Мануал по ремонту evo

Руководства и мануалы Mitsubishi Lancer Evolution 1

Руководства и мануалы Mitsubishi Lancer Evolution 2

Распиновка разъема подключения ECU Lancer Evo I (52,8 Kb)

Распиновка разъема подключения ECU Lancer Evo II (52,8 Kb)

Руководства и мануалы Mitsubishi Lancer Evolution 3

Руководства и мануалы Mitsubishi Lancer Evolution 4

Распиновка разъема подключения ECU Lancer Evo III (52,8 Kb)

Распиновка разъема подключения ECU Lancer Evo IV (103 Kb)

Преобразование ECU Evo 4, 5, 6 в Evo 7, 8 (382 Kb)

Руководства и мануалы Mitsubishi Lancer EVO 4 и EVO 5

Руководства и мануалы Mitsubishi Lancer Evolution 6

Техническая информация 1998 Lancer Evo 4 — 5 (2,25 Mb)

Руководство по ремонту 1998 Lancer Evo 4 — 5 (11,6 Mb)

Электрические схемы Lancer Evo 4 и Evo 5 (4,47 Mb)

Распиновка разъема подключения ECU Lancer Evo V (104 Kb)

Техническая информация 1999 Lancer Evo 6 (778 Kb)

Руководство по ремонту 1999 Lancer Evo 6 (10,2 Mb)

Электрические схемы Lancer Evo 6 (6,69 Mb)

Распиновка разъема подключения ECU Lancer Evo VI (103 Kb)

Руководства и мануалы Mitsubishi Lancer Evolution 7

Руководства и мануалы Mitsubishi Lancer Evolution 8

Техническая информация 2001 Lancer Evo 7 (4,68 Mb)

Руководство по ремонту 2001 Lancer Evo 7 (57,2 Mb)

Электрические схемы Lancer Evo 7 (22,4 Mb)

Распиновка разъема подключения ECU Lancer Evo VII (109 Kb)

Распиновка разъема подключения ECU Lancer Evo VII GT-A (166 Kb)

Распиновка разъемов подключения коробки передач Lancer Evo VII GT-A (42,3 Kb)

Техническая информация 2003 Lancer Evo 8 (1,18 Mb)

Руководство по ремонту 2003 Lancer Evo 8 (2,96 Mb)

Руководство по обслуживанию двигателя 4G63 (546 Kb)

Руководство по обслуживанию коробки передач (1,26 Mb)

Руководства 2003 Lancer Evo 8 USDM

Руководство по ремонту 2004 Lancer Evo 8 MR

Электрические схемы Lancer Evo 8 MR

Электрические схемы Lancer Evo 8 USDM

Руководства и мануалы Mitsubishi Lancer Evolution 9

Руководства и мануалы Mitsubishi Lancer Evolution 10

Руководство по ремонту 2005 Lancer Evo 9

Руководства 2005 Lancer Evo 9

Руководство по эксплуатации Lancer Evo 9 (на русском языке) 113 Mb

Электрические схемы Lancer Evo 9

Распиновка разъема подключения ECU Lancer Evo IX (119 Kb)

Схема ECU Lancer Evo 9 USDM (111 Kb)

Руководство по эксплуатации 2010 Lancer Evo 10

Руководства 2010 Lancer Evo 10

Обзор технической части Lancer Evo 10

Руководство по эксплуатации Lancer Evo X (на русском языке) 176 Mb NEW

Руководство по эксплуатации Lancer Evo X (на японском языке) (7,29 Mb)

Распиновка разъема подключения ECU Lancer Evo X (102 Kb)

Руководства и мануалы Mitsubishi Lancer RalliART / Galant Fortis

Руководство по эксплуатации Lancer RalliART/Galant Fortis (на русском языке) 127 Mb

Мультимедийное руководство на английском языке по техническому обслуживанию и ремонту автомобилей Mitsubishi Lancer/Lancer SportBack/Lancer Evolution 2004 года выпуска.

• Автор: —
• Издательство: Mitsubishi Motors
• Год издания: 2003
• Страниц: —
• Формат: —
• Размер: 191,5 Mb

Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution IX 2006 года выпуска.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2005
• Страниц: —
• Формат: PDF
• Размер: 14,4 Mb

Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution X 2010 года выпуска.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2009
• Страниц: 5668
• Формат: PDF
• Размер: 151,9 Mb

Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution VIII 2003 года выпуска.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2003
• Страниц: —
• Формат: PDF
• Размер: 129,3 Mb

Техническое описание на английском языке автомобилей Mitsubishi Lancer Evolution IV/V.

• Автор: —
• Издательство: Ralliart Inc.
• Год издания: 1998
• Страниц: —
• Формат: PDF
• Размер: 2,1 Mb

Руководство на английском языке по техническому обслуживанию и ремонту автомобилей Mitsubishi Lancer Evolution IV/V.

• Автор: —
• Издательство: Ralliart Inc.
• Год издания: 1998
• Страниц: —
• Формат: PDF
• Размер: 10,3 Mb

Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution IX.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2005
• Страниц: —
• Формат: PDF
• Размер: 144,1 Mb

Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution VI.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 1999
• Страниц: —
• Формат: PDF
• Размер: 9,6 Mb

Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution VII.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2001
• Страниц: —
• Формат: PDF
• Размер: 55,3 Mb

Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution VIII MR.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2004
• Страниц: —
• Формат: PDF
• Размер: 15,0 Mb

Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution VIII.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2003
• Страниц: —
• Формат: PDF
• Размер: 10,7 Mb

Сборник руководств (Tehnical Information Manual, Body Repair Manual, Service Manual) на английском языке по техническому обслуживанию и ремонту автомобиля Mitsubishi Lancer Evolution X 2008 года выпуска.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2007
• Страниц: —
• Формат: PDF
• Размер: 167,6 Mb

Руководство по эксплуатации и техническому обслуживанию автомобиля Mitsubishi Lancer Evolution IX.

• Автор: —
• Издательство: Mitsubishi Motors Corp.
• Год издания: 2006
• Страниц: —
• Формат: PDF
• Размер: 68,4 Mb

Mitsubishi Lancer Evolution X: Руководства по ремонту и обслуживанию

• Page 1
  WORKSHOP MANUAL EVOLUTION-IV EVOLUTION-V Pub. No. S9806CNCP9…

• Page 2: Table Of Contents

  General ……Engine ……Engine Lubrication .

• Page 3
  00-1 GENERAL CONTENTS MODELS ………..
• Page 4
  00-2 GENERAL – Models MODELS <LANCER EVOLUTION-IV> Model Class Model Grade Engine model Transmission Fuel supply code code year model system E-CN9A SNDF ’97 4G63 (2,000-DOHC – W5M51 Electronically 16 valves-intercooler 16 valves-intercooler (4WD-5M/T) (4WD-5M/T) controlled controlled fuel fuel SRGF ’97…

• Page 5: Engine

  11-1 ENGINE CONTENTS SERVICE SPECIFICATIONS ….CRANKSHAFT PULLEY ….SEALANTS .

• Page 6: Service Specifications

  Specified sealants Rocker cover Semi-drying sealant: THREEBOND 1207D [MZ 100168] (containing 150 g) Oil pan Semi-drying sealant: THREEBOND 1207F [MZ 100191] (containing 150 g) NOTE: Given in [ ] are MITSUBISHI GENUINE PART numbers. SPECIAL TOOLS Tool Number Name MD998782…

• Page 7
  11-3 ENGINE – Special Tools Tool Number Name MD998719 Crankshaft pulley Holding the crankshaft pulley holder pin Holding the camshaft sprocket MD998715 Pulley holder pin MD998713 Camshaft oil seal Pressfitting the camshaft oil seal installer MD998727 Oil pan remover Removing the oil pan MD998781 Flywheel stopper Securing the flywheel or drive plate…

• Page 8: Engine Adjustments

  11-4 ENGINE – Special Tools / Engine Adjustments Tool Number Name MB991654 Cylinder head bolt Removing and reinstalling the cylinder head wrench bolt MD998767 Tensioner pulley Timing belt tension adjustment socket wrench Recommended Engine lifter Supporting the engine assembly during tool MZ203826 removal and installation of the transmission by Anzen…

• Page 9: Auto Tensioner Check

  11-5 ENGINE – Engine Adjustments 2. AUTO TENSIONER CHECK (1) Stop the engine from the idle speed and check that the belt rests within the auto tensioner pulley width. (2) Remove the drive belt. Tool mounting hole (For the removal of the drive belt, refer to P.11-9.) (3) Fit a spinner handle or similar tool into the tool mounting hole of the auto tensioner and turn the tensioner clockwise and counterclockwise to ensure that it does not bind.

• Page 10
  11-6 ENGINE – Engine Adjustments (3) If the noise is not eliminated by racing, follow these steps Timing belt side to check the lash adjuster. a. Stop the engine. b. Bring no. 1 cylinder to TDC on the compression stroke. c.

• Page 11: Lash Adjuster Replacement

  11-7 ENGINE – Engine Adjustments 4. LASH ADJUSTER REPLACEMENT Refer to (4) of the preceding paragraph. 5. IGNITION TIMING CHECK Check that ignition timing is at the standard value. Standard value: approx. 5_BTDC NOTE Ignition timing is variable within about ±7_, even under normal operating.

• Page 12: Manifold Vacuum Check

  11-8 ENGINE – Engine Adjustments (5) Set compression gauge to one of the spark plug holes. (6) Crank the engine with the throttle valve fully open and Compression gauge measure the compression pressure. Standard value (at engine speed of 250 r/min): 11.5 kg/cm Limit (at engine speed of 250 r/min): 9.7 kg/cm (7) Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders…

• Page 13: Crankshaft Pulley

  11-9 ENGINE – Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11-4.) Under Cover Installation 25 {2.5} Unit: Nm {kgf@m} Removal steps AA» 1. Drive belt 2. Crankshaft pulley REMOVAL SERVICE POINT AA»…

• Page 14: Camshaft And Camshaft Oil Seal

  11-10 ENGINE – Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (1) Engine Coolant Draining and Refilling (4) Air Pipe Removal and Installation (2) Air Hose C Removal and Installation (Refer to GROUP 15 – Air Control Valve.) (Refer to GROUP 15 –…

• Page 15
  11-11 ENGINE – Camshaft and Camshaft Oil Seal Grease and adhesive application points 10 mm 10 mm 10 mm Timing belt side Semi-drying sealant: THREEBOND 1207D Engine oil φ 3 mm Timing belt side Semi-drying sealant: THREEBOND 1207F Semi-drying sealant: THREEBOND 1207D REMOVAL SERVICE POINT AA»…
• Page 16
  11-12 ENGINE – Camshaft and Camshaft Oil Seal «BA CAM CAP / REAR CAP / FRONT CAM CAP INSTALLATION Dowel pin (1) Locate the camshaft dowel pins as illustrated. Approx. 12_ Intake side Exhaust side (2) Temporarily tighten cam cap in two to three steps, then torque it to specification.

• Page 17: Oil Pan

  11-13 ENGINE – Oil Pan OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (1) Under Cover Removal and Installation (3) Oil Level Gauge Removal and Installation (2) Front Exhaust Pipe Removal and Installation (4) Engine Oil Draining and Supplying (Refer to GROUP 15.) Identification of bolt location φ…

• Page 18
  11-14 ENGINE – Oil Pan REMOVAL SERVICE POINT MD998727 MD998727 AA» OIL PAN REMOVAL INSTALLATION SERVICE POINTS «AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces Drain plug gasket Oil pan side as shown in the illustration.
• Page 19
  11-15 ENGINE – Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION 127 – 137 {13.0 – 14.0} Engine oil Unit: Nm {kgf@m} Crankshaft front oil seal removal Crankshaft rear oil seal removal steps steps D Timing belt and timing belt B D Transmission assembly D Clutch cover and disc (Refer to P.11-21.)

• Page 20: Crankshaft Oil Seal

  11-16 ENGINE – Crankshaft Oil Seal REMOVAL SERVICE POINT AA» FLYWHEEL ASSEMBLY REMOVAL Use the special tool to secure the flywheel assembly and remove the bolts. MD998781 INSTALLATION SERVICE POINTS Crankshaft rear oil seal «AA CRANKSHAFT REAR OIL SEAL INSTALLATION Crankshaft (1) Apply a small mount of engine oil to the entire MB990938…

• Page 21: Cylinder Head Gasket

  11-17 ENGINE – Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Fuel Discharge Prevention (1) Front Exhaust Pipe Installation (2) Engine Oil Removal (Refer to GROUP 15.) (3) Strut Tower Bar Removal (2) Thermostat Case Assembly Installation (4) Timing Belt Removal (Refer to P.11-21.) (Refer to GROUP 14 –…

• Page 22
  11-18 ENGINE – Cylinder Head Gasket 78 → 0 → 20 → +90_ → +90_ {8.0 → 0 → 2.0 → +90_ → +90_} 3.4 {0.35} 22 {2.2} 30 {3.1} 9 {0.9} 10 mm 10 mm 10 mm 10 mm 10 mm 9 {0.9} 30 {3.1}…
• Page 23
  11-19 ENGINE – Cylinder Head Gasket REMOVAL SERVICE POINT AA» CYLINDER HEAD BOLT REMOVAL Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head assembly. MB991654 Front of engine Intake side Exhaust side INSTALLATION SERVICE POINTS…
• Page 24
  11-20 ENGINE – Cylinder Head Gasket (3) Tighten the bolts by the following procedure. Step Operation Tighten to 78 Nm {8.0 kgf@m} in the order shown in the illustration. Fully loosen in the reverse order of that shown in the illustration.

