM HOSE CONNECTION Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure by using the hose clip. "BA CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON Calculate clearance A from the B, C and D measurements.
Page 244: Body
35A-7 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster MASTER CYLINDER DISASSEMBLY AND REASSEMBLY Master cylinder kit Brake fluid: DOT3 or DOT4 Disassembly steps 1. Reservoir cap assembly 8. Reservoir tank 2. Reservoir cap 9. Reservoir seal AA" 3. Diaphragm 10.
Page 245 35A-8 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster DISASSEMBLY SERVICE POINTS AA" PISTON STOPPER BOLT DISASSEMBLY Remove the piston stopper bolt, while depressing the piston. AB" PISTON STOPPER RING DISASSEMBLY Remove the piston stopper ring, while depressing the piston. INSPECTION Check the inner surface of master cylinder body for rust or pitting.
Page 246: Disc Brake
35A-9 BASIC BRAKE SYSTEM – Disc Brake DISC BRAKE <EVOLUTION-VI WITH BREMBO BRAKING SYSTEM> DISASSEMBLY AND REASSEMBLY Front Brake Brake caliper kit Seal & boot kit Shim set Clip set Pad set Disassembly steps 1. Pin 6. Air bleeder screw 2.
Page 247 35A-10 BASIC BRAKE SYSTEM – Disc Brake Rear Brake Seal & boot kit Shim set Brake caliper kit Clip set Pad set Disassembly steps 1. Pin 6. Air bleeder screw 2. Cross spring 7. Piston boot 3. Pad & wear indicator assembly 8.
Page 248 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B – Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.
Page 249 37A-2 STEERING – General / Steering Wheel and Shaft GENERAL OUTLINE OF CHANGE The service procedures for left-hand drive vehicles have been established as described below. The service procedures for components not mentioned below are the same as for the preceding models. STEERING WHEEL AND SHAFT <L.H.
Page 250 37A-3 STEERING – Steering Wheel and Shaft REMOVAL SERVICE POINT AA" STEERING WHEEL REMOVAL MB990803 INSTALLATION SERVICE POINT "AA CLOCK SPRING AND COLUMN SWITCH / COLUMN SWITCH INSTALLATION Tighten the screws in an alphabetical order. DISASSEMBLY AND REASSEMBLY Disassembly steps AA"...
Page 251 37A-4 STEERING – Steering Wheel and Shaft DISASSEMBLY SERVICE POINT Steering lock bracket AA" STEERING LOCK BRACKET / STEERING LOCK CYLINDER REMOVAL If it is necessary to remove the steering lock cylinder, use a hacksaw to cut the special bolts at the steering lock bracket side.
Page 252 37A-5 STEERING – Power Steering Gear Box POWER STEERING GEAR BOX <L.H. DRIVE VEHICLES> REMOVAL AND INSTALLATION CAUTION: SRS For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative, risking serious driver injury.
Page 253 37A-6 STEERING – Power Steering Gear Box REMOVAL SERVICE POINTS Cord AA" TIE-ROD END AND KNUCKLE DISCONNECTION Ball joint Caution 1. In order not to damage the ball joint thread, the tie rod end mounting nut must be only loosened but not MB990635 or MB991113 removed from the ball joint.
Page 254 37A-7 STEERING – Power Steering Gear Box If the total pinion starting torque cannot be adjusted to within the standard range by adjusting the rack support cover, check the rack support cover, rack support spring, rack support and replace any parts if necessary. CHECK THE TIE ROD FOR SWING RESISTANCE 1.
Page 255 37A-8 STEERING – Power Steering Gear Box DISASSEMBLY AND REASSEMBLY Flare nut 13 Nm 21 Nm Steering gear seal set 59 Nm 25 Nm 49 – 59 Nm 59 Nm 88 Nm Disassembly steps AB" 1. Feed pipe 19. Pinion and valve assembly AC"...
Page 256 37A-9 STEERING – Power Steering Gear Box Lubrication and Sealing Points Grease: Repair kit grease Fluid: Automatic transmission fluid DEXRON or DEXRON II Fluid: Automatic transmission fluid Fluid: DEXRON or DEXRON II Automatic transmission fluid DEXRON or DEXRON II Fluid: Automatic transmission fluid DEXRON...
Page 257 37A-10 STEERING – Power Steering Gear Box DISASSEMBLY SERVICE POINTS AA" RACK SUPPORT COVER REMOVAL Use the special tool to remove the rack support cover from the gear box. MB990607 AB" OIL SEAL / PINION AND VALVE ASSEMBLY REMOVAL Using a plastic hammer, gently tap the pinion to remove it. AC"...
Page 258 37A-11 STEERING – Power Steering Gear Box AF" RACK STOPPER / RACK BUSHING / RACK REMOVAL Pull out the rack assembly gently, and remove the rack stopper and rack bushing together. AG" OIL SEAL REMOVAL Partially bend the oil seal to remove from the rack bushing. Caution Do not damage the oil seal press fitting surface of the Rack bushing...
Page 259 37A-12 STEERING – Power Steering Gear Box REASSEMBLY SERVICE POINTS "AA GEAR HOUSING MOUNTING RUBBER 3.1 mm INSTALLATION 1. Install the gear housing mounting rubber on the rack housing so that the dimension shown is achieved. NOTE The gear housing mounting rubber can be installed regardless of the installation direction of the slit.
Page 260 37A-13 STEERING – Power Steering Gear Box 2. Cover rack serrations with special tool. 3. Apply the specified fluid on the special tool. MB991214 Specified fluid: Automatic transmission fluid DEXRON or DEXRON II 4. Match the oil seal centre with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side.
Page 261 37A-14 STEERING – Power Steering Gear Box 2. Apply a coating of the specified fluid to the outside of the ball bearing. Using the special tools, press the ball bearing into the valve housing. MB990938 Specified fluid: Automatic transmission fluid DEXRON or DEXRON II MB991203 Ball bearing...
Page 262 37A-15 STEERING – Power Steering Gear Box 3. Using the special tools, rotate the pinion gear at the rate of one rotation in approximately 4 to 6 seconds to check MB991006 the total pinion torque. Standard value: 0.9 – 1.7 Nm [Change in torque: 0.4 Nm] Caution (1) When adjusting, set the standard value at its...
Page 263 37A-16 STEERING – Power Steering Gear Box 2. Use the special tool to crimp the bellows band. Caution (1) Hold the rack housing, and use the special tool to crimp the bellows band securely. (2) Crimp the bellows band until the special tool touches the stopper.
Page 264 37A-17 STEERING – Power Steering Gear Box INSPECTION RACK CHECK Check the rack tooth surfaces for damage or wear. Check the oil seal contact surfaces for uneven wear. Check the rack for bends. PINION AND VALVE ASSEMBLY CHECK Check the pinion gear tooth surfaces for damage or wear. Check for worn or defective seal ring.
Page 265 42-1 BODY CONTENTS GENERAL ......SUNROOF ......OUTLINE OF CHANGE .
Page 266: General
42-2 BODY – General / Keyless Entry System GENERAL OUTLINE OF CHANGE The descriptions of the troubleshooting using on MUT-II tester have been incorporated. KEYLESS ENTRY SYSTEM SPECIAL TOOL Tool Number Name MB991502 MUT-II sub assembly Recording secret codes TROUBLESHOOTING INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection procedure No.
Page 267 42-3 BODY – Keyless Entry System From previous page Check the following connectors: Measure at the receiver connector D-01. D Disconnect the connector, and measure at the harness side. B-49, B-73, B-75, B-76 D Voltage between 9 and body earth D Voltage between 10 and body earth OK: System voltage Check trouble symptoms.
Page 268 42-4 BODY – Keyless Entry System INSPECTION PROCEDURE 2 All of the doors can be locked and unlocked using the Probable cause transmitter, but the room lamp does not flash or illuminate. (However, the room lamp operates normally when the doors are opened and closed.) D Malfunction of receiver If the room lamp operates normally when the doors are opened and closed, the cause D Malfunction of connector or wiring harness...
Page 269 42-5 BODY – Keyless Entry System From previous page Check the following connectors: Measure at the receiver connector D-01. D Disconnect the connector, and measure at the harness side. B-49, B-75, D-01 D Voltage between 9 and body earth D Voltage between 10 and body earth OK: System voltage Check trouble symptoms.
Page 270 42-6 BODY – Keyless Entry System Terminal Signal name Conditions Terminal voltage Door lock output When activated When not activated System voltage Door unlock output When activated When not activated System voltage Earth At all times NOTE Values marked with * should be measured using an oscilloscope. (The value will alternate between 0 V and 0.03 V if a circuit tester is used.)
Page 271: Keyless Entry System
42-7 BODY – Keyless Entry System KEYLESS ENTRY SYSTEM REMOVAL AND INSTALLATION Keyless entry receiver removal ETACS-ECU removal steps 2. ETACS-ECU D Front seat assembly (driver’s side) 1. Keyless entry receiver TRANSMITTER DISASSEMBLY AND REASSEMBLY Post-assembly Operation Transmitter operation check "AA 3.
Page 272 42-8 BODY – Keyless Entry System ASSEMBLY SERVICE POINTS "AA BATTERY INSTALLATION Install a new battery with ( ) side upward. Battery required for replacement: Lithium battery CR1216 SECRET CODE REGISTRATION METHOD Each individual secret code is registered inside NOTE the transmitter, and so it is necessary to register The doors will lock and unlock once at this these codes with the EEPROM inside the receiver...
Page 273: Sunroof
42-9 BODY – BODY – Sunroof Sunroof SUNROOF SERVICE SPECIFICATIONS Items Standard value Roof lid glass operating current A (at 20_C) 7 or less Sunroof motor clutch slippage torque Nm 4.7 – 6.2 SEALANT Item Specified sealant Rail cover assembly 3M ATD Part No.8531 or 3M Part No.8646 or equivalent TROUBLESHOOTING INSPECTION CHART FOR TROUBLE SYMPTOMS...
Page 274 42-10 BODY – Sunroof (1) NG Check the following connectors: Measure at the sunroof-ECU connector D-10. Repair D Disconnect the connector and measure at the harness side. B-44, B-74, B-76, D-10 D Ignition switch: ON (1) Voltage between 5 and body earth OK: System voltage Check trouble symptoms.
Page 275 42-11 BODY – Sunroof Inspection Procedure 2 The motor does not reverse its direction when a load of Probable cause 140 N or more is applied while the sunroof is closing. D Malfunction of sunroof-ECU The sunroof-ECU monitors the load conditions from the amount of current flowing to the motor.
