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Mitsubishi MOTORS Lancer Evolution VIII 2003, Technical Information Manual, Page: 318 / 368

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Mitsubishi MOTORS Lancer Evolution VIII 2003 Technical Information Manual Download Page 318

ALUMINUM PANEL

WELDED PANEL REPLACEMENT

3-42

CAUTION

Aluminum plates are softer than steel sheets, therefore 
select an appropriate abrasive to prevent the surface from 
deep scratch.

4. Sanding: Grind the surface by a disk sander or a double-

action sander.

•

Disk sander: 100 to 120 grit

•

Double-action sander: 150 to 180 grit

Correction of cuts and cracks

For steel panel, MIG welding with CO

2

 is used to correct cuts, 

cracks, or holes, however, for aluminum panel, use MIG or TIG 
welding with argon gas (inert gas) as shielding gas.

.

MIG welding

CAUTION

•

Caution for excessive stretch or damage of the panel.

•

Minimize the gap of the butt joint.

1. Correction of metal sheet: Correct the damaged area by 

hammering lightly while heating it. If any area is stretched by 
hammering, grind it off with a pneumatic saw.

CAUTION

•

To minimize distortion and meltdown, divide a welding 
area into several short segments, and weld one seg-
ment at a time.

•

Degrease the welding area by white gasoline or the like.

•

Remove the oxide coating on the welding area, includ-
ing its back, with a stainless steel wire brush just 
before welding. Welding shall be started as soon as the 
oxide coating is removed.

2. Welding: Use a special welding machine for both aluminum 

panels or a welding machine for aluminum panels and steel 
sheets.

CAUTION

Do not over-grind the base of the panel.

3. Inspection of welding area: Refinish the welding area by a 

100-grit disk sander, and then check for any faulty welding 
by the visible dye penetrate testing.

AB202109

AB202121

AB202118

AB202117

Summary of Contents for Lancer Evolution VIII 2003

Page 1: ...hnical Information and Body Repair Service The Body Repair sections immediate ly follow Group 55 Heater Air Conditioning and Ven tilation Please read this manual carefully so that it will be of assistance for your service and sales activities Please note the following service manuals are also available and should be used in conjunction with this manual SERVICE MANUAL MSSP 206B 2003 PARTS CATALOG B...

Page 2: ...52B 1 GROUP 52B SUPPLEMENTAL RESTRAINT SYSTEM SRS CONTENTS GENERAL DESCRIPTION 52B 2 SYSTEM OPERATION 52B 7 SRS ECU 52B 10 ...

Page 3: ...rear end A vehicle rolls over or is in a similar position Driverís and front passengerís air bags and seat belts with pre tensioner are standard increasing the passive safety level SUPPLEMENTAL RESTRAINT SYSTEM SRS The SRS is designed to supplement the front seat belts It eliminates or reduces or injury to the front passenger s by deploying air bag s in case of a head on collision SEAT BELT WITH P...

Page 4: ...ment panel indicates the operational status of the SRS A clock spring is installed in the steering column The SRS ECU detects the impact produced at the time of a collision from the safing and analog G sen sors and supplies squib ignition current to the air bag modules The SRS ECU has the following functions This triggers the air bag modules Power supply backup function backup con denser that depl...

Page 5: ...BAG DRIVE CIRCUIT AIR BAG DRIVE CIRCUIT AIR BAG DRIVE CIRCUIT AIR BAG DRIVE CIRCUIT FRONT IMPACT SENSOR INTERFACE CIRCUIT DATA LINK CONNECTOR FOR SCAN TOOL ON ON OFF OFF CONNECTOR LOCK SWITCH IGNITION SWITCH IG1 No 2 7 5A No 3 7 5A COMBINATION METER SRS WARNING LIGHT ON ON OFF OFF CONNECTOR LOCK SWITCH DRIVER S AIR BAG MODULE CLOCK SPRING ON OFF OFF OFF ON ON PASSENGER S FRONT AIR BAG MODULE OFF O...

Page 6: ...ing and the services of SRS air bag air attached on the position shown in the following illustration AC211604AB COVER CLOCK SPRING B PASSENGER S FRONT AIR BAG MODULE C SRS ECU D SUN VISOR E E STEERING JOINT COVER H I GLOVE BOX F G A SEAT BELT WITH PRE TENSIONER DRIVER S AND FRONT PASSENGER S SEATBELT FRONT IMPACT SENSOR J ...

Page 7: ...EVER put a rear facing child seat in the front Sit as far back as possible from the air bag ALWAYS use SEAT BELTS and CHILD RESTRAINTS F AIR BAG SYSTEM INFORMATION THIS VEHICLE HAS AN AIR BAG SYSTEM WHICH WILL SUPPLEMENT THE SEAT BELT IN CERTAIN FRONTAL COLLISIONS THE AIR BAG IS NOT A SUBSTITUTE FOR THE SEAT BELT IN ANY TYPE OF COLLISION THE DRIVER AND ALL OTHER OCCUPANTS SHOULD WEAR SEAT BELTS AT...

Page 8: ... air bag to reduce the shock from the impact An inflator that does not contain sodium azide is used G WARNING CHILDREN CAN BE KILLED OR INJURED BY PASSENGER AIR BAG THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN 12 AND UNDER MAKE SURE ALL CHILDREN USE SEAT BELTS OR CHILD SEAT NOT TO BE REMOVED EXCEPT BY OWNER H CAUTION SRS FIX STRG WHEEL AT TIRES STRAIGHT AHEAD BEFORE GEARBOX REMOVAL OTHERWISE MAY...

Page 9: ...t upon front impact to reduce forward shifting of the passenger The seat belt pre tensioner is built into the driver s and passenger s front seat belt retractor Upon front impact the pretensioner ignites the gas generator and emits gas with the SRS ECU signal when the front impact sensor attached to the front of the body detects an impact that exceeds the permis sible limit The gas pressure shifts...

Page 10: ...H PRE TENSIONER DRIVER S SIDE CLOCK SPRING DRIVER S AIR BAG MODULE PASSENGER S FRONT AIR BAG MODULE SEAT BELT WITH PRE TENSIONER FRONT PASSENGER S SIDE A A A A AF AC006197 OFF ON OFF ON SQUIB SRS ECU SQUIB SRS ECU OFF OFF ON ON A A CONNECTOR DISCONNECTED CONNECTOR SHORTING MECHANISM E G SRS ECU CONNECTOR ECU SIDE CONNECTOR WIRING HARNESS SIDE CONNECTOR TERMINAL MALE PARTITION PANEL PARTITION PANEL...

Page 11: ...nsor for frontal collisions and a safing G sensor for side collisions In frontal collisions the driverís and passengerís front air bags deploy and the seat belt pre tensioners are activated only when both the analog and safing G sensors detect simulta neously a collision induced G of a level exceeding the threshold as in the case with the conventional system In the case of side collisions the side...

Page 12: ... 16 Safing G sensor open circuited for frontal collision 21 3 Driver s air bag squib short circuited 22 3 Driver s air bag squib open circuited 24 3 Passenger s front air bag squib short circuited 25 3 Passenger s front air bag squib open circuited 26 3 Driver s pre tensioner squib short circuited 27 3 Driver s pre tensioner squib open circuited 28 3 Passenger s front pre tensioner squib short cir...

Page 13: ...ve circuit system detected open 58 Passengerís seat belt pre tensioner squib ignition drive circuit system detected short 59 Passengerís seat belt pre tensioner squib ignition drive circuit system detected open 61 Driver s air bag squib drive circuit power supply side short circuited 62 Driver s air bag squib drive circuit ground side short circuited 64 Passenger s front air bag squib drive circui...

Page 14: ...36 1 GROUP 36 PARKING BRAKE CONTENTS GENERAL INFORMATION 36 2 ...

Page 15: ...GENERAL INFORMATION PARKING BRAKE 36 2 GENERAL INFORMATION M2360000100173 FEATURE The parking brakes are a mechanical rear wheel brake design and controlled by a lever CONSTRUCTION DIAGRAM AC211553AB ...

Page 16: ...35B 1 GROUP 35B FOUR WHEEL ANTI LOCK BRAKE SYSTEM 4ABS CONTENTS GENERAL DESCRIPTION 35B 2 SENSORS 35B 6 ACTUATORS 35B 8 BRAKE MODULATOR ABS ECU 35B 9 SYSTEM OPERATION 35B 10 ...

Page 17: ...wer is electronically controlled to optimize performance in accordance with road and load conditions and to ensure optimal distri bution of braking force between the front and rear brakes Rear brake fluid pressure control employs a brake modulator hydraulic unit solenoid valve that made it possible to eliminate the pressure control valves proportioning valves Effective use of rear wheel brake forc...

Page 18: ... is in straight ahead position Stoplight switch 5 Sends a signal to the ABS ECU to indicate whether the brake pedal is depressed or not Parking brake switch 6 Sends a signal to the ABS ECU to indicate whether the parking brake lever is pulled or not Actuator Hydraulic unit 7 Drives the solenoid valves according to signals from the ABS ECU in order to control the brake hydraulic pressure for each w...

Page 19: ... SOLENOID VALVE IN STOPLIGHT SWITCH ECU POWER SUPPLY ABS ECU ABS WARNING LIGHT DATA LINK CONNECTOR ABS SENSOR RL ABS SENSOR RR ABS SENSOR FR STOPLIGHT SWITCH REAR RIGHT WHEEL RR ABS SENSOR FRONT RIGHT WHEEL FR ABS SENSOR FRONT LEFT WHEEL FL REAR LEFT WHEEL RL ABS SENSOR LATERAL G SENSOR LONGITUDINAL G SENSOR ABS SENSOR PARKING BRAKE SWITCH STEERING ANGULAR VELOCITY SENSOR LATERAL G SENSOR LONGITUD...

Page 20: ...X STOPLIGHT SWITCH SOLENOID VALVE POWER SUPPLY MOTOR POWER SUPPLY STOPLIGHT SWITCH MONITOR ECU POWER SUPPLY ABS SENSOR DATA LINK CONNECTOR COMMUNICATION LINE CONTROL LINE MOTOR SOLENOID VALVE HYDRAULIC UNIT COMBINATION METER STOPLIGHT FUSIBLE LINK 1 LATERAL G SENSOR LONGITUDINAL G SENSOR STEERING ANGULAR VELOCITY SENSOR LATERAL G SENSOR INPUT STEERING ANGULAR VELOCITY SENSOR INPUT LATERAL G SENSOR...

Page 21: ...ar to improve serviceability LATERAL G SENSOR LONGITUDINAL G SENSOR The longitudinal G sensor detects the acceleration in the lateral direction of the vehicle and are basically the same as those used conventionally The lateral G sensor is used for detecting the acceleration along the sides of the vehicle by changing the installing direction by 90 degree angle The same sensor as the longitudinal G ...

Page 22: ...alculates the steering angle by reading the signals of the steering angular velocity sensor after every certain period of time and calculating the total of the ST 1 signal and ST 2 signal The steering angle is obtained by taking the neutral position ST N output is L center as 0 degree angle and if there are changes the steering angle is added with 2 degree angle for right and 2 degree angle for le...

Page 23: ...rake lever is released The ABS ECU detects whether the parking brake switch is on or off by means of fluctuations in voltage ON less than 1 volt OFF system voltage This data is used for ABS control ACTUATORS M2351002000099 ABS WARNING LIGHT The ABS ECU controls the power transistor in ABS ECU to turn on and causes the ABS warning light to illuminate in the following cases During initial check when...

Page 24: ... in ABS sensor RL 16 Abnormal drop or rise in ABS ECU power supply voltage 21 ABS sensor FR system 22 ABS sensor FL system 23 ABS sensor RR system 24 ABS sensor RL system 32 Longitudinal G sensor system 41 Solenoid valve FR system 42 Solenoid valve FL system 43 Solenoid valve RR system 44 Solenoid valve RL system 51 Valve relay ON problem 52 Valve relay OFF problem 53 Motor relay OFF problem 54 Mo...

Page 25: ...Parking brake switch ON OFF 32 Longitudinal G sensor V STOPLIGHT SW 36 Stoplight switch ON OFF 37 Steering angular velocity sensor straight ahead position memory ON OFF 71 Lateral G sensor V 74 Steering angular velocity sensor ST N OFF ON 75 Steering angular velocity sensor ST 1 76 Steering angular velocity sensor ST 2 86 Steering angle or OFF when the steering angle is straight ahead position NO ...

Page 26: ...35 1 GROUP 35 SERVICE BRAKES CONTENTS SERVICE BRAKES 35A FOUR WHEEL ANTI LOCK BRAKE SYSTEM 4ABS 35B ...

Page 27: ...NOTES ...

Page 28: ...35A 1 GROUP 35A SERVICE BRAKES CONTENTS GENERAL DESCRIPTION 35A 2 MASTER CYLINDER 35A 4 BRAKE BOOSTER ASSEMBLY 35A 4 FRONT DISC BRAKE 35A 5 REAR DISC BRAKE 35A 6 ...

Page 29: ... posture and steering performance 2 Adoption of an electronic brake force distribution EBD makes it possible to maintain the maxi mum amount of braking force even when the vehicle s load is unevenly distributed 3 Front and rear wheel X type brake line layout is used 4 Ventilated discs improve anti fading performance Improved serviceability 1 A diagnosis function has been adopted for the ABS system...

Page 30: ...ydraulic control method Electronic brake force distribution EBD Front brakes Type 4 opposed piston ventilated disc Disc effective dia thickness mm in 263 32 10 4 1 3 Wheel cylinder I D mm in 40 0 1 58 2 46 0 1 81 2 Pad thickness mm in 10 0 0 39 Clearance adjustment Automatic Rear brakes Type 2 opposed piston ventilated disc Disc effective dia thickness mm in 252 22 9 9 0 9 Wheel cylinder I D mm in...

Page 31: ...s safety BRAKE BOOSTER ASSEMBLY M2350002000148 A 8 9 inch tandem type brake booster assembly has been adopted AC005372AE MASTER CYLINDER BODY SECONDARY PISTON ASSEMBLY BRAKE FLUID RESERVOIR PRIMARY PISTON ASSEMBLY PISTON RETAINER AC206215AC REAR DIAPHRAGM FRONT DIAPHRAGM PUSH ROD DIAPHRAGM RETURN SPRING OPERATING ROD ATMOSPHERIC CHAMBERS ...

Page 32: ...nical type audible wear indicators to notify the driver when the usage limit 2 mm 0 08 in is reached Split fins adopted as the disc fins to improve cool ing performance NOTE Brembo is an italian brake component maker whose name and products are well known in the motorsports world DISC BRAKE NOMENCLATURE AC211388AB FRONT OF VEHICLE PADS 1 V 7 Z 40 46 2 3 4 AC211390 NO ITEM CONTENT 1 Brake disc type...