• Page 25: Timing Belt

  11-21 ENGINE – Timing Belt TIMING BELT REMOVAL AND INSTALLATION 11 {1.1} 3.5 {0.35} 49 {5.0} 24 {2.4} 24 {2.4} 11 {1.1} 11 {1.1} 118 {12.0} 49 {5.0} 9 {0.9} 30 {3.1} 45 {4.6} 19 {1.9} 88 {9.0} 49 {5.0} 9 {0.9} 54 {5.5} 48 {4.9}…

• Page 26
  11-22 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 27
  11-23 ENGINE – Timing Belt AE» TIMING BELT “B” REMOVAL Make an arrow 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. 6EN1322 AF»…
• Page 28
  11-24 ENGINE – Timing Belt (2) Cracks on rubber back. Cracks Cracks (3) Cracks of canvas. (4) Cracks on rib root. (5) Cracks on belt sides. Peeling of Cracks canvas on sides Cracks on rib root (6) Abnormal wear of belt sides. NOTE The sides are normal if they are sharp as if cut by a knife.
• Page 29
  11-25 ENGINE – Timing Belt INSTALLATION SERVICE POINTS «AA CAMSHAFT SPROCKET BOLT TIGHTENING Using a wrench, hold the camshaft at its hexagon and tighten the bolt to the specification. Caution Locking the camshaft sprocket with a tool damages the sprocket. «BA ENGINE SUPPORT BRACKET LEFT INSTALLATION Coat the bolts illustrated with sealant before tightening.
• Page 30
  11-26 ENGINE – Timing Belt «DA SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: THREEBOND 1212D or equivalent 10 mm Apply sealant 10 mm 10 mm Apply sealant 10 mm Apply sealant «EA SPACER INSTALLATION Oil seal Spacer…
• Page 31
  11-27 ENGINE – Timing Belt (3) Make sure that the relationship between the tensioner Tension side of timing belt pulley center and the bolt center is as shown in the Tensioner “B” illustration. Timing belt “B” Center of tensioner Center pulley of bolt (4) Move the tensioner “B”…
• Page 32
  11-28 ENGINE – Timing Belt c. Insert a wire (1.4 mm in diameter) into the set holes. d. Unclamp the auto tensioner from the vise. (2) Install the auto tensioner. Leave the wire installed in the auto tensioner until the timing belt is installed. 6AE0050 «KA TENSIONER PULLEY INSTALLATION Install the tensioner pulley as shown in the illustration.
• Page 33
  11-29 ENGINE – Timing Belt (4) Align the timing mark on the oil pump sprocket with its mating mark. (5) Remove the plug on the left side of the cylinder block and insert a Phillips screwdriver (shank diameter 8 mm) through the hole.
• Page 34
  11-30 ENGINE – Timing Belt (10)Fit the timing belt over the idler pulley, oil pump sprocket and crankshaft sprocket in this order. NOTE Be careful that the belt does not become slack. Oil pump sprocket Crankshaft sprocket (11)Fit the timing belt over the tensioner pulley. NOTE When fitting the timing belt over the tensioner pulley, turn…
• Page 35
  11-31 ENGINE – Timing Belt (17)Loosen the retaining bolt of the tensioner pulley. MD998767 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 36: Engine Assembly

  11-32 ENGINE – Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Fuel Discharge Prevention (1) Front Exhaust Pipe Installation (2) Hood Removal (Refer to GROUP 15.) (3) Strut Tower Bar Removal (2) Under Cover Installation (4) Air Hose C Removal (3) Radiator Assembly Installation (Refer to GROUP 15 –…

• Page 37
  11-33 ENGINE – Engine Assembly 39 {4.0} 9 {0.9} 12 {1.2} 57 {5.8} 98 {10.0}* Unit: Nm {kgf@m} 19. Solenoid valve connector 26. A/C relay box 20. Vacuum tank/solenoid valve/vacuum 27. A/C receiver bracket mounting bolt hose assembly 28. Oil pressure hose mounting bolt AC»…
• Page 38
  11-34 ENGINE – Engine Assembly REMOVAL SERVICE POINTS AA» DRIVE BELT REMOVAL Auto tensioner (1) Align the hole in the auto tensioner bracket with that in the arm and insert a screwdriver into the holes. (2) Remove the drive belt. Hole in arm Hole in bracket Phillips…
• Page 39
  11-35 ENGINE – Engine Assembly AE» ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment. INSTALLATION SERVICE POINTS «AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

• Page 40: Engine Lubrication

  12-1 ENGINE LUBRICATION CONTENTS LUBRICANTS ……….ENGINE OIL COOLER .

• Page 41
  12-2 ENGINE LUBRICATION – Lubricants / Engine Oil Cooler LUBRICANTS Items Capacity dm Engine oil Quantity in oil filter 0.3 {0.3} Quantity in oil cooler 0.16 {0.16} Total quantity 5.1 {5.1} Brand DIA QUEEN MOTOR OIL (Grade SG or higher); or engine oil in a can marked with ILSAC certification.

• Page 42: Fuel

  13-1 FUEL CONTENTS MULTIPOINT INJECTION (MPI) ..Fuel Pressure Measurement … MPI System Components Layout ..GENERAL INFORMATION ….Intake Air Temperature Sensor Check Engine Coolant Temperature SERVICE SPECIFICATIONS…

• Page 43: Multipoint Injection (Mpi)

  13-2 MPI – General Information MULTIPOINT INJECTION (MPI) GENERAL INFORMATION OMPI 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…

• Page 44: Service Specifications

  Oxygen sensor output voltage 0.6 – 1.0 Fuel pressure control valve coil resistance (at 20_C) Ω 28 – 36 SEALANT Item Specified sealant Coolant temperature sensor Drying sealant: HELMESEAL H-1M [0110513] NOTE: Given in [ ] are MITSUBISHI GENUINE PART numbers.

• Page 45: Special Tools

  13-4 MPI – Special Tools SPECIAL TOOLS Tool Number Name MB991348 Test harness set Measurement of voltage during trouble- shooting Inspection using an oscilloscope MB991519 Alternator harness Measurement of voltage during connector troubleshooting MB991536 TPS check Adjustment of idle switch and throttle position harness sensor (TPS) MD998464…

• Page 46
  13-5 MPI – Special Tools Tool Number Name MD998746 Clip Checking the spray condition of injectors MD998709 Adaptor hose Measurement of fuel pressure MD998742 Hose adaptor MB991637 Fuel pressure gauge set MB991223 Inspection test Measurement of terminal voltage herness set Red harness Pin contact pressure…

• Page 47: Troubleshooting

  13-6 MPI – Troubleshooting TROUBLESHOOTING 1. DIAGNOSIS FUNCTION 1-1 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. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.

• Page 48
  13-7 MPI – Troubleshooting 1-3 ERASING DIAGNOSIS CODES (1) Turn the ignition switch to OFF. (2) After disconnecting the battery cable from the battery (–) terminal for 10 seconds or more, reconnect the cable. (3) After the engine has warmed up, run it at idle for about 15 minutes. 1-4 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.
• Page 49
  13-8 MPI – Troubleshooting 2. INSPECTION CHART FOR DIAGNOSIS CODES Code No. Diagnosis item Reference page Air flow sensor (AFS) system 13-8 Intake air temperature sensor system 13-9 Throttle position sensor (TPS) system 13-9 Engine coolant temperature sensor system 13-10 Crank angle sensor system 13-11 Camshaft position sensor system…
• Page 50
  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 circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the intake air after the engine starts.
• Page 51
  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 circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the engine coolant after the engine starts.
• Page 52
  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 circuit Set conditions short-circuited 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 53
  13-12 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 circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed after the engine starts.
• Page 54
  13-13 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 circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the barometric pressure after the engine starts.
• Page 55
  13-14 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 circuit D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the detonation sensor after the engine starts.
• Page 56
  13-15 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 circuit D Engine is not being cranked.
• Page 57
  13-16 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 approximately 50 r/min or more. D Malfunction of the engine-ECU. Set conditions D Input voltage at the alternator FR terminal is 4.5 V or more for 20 seconds.
• Page 58
  13-17 MPI – Troubleshooting 4. PROBLEM SYMPTOMS TABLE 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. Hard starting Engine starts after cranking a while.
• Page 59
  13-18 MPI – Troubleshooting 5. SERVICE DATA LIST <EVOLUTION-IV> Item Inspection Inspection contents Normal condition item Oxygen Engine: After having been warmed When at 4,000 r/min, engine is 200 mV or less sensor suddenly decelerated Air/fuel mixture is made leaner when Air/fuel mixture is made leaner when When engine is suddenly 600 –…
• Page 60
  13-19 MPI – Troubleshooting Item Inspection Inspection contents Normal condition item Engine Ignition switch: ON or with engine When engine coolant temper- –20_C coolant running ature is –20_C temperature temperature When engine coolant temper- sensor ature is 0_C When engine coolant temper- 20_C ature is 20_C When engine coolant temper-…
• Page 61
  13-20 MPI – Troubleshooting Item Inspection Inspection contents Normal condition item Injector Engine: Cranking When engine coolant temper- 27 – 41 ms drive time* ature is 0_C (injection is carried out for all cylinders simultaneously) When engine coolant temper- 14 – 22 ms ature is 20_C When engine coolant temper- 3.9 –…
• Page 62
  13-21 MPI – Troubleshooting <EVOLUTION-V> Descriptions other than those given below are the same as for the EVOLUTION-IV. Item Inspection Inspection contents Normal condition item Air flow Engine coolant temperature: Engine is idling 12 – 38 Hz sensor* 80 – 95_C sensor* 80 –…
• Page 63
  13-22 MPI – Troubleshooting 6. ENGINE-ECU INSPECTION 6-1 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.
• Page 64
  13-23 MPI – Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Fan motor relay (LOW) Fan not operating (coolant temperature: 90_C or Battery voltage below) Fan at low speed (coolant temperature: 90 – 100_C) 0 – 3 V A/C relay Engine: Idling Battery voltage, or 6 V…
• Page 65
  13-24 MPI – Troubleshooting Terminal Check item Check condition (Engine condition) Normal condition Intake air temperature Ignition switch: ON When intake air tempera- 3.2 – 3.8 V sensor ture is 0_C When intake air tempera- 2.3 – 2.9 V ture is 20_C When intake air tempera- 1.5 –…
• Page 66
  13-25 MPI – Troubleshooting 6-2 RESISTANCE AND CONTINUITY BETWEEN HARNESS SIDE CONNECTORS AND TERMINALS Engine-ECU Harness Side Connector Terminal Arrangement Terminal No. Inspection item Normal condition (Check condition) 2 – 3 Ω (At 20_C) 1 – 12 No.1 injector 14 – 12 No.2 injector 2 –…
• Page 67
  13-26 MPI – Troubleshooting 7. INSPECTION PROCEDURE USING OSCILLOSCOPE 7-1 AIR FLOW SENSOR (AFS) Observing waveforms displayed on the oscilloscope allows you to visually identify possible unusual disturbances in waveform that could temporarily occur in the air flow sensor output. <Measurement procedure>…
• Page 68
  13-27 MPI – Troubleshooting <Standard waveform> Point A Observation conditions × 10 Probe selector switch AC-GND-DC Point B Solenoid counter emf (approx. 7 × 10 V) Injector VOLTS/DIV. drive time Power supply voltage TIME/DIV. 0.5 ms Misc. – Engine speed Idle <Explanation on waveform>…
• Page 69
  13-28 MPI – Troubleshooting Injector Power Supply Voltage (Oscilloscope 2) <Measurement procedure> (1) Disconnect the resistor connector and connect the special tool (Harness Connector: MD998463) to the circuit. (2) Connect the oscilloscope probe to resistor connector terminal (1) (special tool red clip) when the waveform is observed with no.
• Page 70
  13-29 MPI – Troubleshooting <Explanation of waveform> The injector power supply voltage waveform shows a voltage drop caused by resistance of the resistor. As the amount of current increases, voltage gradually decreases and a spike occurs at the plunger fully opened position due to counter emf.

• Page 71: On-Vehicle Service

  13-30 MPI – On-vehicle Service ON-VEHICLE SERVICE 1. IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR (TPS) ADJUSTMENT The thickness of the feeler gauge inserted between the fixed SAS and throttle lever should be 0.45 mm. 2. FIXED SAS ADJUSTMENT <EVOLUTION-IV> Turn down one turn after the fixed SAS has touched the throttle lever.

• Page 72: Mpi System Components Layout

  13-31 MPI – On-vehicle Service 5. MPI SYSTEM COMPONENTS LAYOUT Name Symbol Name Symbol A/C switch Exhaust temperature warning lamp A/C relay Fuel pressure control valve Air flow sensor (with a built-in intake air temperature Ignition coil and power transistor unit sensor and barometric pressure sensor) sensor and barometric pressure sensor) Injector…

• Page 73: Intake Air Temperature Sensor Check

  13-32 MPI – On-vehicle Service 6. INTAKE AIR TEMPERATURE SENSOR Equipment sideconnector CHECK 1. Disconnect the air flow sensor connector. 2. Measure resistance between terminals 5 and 6. Standard value: 2.3 – 3.0 kΩ (at 20_C) 0.30 – 0.42 kΩ (at 80_C) Air flow sensor 3.

• Page 74
  13-33 MPI – On-vehicle Service (2) Check that there is continuity (11 to 18 Ω at 20_C) across terminal no. 1 (special tool red clip) and terminal no. 3 (special tool blue clip) of the oxygen sensor connector. Red clip (3) If there is no continuity, replace the oxygen sensor.

• Page 75: Injector Check

  13-34 MPI – On-vehicle Service 9. INJECTOR CHECK Injection Condition Check (1) Release the residual pressure from the fuel pipe line to prevent fuel from flowing out. (2) Remove the injector. (3) Set up the special tools (Injector Test Set, Adapter, Fuel Pressure Regulator, and Clip) as illustrated below.

• Page 76: Fuel Pump Relay No.2 Check

  13-35 MPI – On-vehicle Service 11. FUEL PUMP RELAY NO.2 CHECK (1) Remove fuel pump relay No.2. Fuel pump relay No.2 (2) Using jumper wires, connect fuel pump relay No.2 terminal (3) to battery (+) terminal, and terminal (1) to battery (–) terminal, respectively.

• Page 77: Injector

  13-36 MPI – Injector INJECTOR REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Fuel Discharge Prevention (1) Air Hose D Installation (2) Air Hose D Removal (Refer to GROUP15 – Intercooler.) (Refer to GROUP15 – Intercooler.) (2) Fuel Leakage Check 3, 6 O-ring 10 –…

• Page 78: Throttle Body

  13-37 MPI – Throttle Body THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Engine Coolant Draining (1) Strut Tower Bar Installation (2) Air Hose D Removal (2) Air Hose D Installation (Refer to GROUP 15 – Intercooler.) (Refer to GROUP 15 – Intercooler.) (3) Strut Tower Bar Removal (3) Engine Coolant Supplying (4) Accelerator Cable Adjustment…

• Page 79: Engine Cooling

  14-1 ENGINE COOLING CONTENTS SERVICE SPECIFICATIONS ….THERMOSTAT ……LUBRICANT .