Page 276 42-12 BODY – Sunroof TERMINAL VOLTAGE CHART Terminal No. Check Item Check Condition Normal Condition Door switch input Driver’s door switch System voltage Sunroof switch (up) input Sunroof switch (up position) (up position) System voltage Sunroof switch (close or Sunroof switch (close down) input down) input position or down position)
Page 277: On-Vehicle Service
42-13 BODY – Sunroof ON-VEHICLE SERVICE Hose WATER TEST Check if there are any leaks in the sunroof by the following Apporox. 30cm procedure. 1. Fully close the roof lid glass. 2. Adjust the water pressure so that water comes out of the hose to a height of approximately 50 cm when the hose is held vertically facing upwards.
Page 278: Sunroof
42-14 BODY – Sunroof SUNROOF REMOVAL AND INSTALLATION Post-installation Operation <Roof lid glass assembly, Sunroof assembly> Sunroof Water Test (Refer to P.42-13.) Sunroof Fit Adjustment (Refer to P.42-13.) NOTE :Clip position Roof lid glass assembly removal Sunroof-ECU removal steps steps 5.
Page 279 42-15 BODY – Sunroof REMOVAL SERVICE POINTS AA" SIDE DECORATION COVER REMOVAL Remove the clips, and then remove the side decoration cover. Clip Side decoration cover AB" DRAIN HOSE REMOVAL Drain hose Tie a cord to the end of the drain hose, and wind tape around the tie until it is smooth.
Page 280 42-16 BODY – Sunroof 3. Make the drain hose protrusion from the grommet as shown in the illustration. Grommet 20 – 30 mm INSPECTION ROOF LID GLASS OPERATION CURRENT CHECK 1. Remove the sunroof fuse and connect a circuit analyser as shown in the illustration.
Page 281 42-17 BODY – Sunroof SUNROOF MOTOR CHECK Drive gear Check the direction of rotation of the drive gear when the Right rotation Left rotation battery is connected to the connector. Battery connection terminal Drive gear rotation direction Left Right LIMIT SWITCH CONTINUITY CHECK 1.
Page 282 42-18 BODY – Sunroof DISASSEMBLY AND REASSEMBLY Sealant: 3M ATD Part No.8531 or 3M Part No.8646, or equivalent NOTE :Clip position Disassembly steps 1. Side decoration cover 7. Drive unit assembly (Refer to P.42-15.) 8. Decoration link 2. Roof lid glass assembly 9.
Page 283 51-1 EXTERIOR CONTENTS GENERAL ....... WASHER TANK AND HOSES ... . Outline of Change .
Page 284: General
51-2 EXTERIOR – General / Special Tool / Front Bumper GENERAL OUTLINE OF CHANGE As the following changes had been made, the service procedures for the relating components have been newly established. Front bumper and aero parts changed Front and rear window washer tank relocated to the luggage compartment Intercooler &...
Page 285 51-3 EXTERIOR – Front Bumper DISASSEMBLY AND REASSEMBLY Disassembly steps D Front airdam (Refer to P.51-4) AA" 11. Clip 1. Licence plate bracket 12. Bumper upper reinforcement 2. Licence plate garnish assembly 3. Three-diamond mark 13. Bumper lower reinforcement 4. Front fog lamp cover 14.
Page 286: Aero Parts
51-4 EXTERIOR – Front Bumper / Aero Parts DISASSEMBLY SERVICE POINT AA" CLIP REMOVAL 1. Use the special tool to pull up the center pin in the clip. MB990784 MB990784 2. Remove the clip. Clip AERO PARTS REMOVAL AND INSTALLATION Front airdam removal steps 1.
Page 287 51-5 EXTERIOR – Aero Parts 5 Nm Adhesive tape: double-sided tape [1.6 mm thickness] Rear spoiler removal steps 1. Rear spoiler 2. Packing 3. High-mount stop lamp...
Page 288: Washer Tank And Hoses
51-6 EXTERIOR – Washer Tank and Hoses WASHER TANK AND HOSES REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Washer Fluid Draining and Pouring Trunk Side Trim (L.H.) Removal and Installation <GSR> To rear washer 5 Nm To windshield washer Washer tank removal steps Washer hose removal steps D Front seat and rear seat 1.
Page 289: Intercooler & Radiator Water Spray System
51-7 EXTERIOR – Intercooler & Radiator Water Spray System INTERCOOLER & RADIATOR WATER SPRAY SYSTEM REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Front Bumper Removal and Installation (Refer to P.51-2) 2.5 Nm 2.5 Nm 1. Clamp Water spray motor removal steps 2.
Page 290: Marks
51-8 EXTERIOR – Marks MARKS REMOVAL AND INSTALLATION "AA 1. Three-diamond mark "AA 2. EVOLUTION-VI mark "AA 3. LANCER mark INSTALLATION SERVICE POINT "AA MARK INSTALLATION Mounting Positions 1. Three-diamond mark 44 mm Center of vehicle...
Page 291 51-9 EXTERIOR – Marks 2. EVOLUTION-VI mark Application tape end Align right side edge of application tape with Align bottom edge of trunk lid opening line. application tape with that of trunk lid. 3. LANCER mark Trunk lid opening line 18 mm 38 mm Rear bumper line...
Page 292 52B-1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS GENERAL INFORMATION ....WARNING/CAUTION LABELS ..SRS SERVICE PRECAUTIONS ... SRS AIR BAG CONTROL UNIT (SRS-ECU) .
Page 293: General Information
52B-2 SRS – General Information GENERAL INFORMATION To improve safety, the SRS is available as optional status of the SRS. The clock spring is installed part. in the steering column. The SRS consists of two air bag modules, SRS Only authorized service personnel should do work air bag control unit (SRS-ECU), SRS warning lamp on or around the SRS components.
Page 294: Srs Service Precautions
52B-3 SRS – SRS Service Precautions SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others NOTE from accidental deployment of the air bag during *: Vehicles with front passenger’s air bag servicing, read and carefully follow all the If any of these components are diagnosed as precautions and procedures described in this faulty, they should only be replaced, in...
Page 295 52B-4 SRS – SRS Service Precautions SRS-ECU Harness connector Destination of harness Corrective action terminal No. (No. of terminals, colour) 1 to 4 21 pins, yellow – – Body wiring harness Clock spring Air bag Correct or replace each module (Driver’s side) module (Driver’s side) wiring harness Replace wiring harness.
Page 296: Special Tools
52B-5 SRS – Special Tools / Test Equipment SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub Reading diagnosis codes assembly Erasing diagnosis code Reading trouble period Reading erase times MB991613 SRS check Checking the SRS electrical circuitry harness MB990803 Steering wheel Steering wheel removal puller MB686560...
Page 297: Troubleshooting
52B-6 SRS – Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION DIAGNOSIS CODES CHECK Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check diagnosis codes.
Page 298 52B-7 SRS – Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No.14 Analog G-sensor system in the SRS-ECU Probable cause D Malfunction of SRS-ECU The SRS-ECU monitors the output of the analog G-sensor inside the SRS-ECU. It outputs this code when any of the following are detected. D When the analog G-sensor is not operating D When the characteristics of the analog G-sensor are abnormal D When the output from the analog G-sensor is abnormal...
Page 299 52B-8 SRS – Troubleshooting Code No.21, 22, 61 or 62 Driver’s side air bag module Probable cause (squib) system D Malfunction of clock spring These diagnosis codes are output if there is abnormal resistance between the input D Partial disconnection due to incorrect clock spring terminals of the driver’s side air bag module (squib).
Page 300 52B-9 SRS – Troubleshooting Code No.24, 25, 64 or 65 Front passenger’s side air bag Probable cause module (squib) system D Malfunction of wiring harnesses or connectors These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of front passenger’s side air bag module terminals of the driver’s side air bag module (squib).
Page 301 52B-10 SRS – Troubleshooting Code No.34 Connector lock system Probable cause D Malfunction of connectors This diagnosis code is output if a poor connection of the SRS-ECU is detected. However, D Malfunction of SRS-ECU if the vehicle condition returns to normal, diagnosis code No.34 will be automatically erased, and the SRS warning lamp will switch off.
Page 302 52B-11 SRS – Troubleshooting Code No.42 IG (B) power circuit system Probable cause D Malfunction of wiring harnesses or connectors This diagnosis code is output if the voltage between the IG (B) terminal and the earth is lower than the specified value for a continuous period of 5 seconds or more. However, if the vehicle condition returns to normal, diagnosis code No.42 will be automatically erased, and the SRS warning lamp will switch off.
Page 303 52B-12 SRS – Troubleshooting Code No.43 SRS warning lamp drive circuit system Probable cause (Lamp does not illuminate.) D Malfunction of wiring harnesses or connectors This diagnosis code is output when an open circuit occurs for a continuous period D Blown bulb of 5 seconds while the SRS-ECU in monitoring the SRS warning lamp and the lamp D Malfunction of SRS-ECU is OFF (transistor OFF).
Page 304 52B-13 SRS – Troubleshooting Code No.44 SRS warning lamp drive circuit system Probable cause D Malfunction of wiring harnesses or connectors This diagnosis code is output when a short occurs in the lamp drive circuit or a D Malfunction of SRS-ECU malfunction of the output transistor inside the SRS-ECU is detected while the SRS-ECU is monitoring the SRS warning lamp drive circuit.
Page 305 52B-14 SRS – Troubleshooting SRS WARNING LAMP INSPECTION 1. Check to be sure that the SRS warning lamp illuminates when the ignition switch is in the ON position. 2. Check to be sure that it illuminates for approximately 7 seconds and then switches off. 3.
Page 306: Srs Maintenance
52B-15 SRS – Troubleshooting / SRS Maintenance Inspection Procedure 2 Communication with MUT-II is not possible. Probable cause (Communication is not possible with SRS only.) D Malfunction of wiring harnesses or connectors If communication is not possible with the SRS only, the cause is probably an open circuit D Malfunction of SRS-ECU in the diagnosis output circuit of the SRS or in the power circuit (including earth circuit).