Page 33: ...h mechanical type audible wear indicators to notify the driver when the usage limit 2 mm 0 08 in is reached Split fins adopted as the disc fins to improve cool ing performance NOTE Brembo is an italian brake component maker whose name and products are well known in the motorsports world DISC BRAKE NOMENCLATURE AC211389AB FRONT OF VEHICLE PADS 1 V 6 X 40 2 3 4 AC211391 NO ITEM CONTENT 1 Brake disc ...

Page 34: ...34 1 GROUP 34 REAR SUSPENSION CONTENTS GENERAL DESCRIPTION 34 2 ...

Page 35: ... bushing at the body end and are mounted on the body via the crossmember 3 Alignment and suspension stroke a wider track and optimization of roll center height improves cornering response throughout the range from initial response through to the cornering limit COMPONENT CHARACTERISTICS COMPARED TO THE LANCER 1 Suspension arm made of forged aluminum The trailing arm assembly upper arm assem bly lo...

Page 36: ...G ARM ASSEMBLY FORGED ALUMINUM UPPER ARM ASSEMBLY FORGED ALUMINUM DIFFERENTIAL SUPPORT MEMBER DIFFERENTIAL SUPPORT ARM STABILIZER BAR ASSIST LINK FORGED ALUMINUM STABILIZER BAR LINK ITEM SPECIFICATION Suspension method Trailing arm type multi link ITEM LANCER EVOLUTION LANCER Camber 1 00 0 40 Toe in mm in 3 0 12 3 0 12 ITEM LANCER EVOLUTION LANCER Wire diameter mm in 12 0 5 10 0 4 Average diameter...

Page 37: ...NOTES ...

Page 38: ...33A 1 GROUP 33A FRONT SUSPENSION CONTENTS GENERAL DESCRIPTION 33A 2 LOWER ARM 33A 4 STRUT ASSEMBLY 33A 5 ...

Page 39: ...d produces nimble suspension action In addition outer casings and stoppers on the front bushings A point and pillow ball bushings in the rear G point improves the feeling of stiffness and stroke Increased size of the ball on the ball joints at the knuckle connection B point also improve reli ability Stabilizer A change to pillow ball joints for the stabilizer link improves stabilizer efficiency to...

Page 40: ...LL JOINT FRONT AXLE CROSSMEMBER BAR LOWER ARM BUSHING PILLOW BALL BUSHING A POINT A POINT G POINT B POINT ITEM SPECIFICATION Suspension method MacPherson strut with coil springs ITEM LANCER EVOLUTION LANCER Camber 1 00 Default factory setting 2 00 adjustment possible 0 00 Caster 3 55 2 50 Kingpin inclination 13 45 12 35 Toe in mm in 0 0 1 0 04 ITEM LANCER EVOLUTION LANCER SPORT Wire diameter mm in...

Page 41: ...action In addition outer casings and stoppers on the front bushings and pillow ball bushings in the rear improves the feeling of stiffness and stroke Increased size of the ball on the ball joints at the knuckle connection also improve reliability AC211384 LOWER ARM ASSEMBLY AB ENLARGED BALL DIAMETER PILLOW BALL BUSHING STOPPERS FRONT OF VEHICLE ...

Page 42: ...le is determined by the alignment of an eccentric bolt at the top of the joint between the strut assembly and knuckle Vehicles leave the factory with a camber angle of 1 degree angle selected An arrow on the eccentric bolt is pointing toward the inside of the vehicle For a cam ber angle of 2 degree angle the bolt must be posi tioned with its arrow pointing toward the outside of the vehicle AC21139...

Page 43: ...NOTES ...

Page 44: ...TECHNICAL FEATURES 00 3 EXTERIOR 00 3 INTERIOR 00 4 BODY DIMENSIONS 00 5 ENGINE 00 6 TRANSAXLE 00 6 SUSPENSION 00 7 ACTIVE SAFETY 00 8 PASSIVE SAFETY 00 9 ENVIRONMENTAL PROTECTION 00 10 SERVICEABILITY AND RELIABILITY 00 11 VEHICLE IDENTIFICATION 00 12 GENERAL DATA AND SPECIFICATIONS 00 13 ...

Page 45: ...wheel drive vehicles A C Indicates air conditioning TARGETS OF DEVELOPMENT M2000004000182 Since the modelís introduction in 1992 Mitsubishi Motors has continually evolved the Lancer Evolution series through developments that reflect direct feed back from actual competition in motor sports events around the world This is highlighted by entry in the premier event the WRC World Rally Champion ship Th...

Page 46: ...6 Rear Spoiler Placing top priority on weight reduction the rear spoiler made of carbon fiber is used as a standard The vertical struts give the impression of speedy per formance and the outer surfaces alone are painted to the color key 7 Rear Bumper The design achieves a balance with that of the front bumper while it remains simple and does not appear to protrude or stand out 8 Lancer and Evoluti...

Page 47: ... is used 2 Meter panel The driver oriented meter panel has been designed for easy visibility 3 Center instrument panel It is vertically angled toward the front 4 Separated center panel and floor console 5 Seats High back sport type RECARO seats are used in the front and a high back bench seat is used for the rear AC211416 1 2 3 4 AB 5 ...

Page 48: ...N 1 Overall length mm in 4 535 178 5 7 Tread mm in Front 1 515 59 6 2 Overall width mm in 1 770 69 7 Rear 1 515 59 6 3 Overall height mm in 1 450 57 1 8 Front leg space mm in 930 36 6 9 Rear leg space mm in 785 30 9 4 Wheel base mm in 2 625 103 3 10 Total leg space mm in 1 715 67 5 5 Front overhang mm in 930 36 6 11 Hip point height mm in Front 245 9 6 6 Rear overhang mm in 980 38 6 12 Rear 335 13...

Page 49: ...e 4G63 2 0 liter engine is available with MFI TRANSAXLE M2000021000107 MANUAL TRANSAXLE 5 speed manual transaxle is provided NO ITEM DIMENSION 1 Effective turning radius mm in 5 900 232 3 2 Minimum turning radius mm in 5 600 220 5 3 Front overhang mm in 930 36 6 4 Wheelbase mm in 2 625 103 3 AC005234 1 2 3 4 AB ...

Page 50: ...s and use of aluminum parts for the suspension arms and crossmember reduces weight to the limit In addition ball joints on the sus pension arms reduce friction for superior perfor mance under all driving conditions AC211449 LOWER ARM ASSEMBLY FORGED ALUMINUM STABILIZER BAR COIL SPRING FRONT AXLE No 1 CROSSMEMBER LOWER ARM BUSHING PILLOW BALL BUSHING FRONT AXLE CROSSMEMBER BAR STRUT INVERTED STRUT ...

Page 51: ...ctronic Brake force Distribution system Rear brake power is electronically controlled to optimize performance in accordance with road and load conditions and to ensure optimal distri bution of braking force between the front and rear brakes Rear brake fluid pressure control employs a brake modulator hydraulic unit solenoid valve that made it possible to eliminate the pressure control valves propor...

Page 52: ...t eliminates or reduces injury to the driver and front passengers by deploying air bag s in a head on collision SEAT BELT WITH PRE TENSIONER The seat belts with pre tensioner work simulta neously with the SRS The pre tensioner takes up seat slack immediately in a collision by restraining the person before the air bags deploy This prevents the passengers from moving forward AC211587AB PASSENGER S F...

Page 53: ...nt fog lights Child protection rear door locks Child restraint fitting ENVIRONMENTAL PROTECTION M2000027000138 Mitsubishi has given careful consideration to protec tion of natural resources and the environment in the vehicle Environmentally friendly features are shown below AC211731AB ENLARGED CROSS SECTION OF ROOF BOW REINFORCED CENTER PILLAR ENLARGED CROSS SECTION OF SIDE SILL ENLARGED CROSS SEC...

Page 54: ...service data and to carry out actuator tests It is also possible to read the diagnosis codes by the flashing of the warn ing light in some systems MFI 4ABS SRS air bag Simplified Wiring System SWS PREVENTION OF ATMOSPHERIC POLLUTION PART NAME MAIN DETAIL Recycling Air cleaner case Application of recycled polypropylene material that contains recycled paper makes effective use of resources and reduc...

Page 55: ...acy of transcription of vehicle identification num ber VEHICLE IDENTIFICATION NUMBER LIST Note that vehicle is certified as a 50 state emissions AC100836AB NO ITEM CONTENT 1 Country J Japan 2 Make A Mitsubishi 3 Vehicle type 3 Passenger car 4 Others A Driver and passenger air bags 5 Line H LANCER AWD 6 Price class 8 Sports 7 Body 6 4 door sedan 8 Engine F 2 0L 9 Check digits 0 1 2 3 9 X 10 Model y...

Page 56: ... 515 59 6 Tread rear 6 1 515 59 6 Front overhang 7 930 36 6 Rear overhang 8 980 38 6 Minimum running ground clearance 9 140 5 5 Vehicle weight kg lb Curb weight 1 506 3 320 Gross vehicle weight rating 1 915 4 222 Gross axle weight rating front 1 030 2 271 Gross axle weight rating rear 905 1 995 Seating capacity 5 Engine Model No 4G63 T C I C Piston displacement 2 0L Transaxle Model No W5M51 Type 5...

Page 57: ...NOTES ...

Page 58: ...31 1 GROUP 31 WHEEL AND TIRE CONTENTS GENERAL INFORMATION 31 2 ...

Page 59: ...meter indicates the pitch circle diameter of the wheel installation holes ITEM SPECIFICATION Wheel Type Aluminum type Size 17 8JJ Amount of wheel offset mm in 38 1 5 Pitch circle diameter PCD mm in 114 3 4 50 Tire Size P235 45R17 93W Spare wheel Type Steel type Size 17 4T Amount of wheel offset mm in 30 1 2 Pitch circle diameter PCD mm in 114 3 4 50 Spare tire Size T125 70D17 98M ...

Page 60: ...21 1 GROUP 21 CLUTCH CONTENTS GENERAL DESCRIPTION 21 2 ...

Page 61: ...disc type Dry single plate type Clutch disc facing diameter OD x ID mm in 240 160 9 4 6 3 Clutch cover type Diaphragm spring type Clutch cover setting load N lb 9 320 750 2 095 169 Control system Hydraulic type Release cylinder I D mm in 20 64 0 81 Master cylinder I D mm in 15 87 5 8 Clutch fluid Brake fluid DOT 3 or DOT 4 AC211157AB CLUTCH RELEASE CYLINDER CLUTCH PIPE CLUTCH HOSE RESERVOIR HOSE C...

Page 62: ...37 1 GROUP 37 POWER STEERING CONTENTS GENERAL DESCRIPTION 37 2 STEERING WHEEL 37 3 STEERING SHAFT AND COLUMN 37 4 OIL PUMP 37 6 STEERING GEAR 37 7 OIL RESERVOIR 37 8 ...

Page 63: ... is rubber mounted SPECIFICATIONS ITEM SPECIFICATION Steering wheel Type MOMO leather wrapped 3 spoke type Outside diameter mm in 365 14 4 Maximum number of turns 2 1 Steering column Column mechanism Shock absorbing mechanism and Tilt steering mechanism Power steering type Integral type Oil pump Type vane pump Basic discharge amount cm3 rev cu in rev 9 6 0 59 Relief pressure MPa psi 8 3 9 0 1 204 ...

Page 64: ...apped steering It incorporates an airbag module to protect the driver in the event of a frontal collision The airbag module is equipped with an inflator that does not contain sodium azide AC211250 AB STEERING WHEEL STEERING COLUMN SHAFT ASSEMBLY PRESSURE HOSE OIL RESERVOIR SUCTION HOSE OIL PUMP ASSEMBLY STEERING GEAR ASSEMBLY COOLER TUBE ASSEMBLY RETURN HOSE AC211251 ...

Page 65: ...e of an accident the fol lowing mechanisms improve driver safety A collapsible intermediary shaft prevents the steering column from entering the passenger compartment during initial impact A system for energy absorption is provided by the breakaway steering column which has a one way capsule AC209414AC SECTION B B A A B B ONEWAY CAPSULE SECTION A A RIVET STEERING SHAFT ASSEMBLY TILT LEVER TILT BRA...

Page 66: ...oving into the passenger compartment during the impact SECONDARY IMPACT 1 When the driver s body falls against the deployed air bag the tilt bracket A moves forward by crushing the polyacetal resin causing the steering column assembly to move towards the engine compartment AC211253 AB BEFORE COLLISION AFTER COLLISION COLLAPSE DEVICE AC005366AB BEFORE COLLISION AFTER COLLISION A A SECTION A A B B S...

Page 67: ... towards the engine compartment OIL PUMP M2370004000061 The oil pump is a vane type with a fluid flow control system Steering wheel turning effort is reduced at low engine speeds and is increased at higher speeds The oil pump is the conventional type AC211257AB RIVET U SECTION GROOVE TILT PLATE TILT BRAKET B STEERING COLUMN ASSEMBLY BEFORE COLLISION AFTER COLLISION ...

Page 68: ...nk age valve housing plastic tie rod bellows and hollow type tie rod stud The installation accuracy rigidity and steering stability have been improved by using an eye bushing which secures the steering gear to the crossmember AC211252 AB TIE ROD END GEAR HOUSING GEAR HOUSING VALVE HOUSING TIE ROD BELLOWS CROSSMEMBER CROSSMEMBER HOLLOW INNER PIPE BUSHING ...

Page 69: ...OIL RESERVOIR POWER STEERING 37 8 OIL RESERVOIR M2370005000064 An oil reservoir is rubber mounted AC211259 AB RUBBER MOUNT RUBBER MOUNT A VIEW A ...

Page 70: ...27 1 GROUP 27 REAR AXLE CONTENTS REAR AXLE 27 2 DIFFERENTIAL 27 3 ...

Page 71: ...orporates a TJ type constant velocity joint ABS rotors for detecting the wheel speed are press fitted to the EBJ For environmental protection a lead free grease is used on the joints NOTE EBJ Eight Ball Fixed Joint The use of the smaller sized eight balls inside the joint achieves weight saving and compact size compare with BJ Birfield Joint TJ Tripod Joint SPECIFICATIONS NOTE The wheel bearing is...

Page 72: ... gear Reduction ratio 3 307 Differential gear type Type number of gears Side gear Straight bevel gear 2 Pinion gear Straight bevel gear 4 Number of teeth Drive gear 43 Drive pinion 13 Bearing Outside diameter inside diameter mm in Side 72 0 25 0 2 83 1 0 Front 62 0 25 0 2 44 1 0 Rear 72 0 25 0 2 83 1 0 Differential gear oil Type Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No 8149630EX or equi...