• Page 80: Service Specifications

  When fully open Thermostat lift mm 8.5 or more LUBRICANT Items Brand Quantity dm Coolant capacity (in condenser tank) MITSUBISHI GENUINE DIA QUEEN SUPER 6 {6} LONG LIFE COOLANT ON-VEHICLE SERVICE COOLANT REPLACEMENT CYLINDER BLOCK DRAIN PLUG 44 {4.5} Unit: Nm {kgf@m}…

• Page 81: Thermostat

  14-3 ENGINE COOLING – Thermostat THERMOSTAT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-2.) Air Intake Hose Assembly Removal and Installation (Refer to GROUP 15 – Intercooler.) 13 {1.3} Unit: Nm {kgf@m} Removal steps AA»…

• Page 82
  14-4 ENGINE COOLING – Thermostat INSTALLATION SERVICE POINTS Jiggle valve «AA THERMOSTAT INSTALLATION (1) Install the thermostat so that the jiggle valve is facing straight up. Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat. If the rubber ring is damaged, replace the thermostat.

• Page 83: Water Pump

  14-5 ENGINE COOLING – Water Pump WATER PUMP REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Timing Belt and Timing Belt B Removal and Installation (Refer to P.14-2.) (Refer to GROUP 11.) 22 {2.2} 24 {2.4} 12 –…

• Page 84: Water Hose And Water Pipe

  14-6 ENGINE COOLING – Water Hose and Water Pipe WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (1) Coolant Draining and Refilling (Refer to P.14-2.) (2) Air Hose C Removal and Installation (Refer to GROUP 15 – INTERCOOLER.) (3) Air Control Valve Bracket Removal and Installation (Refer to GROUP 15 –…

• Page 85: Radiator

  14-7 ENGINE COOLING – Radiator RADIATOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to P.14-2.) 12 {1.2} 12 {1.2} 12 {1.2} Unit: Nm {kgf@m} Radiator removal steps Radiator fan motor removal steps 1. Drain plug 1.

• Page 86
  14-8 ENGINE COOLING – Radiator REMOVAL SERVICE POINTS AA» RADIATOR UPPER HOSE / RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. INSTALLATION SERVICE POINT «AA RADIATOR LOWER HOSE / RADIATOR UPPER HOSE CONNECTION (1) Insert each hose as far as the projection of the water inlet or outlet fitting.
• Page 87
  14-9 ENGINE COOLING – Radiator Battery voltage Terminal number Radiator fan motor relay HI When deenergized When energized…

• Page 88: Intake And Exhaust

  15-1 INTAKE AND EXHAUST CONTENTS SERVICE SPECIFICATIONS ….Secondary Air Valve Check … . Vacuum Tank Check .

• Page 89: Service Specifications

  Service Specifications / 15-2 INTAKE AND EXHAUST – Special Tool / On-vehicle Service SERVICE SPECIFICATIONS Items Standard value Limit Turbocharger boost pressure kPa {kg/cm 53 – 87 {0.54 – 0.89} – Wastegate actuator activation pressure kPa {kg/cm Approx. 100 {1.02} –…

• Page 90: Boost Pressure Control System Check

  15-3 INTAKE AND EXHAUST – On-vehicle Service (3) If the boost pressure is lower than the standard value, check for following which are probably the cause: Wastegate actuator inoperative Boost pressure leak Turbocharger defective (4) If the boost pressure is higher than the standard value, boost pressure control is probably faulty.

• Page 91: Wastegate Actuator Check

  15-4 INTAKE AND EXHAUST – On-vehicle Service 3. WASTEGATE ACTUATOR CHECK (1) Connect a hand pump (pressure type) to the nipple. (2) Gradually increase the pressure being applied to check for the pressure at which the wastegate actuator rod starts moving (approx.

• Page 92: Secondary Air Control System Check

  15-5 INTAKE AND EXHAUST – On-vehicle Service 6. SECONDARY AIR CONTROL SYSTEM CHECK (1) Start the engine and let it run at idle speed. (2) Short-circuit the no. 6 terminal of the engine ECU connector using a jumper wire and check at this time that the secondary air valve lifts.

• Page 93: Secondary Air Valve Check

  15-6 INTAKE AND EXHAUST – On-vehicle Service 8. SECONDARY AIR VALVE CHECK (1) Remove the secondary air valve. (2) Connect a hand vacuum pump to the secondary air valve nipple. (3) Apply a vacuum of 67 kPa {500 mmHg} and check that the vacuum is retained.

• Page 94: Intercooler

  15-7 INTAKE AND EXHAUST – Intercooler INTERCOOLER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Bumper Removal and Installation (Refer to GROUP 51.) Hose clamp tightening torque 6 {0.6} 10 – 13 {1.0 – 1.3} 10 – 13 {1.0 – 1.3} 10 –…

• Page 95: Air Control Valve

  15-8 INTAKE AND EXHAUST – Air Control Valve AIR CONTROL VALVE REMOVAL AND INSTALLATION 10 – 12 {1.0 – 1.2} 10 – 12 {1.0 – 1.2} 4 {0.4} 4 {0.4} 12 – 15 {1.2 – 1.5} 24 {2.4} 49 {5.0} 22 {2.2} 24 {2.4} 22 {2.2}…

• Page 96: Intake Manifold

  15-9 INTAKE AND EXHAUST – Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Fuel Discharge Prevention (1) Strut Tower Bar Installation (2) Throttle Body Removal (Refer to GROUP 13.) (2) Air Control Valve Bracket Installation (3) Front Exhaust Pipe Removal (Refer to P.15-14.) (Refer to P.15-8.) (4) Air Control Valve Bracket Removal (Refer to P.15-8.) (3) Front Exhaust Pipe Installation (Refer to P.15-14.)

• Page 97
  15-10 INTAKE AND EXHAUST – Intake Manifold REMOVAL SERVICE POINT AA» DELIVERY PIPE, INJECTOR AND PRESSURE REGULATOR REMOVAL Remove the delivery pipe with the injectors and pressure regulator attached to it. Caution Care must be taken, when removing the delivery pipe, not to drop the injector.

• Page 98: Exhaust Manifold And Turbocharger

  15-11 INTAKE AND EXHAUST – Exhaust Manifold and Turbocharger EXHAUST MANIFOLD AND TURBOCHARGER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (1) Radiator Removal and Installation (4) Air Pipe Assembly Removal and Installation (Refer to GROUP 14.) (Refer to P.15-8.) (2) Air Intake Hose and Air Hose A Removal and (5) Engine Oil Removal and Refilling Installation (Refer to P.15-7.) (3) Front Exhaust Pipe Removal and Installation…

• Page 99
  15-12 INTAKE AND EXHAUST – Exhaust Manifold and Turbocharger REMOVAL SERVICE POINTS AA» OXYGEN SENSOR REMOVAL MB998770 AB» OIL PIPE REMOVAL Caution After the oil pipe has been removed, ensure that no foreign matter will get into the oil passage holes in turbocharger. INSTALLATION SERVICE POINTS «AA TURBOCHARGER INSTALLATION (1) Clean the connections between oil pipe, oil return pipe,…
• Page 100
  15-13 INTAKE AND EXHAUST – Exhaust Manifold and Turbocharger «CA OIL RETURN PIPE GASKET INSTALLATION Print Install the gasket so that its print part is on the oil pan side. Gasket INSPECTION 1. TURBOCHARGER CHECK (1) Visually check the turbine wheel and compressor wheel for damage and cracking.

• Page 101: Exhaust Pipe And Muffler

  15-14 INTAKE AND EXHAUST – Exhaust Pipe and Muffler EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION 44 {4.5} 49 {5.0} 34 {3.5} 19 {1.9} 49 {5.0} 34 {3.5} 13 {1.3} 5 {0.5} Hanger mounting bolt tightening torque 3, 9, 18 13 {1.3} Unit: Nm {kgf@m} Main muffler removal steps…

• Page 102: Engine Electrical

  16-1 ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM ….IGNITION SYSTEM ….ALTERNATOR .

• Page 103: Charging System

  16-2 ENGINE ELECTRICAL – Charging System CHARGING SYSTEM ALTERNATOR REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Under Cover Removal (1) Strut Tower Bar Installation (2) Engine Mount Removal (2) Engine Mount Installation (3) Strut Tower Bar Removal (3) Under Cover Installation (4) Drive Belt Tension Adjustment (Refer to GROUP 11 –…

• Page 104
  16-3 ENGINE ELECTRICAL – Charging System REMOVAL SERVICE POINTS AA» POWER STEERING, A/C COMPRESSOR, AND Auto tensioner ALTERNATOR DRIVE BELT REMOVAL (1) Align the hole in the auto tensioner bracket with that in the arm and insert a screwdriver into the holes. Hole in arm (2) Remove the drive belt.

• Page 105: Ignition System

  16-4 ENGINE ELECTRICAL – Ignition System IGNITION SYSTEM ON-VEHICLE SERVICE 1. IGNITION COIL WITH BUILT-IN POWER TRANSISTOR CHECK Secondary coil resistance measurement Standard value: 15 – 21 kΩ 2. SPARK PLUG CHECK, CLEANING, AND REPLACEMENT Check the plug gap and replace if the limit is exceeded. Caution (1) Do not attempt to adjust the gap of the platinum plug.

• Page 106: Camshaft Position Sensor And Crank Angle Sensor

  16-5 ENGINE ELECTRICAL – Ignition System CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt Removal and Installation (Refer to GROUP 11.) 3 {0.3} 9 {0.9} 39 {4.0} 9 {0.9} 9 {0.9} 49 {5.0} Unit: Nm {kgf@m} Removal steps 1.

• Page 107: Engine And Emission Control

  17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM ..EMISSION CONTROL SYSTEM ..SERVICE SPECIFICATIONS ….ON-VEHICLE SERVICE .

• Page 108
  Engine Control System / 17-2 ENGINE EMISSION CONTROL – Emission Control System <MPI> ENGINE CONTROL SYSTEM SERVICE SPECIFICATIONS Items Standard value 850 ± 50 Idle speed rpm EMISSION CONTROL SYSTEM <MPI> ON-VEHICLE SERVICE SYSTEM CONFIGURATION DIAGRAM Canister Check valve Throttle body Fuel pressure control valve Fuel pressure regulator…
• Page 109
  17-3 ENGINE EMISSION CONTROL – Emission Control System <MPI> VACUUM HOSE PIPING CIRCUIT DIAGRAM Fuel pressure Blue White control valve Surge tank Canister Check valve Secondary air Throttle body control solenoid Fuel valve Wastegate pressure solenoid regulator valve Secondary air valve Bypass valve Vacuum hose color…

• Page 110: Catalytic Converter

  17-4 ENGINE EMISSION CONTROL – Emission Control System <MPI> CATALYTIC CONVERTER REMOVAL AND INSTALLATION 13 {1.3} 19 {1.9} 49 {5.0} 49 {5.0} 34 {3.5} 49 {5.0} 5 {0.5} Unit: Nm {kgf@m} Removal steps 1. Spring 4. High temperature sensor 2. Heat protector <EVOLUTION-IV only>…

• Page 111: Clutch

  21-1 CLUTCH CONTENTS SERVICE SPECIFICATIONS ….CLUTCH PEDAL ……LUBRICANTS .

• Page 112: Service Specifications

  Distance between the clutch pedal and the toeboard when the clutch is disengaged mm 70 or more LUBRICANTS Items Specified lubricants Quantity Clutch fluid MITSUBISHI genuine brake fluid “DIA-QUEEN As required BRAKE FLUID SUPER 4” Push rod assembly Rubber grease Boot Release cylinder push rod…

• Page 113: Bleeding

  (8) Turn back the carpet, etc. 2. BLEEDING Specified fluid: MITSUBISHI genuine brake fluid “DIA-QUEEN BRAKE FLUID SUPER 4” Caution Use the specified brake fluid. Avoid using a mixture of the specified fluid and other fluid.

• Page 114: Clutch Pedal

  21-4 CLUTCH – Clutch Pedal CLUTCH PEDAL REMOVAL AND INSTALLATION Post-installation Operation Clutch Pedal Adjustment (Refer to P.21-2.) 13 {1.3} 12 {1.2} 24 {2.4} 13 {1.3} (Spring installation position) Unit: Nm {kgf@m} Removal steps 1. Clutch master cylinder installation 7. Pipe 8.

• Page 115: Clutch Control

  21-5 CLUTCH – Clutch Control CLUTCH CONTROL REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Clutch Fluid Draining (1) Clutch Fluid Supplying (2) Clutch Line Bleeding (Refer to P.21-3.) (3) Clutch Pedal Adjustment (Refer to P.21-2.) Release Release cylinder fork 13 {1.3} push rod Specified grease: MOLYKOT BR-2 PLUS…

• Page 116: Clutch Master Cylinder

  21-6 CLUTCH – Clutch Control CLUTCH MASTER CYLINDER DISASSEMBLY AND REASSEMBLY 13 {1.3} Unit: Nm {kgf@m} DIA-QUEEN BRAKE Clutch fluid: FLUID SUPER 4 Grease: Rubber grease Piston repair kit Disassembly steps 1. Piston stopper ring 2. Piston assembly 3. Push rod assembly 4.

• Page 117: Manual Transmission

  22-1 MANUAL TRANSMISSION CONTENTS MANUAL TRANSMISSION ……. . . MANUAL TRANSMISSION OVERHAUL .

• Page 118: Manual Transmission

  22A-1 MANUAL TRANSMISSION CONTENTS LUBRICANTS ……TRANSMISSION CONTROL* … . . Shift Lever Assembly .

• Page 119: Special Tools

  LUBRICANT Item Specified lubricant Quantity dm Transmission oil MITSUBISHI genuine “Dia-Queen” multi gear oil <75W/85W> 2.8 (2.8) Transfer oil MITSUBISHI genuine “Dia-Queen Super” hypoid gear oil (GL-5) 0.62 (0.62) SPECIAL TOOLS Tool Number Name MB990635 or Steering linkage Tie rod end and lower arm disconnection…

• Page 120: On-Vehicle Service

  (3) Remove the filler plug and fill with specified oil till the level comes to the lower portion of filler plug hole. Transmission oil Drain plug Specified oil: MITSUBISHI genuine “Dia-Queen” multi gear oil <75W/85W> Quantity: 2.8 dm (2.8 ) (4) Tighten the filler plug to the specified torque.

• Page 121: Transmission Control

  22A-4 MANUAL TRANSMISSION – Transmission Control TRANSMISSION CONTROL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Caution: SRS Air Cleaner Assembly Removal and Installation Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift cable and select cable assembly.