Page 307 52B-16 SRS – SRS Maintenance SRS COMPONENT VISUAL CHECK Insulating tape Battery Turn the ignition key to the LOCK (OFF) position, disconnect the negative battery cable and tape the terminal. Caution Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
Page 308 52B-17 SRS – SRS Maintenance 3. Check connector for damage, terminals deformities, and <Driver’s side> Inflator case harness for binds. 4. Check air bag inflator case for dents, cracks or deformities. 5. Check harness and connectors for damage, and terminals for deformation.
Page 309 52B-18 SRS – SRS Maintenance BODY WIRING HARNESS Body wiring harness NOTE *: Vehicles with front passenger’s air bag 1. Check connector for poor connection. 2. Check harnesses for binds, connectors for damage, and terminals for deformation. REPLACE ANY CONNECTORS OR HARNESS THAT FAIL THE VISUAL INSPECTION.
Page 310: Post-Collision Diagnosis
52B-19 SRS – Post-collision Diagnosis POST-COLLISION DIAGNOSIS To inspect and service the SRS after a collision (whether or not the air bags have deployed), perform the following steps. SRS-ECU MEMORY CHECK 1. Connect the MUT-II to the diagnosis connector (16-pin). Caution Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected.
Page 311 52B-20 SRS – Post-collision Diagnosis REPAIR PROCEDURE WHEN AIR BAG DEPLOYS IN A COLLISION. 1. Replace the following parts with new ones. SRS-ECU (Refer to P.52B-24.) Air bag module (Refer to P.52B-25.) 2. Check the following parts and replace if there are any malfunctions.
Page 312 52B-21 SRS – Post-collision Diagnosis SRS-ECU SRS-ECU 1. Check SRS-ECU case and brackets for dents, cracks or deformation. 2. Check connector for damage, and terminals for deformation. Air bag modules <Driver’s side> Inflator case 1. Check pad cover for dents, cracks or deformation. 2.
Page 313: Individual Component Service
52B-22 SRS – Post-collision Diagnosis / Individual Component Service Steering wheel, steering column and intermediate joint 1. Check wiring harness (built into steering wheel) and connectors for damage, and terminals for deformation. 2. Install air bag module to check fit or alignment with steering wheel.
Page 314: Warning/Caution Labels
52B-23 SRS – Warning/Caution Labels WARNING/CAUTION LABELS A number of caution labels related to the SRS are illustration. Follow label instructions when servicing found in the vehicle, as shown in the following SRS. If labels are dirty or damaged, replace them. Steering wheel Air bag module (driver’s side) Clock spring...
Page 315: Srs Air Bag Control Unit
52B-24 SRS – SRS-ECU SRS AIR BAG CONTROL UNIT (SRS-ECU) Caution 3. Do not drop or subject the SRS-ECU to 1. Disconnect the battery (–) terminal and wait impact or vibration. for 60 seconds or more before starting work. If denting, cracking, deformation, or rust Furthermore, disconnected battery...
Page 316: Air Bag Modules And Clock Spring
52B-25 SRS – SRS-ECU / Air Bag Modules and Clock Spring INSTALLATION SERVICE POINTS "AA SRS-ECU INSTALLATION Caution The SRS may not activate if SRS-ECU is not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger. "BA POST-INSTALLATION INSPECTION 1.
Page 317 52B-26 SRS – Air Bag Modules and Clock Spring REMOVAL AND INSTALLATION <Air bag module (driver’s side), clock spring> Pre-removal Operation After setting the steering wheel and the front wheels to the straight ahead position, remove the ignition key. Battery negative (–) terminal disconnection 41 Nm 8.9 Nm 8.9 Nm...
Page 318 52B-27 SRS – Air Bag Modules and Clock Spring <Air bag module (front passenger‘s side)> Front passenger’s side air bag Front passenger’s side air bag module removal steps module installation steps AD" "AA D Pre-installation inspection 1. Front passenger’s side air bag module 1.
Page 319 52B-28 SRS – Air Bag Modules and Clock Spring AB" STEERING WHEEL REMOVAL MB990803 AC" CLOCK SPRING REMOVAL Caution The removed clock spring should be stored in a clean, dry place. AD" AIR BAG MODULE REMOVAL (FRONT PASSENGER’S SIDE) Caution The removed air bag module should be stored in a clean, dry place with the pad cover face up.
Page 320 52B-29 SRS – Air Bag Modules and Clock Spring "BA CLOCK SPRING INSTALLATION Align the mating marks of the clock spring and, after turning the front wheels to the straight-ahead position, install the Mating marks clock spring to the column switch. Mating Mark Alignment Turn the clock spring clockwise fully, and then turn back it approx.
Page 321 52B-30 SRS – Air Bag Modules and Clock Spring INSPECTION <Driver’s side> Inflator case AIR BAG MODULE CHECK If any improper part is found during the following inspection, replace the air bag modules with a new one. Dispose the old one according to the specified procedure. (Refer to P.52B-32.) Caution Connector...
Page 322 52B-31 SRS – Air Bag Modules and Clock Spring 3. Check that there is continuity between terminal (3) of the clock spring No.1 connector and the No. 2 connector. 4. Joint the No.3 connector and No.4 connector of the clock SRS check harness (MB991613) spring to connector No.6 and connector No.4 respectively, of the SRS check harness.
Page 323: Air Bag Module Disposal Procedures
52B-32 SRS – Air Bag Module Disposal Procedures AIR BAG MODULE DISPOSAL PROCEDURES Before disposing of an air bag or a vehicle which is equipped with it, the procedures below are to be followed to deploy them. UNDEPLOYED AIR BAG MODULE DISPOSAL PROCEDURES Caution 1.
Page 324 52B-33 SRS – Air Bag Module Disposal Procedures 3. Peform the following procedure to deploy each air bag Body wiring harness module. connector (2-pin) <Air bag module (driver’s side)> (1) Remove the steering column cover lower. (2) Remove the connection between the clock spring 2-pin connector (red) and the body wiring harness connector.
Page 325 52B-34 SRS – Air Bag Module Disposal Procedures Caution 1) Before deploying the air bag in this manner, first check to be sure that there is no one in or near the vehicle. 2) The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it.
Page 326 52B-35 SRS – Air Bag Module Disposal Procedures <Air bag module (front passenger’s side)> Body wiring harness (1) Remove the glove box. (Refer to P.52B-27.) connector (2) Remove the connection between the air bag module (2-pin) (front passenger’s side) connector (red 2-pin) and the body wiring harness connector.
Page 327 52B-36 SRS – Air Bag Module Disposal Procedures Caution 1) Before deploying the air bag in this manner, first check to be sure that there is no one in or near the vehicle. 2) The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it.
Page 328 52B-37 SRS – Air Bag Module Disposal Procedures (2) Connect two wires, each six meters or longer, to the Connection two leads of SRS air bag adapter harness B <driver’s Two wires side>, and cover the connections with insulation tape. SRS air bag The other ends of the two wires should be connected adapter...
Page 329 52B-38 SRS – Air Bag Module Disposal Procedures (6) At a location as far away from the air bag module as possible, and from a shielded position, disconnect the two connected wires from each other, and connect them to the two terminals of the battery (which has been removed from the vehicle) to deploy the air bag.
Page 330 52B-39 SRS – Air Bag Module Disposal Procedures <Air bag module (front passenger’s side)> (1) Remove the air bag module from the vehicle. (Refer to P.52B-27.) Caution The connector of the front passenger’s side air bag module is so constructed that the positive negative terminals automatically...
Page 331: Deployed Air Bag Module Disposal Procedures
52B-40 SRS – SRS – Air Bag Module Disposal Procedures Air Bag Module Disposal Procedures (5) Place three old tyres, without wheels, on top of the tyre secured to the air bag module, and secure all tyres with ropes (4 locations). Tyres without wheels NOTE The front passenger’s side air bag is larger in capacity...
Page 332 52B-41 SRS – Air Bag Module Disposal Procedures 3. There may be, adhered to the deployed air bag module, material that could irritate the eye and/or skin, so wear gloves and safety glasses when handling a deployed air bag module. IF AFTER FOLLOWING THESE PRECAUTIONS, ANY MATERIAL DOES GET INTO THE EYES OR ON THE SKIN, IMMEDIATELY RINSE THE AFFECTED AREA WITH A LARGE AMOUNT OF CLEAN...
Page 333 54-1 CHASSIS ELECTRICAL CONTENTS GENERAL ......SPECIAL TOOL ..... . . TROUBLESHOOTING .
Page 334 54-2 ON-VEHICLE SERVICE ....SIDE TURN-SIGNAL LAMP ... . COMBINATION METERS ....HAZARD WARNING LAMP SWITCH, CLOCK .
Page 335: General
54-3 CHASSIS ELECTRICAL – General / Battery GENERAL Outline of Change The following service procedures have been incorporated. BATTERY SERVICE SPECIFICATION Item Specification Specific gravity of the battery fluid 1.220–1.290 [20_C] ON-VEHICLE SERVICE FLUID LEVEL AND SPECIFIC GRAVITY CHECK Good 1.
Page 336 54-4 CHASSIS ELECTRICAL – Battery CHARGING 1. When charging a battery while still installed in the vehicle, disconnect the battery cables to prevent damage to electrical parts. 2. The current normally used for charging a battery should be approximately 1/10th of the battery capacity. 3.
Page 337: Battery Testing Procedure
54-5 CHASSIS ELECTRICAL – Battery BATTERY TESTING PROCEDURE TEST STEP (1) Turn headlamps on for 15 seconds. (2) Turn headlamps off for 2 minutes to allow battery voltage to stabilize. (3) Disconnect cables. Charge battery at 5 amps. (see LOAD TEST RATE CHART) Read open circuit voltage.
Page 338: Ignition Switch
54-6 CHASSIS ELECTRICAL – CHASSIS ELECTRICAL – Ignition Switch Ignition Switch IGNITION SWITCH <EXCEPT EVOLUTION-VI WITH IMMOBILIZER SYSTEM> SPECIAL TOOL Tool Number Name MB991502 MUT-II sub ETACS-ECU input signal checking assembly TROUBLESHOOTING DIAGNOSIS FUNCTION INPUT SIGNAL INSPECTION POINTS <VEHICLES WITH ETACS-ECU> Refer to Group 00 –...