Page 73: ...upport member via the differential mount bracket with insulator The rear is supported with the differential support arm CONSTRUCTION DIAGRAM AC211191 TOE CONTROL BAR DIFFERENTIAL MOUNTING BRACKET LH DIFFERENTIAL MOUNTING BRACKET RH DIFFERENTIAL CARRIER AB DIFFERENTIAL SUPPORT MEMBER INSULATOR DIFFERENTIAL SUPPORT ARM ...

Page 74: ...54 1 GROUP 54 CHASSIS ELECTRICAL CONTENTS CHASSIS ELECTRICAL 54A SIMPLIFIED WIRING SYSTEM SWS 54B ...

Page 75: ...NOTES ...

Page 76: ... 1 GROUP 54A CHASSIS ELECTRICAL CONTENTS GENERAL DESCRIPTION 54A 2 DIAGNOSIS SYSTEM 54A 2 BATTERY 54A 3 IMMOBILIZER SYSTEM 54A 4 LIGHTING 54A 5 COMBINATION METER 54A 8 RADIO CD PLAYER SPEAKER ANTENNA 54A 8 ...

Page 77: ...or is used in the combination meter 8 An immobilizer system is provided Improvements in service quality 1 Data link connectors 2 pieces for inspection with MUT II III are provided DIAGNOSIS SYSTEM M2540001000137 For improved serviceability a data link connector for inspection with MUT II III is built into the instrument panel near the position of the driver s left foot DIAGNOSIS FUNCTION MFI ABS I...

Page 78: ... 16 PIN CONNECTOR BLACK DATA LINK CONNECTOR BLACK 1 Diagnosis control 2 3 4 Grounding 5 Grounding 6 7 MFI ABS SRS 8 9 ETACS ECU 10 11 12 13 14 Simulated vehicle speed signal 15 16 Battery DATA LINK CONNECTOR WHITE 21 25 26 MFI 27 32 ITEM 75D23L Voltage V 12 Capacity 5 hours average Ah 53 Specific gravity of battery electrolyte fully charged at 20 C 1 280 ...

Page 79: ...h pre registered ID codes and if it matches a control signal approving ignition is sent to the engine control module If the ID code does not match in the case of counterfeit ignition keys for example the immobilizer ECU sends a control signal denying ignition to the engine con trol module preventing the engine from starting 5 The system is designed to be maintenance free because the power source f...

Page 80: ...t is exclusive for EVOLU TION HIGH MOUNT STOP LIGHT A high mount stop light is installed to the rear shelf NOTE The brackets show the bulb type CONSTRUCTION DIAGRAM ITEM SPECIFICATIONS Headlight assembly W High beam W halogen bulb 60 HB3 Low beam W discharge bulb 35 D2S Fog light W 51 HB4 Position light W 5 Front turn signal light W 21 Side turn signal light W 21 Rear combination light W Tail W 5 ...

Page 81: ...ge bulb and controller that changes battery power supply into high voltage AC AC210962 AB HIGH MOUNT STOP LIGHT LICENSE PLATE LIGHT REAR COMBINATION LIGHT BACK UP LIGHT TAILLIGHT STOP TAIL LIGHT TURN SIGNAL LIGHT AC210947AB INCEPTIVE GAS XENON ELECTRODE TUNGSTEN DISCHARGE BULB MERCURY METAL IODIDE SODIUM SCANDIUM ELECTRODE TUNGSTEN ...

Page 82: ...passenger seat A rear dome light illuminates the back seat A trunk light immuminates the trunk SPECIFICATIONS CONSTRUCTION DIAGRAM ITEM SPECIFICATIONS Map light and front dome light Map light W quantity 7 5 2 Front dome light W 7 5 Rear dome light W 8 Trunk light W 5 AC210999 REAR DOME LIGHT MAP LIGHT AND FRONT DOME LIGHT TRUNK LIGHT AB ...

Page 83: ...ge has a triangular mark indicating the location of the fuel filler door on the left side of the vehicle A position light indicator is provided to show clearly the taillight lighting condition CONSTRUCTION DIAGRAM RADIO CD PLAYER SPEAKER ANTENNA M2540006000143 RADIO AND CD PLAYER Two types of 1 DIN size integrated audio units are provided for the radio and tape player SPEAKER Six speakers front do...

Page 84: ...A 9 CONSTRUCTION DIAGRAM NOTE The indicates equipped on the left and right sides AC210965 FRONT SPEAKER CD PLAYER CD CHANGER REAR SPEAKER TWEETER ROOF ANTENNA AB SCAN PWR VOL CD PUSHAUDIO TUNE P000 RPT RDM FM AM SEEK TRACK AC211337 RADIO AND CD CHANGER AB ...

Page 85: ...NOTES ...

Page 86: ...RMATION 51 2 BUMPER 51 3 GENERAL INFORMATION 51 3 AERO PARTS 51 4 GENERAL INFORMATION 51 4 WINDSHIELD WIPER AND WASHER 51 5 GENERAL INFORMATION 51 5 REAR WIPER AND WASHER 51 7 GENERAL INFORMATION 51 7 OUTSIDE MIRROR 51 8 GENERAL INFORMATION 51 8 ...

Page 87: ...ments 3 Front Air Dam The design strikes a continuous line with the bumper for an integrated look 4 Rear Spoiler Two types of rear spoiler are available i e Type A and B Type A is made of carbon fiber Type B is equipped with high mount stop light 5 Rear Bumper The design achieves a balance with that of the front bumper while it remains simple and does not appear to protrude or stand out 6 Lancer a...

Page 88: ...rated with rear under spoiler have been adopted for better aerodynamic perfor mance A cooling hole for the intercooler is in the center of the front bumper The front license plate mount is offset from the center to the left side to improve the cooling performance of the intercooler CONSTRUCTION DIAGRAM AC210166 FRONT BUMPER REAR BUMPER AB ...

Page 89: ...s an option CONSTRUCTION DIAGRAM UNDER COVER The large undercover with venturi ducts improve downforce characteristics and drivetrain cooling per formance REAR SPOILER For type A standard the use of carbon fiber for the rear spoiler makes the unit more rigid and thinner for minimum drag that produces efficient downforce For type B option a rear spoiler incorporating high mounted stop light has bee...

Page 90: ...WINDSHIELD WIPER AND WASHER EXTERIOR 51 5 WINDSHIELD WIPER AND WASHER GENERAL INFORMATION M2510000100569 CONSTRUCTION DIAGRAM AC210201 WIPER ARM FRAME AB WIPER LINK ASSEMBLY WIPER MOTOR WIPER BLADE ...

Page 91: ...quiet wiper operation The mist wiper function is activated by moving the wiper switch in the opposite direction The wipers operate at high speed while the mist switch remains on When the mist switch is returned to the OFF position for a moment the wipers operate once at low speed The windshield washer system is 2 nozzle and 4 jet type The wipers wipe when the washer func tion has been activated AC...

Page 92: ...pe away the rain from the glass and then it changes to intermittent operation Reverse gear linked operation when the selector lever is moved to the reverse R position with the rear wiper switch at the intermittent position there is a delay of approximately one second and then the wiper operates two or three times continuously at low speed and then it continues operating in normal intermittent mode...

Page 93: ...OR 51 8 OUTSIDE MIRROR GENERAL INFORMATION M2510000100581 Electric remote control outside mirror have been adopted CONSTRUCTION DIAGRAM AC210398 Y1043AU Y0320AU AB REMOTE CONTROL MIRROR SWITCH OUTSIDE MIRROR MIRROR SURFACE ...

Page 94: ...26 1 GROUP 26 FRONT AXLE CONTENTS GENERAL DESCRIPTION 26 2 ...

Page 95: ...ype constant velocity joint ABS rotors for detecting the wheel speed are press fitted to the EBJ For environmental protection a lead free grease is used on the joints NOTE EBJ Eight Ball Fixed Joint The use of the smaller sized eight balls inside the joint achieves weight saving and compact size compared with a BJ Birfield Joint TJ Tripod Joint SPECIFICATIONS NOTE The wheel bearing is part of the ...

Page 96: ...B 1 GROUP 54B SIMPLIFIED WIRING SYSTEM SWS CONTENTS GENERAL INFORMATION 54B 2 COMMUNICATION METHOD 54B 2 MULTI DISTRIBUTION INPUT OUTPUT BY CIRCUIT 54B 3 DIAGNOSTIC TROUBLE CODE SET 54B 5 TONE ALARM 54B 6 ...

Page 97: ...communication between control units NOTE ETACS Electronic Time and Alarm Con trol System CONSTRUCTION DIAGRAM COMMUNICATION METHOD M2541001000130 The exclusive signal lines for transmitting the multi distribution data are connected as shown between the ETACS ECU column switch incorporated inside the column ECU and front ECU for internal commu nication AC210681AB FRONT ECU ETACS ECU COLMUN SWITCH A...

Page 98: ...pendent variable windshield intermittent wiper Windshield low speed wiper Windshield high speed wiper Windshield washer AC210161 INPUT SWITCH ECU AND SWITCH CONNECTED BY MULTI DISTRIBUTION OUTPUT SIDE TONE ALARM BUILT IN ETACS ECU ETACS ECU COLUMN SWITCH LIGHTING SWITCH IGNITION SWITCH IG1 DOOR SWITCH FRONT LH KEY REMINDER SWITCH AB AC210162 INPUT SWITCH AND SENSOR ECUS AND SWITCH CONNECTED BY MUL...

Page 99: ...MOTOR REAR WASHER MOTOR ETACS ECU COLUMN SWITCH REAR WIPER WASHER SWITCH AC210164 INPUT SWITCH ECUS AND SWITCH CONNECTED BY MULTI DISTRIBUTION OUTPUT SIDE AB ETACS ECU COLUMN SWITCH LIGHTING SWITCH COMBINATION METER HIGH BEAM INDICATOR ILLUMINATION LIGHTS HEADLIGHTS TAILLIGHTS FRONT ECU IGNITION SWITCH IG1 DOOR SWITCH FRONT LH IGNITION SWITCH ACC AC210165 INPUT SWITCH ECU AND SWITCH CONNECTED BY M...

Page 100: ...N position Driver s passengerís or rear door switch Open the door Driver s or passengerís door lock key cylinder switch Turn the key to the lock or unlock position Driver s door lock actuator switch Move the door lock knob from lock position to unlock position or vice versa Door lock switch incorporated in power window main switch and power window sub switch Press LOCK or UNLOCK side Backup light ...

Page 101: ...unction P 54B 9 Timed locking mechanism P 54B 9 POWER WINDOW Power window timer function ETACS ECU power window main switch P 54B 10 Sunroof Sunroof timer function ETACS ECU sunroof ECU P 54B 10 WINDSHIELD WIPER AND WASHER Windshield wiper intermittent control vehicle speed dependent variable type ETACS ECU front ECU column switch P 54B 10 Mist wiper control P 54B 11 Low speed wiper and high speed...

Page 102: ... turned to ON position without fastening the driverís seat belt driverís seat belt switch off the tone alarm will sound for approxi mately six seconds to warn the driver to fasten the seat belt When the driverís seat belt is fastened or the ignition switch is turned to OFF position the tone alarm will stop sounding AC005427AC ON OFF ON KEY REMOVED OFF KEY INSERTED ON OPEN OFF CLOSED ON TONE ALARM ...

Page 103: ...TACS ECU operates its door unlock relay and passes a current through the door lock actuators of all doors for 0 25 seconds and to unlock all doors Door unlocking by operating the front passengerís door lock key cylinder When the ignition key is inserted in the front passengerís door lock key cylinder and turned clockwise to unlock the front pas sengerís door the ETACS ECU operates its door unlock ...

Page 104: ... Then the ETACS ECU operates its door unlock relay and passes a current through the door lock actuators of all doors for 0 25 seconds to unlock all doors Due to this there may be a time lag between the driverís or front passenger s door lock switch actuation and the time when all doors is unlocked KEYLESS ENTRY Keyless entry hazard answerback and horn answerback function When the lock signal is in...

Page 105: ...r the ignition is switched off During this timed operation if the driver s door or passengerís door is opened the sunroof timer function is deactivated from that moment WINDSHIELD WIPER AND WASHER Intermittent control vehicle speed dependent variable type The ETACS ECU calculates the intermittent time according to the vehicle speed calculated from the windshield wiper intermit tent time adjusting ...

Page 106: ...d wiper will operate at high speed Then if the windshield mist wiper switch is turned off the wiper operates at low speed until it stops at the predetermined park position When the windshield mist switch is turned on briefly the wiper operates at low speed once At the point the windshield mist switch is turned ON if the windshield wiper has been operating intermit tently the same operations as the...

Page 107: ... wiper continuously When the windshield washer switch is turned ON if the wind shield wiper is operating intermittently intermittent operations will be continued after continuous opera tion NOTE The wiper drive signal output time varies according to the conditions Refer to the following table for details AC005437AB ON OFF ON OFF ON OFF ON HIGH WINDSHIELD LOW SPEED WIPER SWITCH WINDSHIELD HIGH SPEE...

Page 108: ... 7 4 to 8 second cycle REAR WASHER CONTROL When the ignition switch is at the ACC or ON posi tion if the rear washer switch of the column switch is turned ON the ETACS ECU turns ON the rear washer relay The rear wiper drive signal is turned ON in 0 3 seconds until three seconds after the rear washer switch goes OFF to operate the rear wiper continuously If the rear wiper is in intermittent operati...

Page 109: ...light switch is operated while the low beam headlights are on The fog lights will be switched off when any of the fol lowing conditions is met The fog lights will also be switched off automatically by headlight automatic shutdown function When the high beam headlights are switched on the fog lights will be switched off If the low beam headlights are switched on again the fog lights will illuminate...

Page 110: ...ggle switch DOME LIGHT Dome light control function NOTE The dotted lines in the graph indicate that lighting mode when the ignition switch is turned ON door is locked or any door is opened during the timer illumination time When the dome light switch is at the DOOR position the ETACS ECU controls the lighting of the dome light as follows AC005444AC IGNITION SWITCH TURN SIGNAL LIGHT SWITCH LH TURN ...

Page 111: ...ion can be disabled Refer to P 54B 17 Interior light automatic shutdown function Illuminated interior lights such as the front dome light etc all lights using the dome light fuse as the power supply will automatically go off in the follow ing conditions to prevent the battery from discharging as a result of forgetting to turn off the lights or incom plete closing of the door When the ignition swit...

Page 112: ...Key reminder switch ON Remove the igni tion key Ignition switch Turn to any position other than LOCK OFF position Driverís door switch ON driverís door opened Three minutes pass without configurations performed Another warning tone alarm output is gener ated 3 Configurations of various functions FUNCTION CONFIGURATION PROCEDURE Keyless entry system hazard answerback function When the lock switch o...