• Page 122
  22A-5 MANUAL TRANSMISSION – Transmission Control INSTALLATION SERVICE POINTS «AA SHIFT CABLE AND SELECT CABLE ASSEMBLY Shift lever / SHIFT CABLE CONNECTION / SELECT CABLE CONNECTION (1) Set the transmission side shift lever and the passenger compartment side shift lever to the neutral position. Neutral position (2) For the transmission side, the white and yellow paint marks on the shift and select cable ends should face…

• Page 123: Shift Lever Assembly

  22A-6 MANUAL TRANSMISSION – Transmission Control SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 14 {1.4} 10 {1.0} Unit: Nm {kgf@m} Disassembly steps 1. Bolt 6. Bolt 2. Select lever 7. Cap 3. Bushing 8. Shift lever 4. Return spring 9. Shift lever bushing 5.

• Page 124: Transmission Assembly

  22A-7 MANUAL TRANSMISSION – Transmission Assembly TRANSMISSION ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Transmission Oil Draining (Refer to P.22A-3.) (1) Air Cleaner Assembly Installation (2) Transfer Oil Draining (Refer to P.22A-3.) (2) Battery and Battery Tray Installation (3) Under Cover Removal (3) Front Exhaust Pipe Installation (4) Front Exhaust Pipe Removal (Refer to GROUP 15.)

• Page 125
  22A-8 MANUAL TRANSMISSION – Transmission Assembly 48 {4.9} 26 – 33 {2.7 – 3.4} 59 – 71 {6.0 – 7.2} 39 {4.0} 52 {5.3}* 52 {5.3}* 15 – 33 {1.5 – 3.4} 69 {7.0} 69 {7.0} Unit: Nm {kgf@m} Lifting up of the vehicle AC»…
• Page 126
  22A-9 MANUAL TRANSMISSION – Transmission Assembly REMOVAL SERVICE POINTS AA» CLUTCH RELEASE BEARING SEPARATION (1) Remove the cover from the service hole in the clutch Release fork housing. (2) While pushing the release fork by hand in the direction A, insert a flap-tip screwdriver between the release bearing and the wedge collar.

• Page 127: Transfer Assembly

  Front Exhaust Pipe Removal and Installation (Refer to P.22A-3.) (Refer to GROUP 15.) Transfer Oil Draining and Supplying (Refer to P.22A-3.) 69 {7.0} Gear oil: MITSUBISHI genuine “Dia-Queen Super” hypoid gear oil (GL-5) Unit: Nm {kgf@m} Removal steps D Drive shaft (Refer to P.22A-9.) D Output shaft (Refer to P.22A-9.)

• Page 128
  22B-1 MANUAL TRANSMISSION OVERHAUL CONTENTS GENERAL INFORMATION ….OUTPUT SHAFT ….. . . SPECIFICATIONS .

• Page 129: General Information

  22B-2 MANUAL TRANSMISSION OVERHAUL – General Information GENERAL INFORMATION SECTIONAL VIEW – Without Front Limited Slip Differential (Front LSD)

• Page 130
  22B-3 MANUAL TRANSMISSION OVERHAUL – General Information SECTIONAL VIEW – With Front Limited Slip Differential (Front LSD)

• Page 131: Specifications

  Specifications / 22B-4 MANUAL TRANSMISSION OVERHAUL – Service Specifications SPECIFICATIONS TRANSMISSION MODEL TABLE 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…

• Page 132: Sealants And Adhesives

  22B-5 MANUAL TRANSMISSION OVERHAUL – Sealants and Adhesives SEALANTS AND ADHESIVES TRANSMISSION Items Specified sealants and adhesives Clutch housing-transmission case mating surface THREEBOND 1216 Control housing-transmission case mating surface Under cover-transmission case mating surface Air breather THREEBOND 1501 Center differential drive gear bolt THREEBOND 1303 or LOKTITE 648 TRANSFER Items…

• Page 133: Lubricants

  MANUAL TRANSMISSION Lubricants / Snap Rings, Spacers – 22B-6 OVERHAUL and Thrust Plates for Adjustment LUBRICANTS TRANSMISSION Items Specified lubricants Drive shaft oil seal lip area DIA QUEEN MULTI-GEAR OIL 75W/85W (Transmission oil) (Transmission oil) Input shaft oil seal lip area Control shaft oil seal lip area Select lever shoe MOLYWHITE TA No.1 or No.2…

• Page 134
  MANUAL TRANSMISSION Snap Rings, Spacers and Thrust Plates 22B-7 – OVERHAUL for Adjustment Part name Thickness mm Identification symbol Part No. Thrust plate 3.82 MD748465 (For adj stment of inp t shaft 5th speed gear (For adjustment of input shaft 5th speed gear 3.86 MD748466 clearance)
• Page 135
  MANUAL TRANSMISSION Snap Rings, Spacers and Thrust Plates – 22B-8 OVERHAUL for Adjustment Part name Thickness mm Identification symbol Part No. Snap ring 1.36 Yellow MD748449 (For adj stment of o tp t shaft bearing clear (For adjustment of output shaft bearing clear- 1.40 Green MD748450…

• Page 136: Torque Specifications

  MANUAL TRANSMISSION Snap Rings, Spacers and Thrust Plates – 22B-9 OVERHAUL for Adjustment / Torque Specifications Part name Thickness mm Identification symbol Part No. Spacer 1.19 MD710456 (For adj stment of center differential case (For adjustment of center differential case 1.22 MD700271 preload)

• Page 137: Special Tools

  Torque Specifications / 22B-10 MANUAL TRANSMISSION OVERHAUL – Special tools TRANSFER Items Nm {kgf@m} Transfer cover mounting bolt 23 {2.4} Transmission-transfer mounting bolt 69 {7.0} SPECIAL TOOLS Tool Number Name MB990887 Arm bushing Installation of transfer oil seal remover & installer ring MB990891 Bushing remover &…

• Page 138
  22B-11 MANUAL TRANSMISSION OVERHAUL – Special Tools Tool Number Name MB990938 Handle Use with Installer adapter MB991445 Bushing remover Installation of differential case taper roller and installer base bearing outer race MD998304 Oil seal installer Installation of transfer extension housing oil seal MD998364 Camshaft oil seal…
• Page 139
  22B-12 MANUAL TRANSMISSION OVERHAUL – Special Tools Tool Number Name MD998818 Installer adapter Installation of input shaft front bearing (38) MD998819 Installer adapter Installation of input shaft rear bearing and (40) output shaft taper roller bearing MD998820 Installer adapter Installation of reverse gear bearing sleeve (42) MD998821 Installer…

• Page 140: Transmission

  22B-13 MANUAL TRANSMISSION OVERHAUL – Transmission TRANSMISSION DISASSEMBLY AND REASSEMBLY 18 {1.9} 18 {1.9} 32 {3.3} 32 {3.3} 69 {7.0} 3.9 {0.4} 69 {7.0} 69 {7.0} Unit: Nm {kgf@m} Disassembly steps «HA 7. Speedometer gear 1. Transfer «JA 2. O-ring 8.

• Page 141
  22B-14 MANUAL TRANSMISSION OVERHAUL – Transmission Apply gear oil to all moving parts before installation. 18 {1.9} 30 {3.1} 44 {4.5} 48 {4.9} 3.9 {0.7} Unit: Nm {kgf@m} Disassembly steps «EA 20. Transmission case 12. Interlock plate bolt 13. Gasket 21.
• Page 142
  22B-15 MANUAL TRANSMISSION OVERHAUL – Transmission Apply gear oil to all moving parts before installation. Disassembly steps «CA 28. Spring pin AB» «BA 35. 5th-reverse speed shift rail AB» «BA 36. 5th-reverse speed shift fork 29. 1st-2nd speed shift rail AC»…
• Page 143
  22B-16 MANUAL TRANSMISSION OVERHAUL – Transmission DISASSEMBLY SERVICE POINTS 5th-reverse shift fork AA» SPRING PIN REMOVAL Shift the 5th-reverse shift fork in the direction shown in the illustration. AB» 3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEED 3rd-4th SHIFT FORK / 5TH-REVERSE SPEED SHIFT speed RAIL / 5TH-REVERSE SPEED SHIFT FORK shift rail…
• Page 144
  22B-17 MANUAL TRANSMISSION OVERHAUL – Transmission (3) Place two pieces of solder (1.6 mm in diameter and approx. 10 mm in length) on the transmission case at the positions Solders shown in the illustration. (4) Install the bearing outer race. (5) Install the transmission case and tighten the bolts to the specified torque.
• Page 145
  22B-18 MANUAL TRANSMISSION OVERHAUL – Transmission (2) Slide the shift rails into the shift rail holes in the clutch housing. 3rd-4th speed shift rail 5th-reverse speed shift rail «CA SPRING PIN INSTALLATION Shift rail Install the spring pin with its slit directed as shown in the illustration.
• Page 146
  22B-19 MANUAL TRANSMISSION OVERHAUL – Transmission «GA CONTROL HOUSING INSTALLATION Apply sealant to the illustrated position of the transmission case. Specified sealant: THREEBOND 1216 Caution f 2 mm Squeeze out the sealant uniformly, while making sure that it is not broken or excessively applied. «HA SPEEDOMETER GEAR INSTALLATION Apply transmission oil to the O-ring of the speedometer gear.

• Page 147: Input Shaft

  22B-20 MANUAL TRANSMISSION OVERHAUL – Input Shaft INPUT SHAFT DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation. Disassembly steps «MA 1. Snap ring «EA 12. 3rd-4th speed synchronizer hub AA» «LA 2. Ball bearing 13. Outer synchronizer ring AB»…

• Page 148
  22B-21 MANUAL TRANSMISSION OVERHAUL – Input Shaft DISASSEMBLY SERVICE POINTS MD998801 AA» BALL BEARING REMOVAL AB» THRUST PLATE STOPPER REMOVAL Using a screwdriver, pry up the position shown in the illustration and remove the thrust plate stopper. AC» 5TH SPEED GEAR REMOVAL MD998801 AD»…
• Page 149
  22B-22 MANUAL TRANSMISSION OVERHAUL – Input Shaft REASSEMBLY SERVICE POINTS «AA OIL SEAL INSTALLATION Oil seal 3.5 mm Make sure that the oil seal is pressed into the position shown in the illustration. «BA BALL BEARING INSTALLATION MD998812 MD998813 MD998801 MD998818 «CA SNAP RING INSTALLATION Select and install a snap ring so that the input shaft front…
• Page 150
  22B-23 MANUAL TRANSMISSION OVERHAUL – Input Shaft Caution MD998812 When the hub is installed, make sure that the synchronizer ring is not caught. MD998813 MD998801 MD998825 «FA SYNCHRONIZER SLEEVE INSTALLATION Identification groove (1) Install the synchronizer sleeve in such a way that it will be oriented in the direction shown.
• Page 151
  22B-24 MANUAL TRANSMISSION OVERHAUL – Input Shaft «IA 5TH SPEED GEAR INSTALLATION MD998812 MD998813 MD998825 MD998801 «JA THRUST PLATE INSTALLATION Select and install a thrust plate so that the input shaft 5th Stamped speed gear clearance will have the standard value. surface Standard value: 0 –…
• Page 152
  22B-25 MANUAL TRANSMISSION OVERHAUL – Input Shaft INSPECTION INPUT SHAFT (1) Check the outside diameter of the needle bearing mounting portion for damage, abnormal wear and seizure. (2) Check the splines for damage and wear. NEEDLE ROLLER BEARING (1) Check to ensure that when the input shaft and gear are combined and made to rotate, they rotate smoothly without looseness and noise.
• Page 153
  22B-26 MANUAL TRANSMISSION OVERHAUL – Input Shaft (2) Install the outer ring, inner ring and cone, press them against the gear, and check clearance “A”. If “A” is less Outer ring than the limit, replace. Cone Limit: 0.5 mm Caution When any of the outer ring, inner ring or cone has to be replaced, replace them as a set.

• Page 154: Output Shaft

  22B-27 MANUAL TRANSMISSION OVERHAUL – Output Shaft OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation. Disassembly steps «PA 1. Snap ring 19. Needle roller bearing AA» «OA 2. Taper roller bearing AE» «GA 20. 2nd speed gear sleeve AB»…

• Page 155
  22B-28 MANUAL TRANSMISSION OVERHAUL – Output Shaft DISASSEMBLY SERVICE POINTS MD998801 Taper roller bearing AA» TAPER ROLLER BEARING REMOVAL AB» REVERSE GEAR BEARING SLEEVE REMOVAL Reverse gear MD998801 bearing sleeve Mount a special tool on the reverse gear and remove the reverse gear bearing sleeve.
• Page 156
  22B-29 MANUAL TRANSMISSION OVERHAUL – Output Shaft AF» 1ST SPEED GEAR SLEEVE REMOVAL MD998801 1st speed gear sleeve AG» TAPER ROLLER BEARING REMOVAL Taper roller bearing MD998801 REASSEMBLY SERVICE POINTS «AA OIL SEAL INSTALLATION 3.5 mm Oil seal Make sure that the oil seal is pressed into the position shown in the illustration.
• Page 157
  22B-30 MANUAL TRANSMISSION OVERHAUL – Output Shaft «DA SYNCHRONIZER SPRING INSTALLATION Synchronizer spring «EA 1ST-2ND SPEED SYNCHRONIZER HUB INSTALLATION Install the 1st-2nd speed synchronizer hub in such a way that it will be oriented in the direction shown. Installation direction Caution MD998812 When the hub is installed, make sure that the synchronizer…
• Page 158
  22B-31 MANUAL TRANSMISSION OVERHAUL – Output Shaft «GA 2ND SPEED GEAR SLEEVE INSTALLATION MD998812 MD998814 2nd speed gear sleeve MD998824 MD998364 «HA 3RD SPEED GEAR INSTALLATION MD998812 MD998814 3rd speed gear MD998824 MD998364 «IA SNAP RING INSTALLATION Select and install a snap ring so that the output shaft 3rd speed gear clearance will have the standard value.
• Page 159
  22B-32 MANUAL TRANSMISSION OVERHAUL – Output Shaft «LA SYNCHRONIZER SPRING INSTALLATION Synchronizer spring «MA5TH-REVERSE SPEED SYNCHRONIZER HUB INSTALLATION Install the 5th-reverse speed synchronizer hub in such a way that it will be oriented in the direction shown. Installation direction Caution MD998812 When the hub is installed, make sure that the synchronizer 5th-reverse speed…
• Page 160
  22B-33 MANUAL TRANSMISSION OVERHAUL – Output Shaft «PA SNAP RING INSTALLATION Snap ring Select and install a snap ring so that the output shaft rear bearing clearance will have the standard value. Standard value: 0 – 0.09 mm INSPECTION OUTPUT SHAFT Check the splines for damage and wear.
• Page 161
  22B-34 MANUAL TRANSMISSION OVERHAUL – Output Shaft OUTER SYNCHRONIZER RING / INNER SYNCHRONIZER RING / SYNCHRONIZER CONE Damage, Break Damage, Break (1) Check to ensure that the clutch gear tooth surfaces and cone surfaces are not damaged and broken. Damage, Break (2) Install the outer ring, inner ring and cone, press them Gear…

• Page 162: Reverse Idler Gear

  22B-35 MANUAL TRANSMISSION OVERHAUL – Reverse Idler Gear REVERSE IDLER GEAR DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation. TFM0807 Disassembly steps 1. Snap ring 2. Thrust washer 3. Reverse idler gear 4. Needle roller bearing 5.