Page 339: Chassis Electrical
54-7 CHASSIS ELECTRICAL – Ignition Switch INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Key hole illumination lamp remains illuminated. Probable cause D Malfunction of harness wire The cause is probably a harness short or a defective ETACS-ECU or buzzer ECU. D Malfunction of ETACS-ECU D Malfunction of buzzer ECU Disconnect the ignition key cylinder illumination lamp connector...
Page 340 54-8 CHASSIS ELECTRICAL – Ignition Switch Inspection Procedure 3 While key hole illumination lamp is illuminated, ignition Probable cause key is turned to the ON position but key hole illumination lamp does not switch off. (However, it switch off after 15 seconds.) While the key reminder warning buzzer is sounding, the ignition key is turned to the ON position but the sound...
Page 341 54-9 CHASSIS ELECTRICAL – Ignition Switch Inspection Procedure 4 The key reminder warning buzzer dose not stop sounding Probable cause even if the key is removed. (However, it stops when the driver’s side door is closed.) D Malfunction of key reminder switch The cause is probably a malfunction of the key reminder switch input circuit system, D Malfunction of connector or a malfunction of ETACS-ECU, or a malfunction of buzzer ECU.
Page 342 54-10 CHASSIS ELECTRICAL – Ignition Switch Inspection Procedure 5 The key reminder warning buzzer dose not sound even if Probable cause the driver’s side door is opened while the key is still inserted. (However, the ignition key should be in the OFF position.) D Malfunction of door switch The cause is probably a malfunction of the door switch input circuit system, if the...
Page 343 54-11 CHASSIS ELECTRICAL – Ignition Switch IGNITION SWITCH REMOVAL AND INSTALLATION ETACS-ECU or buzzer ECU removal Ignition switch removal steps steps 4. Hood lock release handle 1. Cowl side trim (R.H.) 5. Driver side lower panel 2. Junction block 6. Column cover, lower 3.
Page 344 54-12 CHASSIS ELECTRICAL – Ignition Switch REMOVAL SERVICE POINT AA" STEERING LOCK CYLINDER REMOVAL 1. Insert the key in the steering lock cylinder and turn it to the “ACC” position. 2. Using a cross-tip (+) screwdriver (small) or a similar tool, push the lock pin of the steering lock cylinder inward and then remove the steering lock cylinder.
Page 345: Special Tool
54-13 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System IGNITION SWITCH AND IMMOBILIZER SYSTEM <EVOLUTION-VI WITH IMMOBILIZER SYSTEM> SPECIAL TOOL Tool Number Name MB991502 MUT-II sub Immobilizer system check assembly (Diagnosis display using the MUT-II) Registration of the ID code TROUBLESHOOTING Caution The ID code should always be re-registered when replacing the immobilizer-ECU.
Page 346 54-14 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Transponder communication system Probable cause D The ID code of the transponder is not sent to the immobilizer-ECU immediately D Radio interference of ID codes D Malfunction of the transponder after the ignition switch is turned to the ON position.
Page 347 54-15 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System Code No. 21 Communication system between MUT-II and Probable cause engine-ECU D Malfunction of harness or connector After the ignition switch is turned to the ON position, the confirmation code is not D Malfunction of the engine-ECU received from the engine-ECU within the allowable time, or an abnormal code is received.
Page 348 54-16 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection procedure No. Reference page Communication with MUT-II is impossible. 54-16 ID code cannot be registered using the MUT-II. 54-17 Engine does not start (Cranking but no initial combustion). 54-17 Malfunction of the immobilizer-ECU power source and earth circuit 54-18...
Page 349 54-17 CHASSIS ELECTRICAL – CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System Ignition Switch and Immobilizer System Inspection Procedure 2 ID code cannot be registered using the MUT-II. Probable cause D Malfunction of the transponder The cause is probably that there is no ID code registered in the immobilizer-ECU, D Malfunction of the ignition key ring antenna or there is a malfunction of the immobilizer-ECU.
Page 350 54-18 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System Inspection Procedure 4 Malfunction of the immobilizer-ECU power supply and earth circuit (1) NG Repair Measure at the immobilizer-ECU con- Check the following connectors: nector B-100. B-76, B-74, B-100 D Disconnect the connector and measure at the harness side.
Page 351 54-19 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System IGNITION SWITCH AND IMMOBILIZER SYSTEM Caution: SRS Before removal of air bag module and clock spring, refer to GROUP 52B – SRS Service Precautions and Air Bag Module and Clock Spring. REMOVAL AND INSTALLATION <L.H.
Page 352 54-20 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System REMOVAL SERVICE POINTS AA" STEERING LOCK CYLINDER REMOVAL 1. Insert the key in the steering lock cylinder and turn it to the “ACC” position. 2. Using a cross-tip (+) screwdriver (small) or a similar tool, push the lock pin of the steering lock cylinder inward and then pull the steering lock cylinder toward you.
Page 353 54-21 CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System ID CODE REGISTRATION METHOD If using an ignition key that has just been newly purchased, or if the immobilizer-ECU has been replaced, you will need to register the ID codes for each ignition key being used into the immobilizer-ECU.
Page 354: Combination Meters
54-22 CHASSIS ELECTRICAL – CHASSIS ELECTRICAL – Combination Meters Combination Meters COMBINATION METERS SERVICE SPECIFICATIONS Items Standard value Limit Speedometer Allowable indication range km/h 37 – 45 – (Speedometer indication error to be (Speedometer indication error to be 75 – 88 –...
Page 355: Sealant
54-23 CHASSIS ELECTRICAL – Combination Meters SEALANT Items Specified sealant Remark Engine coolant temperature gauge 3M Adhesive nut locking No. 4171 or Drying sealant unit threaded portion equivalent SPECIAL TOOLS Tool Number Name MB991223 Harness set Fuel gauge simple check A: MB991219 A: Test harness A: Connector pin contact pressure check...
Page 356: Troubleshooting
54-24 CHASSIS ELECTRICAL – Combination Meters TROUBLESHOOTING INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference procedure page Speedometer does not work. 54-24 Tachometer does not work. 54-25 INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Speedometer does not work. Probable cause D Malfunction of vehicle speed sensor Examine the diagnosis codes registered in the engine-ECU.
Page 357 54-25 CHASSIS ELECTRICAL – Combination Meters Inspection Procedure 2 Tachometer does not work. Probable cause D Malfunction of tachometer The ignition signal may not be input from the engine, or there may be a malfunction D Malfunction of harness or connector in the power supply or earth circuit.
Page 358 54-26 CHASSIS ELECTRICAL – Combination Meters Inspection Procedure 3 Vehicle speed sensor circuit system inspection Signals from the vehicle speed sensor are utilized both in the speedometer and the engine-ECU. Vehicle speed sensor inspection (Refer to P.54-27.) Replace 1. NG Disconnect the vehicle speed sensor connector A-19 and measure Check following...
Page 359: On-Vehicle Service
54-27 CHASSIS ELECTRICAL – CHASSIS ELECTRICAL – Combination Meters Combination Meters ON-VEHICLE SERVICE SPEEDOMETER CHECK 1. Adjust the pressure of the tyres to the specified level. 2. Set the vehicle onto a speedometer tester and use wheel chocks to hold the rear wheels. 3.
Page 360 54-28 CHASSIS ELECTRICAL – Combination Meters FUEL GAUGE SIMPLE CHECK Remove the fuel gauge unit connector. Use the special tool to connect a test lamp (12 V – 3.4 W) to the harness connector. (Refer to Fig.1) When the ignition switch is turned to The needle of the fuel gauge moves.
Page 361 54-29 CHASSIS ELECTRICAL – Combination Meters FUEL GAUGE UNIT FLOAT HEIGHT Move float and measure the height at point F (A) and at point E (B) with float arm touching stopper. Stopper Standard value: Point F Float position Main Point E Stopper Point F 16.4...
Page 362: Combination Meters
54-30 CHASSIS ELECTRICAL – Combination Meters ENGINE COOLANT TEMPERATURE GAUGE UNIT Circuit tester Thermometer CHECK 1. Bleed the engine coolant. 2. Remove the engine coolant temperature gauge unit. 3. Immerse the unit in 70_C water to measure the resistance. Standard value: 104 13.5 4.
Page 363 54-31 CHASSIS ELECTRICAL – CHASSIS ELECTRICAL – CHASSIS ELECTRICAL – Combination Meters Combination Meters Combination Meters INSPECTION FUEL GAUGE RESISTANCE CHECK 1. Remove the power supply tightening screw. Power 2. Use a circuit tester to measure the resistance value supply between the terminals.
Page 364: Headlamp
54-32 CHASSIS ELECTRICAL – Headlamp HEADLAMP SERVICE SPECIFICATIONS Items Standard value Limit Headlamp High Vertical direction 25’ (22 mm) below horizontal line – aiming aiming beam beam Horizontal Left head- Parallel to direction of vehicle travel – [Parenthe- direction lamp sized allowable allowable...
Page 365: Troubleshooting
54-33 CHASSIS ELECTRICAL – Headlamp TROUBLESHOOTING DIAGNOSIS FUNCTION INPUT SIGNAL INSPECTION POINTS <VEHICLES WITH ETACS-ECU> Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points. The lighting monitor buzzer does not sound even when Probable cause the ignition key is removed with the tail lamps or headlamps ON and the driver’s side door open.
Page 366: On-Vehicle Service
54-34 CHASSIS ELECTRICAL – Headlamp ON-VEHICLE SERVICE HEADLAMP AIMING Bring the vehicle in the following conditions before aiming the headlamp. Check the tires for inflation pressure. Pump them up if necessary to the labeled pressure level. Set the vehicle unladen on a level floor. Place one person (approximately 55 kg) on the driver’s seat.
Page 367 54-35 CHASSIS ELECTRICAL – Headlamp Standard values: <Left headlamp> Vertical direction 25’ (22 mm) below hori- zontal line (H) Lamp center Horizontal Left headlamp Parallel to direction of direction vehicle travel Vertical direction Right head- 15’ (13 mm) leftward High lamp from vertical line (V) intensity...
Page 368: Headlamp And Front Turn-Signal Lamp
54-36 CHASSIS ELECTRICAL – CHASSIS ELECTRICAL – Headlamp Headlamp 4. After the bulb is replaced, reinstall the socket cover with the TOP mark facing upward. Position lamp connector NOTE To prevent the clouding of lens and ingress of water into the lamp unit, install the socket cover correctly.