Page 113: ...unds three times d 15 seconds Tone alarm sounds four times e 7 5 seconds Tone alarm sounds five times f Returns to a after e and repeats from a in order Interior light automatic shutdown function When the hazard light switch is turned ON for more than two seconds the interior light cut off function is changed as follows a and b switches alternately a Function available Tone alarm sounds once Initi...

Page 114: ...11A 1 GROUP 11A ENGINE CONTENTS GENERAL SPECIFICATIONS 11A 2 BASE ENGINE 11A 3 ...

Page 115: ...ft configuration GENERAL SPECIFICATIONS ITEM 4G63 DOHC T C Total displacement cc 1 997 Combustion chamber Pent roof type Bore Stroke mm 85 0 88 0 Compression ratio 8 8 Camshaft arrangement DOHC 16 valve Valve timing Intake opening BTDC 17 Intake closing ABDC 59 Exhaust opening BBDC 57 Exhaust closing ATDC 15 Maximum output kW rpm HP r min 202 6 500 271 6 500 Maximum torque N m rpm lbs ft r min 37 ...

Page 116: ...gement There is a squish area provided in the combustion chamber which promotes turbu lence further mixing of the air fuel mixture and more efficient combustion The spark plugs are located at the center of the com bustion cambers The camshaft bearings are placed at six locations on the exhaust side AK204066AB OIL PASSAGES FOR LASH ADJUSTER VALVE SEAT VALVE GUIDE SQUISH AREA SPARK PLUG HOLE EXHAUST...

Page 117: ...auto tensioner absorbs changes in belt tension to prevent the noise problem from getting worse and to improve durability All sprockets are made of a sintered alloy CAMSHAFT The change to a hollow body hollow cast camshaft reduces weight AK204067AB CAMSHAFT SPROCKET CAMSHAFT SPROCKET AUTO TENSIONER TENSIONER PULLEY TENSIONER ARM TENSIONER PULLEY CRANKSHAFT SPROCKET OIL PUMP SPROCKET AK204064 HOLLOW...

Page 118: ...BASE ENGINE ENGINE 11A 5 VALVE The change to natrium filled exhaust valves reduces weight and assists in cooling the bell section AK204065AB NATRIUM FILLED ...

Page 119: ...NOTES ...

Page 120: ...P 15 INTAKE AND EXHAUST CONTENTS AIR INTAKE SYSTEM 15 2 AIR DUCT AND AIR CLEANER 15 2 CHARGE AIR COOLER 15 2 CHARGE AIR COOLER WATER SPRAY 15 3 EXHAUST SYSTEM 15 5 TURBOCHARGER 15 5 EXHAUST PIPE AND MUFFLER 15 6 ...

Page 121: ...plastic to reduce industrial wastes and protect the environment Environmentally friendly unleaded rubber materi als are used for the air intake hose CONSTRUCTION DIAGRAM CHARGE AIR COOLER M2150007000019 By mounting an air cooled charge air cooler to reduce the intake air temperature after boosting engine output has been improved CONSTRUCTION DIAGRAM AC210029 AIR DUCT AIR INTAKE HOSE AIR CLEANER AS...

Page 122: ...system are Sprays water when the water spray switch on the floor console is operated Enables switching between the driver operated manual mode and the auto mode which auto matically sprays water at the optimum operating conditions by signals from the engine control module ECM according to the engine state Two water spray nozzles are located at optimum positions to enhance the charge air cooler eff...

Page 123: ...PRAY SWITCH RHEOSTAT JOINT CONNECTOR 1 RELAY BOX FRONT ECU TAILLIGHT RELAY ENGINE CONTROL MODULE JUNCTION BLOCK CHARGE AIR COOLER WATER SPRAY RELAY CHARGE AIR COOLER WATER SPRAY MOTOR IGNITION SWITCH IG2 JOINT CONNECTOR 2 IGNITION SWITCH IG1 JUNCTION BLOCK JOINT CONNECTOR 4 COMBINATION METER AC210034 ...

Page 124: ...15 Dual exhaust passages from the engine to the tur bine housing prevents obstruction of the flow and guides the exhaust gas smoothly to the turbine to improve low and mid range torque and engine response AK204159AB TWIN SCROLL DUAL EXHAUST MANIFOLD AK204068 A A A A AB TWIN SCROLL ...

Page 125: ...n from the exhaust system All stainless exhaust piping reduces corrosion and heat Thermal insulating cover and materials on front pipe improve emission control performance Seal ring reduces driving noise and vibration dur ing idling The main muffler has a back pressure variable valve CONSTRUCTION DIAGRAM AC210036 AC210035 10020AU Y2187AU WHEN VALVE IS OPEN FLOW OF EXHAUST GAS BACK PRESSURE VARIABL...

Page 126: ...13B 1 GROUP 13B FUEL SUPPLY CONTENTS GENERAL DESCRIPTION 13B 2 FUEL TANK 13B 3 ...

Page 127: ...SPECIFICATIONS CONSTRUCTION DIAGRAM ITEM SPECIFICATION Fuel tank capacity dm3 gal 53 14 0 Fuel pump type Electric Fuel filter type Cartridge incorporates fuel pump module Fuel return system Fuel pressure regulator return Fuel pump pressure regulator pressure kPa psi 294 42 6 Fuel injector Type Electro magnetic Quantity 4 Evaporative emission control system Canister AC210026AB FUEL RAIL FUEL PRESSU...

Page 128: ...e assembly Fuel tank rollover valve assembly Fuel tank shut off valve Fuel tank differential pressure sensor Fuel tank temperature sensor The fuel pump module consists of the following com ponents Fuel pump Fuel level sensor main Fuel filter Fuel feed assist pump CONSTRUCTION DIAGRAM AC210027 FUEL LEVEL SENSOR SUB FUEL TANK DIFFERENTIAL PRESSURE SENSOR FUEL TANK TEMPERATURE SENSOR FUEL PUMP MODULE...

Page 129: ...NOTES ...

Page 130: ...25 1 GROUP 25 PROPELLER SHAFT CONTENTS GENERAL DESCRIPTION 25 2 ...

Page 131: ...ates the length between the center points of each joint CONSTRUCTION DIAGRAM ITEM SPECIFICATION Propeller shaft Type 3 way split 4 joint type propeller shaft Length Outside diameter mm in Front 608 5 x 65 24 0 x 2 56 Center 551 x 65 21 7 x 2 56 Rear 750 5 x 65 29 5 x 2 56 Universal joint Type No 1 Cross type cauking method No 2 Cross type cauking method No 3 Constant velocity type LJ No 4 Cross ty...

Page 132: ...16 1 GROUP 16 ENGINE ELECTRICAL CONTENTS CAMSHAFT POSITION SENSOR 16 2 ...

Page 133: ...16 2 CAMSHAFT POSITION SENSOR M2163002000069 The camshaft position sensor detects the camshaft position using a sensing cylinder which is mounted at the rear end the exhaust camshaft AK204160 CAMSHAFT POSITION SENSOR CAMSHAFT SENSING CYLINDER AB ...

Page 134: ...12 1 GROUP 12 ENGINE LUBRICATION CONTENTS GENERAL DESCRIPTION 12 2 ...

Page 135: ...sembly and brings in the air through the oil cooler duct of the front bumper to cool the engine oil SPECIFICATIONS CONSTRUCTION DIAGRAM ITEM SPECIFICATION Type Drawn cup type Core size mm in Width Height Thickness 160 200 49 6 3 7 9 1 93 Engine oil cooler oil amount dm3 qt 0 35 0 37 Performance kJ h kcal h 29 900 7 143 AC210268 ENGINE OIL COOLER FEED HOSE ENGINE OIL COOLER RETURN HOSE ENGINE OIL C...

Page 136: ...55 1 GROUP 55 HEATER AIR CONDITIONING AND VENTILATION CONTENTS GENERAL INFORMATION 55 2 HEATER AND AIR CONDITIONER SYSTEM 55 4 VENTILATION SYSTEM 55 6 ...

Page 137: ...nt of ventilation system to defog win dows by increasing the outside air intake duct area on the front deck and adopting a large air outlet 2 Windshield defogging speed improvement derived from increase in air volume and wind speed by adopting a blower type defroster and high performance heater Improvements in fuel economy 1 Optimization of idle rotation speed according to air conditioner load 2 I...

Page 138: ...CONDENSOR DISCHARGE FLEXIBLE HOSE A C COMPRESSOR FLEXIBLE SUCTION HOSE LIQUID PIPE B BLOWER ASSEMBLY HEATER UNIT AB FLEXIBLE SUCTION PIPE LIQUID PIPE A CONDENSOR FAN AC211012 HEATER UNIT AIR THERMOMETER SENSOR MOTOR FOR INSIDE OUTSIDE AIR SELECTION DAMPER BLOWER MOTOR BLOWER ASSEMBLY AB RESISTOR ...

Page 139: ...e which does not pass through the core One air mix door is used for temperature con trol The two way blow full mix heater with low ventilation resis tance has increased air volume and has reduced noise CONDENSER The heat exchange efficiency has been improved with a sub cooling type condenser added with a sub cooled section The reduction of line unions by incorporating the condenser and receiver re...

Page 140: ...are heater and air conditioner control improvements Dial type switch Rear window defogger switch with timer Improved appearance by incorporating the center panel AC006080 REAR WINDOW DEFOGGER SWITCH AIR CONDITIONER SWITCH TEMPERATURE ADJUSTMENT SWITCH BLOWER SWITCH OUTLET CHANGEOVER SWITCH INSIDE OUTSIDE AIR CHANGEOVER SWITCH AB ...

Page 141: ...d for defogging windows Increased outside air intake duct area Increased size of air outlet on the back of the rear bumper Installation of blower type defroster AC210428 TO FRONT DOOR WINDOW SIDE DEFROSTER SIDE VENTILATOR CENTER VENTILATOR TO DRIVER SEAT FOOTWELL TO PASSENGER SEAT FOOTWELL SIDE VENTILATOR TO FRONT DOOR WINDOW SIDE DEFROSTER TO WINDSHIELD DEFROSTER AB AC210865 AIR OUTLET AB ...

Page 142: ...32 1 GROUP 32 POWER PLANT MOUNT CONTENTS GENERAL DESCRIPTION 32 2 ...

Page 143: ...Installation of roll stopper in the upper area has reduced engine rolling Furthermore enlarge ment of insulator diameter has reduced idle vibra tion CONSTRUCTION DIAGRAM AC210281 ENGINE FRONT MOUNTING BRACKET TRANSAXLE MOUNTING BODY SIDE BRACKET TRANSAXLE CASE FRONT ROLL STOPPER BRACKET TRANSAXLE CASE REAR ROLL STOPPER BRACKET ENGINE FRONT ROLL STOPPER BRACKET FRONT SUSPENSION CENTERMEMBER FRONT A...

Page 144: ...14 1 GROUP 14 ENGINE COOLING CONTENTS GENERAL DESCRIPTION 14 2 ...

Page 145: ...a tor fins are used The speed of the cooling fan is controlled by a fan control module The engine control module detects driving conditions and controls the fan control module so that the fan operating noise is minimized and fuel efficiency is improved SPECIFICATIONS CONSTRUCTION DIAGRAM ITEM SPECIFICATION Cooling method Water cooled pressurized forced circulation with electrical fan Radiator Type...

Page 146: ...52 1 GROUP 52 INTERIOR AND SUPPLEMENTAL SYSTEM SRS CONTENTS INTERIOR 52A SUPPLEMENTAL RESTRAINT SYSTEM SRS 52B ...

Page 147: ...NOTES ...

Page 148: ...2A INTERIOR CONTENTS GENERAL INFORMATION 52A 2 INSTRUMENT PANEL AND FLOOR CONSOLE 52A 3 ACCESSORIES 52A 4 SEAT 52A 5 FRONT SEAT 52A 5 REAR SEAT 52A 6 SEAT BELT 52A 7 TRIMS 52A 9 INTERIOR TRIMS 52A 9 DOOR TRIM 52A 10 ...

Page 149: ...s sengerís seat Rear seat 3 A seat belt with the force limiter mechanism has been installed as the front seat belt 4 Upper tether anchor 5 ISO FIX child seat fixing bar 6 Head impact reduction pillar trim 7 Folding assist grip 8 Nonflammable materials are used for instrumen tal panel floor console and trims Usability 1 Vanity mirror with lid 2 Ticket holder Driverís side Convenient storage 1 Glove...

Page 150: ...nter panel box convenient for storing accesso ries A pad incorporating the front passengerís air bag door has improved appearance A cup holder has been installed to the rear floor console Ashtrays are in the front and the rear console Nonflammable materials are used for the instru ment panel and the floor console Also material codes are indicated AC210431AB AIR BAG DOOR GLOVE BOX FRONT SEAT ASHTRA...

Page 151: ...to improve con venience Vehicles without sunroof Vanity mirrors with lid are on driverís and front passengerís side A ticket holder is on the driverís side A folding assist grip has been installed to improve safety AC211396 FOLDING ASSIST GRIP VANITY MIRROR WITH LID SUNGLASSES POCKET MAP LAMP TICKET HOLDER VANITY MIRROR WITH LID AB ...

Page 152: ...ing advan tages The fabric for the main cushion section uses an embossed knit in a sporty mesh design The side sections are finished in a suede type material Adjustments for both reclining and sliding are step free to allow occupants to adjust the seats to achieve the best posture for driving AC210102AB RECLINING ADJUSTMENT SLIDING ADJUSTMENT ...

Page 153: ...rear seat offer the following advantages The center armrest has a cup holder An upper tether anchor has been installed on the rear shelf trim and an ISO FIX child seat fixing bar has been installed on the body side AC209729 CUP HOLDER ARMREST AB UPPER TETHER ANCHOR ISO FIX CHILD SEAT FIXING BAR ...

Page 154: ...the driverís seat and the front passengerís seat increase safety A seat belt warning light is installed to the driverís seat REAR SEAT BELT 3 point seat belt with Automatic Locking Retrac tor ALR ELR changeover mechanism LH RH Center is used for the rear seat AC209722 3 POINT SEAT BELT WITH ELR ALR CHANGEOVER MECHANISM ONE TOUCH PUSH BUTTON STYLE ADJUSTABLE SEAT BELT ANCHOR AB SEAT BELT WARNING LI...

Page 155: ...termined force is applied and limits the force OPERATION 1 If a collision energy is transmitted to the seat belt the ELR mechanism will operate to lock the seat belt 2 If the energy increases to a predetermined value the torsion bar will be distorted As the spindle rotates together with the torsion bar the seat belt webbing is pulled out reducing the impact to the occupants AC100083 TORSION BAR SP...