• Page 163: Speedometer Gear

  22B-36 MANUAL TRANSMISSION OVERHAUL – Speedometer Gear SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation. TFM0593 Disassembly steps 1. e-clip 2. Speedometer driven gear 3. O-ring 4. Sleeve…

• Page 164: Select Lever

  22B-37 MANUAL TRANSMISSION OVERHAUL – Select Lever SELECT LEVER DISASSEMBLY AND REASSEMBLY 11 {1.2} Unit: Nm {kgf@m} Disassembly steps «AA 1. Dust cover 6. Select lever shoe 2. Nut 7. Select lever 3. Spring washer 8. Select lever bushing «AA 9. Dust cover 4.

• Page 165: Control Housing

  22B-38 MANUAL TRANSMISSION OVERHAUL – Control Housing CONTROL HOUSING DISASSEMBLY AND REASSEMBLY 18 {1.9} Unit: Nm {kgf@m} Disassembly steps AA» «FA 1. Lock pin 11. Spacer 2. Interlock plate 12. Control shaft «CA 13. Air breather 3. Control finger 4. Pin 14.

• Page 166
  22B-39 MANUAL TRANSMISSION OVERHAUL – Control Housing DISASSEMBLY SERVICE POINT AA» LOCK PIN REMOVAL Lock pin Drive the lock pin out of position from the direction shown. Control finger REASSEMBLY SERVICE POINTS Control housing «AA NEEDLE BEARING INSTALLATION Press fit the needle bearing to the position shown in the illustration, while making sure that the model number stamped Model Needle…
• Page 167
  22B-40 MANUAL TRANSMISSION OVERHAUL – Control Housing «DA SPRING PIN INSTALLATION Control shaft Stopper body Installation direction Slit Spring pin «EA SPRING PIN INSTALLATION Spring pin «FA LOCK PIN INSTALLATION Drive in the lock pin in the direction shown in the illustration. Lock pin Control finger…

• Page 168: Clutch Housing

  22B-41 MANUAL TRANSMISSION OVERHAUL – Clutch Housing CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY 9.8 {1.0} Unit: Nm {kgf@m} 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»…

• Page 169
  22B-42 MANUAL TRANSMISSION OVERHAUL – Clutch Housing DISASSEMBLY SERVICE POINTS MD999566 AA» OUTER RACE REMOVAL Outer race AB» OUTER RACE REMOVAL MD999566 REASSEMBLY SERVICE POINTS Cover-B «AA COVER-A / COVER-B INSTALLATION Install the covers directed as shown in the illustration Cover-A «BA BUSHING INSTALLATION Press fit the bushing to the illustrated position, while making…
• Page 170
  22B-43 MANUAL TRANSMISSION OVERHAUL – Clutch Housing «CA OUTER RACE INSTALLATION MB990938 MB990935 «DA OUTER RACE INSTALLATION MB990938 MB991445 «EA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area. Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W MB990938 MB990928…

• Page 171: Transmission Case

  22B-44 MANUAL TRANSMISSION OVERHAUL – Transmission Case TRANSMISSION CASE DISASSEMBLY AND REASSEMBLY Disassembly steps «CA 1. Oil seal «BA 2. Needle bearing* «AA 3. Bushing* 4. Transmission case NOTE: Never remove the bearing and bushing from the transmission case. Only the case when installing new bearing and bushing into a new transmission case, refer to «AA and «BA.

• Page 172
  22B-45 MANUAL TRANSMISSION OVERHAUL – Transmission Case REASSEMBLY SERVICE POINTS Air purge groove «AA BUSHING INSTALLATION Press fit the bushing to the illustrated position, while making sure that the split ends of the bushing do not coincide with the air purge groove. Bushing Bushing 3 mm…

• Page 173: Center Differential

  22B-46 MANUAL TRANSMISSION OVERHAUL – Center Differential CENTER DIFFERENTIAL DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation. 132 {13.5} Unit: Nm {kgf@m} Disassembly steps «CA 10. Pinion shaft holder «DA 1. Center differential drive gear «CA 11. Pinion «CA 2.

• Page 174
  22B-47 MANUAL TRANSMISSION OVERHAUL – Center Differential AB» TAPER ROLLER BEARING REMOVAL MD998917 Use the special tools to remove the taper roller bearing. MB990932 REASSEMBLY SERVICE POINTS MB990937 «AA TAPER ROLLER BEARING INSTALLATION Use the special tool to install the taper roller bearing. «BA TAPER ROLLER BEARING INSTALLATION Use the special tools to install the taper roller bearing.
• Page 175
  22B-48 MANUAL TRANSMISSION OVERHAUL – Center Differential (5) Install the front output shaft to the side gear and fit the snap ring. (6) Attach the spacer on the other side gear, then install the side gear in the center differential case. NOTE If a new side gear is to be installed, select a spacer with medium thickness (0.8 –…

• Page 176: Transfer

  22B-49 MANUAL TRANSMISSION OVERHAUL – Transfer TRANSFER DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation. 23 {2.4} Unit: Nm {kgf@m} Disassembly steps «FA 1. Air breather 2. Dust seal guard «EA 3. Oil seal «DA 4. Oil seal «AA 5.

• Page 177
  22B-50 MANUAL TRANSMISSION OVERHAUL – Transfer REASSEMBLY SERVICE POINTS «AA O-RING INSTALLATION Apply transmission oil to the O-ring. Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W «BA OIL SEAL INSTALLATION MD998800 (1) Apply transmission oil to the oil seal lip area. Transmission oil: DIA QUEEN MULTI-GEAR OIL 75W/85W (2) By using the special tool, install the oil seal.
• Page 178
  22B-51 MANUAL TRANSMISSION OVERHAUL – Transfer «FA AIR BREATHER INSTALLATION Apply sealant to the air breather. Specified sealant: THREEBOND 1501…

• Page 179: Front Axle

  26-1 FRONT AXLE CONTENTS SERVICE SPECIFICATIONS ….AXLE HUB AND KNUCKLE ….SPECIAL TOOLS .

• Page 180
  26-2 FRONT AXLE – Service Specifications / Special Tools SERVICE SPECIFICATIONS Items Limit Hub axial play mm 0.05 Hub rotation starting torque Nm {kgf@m} 1.8 {1.8} SPECIAL TOOLS Tool Number Name MB990635 Steering linkage Ball joint disconnection MB991113 puller MB990767 End holder Fixing of hub MB991354…
• Page 181
  26-3 FRONT AXLE – Axle Hub and Knuckle AXLE HUB AND KNUCKLE REMOVAL AND INSTALLATION Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger. 25 {2.6} 108 – 127 88 {9.0} {11.0 – 13.0} 25 {2.6} 9 {0.9} 90 –…
• Page 182
  26-4 FRONT AXLE – Axle Hub and Knuckle REMOVAL SERVICE POINTS AA» CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, so that it does not fall. AB» DRIVE SHAFT NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut.
• Page 183
  26-5 FRONT AXLE – Axle Hub and Knuckle INSPECTION MB991000 MB991017 1. HUB ROTATION STARTING TORQUE CHECK (MB990998) MB990326 (1) Install the special tool to the front hub assembly and tighten the nut to the specified torque. (2) Use the special tool to measure the hub rotation starting torque.

• Page 184: Rear Axle

  27-1 REAR AXLE CONTENTS SERVICE SPECIFICATIONS ….REAR HUB ASSEMBLY ….LUBRICANT .

• Page 185: Service Specifications

  Differential MITSUBISHI GENUINE DIA QUEEN SUPER {0.41 ± 0.02 } transfer HYPOID GEAR OIL (GL-5) differential differential Torque transfer MITSUBISHI GENUINE DIA QUEEN AYC FLUID 0.70 *0.05 mechanism {0.70 *0.05 Hydraulic piping fluid MITSUBISHI GENUINE DIA QUEEN ATF-SPII 1 dm…

• Page 186: Special Tools

  27-3 REAR AXLE – Special Tools SPECIAL TOOLS Tool Number Name MB991529 Diagnosis code Inspection of AYC (diagnosis display by AYC check harness warning lamp) MD998330 Oil pressure Hydraulic pressure measurement <vehicles (MD998331) gauge with AYC> (2,942 kPa {30 kgf/cm MB991705 Hose adapter MB990925…

• Page 187
  27-4 REAR AXLE – Special Tools Tool Number Name MB990241 Rear axle shaft Removal of drive shaft puller Removal of rear hub assembly A: MB990242 A: Puller shaft B: MB990244 B: Puller bar MB991354 Puller body A: MB991017 A, B: Front hub Temporary fixing of unit bearing remover &…

• Page 188: Troubleshooting

  27-5 REAR AXLE – Special Tools / Troubleshooting <AYC> Number Name O.D. mm MB990988 MB990551 – MB990989 Base – (MB990990) Tool A (MB990991) Tool B (MB990992) Tool C MB990925 Brass bar Toolbox Bar (one-touch type) Installer adapter Tool number (MB990925) O.D.

• Page 189
  27-6 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) 27-7 FR wheel speed sensor system (open- or short-circuit) 27-7 FL wheel speed sensor system (open- or short-circuit) 27-7 RR wheel speed sensor system (open- or short-circuit) 27-7…
• Page 190
  27-7 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 191
  27-8 REAR AXLE – Troubleshooting <AYC> <Vehicles without ABS> Check the installation of speed sensor. Repair Measure at B-95 AYC-ECU connector. Check the speed sensor. Replace D Disconnect the connector and measure at the harness side. D Resistance across 7-20 (front, LH), Check the following connectors: Repair 6-19 (front, RH), 9-22 (rear, LH),…
• Page 192
  27-9 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 193
  27-10 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 194
  27-11 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 195
  27-12 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 196
  27-13 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 197
  27-14 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 198
  27-15 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 199
  27-16 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 200
  27-17 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 201
  27-18 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 202
  27-19 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 203
  27-20 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 204
  27-21 REAR AXLE – Troubleshooting <AYC> 5. INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Ref. page procedure No. AYC warning lamp does not light up when the ignition key is turned to “ON” (engine 27-21 stationary). AYC warning lamp remains lit up after the engine has started. 27-22 AYC is inoperative.
• Page 205
  27-22 REAR AXLE – Troubleshooting <AYC> INSPECTION PROCEDURE 2 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 AYC-ECU power supply is in normal condition and the diagnosis code is correct.
• Page 206
  27-23 REAR AXLE – Troubleshooting <AYC> INSPECTION PROCEDURE 4 Rear tires are noisy during low-speed cornering. Probable cause 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. Correct Check the AYC for operation.
• Page 207
  27-24 REAR AXLE – Troubleshooting <AYC> 7. CHECK AT AYC-ECU TERMINALS 7-1 TERMINAL VOLTAGE LISTING (1) The voltage is to be measured across each terminal and ground terminal. (2) Fig. below shows the arrangement of the terminals. Terminal Check item Check requirement Normally Lateral acceleration sensor…
• Page 208
  27-25 REAR AXLE – Troubleshooting <AYC> Terminal Check item Check requirement Normally Ignition switch: Accelerator pedal: Fully closed 0.3 – 1.0 V Accelerator pedal: Fully open 4.5 – 5.0 V Diagnosis data input/output 1 V or less Idle position switch Ignition switch: Accelerator pedal: Fully closed 2 V or less…
• Page 209
  27-26 REAR AXLE – Troubleshooting <AYC> 7-2 LISTING OF RESISTANCE AND CONTINUITY ACROSS CONNECTOR TERMINALS ON HARNESS SIDE (1) Measure the resistance and check for continuity with the ignition switch in the “OFF” position and AYC-ECU connector disconnected. (2) Measure the resistance and check for continuity across terminals listed below. (3) Fig.

• Page 210: On-Vehicle Service

  Standard value (A): 6 mm (3) If the gear oil level exceeds the standard value, add the specified gear oil up to the bottom end of the filler plug hole. Specified gear oil: MITSUBISHI GENUINE QUEEN SUPER HYPOID GEAR OIL (GL-5)

• Page 211: 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 212: Fluid Level Check

  (2) Fit the drain plug and tighten it to the specified torque. (3) Remove the filler plug and add the specified gear oil up to the bottom end of the filler plug hole. Specified gear oil: MITSUBISHI GENUINE DIA QUEEN SUPER AYC FLUID Drain plug Quantity used: 0.70 {0.70…

• Page 213: Differential Carrier Oil Seal Replacement

  27-30 REAR AXLE – On-vehicle Service <Vehicles with AYC> (7) After the system has been completely bled of air, check for the fluid level. Caution If the system is not completely bled of air, the hydraulic unit could generate noise, degrading pump durability. 6.

• Page 214: Speed Sensor Output Voltage Measurement

  27-31 REAR AXLE – On-vehicle Service <Vehicles with AYC> 7. 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 215: Action When Battery Runs Out

  27-32 REAR AXLE – On-vehicle Service <Vehicles with AYC> Waveform Observation Points Symptom Probable cause Action Waveform amplitude is too small, or no Defective speed sensor Replace sensor. waveform. Waveform amplitude varies greatly. (No Excessive axle hub lateral and radial runout Replace hub.

• Page 216: Rear Hub Assembly

  27-33 REAR AXLE – Rear Hub Assembly REAR HUB ASSEMBLY REMOVAL AND INSTALLATION 196 – 255 49 – 59 {20.0 – 26.0} {5.0 – 6.0} 118 {12.0} 74 – 88 {7.5 – 9.0} Unit: Nm {kgf@m} Removal steps AA» AB» «AA 6. Drive shaft nut 1.