Page 369 54-37 CHASSIS ELECTRICAL – Headlamp REMOVAL SERVICE POINT AA" FRONT TURN-SIGNAL LAMP REMOVAL Tapping screw 1. Loosen the tapping screw connecting the headlamp to the front turn-signal lamp. Put a screwdriver in the space produced between the headlmap and the front turn-signal lamp.
Page 370 54-38 CHASSIS ELECTRICAL – Headlamp HEADLAMP RELAY CONTINUITYCHECK Battery voltage Terminal No. Not supplied Supplied Headlamp relay...
Page 371: Front Fog Lamp
54-39 CHASSIS ELECTRICAL – Front Fog Lamp FRONT FOG LAMP SERVICE SPECIFICATIONS Items Standard value Headlamp aiming [Paren- Vertical direction 2 (349 mm) below horizontal line (H) thesized allowable beam axis deviations 10 m Horizontal direction 3 (524 mm) leftward from vertical line (V) ahead of headlamp.] ON-VEHICLE SERVICE HEADLAMP AIMING...
Page 372 54-40 CHASSIS ELECTRICAL – Front Fog Lamp Standard values: Lamp center Vertical direction 2 (349 mm) below horizontal line High intensity zone Vertical direction Horizontal direction (524 leftward from High vertical line (V) intensity Caution: zone (1) Perform aiming adjustments, one light at a time, center with the other headlamp disconnected so as not (optical...
Page 373: Fog Lamp
54-41 CHASSIS ELECTRICAL – Front Fog Lamp FOG LAMP REMOVAL AND INSTALLATION 1. Front fog lamp switch Fog lamp removal steps 2. Front bumper 3. Fog lamp bezel 4. Fog lamp assembly INSPECTION FOG LAMP SWITCH CONTINUITY CHECK Switch position Terminal No.
Page 374: Rear Combination Lamp
54-42 CHASSIS ELECTRICAL – Rear Combination Lamp REAR COMBINATION LAMP TROUBLESHOOTING For the troubleshooting of the lighting monitor warning buzzer, refer to P.54-33. REAR COMBINATION LAMP REMOVAL AND INSTALLATION Caution: SRS Before removal of air bag module and clock spring, refer to GROUP 52B – SRS Service Precautions and Air Bag Module and Clock Spring.
Page 375: Side Turn-Signal Lamp
54-43 CHASSIS ELECTRICAL – Side Turn-signal Lamp SIDE TURN-SIGNAL LAMP SPECIAL TOOL Tool Number Name MB990784 Ornament remover Removal of side turn-signal lamp SIDE TURN-SIGNAL LAMP MB990784 MB990784 REMOVAL Lock Fender panel INSTALLATION Lock Fit the hook side rearward. Hook Fender panel...
Page 376: Hazard Warning Lamp Switch, Clock
54-44 CHASSIS ELECTRICAL – Hazard Warning Lamp Switch, Clock HAZARD WARNING LAMP SWITCH, CLOCK SPECIAL TOOL Tool Number Name MB990784 Ornament remover Air conditioner panel removal HAZARD WARNING LAMP SWITCH REMOVAL AND INSTALLATION Hazard warning lamp switch Clock removal steps removal steps 1.
Page 377: Radio And Tape Player
54-45 CHASSIS ELECTRICAL – Radio and Tape Player RADIO AND TAPE PLAYER TROUBLESHOOTING There is noise when the engine is running. Kind of Noise (Parenthe- Symptom Cause Remedy sized noise sounds.) AM, FM: Ignition noise Popping sound becomes Mainly due to the Check the noise capacitor (Popping, snapping,...
Page 378 54-46 CHASSIS ELECTRICAL – Radio and Tape Player NOTE Noise Suppressing Capacitor The capacitor does not allow the passage of DC current but AC current. It decreases in impedance (resistance to AC) as the number of waves increases, making the AC flow easier. A noise suppressing capacitor relying on this property to function is inserted between a noise generating power line and earthing line to suppress noise by earthing noise components (in AC or pulse signal) to the vehicle body.
Page 379: Radio And Tape Player
54-47 CHASSIS ELECTRICAL – Radio and Tape Player / Speaker RADIO AND TAPE PLAYER REMOVAL AND INSTALLATION Removal steps 1. Radio panel 2. Radio and tape player 3. Radio bracket SPEAKER REMOVAL AND INSTALLATION Removal steps 1. Door trim 4. Speaker brakcet 2.
Page 380: Antenna
54-48 CHASSIS ELECTRICAL – Speaker / Antenna <REAR SPEAKER> Rear shelf speaker removal steps 6. Speaker garnish 7. Speaker ANTENNA POLE ANTENNA REMOVAL AND INSTALLATION Removal steps 5. Driver side lower cover 6. Clip 1. Pole 7. Cowl side trim 2.
Page 381: Rear Window Antenna And Glass Diversity Antenna
54-49 CHASSIS ELECTRICAL – Antenna REMOVAL SERVICE POINT AA" ANTENNA ASSEMBLY REMOVAL To facilitate the installation work of the antenna assembly, perform the following before removing the feeder cable: Feeder cable 1. Tie a cord to the end of the feeder cable. Cord 2.
Page 382: Rear Window Defogger
54-50 CHASSIS ELECTRICAL – Antenna / Rear Window Defogger REMOVAL SERVICE POINT AA" ANTENNA AMPLIFIER ASSEMBLY REMOVAL Take off the left-hand edge of the hand lining and undo the clips of the antenna amplifier assembly. REAR WINDOW DEFOGGER Normal characteristic curve Voltage TROUBLESHOOTING <VEHICLES WITH AUTOMATIC A/C>...
Page 383: Rear Window Defogger Switch
54-51 CHASSIS ELECTRICAL – Rear Window Defogger REAR WINDOW DEFOGGER SWITCH <VEHICLES WITH AUTOMATIC A/C> REMOVAL AND INSTALLATION Refer to GROUP – Heater Control Assembly. INSPECTION DEFOGGER SWITCH CONTINUITY CHECK Switch Terminal No. position – –...
Page 384 55-1 HEATER, AIR CONDITIONER AND VENTILATION CONTENTS HEATER AND MANUAL AIR HEATER CONTROL ASSEMBLY AND A/C SWITCH ....... CONDITIONER .
Page 385 55-2 FULL-AUTOMATIC AIR DAMPER CONTROL MOTOR ASSEMBLY AND POWER TRANSISTOR ... . CONDITIONER ..... PHOTO SENSOR .
Page 386: Heater And Manual Air Conditioner
HEATER AND MANUAL General / Service Specifications / – 55-3 AIR CONDITIONER Lubricants / Special Tools HEATER AND MANUAL AIR CONDITIONER GENERAL OUTLINE OF CHANGE The following service procedures have been established. SERVICE SPECIFICATIONS Items Standard value Idle speed r/min Idle up speed r/min Resistor (for blower motor) HI –...
Page 387 55-4 HEATER AND MANUAL AIR CONDITIONER – Troubleshooting TROUBLESHOOTING TROUBLESHOOTING PROCEDURES 1. Check air ducts, control rods, etc. for improper connection. 2. Check that the electrical connectors of the relevant components are connected securely and the fuse is not blown. 3.
Page 388 55-5 HEATER AND MANUAL AIR CONDITIONER – Troubleshooting Trouble symp- Problem cause Remedy Refer- ence page When the igni- Refrigerant leak or overfilling of refriger- Replenish the refrigerant, repair the 55-6 tion switch is leak or take out some of the “ON”, the A/C refrigerant does not oper...
Page 389: On-Vehicle Service
Troubleshooting / 55-6 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL Terminal Check item Checking requirements Normal condition Output from ECU to A/C compressor A/C compressor relay: OFF System voltage relay relay A/C compressor relay: ON Input from A/C switch to ECU A/C switch: OFF A/C switch: ON...
Page 390 55-7 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service 2. Charging 1. Open the low-pressure valve of the gauge manifold. Keep Low- High- Low- High- pressure the high-pressure valve closed. pressure pressure pressure valve valve gauge gauge 2. With the handles turned back all the way (valve closed), install the adaptor valve to the low-pressure side of the Gauge manifold...
Page 391 55-8 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service 12. Evacuate to a vacuum reading of 100 kPa or higher (takes approx. 10 minutes). Start evacuation Approx. for 10 minutes up to 100 kPa Stop evacuation Wait for 5 minutes If faulty Air-tight check Refrigerant charging...
Page 392: Refrigerant Charging Amount Check
55-9 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service 27. Remove the quick joint 2 from the low-pressure service valve. 28. Remove the service can. NOTE If the service can is not emptied completely, keep the handles of the charging valve and adaptor valve 1 closed for the next charging.
Page 393: Replenishing System
55-10 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service REPLENISHING SYSTEM Adapter valve Charging 1. Connect the charging hose (blue) to the adapter valve (for low pressure) valve 1 with the handle fully turned back (valve closed). 2. Connect the charging hose (blue) to the quick joint 2 and to the low pressure service valve.
Page 394: Discharging System
55-11 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service DISCHARGING SYSTEM 1. Run the engine at an engine speed of 1,200–1,500 r/min Sleeve for approximately 5 minutes with the A/C operating to return to the oil. NOTE Charging hose Returning the oil will be more effective if it is done while (blue) driving.
Page 395 55-12 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service Caution (1) To connect the quick joint, press section “A” firmly against the service valve until a click is heard. (2) When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose.
Page 396: Dual Pressure Switch Simple Check
55-13 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service DUAL PRESSURE SWITCH SIMPLE CHECK Dual pressure switch Measure the high-pressure side pressure. If there is a continuity between the dual pressure switch terminals with the dual pressure switch in ON condition as shown in the graph at left, the switch is in good condition.
Page 397: Idle-Up Operation Check
55-14 HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service A/C COMPRESSOR RELAY, CONDENSER FAN RELAY Radiator Fan control relay fan relay Battery voltage Terminal No. Condenser Compressor fan relay relay Power is not supplied Power is supplied IDLE-UP OPERATION CHECK 1.
Page 398: Heater Control Assembly And A/Cswitch
HEATER AND MANUAL 55-15 AIR CONDITIONER – Heater Control Assembly and A/C Switch HEATER CONTROL ASSEMBLY AND A/C SWITCH REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Instrument Lower Panel and Heater Control Panel Removal and Installation Floor Console Assembly Removal and Installation Foot Duct Removal and Installation (Refer to P.55-31.) Removal steps...
Page 399 HEATER AND MANUAL 55-16 AIR CONDITIONER – Heater Control Assembly and A/C Switch INSTALLATION SERVICE POINT Clamp "AA HEATER CONTROL ASSEMBLY INSTALLATION Boss 1. Cut off the bosses and clamp shown before installing a new heater control assembly. 2. Install the heater control assembly mounting screws. Boss 3.
Page 400 HEATER AND MANUAL 55-17 AIR CONDITIONER – Heater Control Assembly and A/C Switch 5. Follow the steps below to install the inside/outside air changeover damper lever cable. (1) Set the inside/outside air changeover damper link on the blower unit to the INSIDE position. (2) Set the inside/outside air changeover damper knob of the heater control assembly to the INSIDE position.
Page 401: Heater Unit And Blower Unit
HEATER AND MANUAL 55-18 AIR CONDITIONER – Heater Unit and Blower Unit HEATER UNIT AND BLOWER UNIT <VEHICLES WITHOUT AIR CONDITIONER> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling Air Cleaner Cover and Hose Removal and Installation Floor Console and Instrument Panel Removal and Installation...