Page 156: ...e impacts and the resin materials for the trims are unbreakable materials Nonflammable materials are used for the trims Also material codes are indicated for recycling AC209732 ENERGY ABSORPTION RIB FRONT PILLAR TRIM BACK SIDE COWL SIDE TRIM FRONT PILLAR TRIM FRONT SCUFF PLATE LOWER CENTER PILLAR TRIM REAR SCUFF PLATE UPPER CENTER PILLAR TRIM REAR PILLAR TRIM REAR SHELF TRIM AB ENERGY ABSORPTION R...

Page 157: ...s used for door trim to pro tect passengers in the event of a side collision and improve safety Cloth covers part of door trim A large door pocket is used for the front door trim AC210219 FRONT DOOR TRIM REAR DOOR TRIM DOOR POCKET AB CLOTH COVERED PART CLOTH COVERED PART ...

Page 158: ...17 1 GROUP 17 ENGINE AND EMISSION CONTROL CONTENTS ACCELERATOR SYSTEM 17 2 GENERAL DESCRIPTION 17 2 EMISSION CONTROL 17 3 GENERAL DESCRIPTION 17 3 ...

Page 159: ...c bushing and rubber damper have been attached to the end of the accel erator cable to prevent noise and vibration when the cable and accelerator pedal arm contact CONSTRUCTION DIAGRAM AC210037 AC210048 AC210047 AB PLASTIC BUSHING ACCELERATOR CABLE ACCELERATOR PEDAL BRACKET ACCELERATOR PEDAL ARM ACCELERATOR CABLE ACCELERATOR PEDAL ARM RUBBER DUMPER ACCELERATOR PEDAL ARM STOPPER ...

Page 160: ...stem Closed type Evaporative emission system Electronic control type Evaporative emission purge solenoid Duty type Evaporative emission ventilation solenoid Duty type Exhaust gas recirculation EGR system Electronic control type EGR vacuum regulator solenoid valve Duty type Air fuel ratio closed loop control Heated oxygen sensor signal used Catalytic converter Three way catalyst AK202523 EVAPORATIV...

Page 161: ...NOTES ...

Page 162: ...13 1 GROUP 13 FUEL CONTENTS MULTIPORT FUEL SYSTEM MFI 13A FUEL SUPPLY 13B ...

Page 163: ...NOTES ...

Page 164: ...TION CONTROL 13A 5 IDLE AIR CONTROL IAC 13A 6 IGNITION TIMING AND DISTRIBUTION CONTROL 13A 7 FUEL PUMP CONTROL 13A 8 FAN MOTOR CONTROL 13A 9 FUEL PRESSURE CONTROL INTAKE CHARGE PRESSURE CONTROL 13A 9 CHARGE AIR COOLER WATER SPRAY CONTROL 13A 9 OTHER CONTROL FUNCTIONS 13A 9 ON BOARD DIAGNOSTICS 13A 10 ...

Page 165: ... spray control Improves output performance during high load operating conditions by spraying water on the charge air cooler which cools the intake air if the AUTO mode is selected Fuel pump discharge volume switching control Reduces the discharge of fuel vapors when the load on the engine is low by decreasing the fuel pump speed which decreases the fuel return volume This function is basically the...

Page 166: ...uel tank differential pressure sensor Service engine soon malfunction indicator lamp Diagnostic output terminal Heated oxygen sensor heater Fuel pump relay 2 ON OFF EVAP ventilation solenoid MFI relay Idle air control motor Stepper motor 1 Fuel injection control 2 Idle speed control 3 Ignition timing control 6 Heated oxygen sensor heater control 7 A C compressor clutch relay control 8 Fuel pressur...

Page 167: ...the contacts of the clutch pedal position switch close This causes the positive battery voltage applied by the engine con trol module ECM to be grounded to the body via the clutch pedal assembly Upon detecting this signal the ECM makes fuel injection volume corrections during a shift change thus reducing the discharge of hydrocarbon HC emissions associ ated with insufficient release of the acceler...

Page 168: ...al while shift ing gears this control changes the fuel injection vol ume for a predetermined length of time after the verification time has elapsed System Configuration Diagram AK202520 TO FUEL TANK FROM FUEL PUMP FUEL PRESSURE REGULATOR INJECTOR ECM FUEL PRESSURE SOLENOID VOLUME AIRFLOW SENSOR BAROMETRIC PRESSURE SENSOR INTAKE AIR TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR THROTTLE POSI...

Page 169: ...ROL IAC MOTOR STEPPER MOTOR FROM AIR CLEANER TO INTAKE MANIFOLD BIMETAL TYPE LIMITER SPEED ADJUSTING SCREW ECM VOLUME AIRFLOW SENSOR BAROMETRIC PRESSURE SENSOR INTAKE AIR TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR THROTTLE POSITION SENSOR CRANKSHAFT POSITION SENSOR A C SWITCH A C LOAD SIGNAL VEHICLE SPEED SENSOR POWER STEERING PRESSURE SWITCH GENERATOR FR TERMINAL IGNITION SWITCH IG IGNI...

Page 170: ...L engine installed in the ECLIPSE System Configuration Diagram AK203777 SPARK PLUG CYLINDER NO TO TACHOMETER IGNITION SWITCH BATTERY IGNITION COIL B IGNITION COIL A 2 3 4 1 ECM VOLUME AIRFLOW SENSOR BAROMETRIC PRESSURE SENSOR INTAKE AIR TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR CRANKSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR VEHICLE SPEED SENSOR KNOCK SENSOR IGNITION SWITCH ST DIAGN...

Page 171: ...the power transistor ON which causes the current to flow through the coil of the fuel pump relay 3 Accordingly the contacts of the relay open causing the current to the fuel pump to flow via the fuel pump resistor Because the resis tor drops the voltage of the current the supply volt age to the fuel pump decreases As a result the pump speed decreases thus reducing the fuel dis charge volume of the...

Page 172: ...en the charge air cooler water spray switch is turned ON in the AUTO mode and the engine is operating at high load conditions the ECM turns the charge air cooler spray relay ON to spray water on the charge air cooler and illuminates the charge air cooler spray lamp on the combination meter When the charge air cooler water spray switch is pressed in the MANUAL mode the ECM turns ON the charge air c...

Page 173: ...igh input P0116 Engine coolant temperature circuit range performance problem P0117 Engine coolant temperature circuit low input P0118 Engine coolant temperature circuit high input P0121 Throttle position sensor circuit range performance problem P0122 Throttle position sensor circuit low input P0123 Throttle position sensor circuit high input P0125 Insufficient coolant temperature for closed loop f...

Page 174: ...d P0403 Exhaust gas recirculation control circuit P0420 Catalyst efficiency below threshold P0441 Evaporative emission system incorrect purge flow P0442 Evaporative emission system leak detected Small leak P0443 Evaporative emission system purge control valve circuit P0446 Evaporative emission system vent control circuit P0451 Evaporative emission system pressure sensor range performance P0452 Eva...

Page 175: ...RO SENSOR 25 Barometric pressure sensor kPa in Hg BATT VOLTAGE 16 Power supply voltage V CKP SENSOR 22 Crankshaft position sensor r min CRANK SIGNAL 18 Cranking signal ignition switch ST ON OFF ECT SENSOR 21 Engine coolant temperature sensor C F FUEL TEMP 4A Fuel tank temperature sensor C F HO2S BANK1 S1 11 Heated oxygen sensor front mV HO2S BANK1 S2 59 Heated oxygen sensor rear mV IAC VALVE POS 4...

Page 176: ...denser fan Relay HI Condenser fan motor operates at high speed CONDEN FAN LO 38 Condenser fan Relay LO Condenser fan motor operates at Low speed EGR VACUUM REGULATOR SOLENOID VALVE 10 EGR vacuum regulator solenoid valve Solenoid valve turns from OFF to ON EVAP PURGE SOL 08 Evaporative emission purge solenoid Solenoid valve turns from OFF to ON EVAP VENT SOL 29 Evaporative emission ventilation sole...

Page 177: ...NOTES ...

Page 178: ...22A 1 GROUP 22A MANUAL TRANSAXLE CONTENTS GENERAL DESCRIPTION 22A 2 AWD SYSTEM 22A 4 TRANSMISSION CONTROL 22A 5 ...

Page 179: ... ITEM SPECIFICATION Transaxle model W5M51 Engine model 4G63 DOHC Intercooler Turbo Transaxle type 5 speed forward 1 speed reverse constant mesh Transaxle gear ratio 1st 2 928 2nd 1 950 3rd 1 407 4th 1 031 5th 0 720 Reverse 3 416 Final reduction ratio Differential gear ratio 4 529 Speedometer gear ratio 31 36 Transaxle oil Specified lubricants Gear oil API classification GL 4 SAE 75W 85W or 75W 90 ...

Page 180: ...EAR 4 TRANSAXLE CASE 5 CLUTCH HOUSING 6 REVERSE BEARING RETAINER 7 INPUT SHAFT 8 OUTPUT SHAFT 9 FRONT DIFFERENTIAL 10 VISCOUS COUPLING UNIT VCU 11 TRANSFER CASE 12 HYPOID PINION 13 CENTER DIFFERENTIAL 14 1ST SPEED GEAR 15 1ST 2ND SPEED SYNCHRONIZER HUB 16 2ND SPEED GEAR 17 5TH SPEED GEAR 18 5TH REVERSE SPEED SYNCHRONIZER HUB 19 REVERSE SPEED GEAR 20 REVERSE IDLER GEAR ...

Page 181: ...e transfer For FWD models the center differ ential is housed in the transaxle in the place of the front differential for FWD A viscous coupling unit VCU is used for the cen ter differential limited slip device and is located in the rear of the front differential AC207584 VISCOUS COUPLING UNIT VCU FRONT DIFFERENTIAL REAR DIFFERENTIAL CENTER DIFFERENTIAL TARNSFER ENGINE TRANSAXLE AB ...

Page 182: ...fulcrum type The base bracket is made of synthetic resin for the weight reduction The shift and select cable securing portions have been elastically supported to reduce noise and vibration A mass filled shift knob minimizes binding during shifting AC207487 SELECT CABLE AB TRANSAXLE CONTROL CABLE ASSEMBLY SHIFT KNOB SHIFT LEVER ASSEMBLY SHIFT CABLE ...

Page 183: ...NOTES ...

Page 184: ...ENDER 42 3 STRUT TOWER BAR 42 3 GENERAL INFORMATION 42 3 MAIN BODY 42 4 BODY PANELING 42 4 BODY SHELL 42 5 QUIETNESS 42 8 BODY COLOR CHARTS 42 9 DOOR 42 10 DOOR LOCK 42 10 KEYLESS ENTRY SYSTEM 42 12 WINDOW GLASS REGULATOR 42 14 LID 42 15 TRUNK LID 42 15 WINDOW GLASS 42 16 SUNROOF 42 17 ...

Page 185: ...ch are adopted 3 Inside lock cables are used on the front doors to improve safety in case of impact 4 A trunk lid latch which prevents a person from being confined in the luggage compartment in an accident is used 5 Impact safety body RISE Realized Impact Safety Evolution is adopted for the main body mono coque body 6 Side door beams are utilized to improve safety in case of side impact Improvemen...

Page 186: ...outlet garnish is used to prevent overheating of the engine compartment CONSTRUCTION DIAGRAM STRUT TOWER BAR GENERAL INFORMATION M2420001300010 A strut tower bar is added to the strut attachment point to improve body rigidity and steering feel CONSTRUCTION DIAGRAM AC210246 FENDER AB HOOD HOOD AIR OUTLET GARNISH AC107159 PLATE PLATE AF STRUT TOWER BAR ...

Page 187: ...rmance It has been made lighter by adopting aluminum alloy panels for the hood panel and front fender A lighter weight main body and better anti corrosive properties are achieved by the use of highly tensile steel plate and anti corrosion steel plate AB201073 Anti corrosion steel panels High tensile steel panels ...

Page 188: ...enlarged and linear cross section of front side member 2 Addition of dash panel cross member 3 Application of thicker dash panel lower 4 Enlarged cross section of front floor side member 5 Enlarged cross section of side sill outer reinforce ment 6 Thicker front pillar reinforcement and center pillar reinforcement 7 Enlarged cross section of roof bow AB201008 6 1 2 4 3 6 7 5 AB ...

Page 189: ... increased The thickness of the center pillar reinforcement applied at the upper is increased NOTE Steel plates with different thickness welded together to make one steel plate AB201040 THE THICKNESS OF THE FRONT SIDEMEMBER INNER PLATE LOCATED BEHIND THIS PART IS INCREASED FRONT SIDEMEMBER INNER CENTER PILLAR REINFORCEMENT WITHOUT THE SIDE OUTER PANEL THE THICKNESS OF THE CENTER PILLAR REINFORCEME...

Page 190: ...each other to increase torsional rigidity 3 A closed surface structure is achieved by adding a rear shelf extension to the front of the rear shelf The top of the rear shelf and rear wheel house have been additionally joined with a rear pillar reinforcement and the rear shelf and rear floor with a seat back plate to improve twisting rigidity 4 Additional welded positions at the door opening improve...

Page 191: ... noise penetration 2 Steel plate restricted anti vibration materials silencer sandwiched inside the panel are used to suppress operating sounds and engine vibra tion 3 Filling high rigid foam materials into the side sill and the roof side rail to suppress panel vibration reduces road noise 4 Urethane foam has been inserted into the center pillar to prevent noise penetration AB201074 AB201074AB 1 1...

Page 192: ...ER COLOR NAME COMPOSITION OF FILM COLOR NUMBER COLOR NAME SILVER A31 CMA10031 Cool Silver Metallic AC10595 GRAY BRIGHT BLUE T10 CMT10010 French Blue Solid CMB17004 BRIGHT BLUE BLACK X42 AC11342 Amethyst Black Interferenced Pearl AC10903 BLACK WHITE W83 AC10983 Scotia White Solid AC10863 WHITE RED P85 AC11185 Palma Red Solid AC10795 RED YELLOW Y01 CMY10001 Dandelion Yellow Solid AC10911 YELLOW ...

Page 193: ...lock prevention function by ETACS con trol when the ignition key is left has been adopted Refer to GROUP 54B SIMPLIFIED WIRING SYSTEM P 54B 6 AC101136 AC101137 AC211879 AB FRONT REAR DRIVER S SIDE PASSENGER S SIDE DOOR LOCK SWITCH INSIDE LOCK CABLE INSIDE HANDLE OUTSIDE HANDLE DOOR LATCH ASSEMBLY DOOR LOCK ACTUATOR OUTSIDE HANDLE DOOR LATCH ASSEMBLY DOOR LOCK ACTUATOR INSIDE HANDLE ROD INSIDE LOCK...