• Page 217
  27-34 REAR AXLE – Rear Hub Assembly INSTALLATION SERVICE POINT Washer «AA DRIVE SHAFT NUT INSTALLATION (1) Install the washer on the drive shaft in the direction shown on the left. (2) Using the special tool, tighten the drive shaft nut to the specified torque.

• Page 218: Knuckle

  27-35 REAR AXLE – Knuckle KNUCKLE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Rear Hub Assembly and Backing Plate Removal (1) Check Each Ball Joint Dust Cover for Cracks or (Refer to P.27-33.) Damage by Pushing It with Finger. (2) Rear Hub Assembly and Backing Plate Installation (Refer to P.27-33.) 74 –…

• Page 219: Drive Shaft

  27-36 REAR AXLE – Drive Shaft DRIVE SHAFT REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Gear Oil Draining (Refer to P.27-28.) (1) Checking Each Ball Joint Dust Cover for Cracks (2) Center Exhaust Pipe Removal and Damages by Pressing Dust Cover with Finger (Refer to GROUP 15.) (2) Center Exhaust Pipe Installation (Refer to GROUP 15.)

• Page 220
  27-37 REAR AXLE – Drive Shaft REMOVAL SERVICE POINTS AA» DRIVE SHAFT NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing with the drive shaft nut loosened. MB990767 AB» DRIVE SHAFT REMOVAL MB990767 (1) Using the special tool, drive the drive shaft out of the hub.
• Page 221
  27-38 REAR AXLE – Drive Shaft INSTALLATION SERVICE POINTS «AA DRIVE SHAFT INSTALLATION Caution Use care not to allow the drive shaft splines to damage the oil seal of the differential carrier. «BA DRIVE SHAFT NUT INSTALLATION Washer (1) Install the washer on the drive shaft in the direction shown on the left.

• Page 222: Differential Carrier

  27-39 REAR AXLE – Differential Carrier <EVOLUTION-IV, EVOLUTION-V GSR> DIFFERENTIAL CARRIER <EVOLUTION-IV, EVOLUTION-V GSR> REMOVAL AND INSTALLATION <Vehicles with AYC> Pre-removal Operation Post-installation Operation (1) Hydraulic Piping Fluid Draining (1) Drive Shaft Installation (Refer to P.27-36.) (2) Gear Oil Draining (Refer to P.27-28.) (2) Rear Stabilizer Installation (Refer to GROUP 34.) (3) Lower Arm Assembly Removal (3) Lower Arm Assembly Installation…

• Page 223
  27-40 REAR AXLE – Differential Carrier <EVOLUTION-IV, EVOLUTION-V GSR> REMOVAL SERVICE POINT AA» REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY REMOVAL (1) Using a jack, support the differential carrier from its underside. (2) Remove the rear crossmember mounting bolts and remove the differential carrier, where it is attached to the rear crossmember, from the vehicle.

• Page 224: Evolution-V Rs

  27-41 REAR AXLE – Differential Carrier <EVOLUTION-V RS> DIFFERENTIAL CARRIER <EVOLUTION-V RS> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Differential Gear Oil Draining (1) Drive Shaft Installation (2) Lower Arm Assembly Removal (2) Rear Stabilizer Installation (3) Rear Stabilizer Removal (3) Lower Arm Assembly Installation (4) Drive Shaft Removal (4) Differential Gear Oil Filling…

• Page 225
  27-42 REAR AXLE – Differential Carrier <EVOLUTION-V RS> REMOVAL SERVICE POINTS AA» PROPELLER SHAFT DISCONNECTION Make an alignment mark on the companion flange and flange yoke, then disconnect the propeller shaft from the companion flange. Caution Suspend the propeller shaft from the body with a wire to prevent the bend at the joint from catching and damaging the joint boot.

• Page 226: Torque Transfer Differential

  27-43 REAR AXLE – Torque Transfer Differential <Vehicles with AYC> TORQUE TRANSFER DIFFERENTIAL <VEHICLES WITH AYC> DISASSEMBLY AND REASSEMBLY 49 {5.0} 9 {0.9} 186 {19.0} 49 {5.0} 9 {0.9} 49 {5.0} Unit: Nm {kgf@m} Disassembly steps 1. Drain plug 11. Oil seal «BA 12.

• Page 227
  27-44 REAR AXLE – Torque Transfer Differential <Vehicles with AYC> GREASE AND SEALANT APPLICATION POINTS Semi-drying sealant: THREEBOND 1281B Grease: Vaseline φ3.0 mm Semi-drying sealant: THREEBOND 1281B…
• Page 228
  27-45 REAR AXLE – Torque Transfer Differential <Vehicles with AYC> DISASSEMBLY SERVICE POINT AA» SELF-LOCKING NUT REMOVAL MB990850 ASSEMBLY SERVICE POINTS MD998829 «AA OIL SEAL INSTALLATION (1) Using the special tool, pressfit the oil seal as far as it will go. (2) Apply the specified grease to the oil seal lip.

• Page 229: Lsd Case Assembly

  27-46 REAR AXLE – LSD Case Assembly <Vehicles without AYC> LSD CASE ASSEMBLY <VEHICLES WITHOUT AYC> DISASSEMBLY AND REASSEMBLY Differential gear set 11 12 Disassembly steps «CA D LSD differential torque check 11. Pinion gear AA» «BA 1. Screw 12. Pinion shaft 2.

• Page 230
  27-47 REAR AXLE – LSD Case Assembly <Vehicles without AYC> ASSEMBLY SERVICE POINTS «AA INSTALLATION TO DIFFERENTIAL CASE B Before starting the assembly procedure, perform the following steps to adjust dimensional differences (clutch plate friction force) in the axial direction of the components inside the differential case and axial clearance of the differential side gear.
• Page 231
  27-48 REAR AXLE – LSD Case Assembly <Vehicles without AYC> «BA SCREW TIGHTENING (1) Align the alignment mark on differential case A with that on differential case B. (2) Tighten the screws connecting differential case A and B a uniform amount little by little in the diagonal order. NOTE If tightening the screws does not bring the two cases properly together, spring plates are not probably…
• Page 232
  27-49 REAR AXLE – LSD Case Assembly <Vehicles without AYC> Grind a dented or scratched part with oil stone and then lap and correct with a compound on a surface plate. NOTE If the inner periphery of the friction face shows traces of harsh contact, it is because of the spring tension of each plate, disc and other part.

• Page 233: Hydraulic Unit

  27-50 REAR AXLE – Hydraulic Unit <Vehicles with AYC> HYDRAULIC UNIT <VEHICLES WITH AYC> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Trunk Side Trim Removal (1) Hydraulic Piping Fluid Filling and Bleeding (2) Hydraulic Piping Fluid Draining (Refer to P.27-29.) (2) Trunk Side Trim Installation 12 {1.2} 18 {1.8}…

• Page 234
  27-51 REAR AXLE – Hydraulic Unit <Vehicles with AYC> INSTALLATION SERVICE POINTS «AA GROMMET INSTALLATION Grommet On the vehicle mounted with a sun roof, mount the drain pipe to the grommet as illustrated. Drain pipe 25 ± 5 mm «BA SUCTION HOSE / RETURN HOSE INSTALLATION Fit the suction hose and return hose to the nipple of hydraulic unit as illustrated.

• Page 235: Sensor Relay

  27-52 REAR AXLE – Sensor Relay <Vehicles with AYC> SENSOR RELAY <VEHICLES WITH AYC> REMOVAL AND INSTALLATION Steer sensor removal steps Acceleration sensor and AYC relay removal D Steering wheel and column cover (Refer to GROUP 37 – Steering Wheel 2.

• Page 236: Ayc-Ecu

  27-53 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: Power Plant Mount

  32-1 POWER PLANT MOUNT CONTENTS ROLL STOPPER AND CENTERMEMBER ….. .

• Page 238
  32-2 POWER PLANT MOUNT – Roll Stopper and Centermember ROLL STOPPER AND CENTERMEMBER REMOVAL AND INSTALLATION Caution When tightening the portion marked with *, first temporarily tighten it, then torque to specification with the engine weight applied to the body. 34 {3.5} 34 {3.5} 52 {5.3}*…

• Page 239: Front Suspension

  33A-1 FRONT SUSPENSION CONTENTS SERVICE SPECIFICATIONS ….STRUT ASSEMBLY ….. . SPECIAL TOOLS .

• Page 240: Service Specifications

  33A-2 FRONT SUSPENSION – Service Specifications / Special Tools SERVICE SPECIFICATIONS <EVOLUTION-IV> Items Standard value –3 X 3 Toe-in mm –1_00’ ± 30’ Camber (difference between right and left wheel: less than 30’) 3_50’ ± 30’ Caster (difference between right and left wheel: less than 30’) Kingpin inclination 13_25’…

• Page 241: On-Vehicle Service

  33A-3 FRONT SUSPENSION – On-vehicle Service ON-VEHICLE SERVICE <Camber: –1_00’> <Camber: –2_00’> Bolt coupling strut WHEEL ALIGNMENT CHECK AND assembly to knuckle ADJUSTMENT <EVOLUTION-V> Use the conventional procedures to measure wheel alignment. 1. CAMBER Standard value: –1_00’ ± 30’ (difference between right and left wheel: less than 30’) or –2_00’…

• Page 242: Strut Assembly

  33A-4 FRONT SUSPENSION – Strut Assembly STRUT ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Front Wheel Alignment Adjustment (Refer to P.33A-3.) 44 {4.5} 108 – 127 {11.0 – 13.0} Unit: Nm {kgf@m} Removal steps 1. Brake hose clamp 4. Strut tower bar 2.

• Page 243: Lower Arm

  33A-5 FRONT SUSPENSION – Lower Arm <EVOLUTION-IV> LOWER ARM <EVOLUTION-IV> REMOVAL AND INSTALLATION Post-installation Operation (1) Push the Dust Cover of the Lower Arm and Stabilizer Link Ball Joint with a Finger to Check for Possible Cracks or Damage. (2) Wheel Alignment Check and Adjustment 113 {11.5} Molybdenum disulfide-base chassis grease:…

• Page 244
  33A-6 FRONT SUSPENSION – Lower Arm <EVOLUTION-IV> INSTALLATION SERVICE POINT Bushing assembly «AA BUSHING ASSEMBLY INSTALLATION Install the bushing assembly to the lower arm assembly with a relative angle as shown and tighten the self-locking nut to the specified torque. Tightening torque: 137 Nm {14.0 kgf@m} Lower arm assembly INSPECTION…

• Page 245: Lower Arm

  33A-7 FRONT SUSPENSION – Lower Arm <EVOLUTION-V> LOWER ARM <EVOLUTION-V> REMOVAL AND INSTALLATION Caution Post-installation Operation To prevent bushing from being galled, the part (1) Push the Dust Cover of the Lower Arm and Stabilizer marked with * should be first temporarily tightened, Link Ball Joint with a Finger to Check for Possible then torqued to specification with the vehicle on Cracks or Damage.

• Page 246
  33A-8 FRONT SUSPENSION – Lower Arm <EVOLUTION-V> INSTALLATION SERVICE POINTS Knuckle «AA BUSHING ASSEMBLY INSTALLATION Follow the conventional procedure. Lower arm assembly «BA LOWER ARM TO KNUCKLE COUPLING BOLT INSTALLATION (1) Install the lower arm assembly to the knuckle. Caution To prevent the dust cover lip from being recessed and grease from flowing out, ensure that protrusion A of the ball joint stud from knuckle measures 4 mm…

• Page 247: Stabilizer Bar

  33A-9 FRONT SUSPENSION – Stabilizer Bar STABILIZER BAR REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Crossmember Removal (1) Crossmember Installation (2) Check the Stabilizer Link Ball Joint Dust Cover for Cracks or Damage by Pushing it with Finger. 22 {2.2} 39 {4.0} SHOWA SHELL SEKIYU VARIANT R-2 or equivalent…

• Page 248
  33A-10 FRONT SUSPENSION – Stabilizer Bar INSPECTION STABILIZER LINK BALL JOINT ROTATION STARTING TORQUE Follow the conventional procedures. STABILIZER LINK DUST COVER REPLACEMENT Replace the dust cover by using the conventional procedure only if it has been inadvertently damaged during servicing. After the dust cover has been replaced with a new one, push it with a finger to check for possible cracks or damage.

• Page 249: Rear Suspension

  34-1 REAR SUSPENSION CONTENTS SERVICE SPECIFICATIONS ….UPPER ARM ASSEMBLY ….LUBRICANT .

• Page 250: Service Specifications

  34-2 REAR SUSPENSION – Service Specifications / Lubricant / Special Tools SERVICE SPECIFICATIONS Items Standard value 3 ± 2 Toe-in mm –1_00 ± 30’ Camber 0_00 ± 9’ Rear thrust angle Upper arm ball joint turning torque Nm {kgf@cm} 0.5 – 2.5 {5 – 25} Trailing arm ball joint turning torque Nm {kgf@cm} 0.5 –…

• Page 251: On-Vehicle Service

  34-3 REAR SUSPENSION – On-vehicle Service ON-VEHICLE SERVICE 1. REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT (1) The rear suspension and wheels should be serviced to the normal condition prior to measurement of wheel alignment. (2) Measure the wheel alignment with the vehicle parked on level ground.

• Page 252: Rear Suspension Assembly

  34-4 REAR SUSPENSION – Rear Suspension Assembly REAR SUSPENSION ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation (1) Center Exhaust Pipe Removal (1) AYC Fluid Refilling and Bleeding (Refer to GROUP 15.) (Refer to GROUP 27 – On-vehicle Service.) (2) Trunk Room Side Trim Removal <GSR> (2) Center Exhaust Pipe Installation (3) AYC Fluid Draining (Refer to GROUP 15.)

• Page 253
  34-5 REAR SUSPENSION – Rear Suspension Assembly REMOVAL SERVICE POINTS AA» BRAKE CALIPER ASSEMBLY REMOVAL Remove the brake caliper assembly and secure it with a wire. AB» PROPELLER SHAFT DISCONNECTION (1) Make an alignment mark on the differential carrier companion flange and propeller shaft flange yoke. (2) Remove the mounting bolts and nuts of the differential carrier and propeller shaft.