Page 402: Heater Unit, Cooling And Blower Unit
HEATER AND MANUAL 55-19 AIR CONDITIONER – Heater Unit, Cooling and Blower Unit HEATER UNIT, COOLING AND BLOWER UNIT <VEHICLES WITH AIR CONDITIONER> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling Discharging and Charging of Refrigerant (Refer to P.55-6.) Air Cleaner Cover and Hose Removal and Installation...

Page 403: Blower Motor Assembly, Resistor And Evaporator
HEATER AND MANUAL 55-20 AIR CONDITIONER – Blower Motor Assembly, Resistor and Evaporator BLOWER MOTOR ASSEMBLY, RESISTOR AND EVAPORATOR REMOVAL AND INSTALLATION Piping connection O-ring A/C Compressor oil: SUN PAG 56 Blower motor assembly removal Evaporator removal steps steps <Vehicles with A/C> D Discharging and Charging of 1.
Page 404 HEATER AND MANUAL 55-21 AIR CONDITIONER – Blower Motor Assembly, Resistor and Evaporator AB" CASE COVER, EVAPORATOR REMOVAL The evaporator, which has been installed in a factory, has no case cover. Follow the steps below to remove that evaporator. 1. Cut the case along the shown line to remove the cooling and blower unit.
Page 405 HEATER AND MANUAL 55-22 AIR CONDITIONER – Blower Motor Assembly, Resistor and Evaporator AIR THERMO-SENSOR CHECK Measure the resistance between the sensor terminals in two or more different temperature conditions. The resistance values must conform to the values shown in the graph. NOTE The temperatures at checking must be within the range shown in the characteristic curve.
Page 406: Compressor And Tension Pulley
HEATER AND MANUAL 55-23 AIR CONDITIONER – Compressor and Tension Pulley COMPRESSOR AND TENSION PULLEY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Discharging of Refrigerant (Refer to P.55-6.) Drive Belt Tension Adjustment Charging of Refrigerant (Refer to P.55-6.) Piping connection O-ring A/C Compressor oil: SUN PAG 56 59 –...
Page 407 HEATER AND MANUAL 55-24 AIR CONDITIONER – Compressor and Tension Pulley REMOVAL SERVICE POINTS AA" DRIVE BELT REMOVAL 1. Align the hole in the auto-tensioner bracket with that in Auto-tensioner the arm and insert a screwdriver into the holes. 2. Remove the drive belt. Hole in Hole in bracket...
Page 408 HEATER AND MANUAL 55-25 AIR CONDITIONER – Compressor and Tension Pulley INSTALLATION SERVICE POINT "AA COMPRESSOR INSTALLATION If a new compressor is installed, first adjust the amount of oil according to the procedures described below, and then install the compressor. 1.
Page 409 HEATER AND MANUAL 55-26 AIR CONDITIONER – Compressor and Tension Pulley MAGNETIC CLUTCH DISASSEMBLY AND REASSEMBLY Disassembly steps "EA D Air gap adjustment "BA 4. Snap ring AA" "DA 1. Self-locking nut 5. Rotor "CA 2. Armature "AA 6. Field core 3.
Page 410 HEATER AND MANUAL 55-27 AIR CONDITIONER – Compressor and Tension Pulley "BA SNAP RING INSTALLATION Snap ring Rotor Field core Install the snap ring using a pair of snap ring pliers so that the tapered surface is at the outer side. Tapered part "CA ARMATURE INSTALLATION Armature...
Page 411: Condenser And Condenser Fan
HEATER AND MANUAL 55-28 AIR CONDITIONER – Condenser and Condenser Fan CONDENSER AND CONDENSER FAN REMOVAL AND INSTALLATION 12 Nm Piping connection O-ring A/C Compressor oil: SUN PAG 56 Condenser fan removal steps Condenser removal steps D Front bumper D Discharging and charging of AA"...
Page 412 HEATER AND MANUAL 55-29 AIR CONDITIONER – Condenser and Condenser Fan REMOVAL SERVICE POINTS AA" FAN MOTOR AND SHROUD ASSEMBLY REMOVAL Remove the clamp bolt of the power steering oil cooler pipe. Remove the fan motor and shroud assembly while pulling the power steering oil cooler pipe toward you.
Page 413: Refrigerant Line
HEATER AND MANUAL 55-30 AIR CONDITIONER – Refrigerant Line REFRIGERANT LINE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Discharging and Charging of Refrigerant (Refer to P.55-6.) Air Cleaner Case and Hose Removal and Installation Piping connection O-ring A/C Compressor oil: SUN PAG 56 AA"...
Page 414: Ducts
HEATER AND MANUAL 55-31 AIR CONDITIONER – Ducts DUCTS REMOVAL AND INSTALLATION <Standard model> <Vehicles for cold regions> 1. Center air outlet assembly Rear heater duct removal steps 2. Center ventilation duct D Front seat assembly (Refer to P.55-18, 19.) D Floor console assembly 3.
Page 415 HEATER AND MANUAL 55-32 AIR CONDITIONER – Ducts Rear ventilation duct removal steps D Rear bumper assembly D Trunk side trim 9. Rear ventilation duct...
Page 416: Full-Automatic Air Conditioner
General / Service Specifications / 55-33 FULL-AUTOMATIC AIR CONDITIONER – Lubricants / Special Tools FULL-AUTOMATIC AIR CONDITIONER GENERAL OUTLINE OF CHANGE The following service procedures have been established. SERVICE SPECIFICATIONS Items Standard value 750 " 50 Idle speed r/min 850 " 50 Idle-up speed r/min Air gap (Compressor) mm 0.4 –...
Page 417 55-34 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION DIAGNOSIS CODES CHECK Connect the MUT-II or a voltmeter to the diagnosis connector (16-pin), then check diagnosis codes. (Refer to GROUP 00 –...
Page 418 55-35 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Code No.13 Outside air temperature sensor system (open Probable cause circuit) D Malfunction of the outside air temperature sensor This diagnosis code is output if the power supply line or input line of the outside D Malfunction of connector, harness air temperature sensor is open-circuited and no signal is input from the outside D Malfunction of the A/C-ECU...
Page 419 55-36 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Code No.15 Heater water temperature sensor system Probable cause (open circuit) D Malfunction of the heater water temperature This diagnosis code is output if the power supply line or input line of the heater water temperature sensor is open-circuited and no heater water temperature sensor sensor D Malfunction of connector, harness...
Page 420 55-37 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Code No.21 Air thermo sensor system (open circuit) Probable cause D Malfunction of the air thermo sensor This diagnosis code is output if the power supply line or input line of the air thermo D Malfunction of connector, harness sensor is open-circuited and no air thermo sensor signals are input to A/C-ECU.
Page 421 55-38 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Code No.31 Potentiometer system of air mix damper motor Probable cause assembly D Malfunction of the air mix damper potentiometer This diagnosis code is output if no signals are input from air mix damper potentiometer D Malfunction of connector, harness to A/C-ECU because of short-circuit or open-circuit in the harness.
Page 422 55-39 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Code No.32 Potentiometer system of air outlet changeover Probable cause damper motor assembly D Malfunction of the air outlet changeover damper This diagnosis code is output if no signals are input from air outlet changeover damper potentiometer to A/C-ECU because of short-circuit or open-circuit in the potentiometer D Malfunction of connector, harness...
Page 423 55-40 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Code No.41 Drive system of air mix damper motor Probable cause assembly D Malfunction of the air mix damper motor assembly This diagnosis code is output if the air mix damper fails to be turned to the preset D Malfunction of connector, harness opening.
Page 424 55-41 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection proce- Reference page dure No. Communication with the MUT-II is not possible. 55-42 Air conditioner does not operate. 55-43 A/C graphic display on control panel is blank. 55-44 Temperature cannot be set.
Page 425 55-42 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection procedure 1 Communication with the MUT-II is not possible. Probable cause D Malfunction of connector or harness If communication with all other systems is not possible, there is a high D Malfunction of A/C-ECU possibility that there is a malfunction of the diagnosis line.