Page 194: ...s side door Lock Lock Lock Lock Unlock Unlock Unlock Unlock Inside lock knob Lock Lock Lock Lock Unlock Unlock Door lock switch Lock Lock Lock Lock Unlock Unlock Unlock Unlock Key cylinder Passengerís side door Lock Lock Lock Lock Unlock Unlock Unlock Unlock Inside lock knob Lock Lock Unlock Unlock Door lock switch Lock Lock Lock Lock Unlock Unlock Unlock Unlock Inside lock knob Rear door Lock Loc...

Page 195: ...g type There are two buttons on the transmitter the lock button and the unlock button When either is pressed the transmitter emits a radio signal representing a specific ID code Y0232AU X1683CA AC101142AB ETACS ECU RECEIVER AND ANTENNA INCORPORATED ELECTRIC SIGNAL RADIO SIGNAL LOCK BUTTON UNLOCK BUTTON TRANSMITTER The signal causes the dome light to flash twice when the door is locked or come on f...

Page 196: ...VER OUTPUT AND OPERATION When the ETACS ECU receiver sends a signal to the door lock actuators the turn signal lights and dome light illuminate and horn sounds when lock ing indicating that the keyless entry system is acti vated TIMER LOCK FUNCTION The ETACS ECU receiver sends a door lock signal automatically unless any door is opened within 30 seconds after the doors have been unlocked by the key...

Page 197: ...vents the switches of all other doors from being oper ated For the control of the power window timer of the ETACS ECU Refer to GROUP 54B SIMPLI FIED WIRING SYSTEM P 54B 6 The power window system stays operative for approximately 30 seconds after the ignition switch is turned OFF Refer to GROUP 54B SIMPLIFIED WIRING SYSTEM P 54B 6 AC101139 AC210231AB FRONT REAR POWER WINDOW MAIN SWITCH DRIVER S SID...

Page 198: ...he emergency trunk lid release handle glows by absorbing light so you can operate the handle even in a dark luggage compartment NOTE The glow time depends on the degree of the light absorption but the handle will glow four hours in maximum when a beam of sun light has remained on its surface for 30 seconds or more The glow performance depends on environmen tal conditions AC101145 AC101168 AC101169...

Page 199: ...C005392 1 6 5 4 3 2 AB NO NAME TYPE THICKNESS mm in COLORING VISIBLE LIGHT PERMEATION RATE 1 Windshield Laminated glass 4 3 0 2 Green 80 2 Front door window glass Tempered glass 3 1 0 1 Green 74 3 Rear door window glass 3 1 0 1 Green 82 4 Rear stationary window glass 3 1 0 1 Green 82 5 Rear window glass 3 1 0 1 Green 82 6 Roof lid glass 4 0 0 2 Dark gray 18 ...

Page 200: ...ce is applied is featured Due to the elimination of manual operation in the event of a malfunction a new function of moving the roof approximately 30 mm increments to the fully closed position is adopted This occurs whenever the close down switch is pressed after jamming prevention mechanism is disabled when a reverse movement repeated for 5 times or more is triggered by deformation or when jam mi...

Page 201: ...sing It consists of the motor body drive gear and sunroof ECU SUNROOF ECU The sunroof ECU has a built in microprocessor which controls motor operation in accordance with signals from the sunroof switches and from the ETACS SYSTEM DIAGRAM AC210361 DRIVE GEAR AB SUNROOF ECU 3 2 8 7 6 10 M AC210351 5 4 3 2 1 10 9 8 7 6 1 5 AB IGNITION SWITCH ETACS ECU CLOSE DOWN SWITCH UP SWITCH OPEN SWITCH SUNROOF S...

Page 202: ...is the welding method All of the vehicleís original strength and durability can be maintained by following the welding procedures contained in this manual Now that in order to maximize the efficiency of the repair work first both the extent of the damage and the replacement parts that are needed must be calculated accurately and then the actual work must be performed accurately and efficiently The...

Page 203: ...7 1 GROUP 7 WIRING AND PIPING DIAGRAM CONTENTS PIPING DIAGRAM 7 2 ...

Page 204: ...00026 Drain hose is equipped routed in some parts of closed section structures of the body construction These drain hose must be removed before body pan els in these areas can be replaced AB202303AB A B DRAIN HOSE VHICLES WITH SUNROOF DRAIN HOSE VHICLES WITH SUNROOF A B ...

Page 205: ...TACHMENT OF SILENCERS 9 24 POSITIONING DIMENSIONS FOR OPENINGS 9 25 STANDARD PROCEDURES FOR SHEET METAL WORK 9 25 USING A FRAME STRAIGHTENER 9 27 FRAME REPAIR PROCEDURES 9 28 NOTES REGARDING REPAIR WORK 9 30 HEAT WITHSTAND TEMPERATURES OF RESIN PLASTIC PARTS 9 32 HOW TO DISTINGUISH TYPES OF PLASTICS 9 35 CORROSION PROTECTION 9 36 ANTICORROSION TREATMENT AT THE FACTORY 9 36 ANTICORROSION TREATMENT ...

Page 206: ...ANCE SPOT WELDING M4090002000017 Electric resistance spot welding is a method for fus ing metal parts together Two or three metal sheets are positioned between two copper alloy electrode tips and pressure and a large current are then applied thus causing the contacting surfaces to heat up and fuse together because of the electric contact resistance ADVANTAGES OF ELECTRIC RESISTANCE SPOT WELDING Be...

Page 207: ...cation stage While an ample amount of pressure is being applied the current is sent through the electrode tips The contact resistance causes the contact surfaces of the steel panels to heat up and fuse together 3 Holding stage When the current application is finished and a nugget a solidified piece of molten metal forms at the weld the pressure application is continued in order to strengthen the w...

Page 208: ...ch continues to increase proportionately between points B and C however for thin panels 1 6 mm 0 06 inch or less the weld strength reaches a peak very quickly and will increase only slightly even if the current level increases between points B and C Then for both thick panels and thin panels the mol ten metal will scatter if the current level increases past a certain point AB200029 AB200029 SMALL ...

Page 209: ... inches in order to ensure nugget strength 4 The weld points The overall strength will increase as the pitch decreases however if the pitch decreases too much the current will be short circuit diverted to the previous weld point and the strength of the individual nuggets will be insuf ficient Make the spot welds at the center of the flanges to provide sufficient adhesion When welding at an edge ma...

Page 210: ... POINTS 8 POINTS 11 POINTS 11 POINTS REPAIR WELDS R As shown by the Welding Requirements table the number of repair welds is as follows 8 points 130 10 4 points The number of weld points should therefore be ten or eleven If however a pitch of 26 mm 1 0 inch or more cannot be maintained the plug welding method eight weld points should be used PANEL THICKNESS mm in NUMBER OF REPAIR WELD PERCENTAGE O...

Page 211: ...pressure CHECKING NUGGET STRENGTH FOLLOWING SPOT WELDING CAUTION Stop wedging the tip or the chisel or flat tipped screw driver as soon as the size of the nuggets can be deter mined do not wedge it in more than 30 mm 1 2 inches After checking the nugget diameter correct the place where the checking was done Wedge the tip of a chisel or flat tipped screwdriver into the space between two weld points...

Page 212: ... used in areas where regular spot welding cannot be done The two panels are stacked together the tip of the torch one designed for use in MIG spot welding is positioned on one side an arc is generated for a short time and a par tial melting is done to obtain a spot weld Procedure CAUTION Make sure that the area to be welded is per fectly clean remove oxidation film scales rust dirt etc The two pan...

Page 213: ...by grinder etc Unnecessary Power High voltage low current 15 30 V 50 200 A Low voltage high current 2 4 V 4 10 kA Flux material CO2 carbonic acid gas Weld wire Unnecessary Weld points 10 minutes rate of use 25 points or less Arc instability and contact tip burn if rate of use is exceeded 50 60 points Welding rod deformation and transformer overheating if rate of use is exceeded Distortion caused b...

Page 214: ...ne of the panels to be welded together positioning the torch at a right angle to the holes and then filling in the holes one at a time CONTINUOUS WELDING There are several types of continuous welding fillet lap joint welding butt welding T joint welding gap welding etc these are called short circuit arc welding and provide a stable arc at a relatively low current Torch angle and welding technique ...

Page 215: ...he welding bead should be shorter as the thickness of the panels being welded decreases OTHER TYPES OF WELDING M4090004000013 BRAZING In brazing a filler metal is melted into the joint of the panels to be welded at a comparatively low tempera ture to fuse them together without melting the panels themselves In other words through the aid of a flux and because of the capillarity phenomenon the mol t...

Page 216: ... heat The joint of the panels must overlap as indicated in the illustration GAS WELDING Gas welding is a method in which a high temperature flame is used to melt both a welding rod and the base metal panels to make a fused joint Oxy acetylene is the most common type of gas welding However because of the extremely high tempera ture of the fused joint the strength of the steel plate deterio rates an...

Page 217: ... oxygen rich flame This flame has an excess of oxygen or a defi ciency of acetylene The flame core is shorter and sharper and the entire flame has a blackish purplish color The combustion is unstable and the flame flickers continuously Notes with regard to gas welding 1 Handle the oxygen and acetylene tanks carefully 2 Adjust the flame in accordance with the type of metal being welded 3 Select a n...

Page 218: ...re not be replaced or any other such parts There are harnesses hoses and other such parts routed inside the front pillar the rear pillar the fender shield the side sill etc perform the repair work only after any such material has been removed For overlap cutting allow an overlap of approximately 30 to 50 mm 1 2 to 2 0 inches when performing the cutting operation 1 Rough cutting of panels First mak...

Page 219: ...s CAUTION When performing this operation warping of the surround ing panels may occur if an excessive amount of heat is applied therefore be careful to avoid doing this 5 Finishing work of spot welding Grind and smooth any weld traces which might be left on the body surface by using an air grinder or similar tool being careful not to damage any of the panels which is not to be replaced When perfor...

Page 220: ... Rough cutting of new parts Cut off the unnecessary portions of new parts Allow an overlap of approximately 30 to 50 mm 1 2 to 2 0 inches when performing overlap cutting of the pillars side sills or other locations CAUTION Carefully select the location for cutting taking care not to cut a reinforcement at the inner side of a pillar etc or a panel that is not to be replaced 10 Overlap cutting of ne...

Page 221: ...r to obtain maximum strength Three layer construction When cutting a front pillar or center pillar which has a three layer including a reinforcement construction double box construction cut the outer panel and the reinforcement at the same position and don t forget to butt weld the rein forcement If the inner panel is an assembly replacement part cut it at two places in order to provide ample work...

Page 222: ...cessary in order to obtain agreement with the mea surements 2 In addition make temporary welds and then check to con firm that the closing and fit of the doors fenders etc are correct For parts which should be symmetrical to the body center measure the distances from the body center point to both the left part and the right part and confirm that the dis tances are the same CAUTION Weld completely ...

Page 223: ...ug welding If spot welds cannot be made make holes for plug welding in the new parts and then MIG weld Because the quality of the fusion varies according to the size of the holes they should be about 5 to 6 mm 0 2 inch in diameter In addition be sure the two surfaces are in complete contact with each other by using vise grip pliers to securely hold them NOTE Depending on the working conditions it ...

Page 224: ...ork for butt welding and plug welding Do the finishing work to smooth the protruding weld traces However the butt joints of reinforcements and other internal parts will be stronger if the weld traces are not finished 19 Application of body sealant Apply a coating of sealant carefully without breaks as described in the section of the manual corresponding to that model NOTE After application has bee...

Page 225: ... unit con struction body makes some contribution more or less to the overall strength of that body it is neces sary to sufficiently understand the actual function of any part to be repaired before attempting any repair or welding procedure STRENGTH AND RIGIDITY 1 The suspension installation part plays an impor tant role determining the wheel alignment Wheel misalignment is of course potentially va...

Page 226: ...y is repaired 4 Use spot sealer if spot welds are made 5 Repair any scratches to panels made by mold ings sashes etc 6 Carefully apply body sealant to panel connection joints and other fitting places 7 Tape over any unused holes in the panel inner side by using sealing tape VIBRATION AND NOISE 1 Prevent any decrease of tensional rigidity caused by welding distortion 2 Carefully apply body sealant ...

Page 227: ...re 3 Take care not to peel off the theft protection labels from either the original or the supplementary parts HOW TO PEEL OFF THE SURFACE MASKING FILM FROM THE THEFT PROTECTION LABEL CAUTION Be careful not to damage the paint surface or the label itself 1 Using a sharp knife at the corner of the label surface lift up the masking film only 2 Grasp the masking film and peel it all off NOTE If the m...

Page 228: ...etailed infor mation concerning the locations where silencers are to be attached for individual models refer to the manual for that model 1 Heat the silencer layer petroleum asphalt sheet with a blow drier to soften it 2 Align the silencer layer in the position where it is to be installed and then press it down with a roller or a block of wood so that it adheres well NOTE An infrared lamp can also...

Page 229: ...and then weld STANDARD PROCEDURES FOR SHEET METAL WORK M4090012000018 REPAIRS USING A HAMMER AND DOLLY It a damaged external panel etc can be reused the usual way to repair it is by using a hammer and dolly to hammer out the damaged area The following describes these repair procedures 1 Check whether or not there is foreign material mud etc on the panel surface If so clean it away CAUTION The surf...

Page 230: ... much this will reduce the strength and rigidity of the panel Do not use the file in one direction only alternate use in two directions diagonally opposite each other 4 Next file the area so that convex and concave parts are no longer clearly visible and at the same time remove small projections 5 After once again smoothing the clearly visible dents and projections by using the hammer and dolly fo...

Page 231: ...rame straightened etc be removed Decide upon the work steps and restoration methods to be followed after the rough overall repairs are completed Select the frame straightener based upon the results of above and use it to pull in the appropriate direc tion More than one direction may be appropriate depending upon the damage If the damage is of a moderate degree or less it may be possible to do all ...

Page 232: ...fully observe the shape of the dam aged part and to in that way fully understand the cause of the damage CHECKING FOR FRAME CRACKING OR FLANKING Check by using a test hammer for flaking or cracking of the welded surface of the sidemembers crossmembers and brack ets REPAIRING CRACKS If the check reveals a crack s in the frame repair as described bellow 1 Remove the components near the crack 2 Make ...

Page 233: ... of stress prepare a reinforcement plate that has been cut to 30 45 degree angle at both ends CAUTION Be sure that the edges of the reinforcement plate are not near any place where a concentration of stress of the crossmember or spring hanger installation part etc could easily occur 7 Attach the reinforcement plate to the repaired crack area by MIG welding In order to avoid a concentration of stre...

Page 234: ...tery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected 3 Warning labels must be heeded when servicing or handling SRS components 4 Always use the de...