• Page 254: Upper Arm Assembly

  34-6 REAR SUSPENSION – Upper Arm Assembly UPPER ARM ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation (1) Push the Dust Cover of the Upper Arm Ball Joint with a Finger to Check for Possible Cracks or Damage. (2) Wheel Alignment Check and Adjustment (Refer to P.34-3.) 59 –…

• Page 255
  34-7 REAR SUSPENSION – Upper Arm Assembly INSPECTION 1. UPPER ARM BALL JOINT TURNING TORQUE MB990326 CHECK (1) Rock the upper arm ball joint stud several times; then, mount a nut to the stud and, using the special tool, measure the turning torque of the upper arm ball joint. Standard value: 0.5 –…

• Page 256: Trailing Arm Assembly

  34-8 REAR SUSPENSION – Trailing Arm Assembly TRAILING ARM ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation (1) Push the Dust Cover of the Trailing Arm Ball Joint with a Finger to Check for Possible Cracks or Damage. (2) Wheel Alignment Check and Adjustment (Refer to P.34-3.) 74 –…

• Page 257
  34-9 REAR SUSPENSION – Trailing Arm Assembly INSPECTION 1. TRAILING ARM BALL JOINT TURNING TORQUE MB990326 CHECK (1) Rock the trailing arm ball joint stud several times; then, mount a nut to the stud and, using the special tool, measure the turning torque of the ball joint. Standard value: 0.5 –…

• Page 258: Lower Arm And Toe Control Arm Assemblies

  34-10 REAR SUSPENSION – REAR SUSPENSION – Lower Arm and Toe Control Arm Assemblies Lower Arm and Toe Control Arm Assemblies LOWER ARM AND TOE CONTROL ARM ASSEMBLIES REMOVAL AND INSTALLATION Post-installation Operation (1) Check the Toe Control Arm Ball Joint Dust Cover (2) Wheel Alignment Check and Adjustment for Cracks or Damage by Pushing it with Finger (Refer to P.34-3.)

• Page 259
  34-11 REAR SUSPENSION – Lower Arm and Toe Control Arm Assemblies AB» TOE CONTROL ARM AND KNUCKLE MB990635, DISCONNECTION MB991113 or MB991406 Caution (1) Use the special tool to loosen the nut only; do not Ball joint removal it from the ball joint. String (2) Tie the special tool with a cord not to let it fall off.
• Page 260
  34-12 REAR SUSPENSION – Lower Arm and Toe Control Arm Assemblies 2. TOE CONTROL ARM SLIDE BUSHING OPERATING TORQUE CHECK MB990326 (1) Insert a bolt into the slide bushing of the toe control arm. Fit a washer onto the bolt from the opposite end and screw a nut onto it.

• Page 261: Shock Absorber Assembly

  34-13 REAR SUSPENSION – Shock Absorber Assembly SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Trunk Room Side Trim Removal and Installation <GSR> 44 {4.5} 88 {9.0}* Unit: Nm {kgf@m} Removal steps 1. Cap Caution 2. Shock absorber mounting nuts The part marked with * should be first temporarily 3.

• Page 262: Stabilizer Bar

  34-14 REAR SUSPENSION – Stabilizer Bar STABILIZER BAR REMOVAL AND INSTALLATION Post-installation Operation Check the Stabilizer Link Ball Joint Dust Cover for Cracks or Damage by Pushing it with Finger. 39 {4.0} 39 {4.0} 20 {2.0} 39 {4.0} Unit: Nm {kgf@m} Removal steps 1.

• Page 263
  34-15 REAR SUSPENSION – Stabilizer Bar INSTALLATION SERVICE POINT «AA STABILIZER BAR / BUSHING / STABILIZER BAR BRACKET INSTALLATION Position the stabilizer bar such that the identification mark may protrude toward the vehicle center as shown in the figure, and tighten first the stabilizer bar bracket mounting bolt 1 then the mounting bolt 2.
• Page 264
  34-16 REAR SUSPENSION – Stabilizer Bar STABILIZER LINK BALL JOINT DUST COVER REPLACEMENT Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: (1) Remove the clip ring and the dust cover. Clip ring (2) Apply the specified grease to the lip and inside of the dust cover.

• Page 265: Service Brakes

  35-1 SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM ……..ANTI-LOCK BRAKING SYSTEM (ABS) .

• Page 266: General

  35A-1 BASIC BRAKE SYSTEM CONTENTS GENERAL ……. MASTER CYLINDER AND BRAKE BOOSTER .

• Page 267: 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 268
  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 269: 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 270: 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 271
  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 272: Master Cylinder

  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 273
  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 274: 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 275
  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 276
  35B-1 ANTI-LOCK BRAKING SYSTEM (ABS) CONTENTS TROUBLESHOOTING ….ON-VEHICLE SERVICE ….Inspection Chart for Diagnosis Codes .

• Page 277: Troubleshooting

  35B-2 ABS – Troubleshooting The EVOLUTION-V is provided with a lateral acceleration sensor in addition to the longitudinal acceleration sensor, and the ABS-ECU connector is changed in terminal arrangement. When servicing EVOLUTION-V, therefore, use the following service procedures. TROUBLESHOOTING 1. INSPECTION CHART FOR DIAGNOSIS CODES Diagnosis Diagnosis items Reference Page…

• Page 278: Inspection Procedure For Diagnostic Trouble Codes

  35B-3 ABS – Troubleshooting 2. INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES Code Nos.11, 12, 13 and 14: Wheel speed sensor Probable cause (open circuit or short circuit) Code Nos.21, 22, 23 and 24: Wheel speed sensor D Malfunction of wheel speed sensor Code Nos 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit or D Malfunction of wiring harness or connector short-circuit in the (+) wire or (–) wire in any one of the four wheel speed sensors.

• Page 279
  35B-4 ABS – Troubleshooting Code No.15: Wheel speed sensor (abnormal output Probable cause signal) D The four vehicle tires are of different sizes This code is output when there is an abnormality in the output signal from any one D Malfunction of wheel speed sensor of the four wheel speed sensors while driving (except for an open circuit or short D Malfunction of wiring harness or connector circuit).
• Page 280
  35B-5 ABS – Troubleshooting Code No.16: ABS-ECU power supply system (abnormal Probable cause voltage drop or rise) D Malfunction of battery This code is output if the ABS-ECU or valve relay power supply voltage drops below D Malfunction of wiring harness or connector or rises above the rated values.
• Page 281
  35B-6 ABS – ABS – Troubleshooting Troubleshooting Code No. 27: AYC monitor system (defective AYC) Probable cause D Defective AYC-ECU This code is output when the AYC monitor signal becomes faulty. D Defective ABS-ECU D Defective harness or connector Check the following connectors: Repair B-25, B-96 Check the harness between ABS-ECU…
• Page 282
  35B-7 ABS – Troubleshooting Code No.33: Stop lamp switch system (open circuit or Probable cause stop lamp stays ON) D Malfunction of stop lamp switch This code is output, if the stop lamp switch is continuously on for 15 minutes or D Malfunction of wiring harness or connector more.
• Page 283
  35B-8 ABS – Troubleshooting Code No. 51: Valve relay system Probable cause D Defective ABS valve relay This code is output under any of the following conditions: D The solenoid valve power is not supplied when ABS-ECU attempts to turn ON D Defective harness or connector D Defective ABS-ECU the valve relay as part of the initial check when the ignition switch is turned ON.
• Page 284
  35B-9 ABS – Troubleshooting Code No. 53: Motor relay system Probable cause D Defective motor relay This code is output under any of the following conditions: D No signals are input to the motor monitor when the motor relay is ON (motor D Defective harness or connector D Defective hydraulic unit does not run, etc.).
• Page 285
  35B-10 ABS – Troubleshooting Code No. 71: Acceleration sensor (lateral acceleration) Probable cause system D Defective acceleration sensor (lateral acceleration) This code is output under either of the following conditions: D The output from the acceleration sensor (lateral acceleration) becomes 0.5 V or D Defective harness or connector D Defective ABS-ECU less, or 4.5 V or more.

• Page 286: Inspection Chart For Trouble Symptoms

  35B-11 ABS – Troubleshooting 3. INSPECTION CHART FOR TROUBLE SYMPTOMS Get an understanding of the trouble symptoms and check according to the inspection procedure chart. Trouble symptoms Inspection pro- Reference page cedure No. When the ignition key is turned to “ON” (engine stopped), the ABS warning lamp 35B-12 does not illuminate.

• Page 287: Inspection Procedure For Trouble Symptoms

  35B-12 ABS – Troubleshooting 4. INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 When the ignition key is turned to “ON” (engine stopped), Probable cause the ABS warning lamp does not illuminate. The ABS-ECU turns the valve relay ON → OFF → ON for initial checking when D Blown fuse D Burn out ABS warning lamp bulb it is powered ON.

• Page 288
  35B-13 ABS – Troubleshooting INSPECTION PROCEDURE 2 Even after the engine is started, the ABS warning lamp Probable cause remains illuminated. D Malfunction of combination meter The cause is probably a short-circuit in the ABS warning lamp illumination circuit. D Malfunction of ABS-ECU D Malfunction of wiring harness (short circuit) NOTE This trouble symptom is limited to cases where ABS-ECU power supply is normal and the diagnosis…
• Page 289
  35B-14 ABS – Troubleshooting INSPECTION PROCEDURE 4 When the ignition key is turned to “START”, the ABS Probable cause warning lamp does not illuminate. D Malfunction of wiring harness or connector The ABS-ECU is powered through IG2 which is turned off when the ignition key D Malfunction of valve relay is in START position.

• Page 290: Check At Abs-Ecu Terminals

  35B-15 ABS – Troubleshooting 5. CHECK AT ABS-ECU TERMINALS 5-1 TERMINAL VOLTAGE LISTING (1) The voltage is to be measured across each terminal and ground terminal. (2) Fig. below shows the arrangement of the terminals. Terminal Check item Check requirement Normally Solenoid valve OUT (FL) output Ignition switch: ON (after initial check)

• Page 291
  35B-16 ABS – Troubleshooting Terminal Check item Check requirement Normally Wheel speed (RR) output Vehicle stationary 1 V or less Moving forward slowly 0 – 5 V Valve relay monitor input Ignition switch: ON (after initial check) Battery voltage Motor relay monitor output Ignition switch: When motor is energized When motor is deenergized…

• Page 292: On-Vehicle Service

  35B-17 ABS – On-vehicle Service / Lateral Acceleration Sensor ON-VEHICLE SERVICE ABS-ECU connector harness side WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT <EVOLUTION-V> The EVOLUTION-V has the ABS-ECU connector terminal arranged as shown at left. Accordingly, the terminals to measure the output voltage of the wheel speed sensors are different from EVOLUTION-V.

• Page 293: Wheel Speed Sensor

  35B-18 ABS – Wheel Speed Sensor WHEEL SPEED SENSOR REMOVAL AND INSTALLATION Post-installation Operation Wheel Speed Sensor Output Voltage Measurement 25 {2.6} 25 {2.6} 25 {2.6} Unit: Nm {kgf@m} Front speed sensor removal steps D Splash shield NOTE 1. Front speed sensor The front rotor and rear rotor are integrated with the drive 2.

• Page 294: Parking Brakes

  36-1 PARKING BRAKES CONTENTS SERVICE SPECIFICATIONS ….ON-VEHICLE SERVICE ….Parking Brake Lever Stroke Check and LUBRICANTS .

• Page 295
  36-2 PARKING BRAKE – Service Specifications / Lubricants / Special Tools The parking brake is designed as a drum-in-disc brake acting on the rear wheel. This brake is a little different in construction between EVOLUTION-IV and EVOLUTION-V but much alike in the service procedure of the parking brake section.
• Page 296
  36-3 PARKING BRAKE – On-vehicle Service ON-VEHICLE SERVICE 1. PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 1-1 STROKE CHECK Standard value: 5 – 7 notches [Operating force of approx. 196 N {20 kgf}] 1-2 STROKE ADJUSTMENT Adjusting nut Rear floor console If the parking brake lever stroke is not the standard value, adjust as described below.
• Page 297
  36-4 PARKING BRAKE – On-vehicle Service 2. LINING RUNNING-IN Carry out running-in by the following procedure when replacing the parking brake linings or the rear brake disc rotors, or when brake performance is insufficient. Caution Carry out running-in in a place with good visibility, and pay careful attention to safety.

• Page 298: Parking Brake

  36-5 PARKING BRAKE – Parking Brake Cable PARKING BRAKE CABLE REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Floor Console and Rear Seat Removal (1) Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3.) (2) Floor Console and Rear Seat Installation 49 –…

• Page 299
  36-6 PARKING BRAKE – Parking Brake Cable REMOVAL SERVICE POINTS Shoe AA» REAR BRAKE CALIPER ASSEMBLY REMOVAL hold-down Remove the rear brake caliper assembly and support it with wire or similar. AB» SHOE HOLD-DOWN CUP REMOVAL Extend the shoe and lining assembly, and remove the shoe hold-down cup.
• Page 300
  36-7 PARKING BRAKE – Parking Brake Drum PARKING BRAKE DRUM REMOVAL AND INSTALLATION Post-installation Operation Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3.) 49 – 59 {5.0 – 6.0} 196 – 255 {20.0 – 26.0} 118 {12.0} 74 – 88 {7.5 –…
• Page 301
  36-8 PARKING BRAKE – Parking Brake Drum REMOVAL SERVICE POINTS AA» DRIVE SHAFT NUT REMOVAL MB990767 AB» REAR HUB ASSEMBLY REMOVAL MB990244 (1) Using the special tool, remove the drive shaft from the rear hub assembly. (2) Remove the mounting bolts and remove the rear hub MB990767 assembly from the knuckle.

• Page 302: Steering

  37A-1 STEERING CONTENTS SERVICE SPECIFICATIONS ….STEERING WHEEL <EVOLUTION-IV RS> ….SPECIAL TOOLS .