Page 426 55-43 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 2 Air conditioner does not operate. Probable cause D Malfunction of blower If the A/C does not operate when the A/C switch is on and the temperature D Insufficient refrigerant setting is at 17_C, the cause is probably insufficient refrigerant, or a D Malfunction of magnetic clutch malfunction of the blower or of the magnet clutch power supply.
Page 427 55-44 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 3 A/C graphic display on control panel is blank. Probable cause D Malfunction of connector or harness The cause is probably a malfunction of the A/C-ECU power supply system D Malfunction of A/C-ECU (earth).
Page 428 55-45 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 7 Blower does not operate. Probable cause D Malfunction of blower motor relay If no air comes out of the blower even though the blower switch is on, the D Malfunction of blower motor cause is probably a malfunction of the blower motor relay circuit.
Page 429 55-46 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 8 Blower does not operate in HI mode. Probable cause D Malfunction of blower motor HI relay If the blower does not operate in HI mode when the temperature is set to 17 or D Malfunction of blower motor 32, the cause is probably a malfunction of the blower motor HI relay circuit system.
Page 430 55-47 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 9 Blower air amount cannot be changed. Probable cause D Malfunction of power transistor If the blower does not operate in any mode other than HI setting, the cause is D Malfunction of connector or harness probably a malfunction of the power transistor system.
Page 431 55-48 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 11 Inside/outside air changeover is not possible. Probable cause D Malfunction of inside/outside air changeover If inside/outside air changeover is not possible even when the inside/outside air changeover switch is on, the cause is probably a malfunction of the damper motor D Malfunction of inside/outside air changeover inside/outside air changeover damper motor.
Page 432 55-49 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 12 Defroster function does not operate. Probable cause D Malfunction of air conditioner drive system If the defroster function does not operate when the defroster switch is turned D Malfunction of air outlet changeover damper drive on, the cause is probably a malfunction of the A/C or of the air outlet port changeover circuit.
Page 433 55-50 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 13 Condenser fan does not operate. Probable cause D Malfunction of condenser fan motor If the condenser fan does not turn when the A/C is ON, the cause is probably D Malfunction of condenser fan motor relay (HI, LO) a malfunction of the condenser fan motor activation circuit.
Page 434 55-51 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting From the previous page (1) NG Check the following connectors: Measure at the radiator fan motor relay (HI) connector A-114X. D Disconnect the connector. A-114X, A-28, B-59 (1) Continuity between 4-B-59 and connector terminal (20) (2) NG OK: Continuity (2) Voltage between terminal (2) and body earth (Ignition...
Page 435 55-52 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 15 A/C-ECU power supply circuit check Measure at the A/C-ECU connector B-04. Check the following connectors: D Disconnect the connector, and measure at the harness B-49, B-75, B-73 side connector. D Voltage between terminal (3) and body earth OK: System voltage Repair Check the trouble symptom.
Page 436 55-53 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Inspection procedure 16 A/C compressor control circuit check Measure at the A/C-ECU connector B-05. Check the following connector: D Blower switch and A/C switch: ON B-05 D Setting temperature: 17_C D Connect the connector. D Voltage between terminal (34) and body earth (Ignition Repair switch: ON)
Page 437 55-54 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting DATA LIST REFERENCE TABLE Check item Check condition Normal condition Inside air temperature sensor Ignition switch: ON Inside air temperature and temper- ature displayed on the MUT-II are MUT-II (11) identical. Outside air temperature sen- Ignition switch: ON Outside air temperature and tem- perature displayed on the MUT-II...
Page 438 55-55 FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting Terminal Check item Check condition Normal condition Heater water temperature sensor When sensor section temperature is 2.3 – 2.9 V input 25_C (4 k ) Air mix damper potentiometer input When damper is moved to MAX. HOT 4.7 –...
Page 439: On-Vehicle Service
Troubleshooting / 55-56 FULL-AUTOMATIC AIR CONDITIONER – On-vehicle Service Terminal Check item Check condition Normal condition Air mix damper motor (MAX. HOT) When damper is moved to MAX. Almost no voltage COOL position (0.5 V) When damper is moved to MAX. HOT 10 V position Inside/outside air changeover damper...
Page 440: Power Relay Check
55-57 FULL-AUTOMATIC AIR CONDITIONER – On-vehicle Service POWER RELAY CHECK Follow the same procedures as for the heater and manual air conditioner except for the following. (Refer to P.55-13.) BLOWER HIGH SPEED RELAY Battery voltage Terminal No. Power is not supplied Power is supplied Blower high speed relay IDLE-UP OPERATION CHECK...
Page 441: Damper Control Motor Assembly
Damper Control Motor Assembly 55-58 FULL-AUTOMATIC AIR CONDITIONER – and Power Transistor DAMPER CONTROL MOTOR ASSEMBLY AND POWER TRANSISTOR REMOVAL AND INSTALLATION Inside/outside air changeover Air mix damper motor removal damper motor removal steps steps D Glove box, glove box frame D Front floor console, console side cover 1.
Page 442 Damper Control Motor Assembly 55-59 FULL-AUTOMATIC AIR CONDITIONER – and Power Transistor INSPECTION INSIDE/OUTSIDE CHANGEOVER DAMPER MOTOR CHECK Battery connection Lever operation terminal Moves to the outside air position Moves to the inside air position Caution Cut off the battery voltage when the lever is in the stop position.
Page 443 Damper Control Motor Assembly 55-60 FULL-AUTOMATIC AIR CONDITIONER – and Power Transistor AIR OUTLET CHANGEOVER DAMPER MOTOR CHECK Motor Battery connection Lever operation terminal Moves to DEF. position Moves to FACE position Caution Cut off the battery voltage when the lever is in the stop position.
Page 444: Photo Sensor
55-61 FULL-AUTOMATIC AIR CONDITIONER – Photo Sensor PHOTO SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Instrument Panel Removal and Installation Removal step 1. Defroster nozzle 2. Photo sensor INSPECTION If the blower speed drops when the receiver section of the photo sensor is covered with your hand, then the photo sensor is normal.
Page 445: Outside Air Temperature
Outside Air Temperature 55-62 FULL-AUTOMATIC AIR CONDITIONER – Sensor OUTSIDE AIR TEMPERATURE SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Radiator Grille Removal and Installation Outside air temperature sensor INSPECTION When the resistance value between the sensor terminals is Resistance k measured under two or more temperature conditions, the resistance value should be close to the values shown in the graph.
Page 446: Heater Water Temperature
Heater Water 55-63 FULL-AUTOMATIC AIR CONDITIONER – Temperature Sensor HEATER WATER TEMPERATURE SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Floor Console Removal and Installation Glove Box Removal and Installation Foot Duct Removal and Installation (Refer to P55-31.) Removal steps AA"...
Page 447: Other Maintenance Service Points
Heater Water Temperature Sensor / 55-64 FULL-AUTOMATIC AIR CONDITIONER – Other Maintenance Service Points INSPECTION Follow the same procedure as for the inspection of the outside temperature sensor. (Refer to P55-62.) OTHER MAINTENANCE SERVICE POINTS The following maintenance service points are the same as for the manual A/C. Items Reference page Dual Pressure Switch...