Page 235: ...that both the ignition and lighting switches are LOCK OFF position before either disconnecting or reconnecting a battery cable If this is not done equip ment containing semiconductors could be damaged Note that the memory of electronic equipment having a memory function will be cleared when the battery cable is disconnected NOTE Vehicles today include a great many electronic parts and components a...

Page 236: ...vers seat covers etc and tape if there is the possibility of damage by tools equipment etc should be used to protect painted surfaces interior exterior parts and components etc from staining and damage For welding operations a heat resistant protective cover should be used to protect glass seats instrument panel carpeting etc HEAT WITHSTAND TEMPERATURES OF RESIN PLASTIC PARTS M4090016000010 Becaus...

Page 237: ... Accelerator pedal pad Wheel cover Speaker garnish Talc filled polypropylene PP TD PPF 100 212 Front deck garnish Stone guard Floor console Instrument panel Talc filled polypropylene 10 PP TD10 PPF 110 to 120 230 to 248 Center pillar trim Talc filled polypropylene 15 PP TD15 PPF 110 to 120 230 to 248 Front pillar trim Center pillar trim Rear pillar trim Talc filled polypropylene 20 PP TD20 PPF 120...

Page 238: ...r reinforced unsaturated polyester UP GT TD SMC BMC 200 392 Rear air spoiler Ethylene vinyl acetate E VAC EVA 60 140 Mud guard Talc filled polypropylene PP E P TD HMPP 80 to 100 176 to 212 Bumper face Side airdam Side protector molding Polyvinyl chloride Polyurethane PVC PUR E 2 Instrument panel pad Thermoplastic elastomer styrene Talc filled polypropylene TES PP TD 100 to 120 212 to 248 Side spla...

Page 239: ...om Burns to black residue Yes Irritating acid odor Polyethylene PE Yellow flame top Blue flame bottom Burns cleanly while melting No Candle like odor Polypropylene PP Yellow flame top Blue flame bottom Burns briskly and drips Slight white smoke No Petroleum like odor Polyurethane PUR Orange Crackles as burns drips No Rubber odor TRUR Orange Polycarbonate PC Yellow Cinders remain To some extent Swe...

Page 240: ...in areas which have a high possibility of painting deficiency ZINC PHOSPHATE COATING In order to improve the adhesive properties of the paint coat on the steel plate and also to improve the finish of the paint coat the entire body is coated with a film of zinc phosphate prior to undergoing the electrodeposition undercoating process 1 Final coat 2 Intermediate coat 3 Anticorrosion primer 4 Undercoa...

Page 241: ...ed are much better than those from conventional anionic electrodeposition BODY SEALING Sealant has been applied to all body panel joints and seams in order to provide resistance to water dust and corrosion UNDERBODY COATING An underbody coating has been applied to the underside of the floor pans the inside of the doors etc in order to provide resistance to vibration corrosion and wear AB200110AB A...

Page 242: ...t ANTICORROSION PRIMER Anticorrosion primer is used at the side sill outer pan els in order to prevent corrosion and to suppress vibration SEALING TAPE Sealing tape is attached at unused holes at the inner side of the panel for waterproofing and anticorrosion protection AB200113 AB200114 AB200114 1 ROCKER PANEL PRIMER APPLICATION AB 1 1 A A AB200115AB Locations for attachment of sealing tape ...

Page 243: ...f hollow parts such as the side sill pillars etc which have been welded are more susceptible to corrosion Spray an aerosol type anticorrosion agent into these parts by using the trim mounting holes and other openings ANTICORROSION TREATMENT OF ROUGH CUTS An anticorrosion agent should be applied to rough cuts made in the course of welding because the surface film has been dam aged by the heat of we...

Page 244: ... sealant is not applied to each of the panel joints and seams Insufficient sealant will result in water leakage corrosion etc NOTE Use a piece of clean cloth dampened in lead free gaso line or a similar material to clean parts and areas where sealant is applied When applying sealant to areas at which the external appearance is important areas which can be seen or where the condition of the paint c...

Page 245: ... area around the place where undercoating is to be applied before applying it Be sure not to apply the undercoating to tires or to the drive shaft and other drive components If the undercoating application inside the wheel housing on the under body etc is insufficient it can result in corrosion Be sure therefore to apply a good coating of undercoating to such parts after repairs are completed AB20...

Page 246: ...NOTES ...

Page 247: ...D 8 2 DOOR 8 3 TRUNK LID 8 4 FUEL FILLER DOOR 8 4 INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS 8 5 AERO PARTS 8 5 ADJUSTMENT OF OTHER PARTS 8 8 FRONT WHEEL ALIGNMENT 8 8 REAR WHEEL ALIGNMENT 8 9 HEADLIGHT AIMING 8 10 FOG LIGHT AIMING 8 11 SUPPLEMENTAL RESTRAINT SYSTEM SRS 8 13 ...

Page 248: ...ing bolt tightening torque 21 4 N m 16 2 ft lb Hood hinge mounting nut tightening torque 11 2 N m 98 17 in lb 2 Rotate the hood bumper by using arrow mark on the hood bumper as a guide to adjust the hood height If the hood bumper is rotated just one turn the hood height changes by approximately 3 mm 0 1 inch 3 If the hood level floating unlock lock is heavy check the cord of the release cable loos...

Page 249: ...s are welded grind off the welding according to the procedure below beforehand 1 Remove the door hinge 2 Use a chisel or grinder to release the door hinge mount ing bolt washer which is welded to the door hinge 3 On completion paint the affected area with a suitable touch in brush to prevent corrosion 4 Install the door hinge 3 When the door is stiff to lock and unlock 1 Adjustment by using the st...

Page 250: ...unk lid is floating if the trunk lid latch is released or if the latch is heavy inspect the arrangement of the release cable loosen the trunk lid striker mounting bolts and move the trunk lid striker to adjust the alignment between the trunk lid and latch Trunk lid striker mounting bolts tightening torque 8 8 2 N m 78 17 in lb FUEL FILLER LID M4080008000069 ADJUSTMENT OF FUEL FILLER LID FIT If the...

Page 251: ...ALLATION AND REMOVAL OF ADHESIVE COMPONENTS REFERENCE MATERIAL 8 5 INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS AERO PARTS M4080015000038 AB202317 SIDE AIR DAM REAR SPOILER TYPE A REAR SPOILER TYPE B AB ...

Page 252: ...e remaining on the body surface AB202318AB ADHESIVE TAPE DOUBLE SIDED TAPE 5 mm 0 20 in WIDTH AND 1 2 mm 0 05 in THICKNESS SIDE AIR DAM DOUBLE SIDED TAPE AB202335AB ADHESIVE TAPE DOUBLE SIDED TAPE A 5 mm 0 2 in WIDTH AND 0 8 mm 0 03 in THICKNESS B 5 mm 0 2 in WIDTH AND 1 2 mm 0 05 in THICKNESS A B DOUBLE SIDED TAPE REAR SPOILER TYPE A AB202336AB ADHESIVE TAPE DOUBLE SIDED TAPE 3 mm 0 12 in THICKNE...

Page 253: ...ssible 2 Use a shop towel moistened with 3M AAD Part number 8906 or equivalent to wipe the side air dam surface 3 Remove only a small portion of the residual adhesive 4 Adhere the double side tape as specified on the side air dam INSTALLATION 1 Tear off the double sided tape backing paper NOTE If you attach the adhesive tape to the edge of the backing paper it will be easy to tear off 2 Install th...

Page 254: ...ning torque 52 2 N m 38 2 ft lb 3 Confirm that the toe in is at the standard value 4 Use a turning radius gauge to check that the steering angle is at the standard value Standard value CAMBER CASTER AND KINGPIN INCLINATION Standard value NOTE 1 difference between right and left wheels must be less than 30 2 Caster and kingpin inclination are preset at the factory and cannot be adjusted SELECTION T...

Page 255: ...on the inner side of the body Left wheel Turning clockwise toe in Right wheel Turning clockwise toe in NOTE The scale has gradations of approximately 3 3 mm 0 13inch single side toe angle equivalent to 19í CAMBER Standard value 1 00í 30í difference between right and left wheel less than 30í If camber and or toe in is not within the standard value adjust by following procedures 1 Carry out camber a...

Page 256: ...from the bulb center marks on the headlight lens 8 Rock vehicle sideways to allow vehicle to assume its normal position 9 Bounce the front suspension through three 3 oscillations by applying the body weight to hood or bumper 10 Four lines of adhesive tape or equivalent markings are required on screen or wall 1 Position a vertical tape or mark so that it is aligned with the vehicle center line 2 Me...

Page 257: ... prevent the plastic headlight lens deformation 4 High beam pattern should be correct when the low beams are adjusted properly FOG LIGHT AIMING M4080013000043 PRE AIMING INSTRUCTIONS 1 Inspect for badly rusted or faulty fog light assemblies 2 These conditions must be corrected before a satisfactory adjustment can be made 3 Inspect tire inflation and adjust if necessary 4 If the fuel tank is not fu...

Page 258: ...s aligned with the vehicle center line 2 Measure the distance from the center marks on the fog light lens to the floor Transfer the measurement to the screen Horizontal tape or mark on the screen is for reference of vertical adjustment 3 Measure the distance from the center line of the vehicle to the center of each fog light Transfer the measurement to the screen Vertical tape or mark on the scree...

Page 259: ...faulty SUPPLEMENTAL RESTRAINT SYSTEM SRS AIR BAG M4080016000020 WARNING Improper service maintenance of any SRS air bag can lead to unintended operations of the SRS system or serious injury If SRS components may be subjected to heat over 90 C 194 F during painting remove the SRS control unit air bag mod ule driverís seat passenger seat clock spring interconnecting wiring SRS warn ing light and pre...

Page 260: ...NOTES ...

Page 261: ...6 1 GROUP 6 BODY COLOR CONTENTS BODY COLOR CODE 6 2 BODY COLOR CHARTS 6 2 BODY COLORING 6 3 HEADLAMP SUPPORT 6 3 DOOR SASH WHEELHOUSE 6 3 ...

Page 262: ...ased NOTE Inner Panel Color refers to the coat color of the engine cabin and floor AC211608AB VEHICLE INFORMATION CODE PLATE AB202021AD BODY COLOR CODE OUTER PANEL COLOR INNER PANEL COLOR COLOR COLOR CODE COLOR NUMBER COLOR NAME COMPOSITION OF FILM COLOR NUMBER COLOR NAME SILVER A31 CMA10031 Cool Silver Metallic AC10595 GRAY BRIGHT BLUE T10 CMT10010 French Blue Solid CMB17004 BRIGHT BLUE BLACK X42...

Page 263: ...OLOR 6 3 BODY COLORING HEADLAMP SUPPORT M4060009000071 Except color code X42 DOOR SASH WHEELHOUSE M4060000100048 Except color code X42 AB202124 BLACK AC10657 AB AB202125 1 2 1 2 1 LUSTROUS BLACK AC10790 2 BLACK AC10657 AB ...

Page 264: ...NOTES ...

Page 265: ...5 1 GROUP 5 SYNTHETIC RESIN PARTS CONTENTS LOCATION OF SYNTHETIC RESIN PARTS 5 2 ...

Page 266: ...27 33 25 35 NO PART NAME NAME OF RESIN ABBREVIATION HEAT WITHSTAND TEMP C F 1 Door mirror Acrylonitrile butadiene styrene ABS 80 176 2 Roof spoiler TYPE B 3 Roof antenna Acrylonitrile ethylene styrene AES 90 194 4 Delta outer garnish Acrylonitrile styrene acrylate ASA AAS 80 176 5 Roof spoiler TYPE A Carbon fibre reinforced plastic CFRP 80 100 176 212 6 Headlight Polycarbonate PC 120 248 7 Rear do...

Page 267: ...e PP 80 176 11 Oil cooler duct 12 Front bumper side core 13 Front bumper center core 14 Rear bumper core 15 Instrument panel 16 Delta inner cover 17 Front pillar trim 18 Inside rear view mirror 19 Center pillar trim 20 Rear door trim 21 Rear pillar trim 22 Rear end trim 23 Rear scuff plate 24 Rear console box 25 Front scuff plate 26 Cowl side trim 27 Front door trim Rubber denatured polypropylene ...

Page 268: ...NOTES ...

Page 269: ...4 1 GROUP 4 CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS 4 2 UNDERCOAT APPLICATION LOCATIONS 4 6 UNDERBODY ANTICORROSION AGENT LOCATIONS 4 7 ...

Page 270: ...requires appearance quality of the application in areas such as the drip rail pillar clinch and so on then apply the sealant so that it is flat or wipe off any excess mounding after the application Be careful not to obstruct the water draining hole NOTE The bold dotted line indicates the application area on the rear FLOOR UPPER BODY AB202132AB 1 2 3 4 AB202133 5 6 7 AB ...

Page 271: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 3 SIDE BODY AB202134 10 AB 8 9 11 12 AB202135 1 AB AB202136AB 2 AB202137 3 AB AB202138AB 4 ...

Page 272: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 4 AB202139AB 5 AB202140AB 6 AB202141AB 7 AB202142AB 8 AB202143AB 9 AB202144 10 AB AB202145AB 11 AB202146AB 12 ...

Page 273: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 5 AB202131 HOOD AB AB202147 FRONT DOOR AB AB202148 REAR DOOR AB AB202149AB TRUNK LID ...

Page 274: ... undercoated for anti corrosive anti rust anti chipping and anti vibration performance After correcting the body restore as shown in the instructions of the figure if necessary Tape the areas marked with an asterisks to protect those areas from getting any undercoating on those areas AB202123AB UNDERCOAT FILM THICKNESS IS AT LEAST 0 5 mm 0 02 inch ...

Page 275: ...revention treatment as indicated in the illustration if necessary Recommend wax Tectyl 506T 506 or S Waxoyl NOTE Take care not to permit the anticorrosion agent to come in contact with body painting brake parts exhaust pipes bearing seals for rear axle and rambler parts such as tires and drive shaft boots If anticorrosion agent gets onto the oxygen sen sor it will cause a drop in the performance o...

Page 276: ...NOTES ...

Page 277: ...NTER PILLAR 3 17 SIDE SILL 3 20 QUARTER OUTER 3 24 REAR END PANEL 3 29 REAR FLOOR 3 30 ROOF 3 28 QUARTER INNER 3 32 QUARTER INNER PARTIAL REPLACEMENT 3 34 FRONT DOOR OUTER PANEL 3 37 REAR DOOR OUTER PANEL 3 38 ALUMINUM PANEL 3 39 ALUMINUM PANEL CHARACTERISTICS 3 39 ALUMINUM PANEL LOCATIONS 3 39 ALUMINUM PANEL REPAIR 3 40 ALUMINUM PANEL PAINT 3 44 ...