• Page 303: Service Specifications

  37A-2 STEERING – Service Specifications / Special Tools / On-vehicle Service SERVICE SPECIFICATIONS Items Standard value 33_30’ ± 2_ Steering angle EVOLUTION-IV Inner wheel Outer wheel 28_20’ 33_10’ ± 2_ EVOLUTION-V Inner wheel Outer wheel 28_10’ Steering gear Pinion total turning torque Total turning torque 0.9 –…

• Page 304: Steering Wheel

  Steering Wheel <EVOLUTION-IV RS> / 37A-3 STEERING – Power Steering Gear & Linkage STEERING WHEEL <EVOLUTION-IV RS> REMOVAL SERVICE POINT STEERING WHEEL REMOVAL (1) Peel off the dual lock fasteners from the steering wheel spokes and remove the horn pad. Dual lock fastener (2) Remove the bolts indicated by arrows in the illustration…

• Page 305
  37A-4 STEERING – Power Steering Gear & Linkage DISASSEMBLY AND REASSEMBLY 22 {2.2} Repair kit grease 28 27 25 {2.5} Steering gear seal kit 59 { 6.0} Flare nut 59 {6.0} 13 {1.3} 88 {9.0} 49 – 59 {5.0 – 6.0} Unit: Nm {kgf@m} Disassembly steps AB»…
• Page 306
  (2) Cover rack serrations with special tool. (3) Apply the specified fluid on the special tool, seal ring Oil seal and O-ring surfaces. Specified fluid: MITSUBISHI GENUINE ATF II Caution Do not use ATF-SP II. (4) Slowly insert the special tool-covered rack into the gear MB991214 housing from power cylinder side.
• Page 307
  37A-6 STEERING – Power Steering Gear & Linkage «JA ADJUSTMENT OF PINION TOTAL TURNING TORQUE MB990607 (1) With special tool, tighten rack support cover to 15 Nm {1.5 kgf@m}. (2) Return rack support cover approx. 30_. (3) Using the special tools, rotate the pinion shaft at the MB991006 rate of one rotation in approximately 4 to 6 seconds to check that the turning torque and the torque fluctuation…

• Page 308: Power Steering Oil Pump

  37A-7 STEERING – Power Steering Oil Pump POWER STEERING OIL PUMP <EVOLUTION-IV> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (1) Power Steering Fluid Supplying (2) Drive Belt Tension Adjusting (Refer to GROUP 11 – On-vehicle Service.) 39 {4.0} 49 {5.0} 49 {5.0}…

• Page 309
  37A-8 STEERING – Power Steering Oil Pump <EVOLUTION-V> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (1) Power Steering Fluid Supplying (2) Drive Belt Tension Adjusting (3) Power Steering Fluid Line Bleeding 12 {1.2} 18 {1.8} 22 {2.2} 22 {2.2} 24 {2.4} 52 {5.3}…

• Page 310: Power Steering Fluid Cooler

  37A-9 STEERING – Power Steering Fluid Cooler POWER STEERING FLUID COOLER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (1) Power Steering Fluid Draining and Refilling (2) Front Bumper Removal and Installation (Refer to GROUP 51.) 12 {1.2} 13 {1.3} Unit: Nm {kgf@m} Removal steps 1.

• Page 311: Body

  42-1 BODY CONTENTS HOOD ……..TYPE A (PROJECTED DIMENSIONS) .

• Page 312: Hood

  42-2 BODY – Hood HOOD REMOVAL AND INSTALLATION 9 {0.9} Unit: Nm {kgf@m} Adjustment of clearance and height Adjustment of hood step and hood around hood striker linkage 1. Hood latch Hood lock release cable removal 2. Hood lock release handle steps 3.

• Page 313: Fender

  42-3 BODY – Fender FENDER <EVOLUTION-V> REMOVAL AND INSTALLATION Caution Pre-removal and Post-installation Operation A rust preventive treatment has been applied to the (1) Front Bumper Removal and Installation washers marked with * to prevent contact corrosion (Refer to GROUP 51.) between aluminum and metal of different kind.

• Page 314: Trunk Lid

  42-4 BODY – Fender / Trunk Lid <EVOLUTION-V> REMOVAL SERVICE POINT AA» SIDE TURN SIGNAL LAMP REMOVAL Fender panel Using a flat-tip screwdriver or similar tool, release the lock Lock from the fender panel and remove the side turn signal lamp. INSTALLATION SERVICE POINT «AA SIDE TURN SIGNAL LAMP INSTALLATION Hook…

• Page 315: Body Construction (Difference Between Evolution-Iv And V)

  42-5 BODY – Body Construction (Difference between EVOLUTION-IV and V) BODY CONSTRUCTION (Difference between EVOLUTION-IV and V) EVOLUTION-V has a different rear suspension configuration from that of EVOLUTION-IV because of adoption of reinforced suspension elements and wide tread tyres. For this reason, the configuration and the dimensions of the following body sections are also different.

• Page 316
  42-6 BODY – Body Construction (Difference between EVOLUTION-IV and V) UNDER BODY Rear Floor The upper link bracket, rear floor sidemember reinforcement and toe control link bracket have been changed in configuration. <EVOLUTION-V> Upper link bracket Rear floor sidemember reinforcement <EVOLUTION-IV>…

• Page 317: Body Dimension

  BODY DIMENSION TYPE A (PROJECTED DIMENSIONS) <EVOLUTION-V> The reference dimensions of the under body have been changed as follow. Those of the other body sections remain unchanged. UNDER BODY Unit: mm 1,232 1,211 indicates that the dimension and the measurement point are the same as those for EVOLUTION-IV.

• Page 318
  Unit: mm 1,222 1,273 1,393 1,627 1,028 indicates that the dimension and the measurement point are the same as those for EVOLUTION-IV. 7, 8 9, 10 Standard measurement point Hole _ Size Standard measurement point Hole _ Size shape shape f –…

• Page 319: Dimensions)

  SUSPENSION INSTALLATION DIMENSIONS Unit: mm 1,093 1,010 1,186 Center of vehicle 11_36’ Center vehicle 21 22 1,145 indicates that the dimension and the measurement point are the same as those for EVOLUTION-IV.

• Page 320
  Unit: mm 1,199 1,068 21 22 indicates that the dimension and the measurement point are the same as those for EVOLUTION-IV. Standard measurement point Hole _ Size Standard measurement point Hole _ Size shape shape f – 110 Center of strut insulator Trailing arm mounting position –…
• Page 321
  TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY Unit: mm 1,232 1,231 1,287 1,395 1,635 1,028 indicates that the dimension and the measurement point are the same as those for EVOLUTION-IV.
• Page 322
  indicates that the dimension and the measurement point are the same as those for EVOLUTION-IV. 7, 8 9, 10 Standard measurement point Hole _ Size Standard measurement point Hole _ Size shape shape f – 30 Rear portion of front bumper stay mounting hole Center bearing mounting bolt end –…
• Page 323
  SUSPENSION INSTALLATION DIMENSIONS Unit : mm 1,186 1,210 1,069 indicates that the dimension and the measurement point are the same as those for EVOLUTION-IV.
• Page 324
  indicates that the dimension and the measurement point are the same as those for EVOLUTION-IV. 2, 13 21, 22 Standard measurement point Hole _ Size Standard measurement point Hole _ Size shape shape Left: f – 14 f – 14 Center of suspension crossmember mounting hole Center of suspension crossmember mounting hole Right: f –…

• Page 325: Exterior

  51-1 EXTERIOR CONTENTS SPECIAL TOOLS ……REAR FENDER GARNISH <EVOLUTION-V> ….. . . FRONT BUMPER <EVOLUTION-IV>…

• Page 326: Special Tools

  51-2 EXTERIOR – Special Tools / Front Bumper <EVOLUTION-IV> SPECIAL TOOLS Tool Number Name MB990784 Ornament remover Removal of front bumper and rear bumper FRONT BUMPER <EVOLUTION-IV> REMOVAL AND INSTALLATION Front bumper assembly…

• Page 327
  51-3 EXTERIOR – Front Bumper <EVOLUTION-IV> DISASSEMBLY AND REASSEMBLY Disassembly steps D Front air dam (Refer to P.51-7.) 8. Bumper bolt plate D Brake duct (Refer to P.51-7.) AA» 9. Clip 1. License plate bracket 10. Bumper upper reinforcement mark 11.

• Page 328: Front Bumper

  51-4 EXTERIOR – Front Bumper <EVOLUTION-V> FRONT BUMPER <EVOLUTION-V> REMOVAL AND INSTALLATION Front bumper assembly…

• Page 329
  51-5 EXTERIOR – Front Bumper <EVOLUTION-V> DISASSEMBLY AND REASSEMBLY 2.5 {0.25} 2.5 {0.25} Unit: Nm {kgf@m} Disassembly steps D Front air dam (Refer to P.51-9.) 9. Fog lamp D Brake duct (Refer to P.51-9.) 10. Bumper bolt plate AA» 1. License plate bracket 11.

• Page 330: Rear Bumper

  51-6 EXTERIOR – Front Bumper <EVOLUTION-V> / Rear Bumper <EVOLUTION-V> DISASSEMBLY SERVICE POINT AA» CLIP REMOVAL (1) Using the special tool, raise the pin at the center of the MB990784 clip. (2) Remove the clip. MB990784 Clip REAR BUMPER <EVOLUTION-V> REMOVAL AND INSTALLATION Rear bumper removal 1.

• Page 331: Aero Parts

  51-7 EXTERIOR – Aero Parts <EVOLUTION-IV> AERO PARTS <EVOLUTION-IV> REMOVAL AND INSTALLATION Insert bolt mounting locations Double-sided adhesive tape: SUMITOMO 3M 4211 or equivalent (width: 5 mm) Primer: SUMITOMO 3M C100 or equivalent Front air dam removal steps Rear air dam removal steps 1.

• Page 332
  51-8 EXTERIOR – Aero Parts <EVOLUTION-IV> Rear spoiler removal steps 7. Rear spoiler 8. High-mount stop lamp…

• Page 333: Aero Parts

  51-9 EXTERIOR – Aero Parts <EVOLUTION-V> AERO PARTS <EVOLUTION-V> REMOVAL AND INSTALLATION Insert bolt mounting locations Double-sided adhesive tape: SUMITOMO 3M 4211 or equivalent (thickness: 1.2 mm) Primer: SUMITOMO 3M 8107 PP parts primer Front air dam removal steps Side air dam removal AA»…

• Page 334
  51-10 EXTERIOR – Aero Parts <EVOLUTION-V> 5 {0.5} 5 {0.5} Unit: Nm {kgf@m} Double-sided adhesive tape: Commercially available product (thickness: 2.0 mm) Rear spoiler removal steps AA» «AA 5. Rear spoiler NOTE 6. High-mount stop lamp undercover The conventional service points apply for removal and 7.

• Page 335: Rear Fender Garnish

  51-11 EXTERIOR – Rear Fender Garnish <EVOLUTION-V> REAR FENDER GARNISH <EVOLUTION-V> REMOVAL AND INSTALLATION NOTE The parts marked with are plastic clips. Section A-A, B-B 4, 6 Double-sided adhesive tape: SUMITOMO 3M 4213 or equivalent (thickness: 0.8 mm) Primer: SUMITOMO 3M 8107 PP parts primer Rear door garnish removal steps Quarter garnish removal steps AA»…

• Page 336
  51-12 EXTERIOR – Water Spray <EVOLUTION-IV> WATER SPRAY <EVOLUTION-IV> REMOVAL AND INSTALLATION 1. Water spray switch 3. Washer motor 4. Water spray motor Removal steps 5. Water spray hose D Front bumper (Refer to P.51-3.) 6. Water spray nozzle 2. Washer tank INSPECTION WATER SPRAY SWITCH CONTINUITY CHECK Switch position…

• Page 337: Intercooler & Radiator Water Spray System

  51-13 EXTERIOR – Intercooler & Radiator Water Spray System <EVOLUTION-V> INTERCOOLER & RADIATOR WATER SPRAY SYSTEM <EVOLUTION-V> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Front Bumper Removal and Installation (Refer to P.51-4.) 2.5 {0.25} 2.5 {0.25} Unit: Nm {kgf@m} 1. Clamp Water spray motor removal steps 2.

• Page 338
  51-14 EXTERIOR – Intercooler & Radiator Water Spray System <EVOLUTION-V> INSTALLATION SERVICE POINT «AA CLIP / WATER SPRAY HOSE INSTALLATION (1) Tape clips as illustrated. (2) Tape the water spray hose as illustrated. (3) Insert the clips positively into the mounting holes. <Top view>…

• Page 339: Mark

  51-15 EXTERIOR – Mark <EVOLUTION-V> MARK <EVOLUTION-V> REMOVAL AND INSTALLATION «AA 1. EVOLUTION-V mark (side) NOTE «AA 2. brembo mark The mark “brembo” represents an Italian disc brake «AA 3. EVOLUTION-V mark (rear) maker, whose disc brakes are used both in front and rear on EVOLUTION-V.

• Page 340
  51-16 EXTERIOR – Mark <EVOLUTION-V> 2. brembo MARK Application tape edge Trunk lid opening line Rear bumper line 3. EVOLUTION-V MARK (REAR) Trunk lid opening line Rear bumper line (2) Installation procedure 1. Using unleaded gasoline, degrease the surface of the body on which the marks are mounted. 2.

• Page 341: Chassis Electrical

  54-1 CHASSIS ELECTRICAL CONTENTS GENERAL ……SPECIAL TOOL ….. . . TROUBLESHOOTING .

• Page 342
  54-2 ON-VEHICLE SERVICE ….SIDE TURN-SIGNAL LAMP … . COMBINATION METERS ….HAZARD WARNING LAMP SWITCH, CLOCK .

• Page 343: 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 344
  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 345: 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 346: 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 347
  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 348
  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 349
  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 350
  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 351
  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 352
  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 353: 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 354
  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 355
  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 356
  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 357
  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 358
  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 359
  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 360
  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 361
  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 362: 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 with –6% to +10%) 75 –…

• Page 363: 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 364: 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 365: Inspection Procedure

  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 366
  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 367: 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 368
  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 369
  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 370: 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 Ω 4.

• Page 371
  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 372: 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 373: 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 374: 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 375
  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 376: 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 377
  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 378
  54-38 CHASSIS ELECTRICAL – Headlamp HEADLAMP RELAY CONTINUITYCHECK Battery voltage Terminal No. Not supplied Supplied Headlamp relay…

• Page 379: 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 380
  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 3° (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 381: 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 382: 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 383: 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 384: 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 385: 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 386
  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 387: 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 388: 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 389: 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 390: 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 391: 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 OFF ←→ ON DEFOGGER SWITCH CONTINUITY CHECK Switch Terminal No. position – –…

1. Manuals
2. Brands
3. Webasto Manuals
4. Automobile Accessories
5. thermo top evo

Manuals and User Guides for Webasto thermo top evo. We have 30 Webasto thermo top evo manuals available for free PDF download: Installation Documentation, Manual, Workshop Manual, Installation Instructions Manual, Installation Manual