Mitsubishi Lancer Evolution-VI Workshop Manual

21 Evolution-VI

Engine

Multipoint Injection (Mpi)

Inspection Chart for Trouble Symptoms

Clutch

On-Vehicle Service

General

Clutch Pedal

Clutch Control

Clutch

Rear Axle

Lubricants

Service Specifications

Lubricant

General

Special Tools

Vehicles with Ayc

Troubleshooting

On-Vehicle Service

Hydraulic Unit

Vehicles with Ayc

Sensor Relay <Vehicles with Ayc

Ayc-Ecu

Rear Axle

Basic Brake System

General/Keyless Entry System

Keyless Entry System

General

Sunroof

Exterior

Supplemental Restraint System (Srs)

Chassis Electrical

Battery

General

Immobilizer System

Ignition Switch <Except Evolution-VI with Immobilizer System

Combination Meters

Headlamp

Front Fog Lamp

Rear Combination Lamp

Side Turn-Signal Lamp

Hazard Warning Lamp Switch, Clock

Radio and Tape Player

Speaker

Antenna

Rear Window Defogger

Heater, Air Conditioner and Ventilation

Heater and Manual Air Conditioner

Full-Automatic Air Conditioner

Quick Links

Chapters

Troubleshooting

Related Manuals for Mitsubishi Lancer Evolution-VI

Summary of Contents for Mitsubishi Lancer Evolution-VI