Page 278: ...PTION Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202217AB REPAIR WELDS B A A B B RIGHT SIDE ...

Page 279: ...HEADLAMP SUPPORT WELDED PANEL REPLACEMENT 3 3 NOTE Partial replacement is okay depending on the range of damage AB201968 CUTTABLE RANGE AB ...

Page 280: ...n on P 3 10 for the welding points with the upper frame extension outer AB201904 SYMBOL OPERATION DESCRIPTION Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202218 A E A AB REPAIR WEL...

Page 281: ...FENDER SHIELD WELDED PANEL REPLACEMENT 3 5 AB202219 C B C D E D AB WITH THE UPPER FRAME EXTENSION OUTER REMOVED B ...

Page 282: ...FENDER SHIELD WELDED PANEL REPLACEMENT 3 6 AB202220 E F H G G H AB 17 POINTS LEFT SIDE ONLY 5 POINTS LEFT SIDE ONLY 9 POINTS LEFT SIDE ONLY 6 POINTS LEFT SIDE ONLY ...

Page 283: ...FENDER SHIELD WELDED PANEL REPLACEMENT 3 7 NOTES ...

Page 284: ...icates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202221AB RIGHT SIDE 83 mm 3 27 in A B D C REPAIR WELDS A 45 mm 1 77 in B CENTER OF FRONT SIDEMEMBER INNER POSITIONING HOLE CENTER OF SPLASH SHIELD MOUNTING HOLE ...

Page 285: ... Section on P 3 2 for the welding point with headlamp support NOTE ON REPAIR WORK REMOVAL 1 Reuse the parts other than the sidemember outer and sidemember inner AB202222AB LEFT SIDE 45 mm 1 77 in 83 mm 3 27 in C D CENTER OF FRONT SIDEMEMBER INNER POSITIONING HOLE CENTER OF SPLASH SHIELD MOUNTING HOLE ...

Page 286: ... Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202202AB REPAIR WELDS A A B C FOAM ACOUSTIC MATERIAL B HIGH RIGIDITY FOAM MATERIAL 180 mm 7 1 in WITH THE UPPER FRAME EXTENSION OUTER R...

Page 287: ...ent upper B 2 To reinforce the strength in the side sill cut area cut the side outer panel 145 mm 5 7 in behind the side sill cut area then cut the side sill outer reinforcement center 60 mm 2 36 in behind the side sill cut area AB202203 D E AB RIGHT SIDE D VEHICLES WITH STANDARD ROOF VEHICLES WITH SUNROOF C AB200367 120 mm 4 7 in 160 mm 6 3 in 80 mm 3 15 in AC FRONT PILLAR REINFORCEMENT UPPER SID...

Page 288: ...orcement upper cut area 6 To assemble Part B weld the front pillar reinforcement upper B then weld the cover of the front pillar reinforcement upper CAUTION Weld and repair if the side sill reinforcement support is damaged 7 Remove the side outer panel from the new front pillar outer parts Cut the front pillar outer by aligning it with the side sill outer reinforcement center on the body side Next...

Page 289: ...ent center 10 Apply in advance body sealant in the areas shown in the figure of the instructions when assembling the side outer panel 11 Assemble the side outer panel then bolt and tape the hole and flange with aluminum tape and fill the hole with foam materials as shown in the figure of the instructions FOAM Hole A 3M ULTRAPRO Panel foam Yellow FOAM Hole B 3M Super panel filler ADHESIVE TYPE BRAN...

Page 290: ... in above the front pillar inner upper 2 To reinforce the strength in the side sill cut area cut the side outer panel 145 mm 5 7 in behind the side sill cut area then cut the side sill outer reinforcement center 60 mm 2 36 in behind the side sill cut area 3 Divide the new front pillar inner upper parts into the front pillar inner upper and the front pillar reinforcement upper AB100787 AB200415 100...

Page 291: ... 1 57 in behind the cut area of the side sill outer reinforcement center 5 When assembling a new front pillar outer parts apply a front pillar silencer protector in advance bury the clearance with butyl tape then apply structural adhesives in the areas shown in the figure of the instructions 6 Weld the side sill reinforcement support then weld the cover of the side sill outer reinforcement center ...

Page 292: ...with aluminum tape and fill the hole with foam materials as shown in the figure of the instructions FOAM Hole A 3M ULTRAPRO Panel foam Yellow FOAM Hole B 3M Super panel filler 9 Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape then melt the foam materials with a soldering gun so a clip etc can thoroughly be inserted in the hole filled with foam materials AB200475A...

Page 293: ...N Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202090AB A B D A C B E E REPAIR WELDS FOAM ACOUSTIC MATERIAL 125 10 mm 4 9 0 39 in 290 10 mm 11 4 0 39 in C HIGH RIGIDITY FOAM MATERIA...

Page 294: ...ed INSTALLATION 1 Remove the side outer panel and side sill outer reinforcement center from the new parts 2 To reinforce the strength of the center pillar upper area that was cut cut the side outer panel 30mm 1 18 in above the cut area of the center pillar top part Cut the new part in the same area CAUTION Weld and repair if the center pillar seatbelt reinforcement is damaged 3 Cut only the center...

Page 295: ...lt and tape the hole and flange with aluminum tape and fill the hole with foam materials A and B as shown in the figure of the instructions FOAM Hole A 3M ULTRAPRO Panel foam Yellow FOAM Hole B 3M Super panel filler 7 Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape then melt the foam materials with a soldering gun so a clip etc can thoroughly be inserted in the h...

Page 296: ...IPTION Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202323 REPAIR WELDS A B C D E 70 mm 2 76 in 70 mm 2 76 in 290 mm 11 4 in A B C FOAM ACOUSTIC MATERIAL HIGH RIGIDITY FOAM MATERIAL...

Page 297: ...orward of the cut area and then remove 2 Cut only the side sill outer reinforcement center of the new side sill outer reinforcement parts from 110mm 4 3 in behind the cut out area then cut from another 10mm 0 39 in behind the cut out area and remove Re use the parts removed AB202327AB F G AB200598AC 60 mm 2 36 in SIDE SILL OUTER REINFORCEMENT CENTER AB200599AB 50 mm 1 97 in SIDE SILL OUTER REINFOR...

Page 298: ...n weld the part cut from the side sill outer reinforcement center 6 Apply in advance body sealant in the areas shown in the figure of the instructions when assembling the side outer panel 7 Assemble the side outer panel then bolt and tape the hole and flange with aluminum tape and fill the hole with foam materials as shown in the figure of the instructions FOAM 3M Super panel filler ADHESIVE TYPE ...

Page 299: ...ENT 3 23 8 Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape then melt the foam materials with a soldering gun so a clip etc can thoroughly be inserted in the hole filled with foam materials AB100787 ...

Page 300: ...RIPTION Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202223AB B C A A B C E D 150 50 mm 6 3 1 97 in 500 50 mm 19 7 1 97 in FOAM ACOUSTIC MATERIAL FOAM ACOUSTIC MATERIAL 3 POINTS LEF...

Page 301: ...UARTER OUTER WELDED PANEL REPLACEMENT 3 25 CAUTION Avoid the fuel filler bracket left side NOTE Parts replacement is advised Depending on the dam aged range AB202224 F E D AB F AB201967AB CUTTABLE RANGE ...

Page 302: ...g the quarter outer apply sealant to the areas indicated in the illustration 2 Assemble the quarter outer panel bolt and tape the hole and flange with aluminum tape then fill the hole with foam materials as shown in the figure of the instructions FOAM 3M ULTRAPRO Panel foam Yellow Y0249AV AB202225AB BODY SEALANT LEFT SIDE ONLY REAR PILLAR SILENCER PROTECTER AB202226AB ...

Page 303: ...t 2 hours after filling the foam materials to remove the bolt and aluminum tape Then melt the foam materials with a soldering gun so a clip etc can thoroughly be inserted in the hole that was clogged with foam materials to bore open the hole AB100787 ...

Page 304: ...elded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202227AB REPAIR WELDS STANDARD ROOF SUN ROOF ADHESIVE A A B C C D A B C D D ADHESIVE TYPE BRAND Urethane body sealer 3M Part No 8542 or equivalent ...

Page 305: ...ON DESCRIPTION Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB201910AB REPAIR WELDS ...

Page 306: ...end cross member AB201915 SYMBOL OPERATION DESCRIPTION Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202228AB REPAIR WELDS F B D E C A B A ...

Page 307: ...AIR WORK REMOVAL Cut the rear floor pan 200 50 mm 7 9 1 97 in from the back of the rear seat back reinforcement as shown in the illus tration AB202229AB RIGHT SIDE ONLY LEFT SIDE ONLY C D F E AB201934 AB 200 50 mm 7 9 1 97 in REAR SEAT BACK REINFORCEMENT ...

Page 308: ...ION Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202230 I F F B A G E H C AB REPAIR WELDS 9 POINTS ON LEFT SIDE 6 POINTS ON RIGHT SIDE RIGHT SIDE ONLY WITH THE QUARTER OUTER REMOVED...

Page 309: ...QUARTER INNER WELDED PANEL REPLACEMENT 3 33 AB202231AB WITH THE SIDE SILL OUTER REINFORCEMENT REAR REMOVED LEFT SIDE ONLY C D F E G H I ...

Page 310: ...he welding points with the quarter outer AB201914 SYMBOL OPERATION DESCRIPTION Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202232 REPAIR WELDS A A AB ...

Page 311: ...r panel as shown in the figure of the instructions use the tape as a guide so about 20mm 0 79 in of the flange remains then cut and remove INSTALLATION 1 For the new quarter inner panel cut the wheel arch end are so that it overlaps with the flange on the body side 2 Overlap assemble and weld the quarter inner panel with the body side flange Weld at a pitch of 40mm 1 57 in AB202008 REAR PILLAR REI...

Page 312: ...QUARTER INNER PARTIAL REPLACEMENT WELDED PANEL REPLACEMENT 3 36 3 Weld the quarter inner panel then apply a body sealing in the area shown in the figure of the instructions AB202293AC BODY SEALING ...

Page 313: ...plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202233 B C B C A AB A REPAIR WELDS 50 mm 1 97 in ADHESIVE 1 ADHESIVE 2 ADHESIVE TYPE BRAND adhesive 1 Urethane body sealer 3M Part No 8542 or equivalent ...

Page 314: ...lug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB202234 A 50 mm 1 97 in B B A C C ADHESIVE 1 ADHESIVE 2 AB REPAIR WELDS ADHESIVE TYPE BRAND adhesive 1 Urethane body sealer 3M Part No 8542 or equivalent a...

Page 315: ...um is 2 7 which is only one third of general steel panel 7 9 However it requires 1 4 times in thickness to obtain the same rigidity as the steel panel resulting in one half in weight 2 More durable Aluminum has the property of creating oxide coating on its surface when it contacts with the air This coating prevents it from being corroded 3 More heat conductive The heat conductivity of aluminum is ...

Page 316: ...st the aluminum plate its surface will exfoliate and cause loading of the disk sander 8 Because the disk sander with the loading will damage the aluminum panel replace it with a new one as soon as possible 9 General tools and sanding tools shall not be shared for both aluminum and steel panels Iron powder remaining on the surface may cause electric corrosion with a different type of metal 10 Durin...

Page 317: ... Because hammering may stretch the panel use a mallet or plastic hammer 2 Distortion check Grind the surface with 80 to 120 grit sandpaper and then check for distortion CAUTION The surface shall be heated to approximately 250 C 482 F when correcting distortion Care must be taken when heating the panel because it can melt without discoloration Cover the perimeter area with a wet rag or the like to ...

Page 318: ...ct the damaged area by hammering lightly while heating it If any area is stretched by hammering grind it off with a pneumatic saw CAUTION To minimize distortion and meltdown divide a welding area into several short segments and weld one seg ment at a time Degrease the welding area by white gasoline or the like Remove the oxide coating on the welding area includ ing its back with a stainless steel ...

Page 319: ...ortion Do not use a draw hammer designed for steel sheets because it may cause the panel crack 5 Straightening Remove distortion by the draw correction procedure with a flattening hammer and a burner CAUTION Remove any spark spot or carbon residue on the surface by a stainless steel wire brush because they will cause improper painting in the following process 6 Finishing Finish the surface with a ...

Page 320: ... not have as good paint adhesion as normal steel sheets The following is a general paint procedure NOTE Refer to paint manufacturers paint specifications for details CAUTION Avoid hasty grinding and minimize grinding heat 1 Remove old paint film 2 Clean and degrease the painted surface CAUTION Apply 2 liquid type epoxy primer to the base of the alumi num panel 3 Apply wash primer to the painted su...

Page 321: ...SUREMENT METHODS 2 2 TYPE A PROJECTED DIMENSIONS 2 4 UNDER BODY 2 4 SUSPENSION INSTALLATION DIMENSIONS 2 6 TYPE B ACTUAL MEASUREMENT DIMENSIONS 2 8 UNDER BODY 2 8 SUSPENSION INSTALLATION DIMENSIONS 2 10 FRONT BODY 2 12 SIDE BODY 2 14 REAR BODY 2 16 INTERIOR 2 18 ...

Page 322: ...s Measure using a tracking gauge or a measuring tape etc NOTE Make the lengths of the tracking gauge probes the same A Aí Do not bend or twist the measuring tape 3 Insert the tracking gauge probes securely into the measure ment holes 4 When the standard dimensions in the illustration are enclosed by oblong this indicates that the symmetrical left and right positions have the same dimensions 5 When...

Page 323: ...en measuring the suspension mounting arm or link mounting position use the suspension mounting bolt etc Type B only 7 The body center points are shown for the purpose of check ing the position of the left and right symmetry location AB100782AB BOLT MEASIREMENT POINT ...

Page 324: ... 10 5 6 7 715 28 1 No STANDARD MEASUREMENT POINT HOLE SHAPE SIZE mm in 1 Center of under cover mounting hole Round 8 0 3 2 Front sidemember inner notch 3 Center of crossmember mounting hole Round 18 0 7 4 Center of front floor sidemember positioning hole Round 25 1 0 5 Tip of center bearing mounting bolt left front side 6 Tip of center bearing mounting bolt right front side 7 Tip of center bearing...

Page 325: ...335 52 6 253 10 0 1 230 48 4 497 19 6 339 13 3 563 22 2 338 13 3 502 19 8 690 27 2 330 13 0 345 13 6 142 5 6 180 7 1 100 3 9 162 6 4 203 8 0 250 9 8 185 7 3 114 4 5 204 8 0 340 13 4 AB201728AC 1 AB202159 2 AB AB201817AB 3 AB201808AB 4 AB201809 5 6 7 8 5 7 6 8 AB AB202160AB 9 AB201811AB 10 AB201818AB 11 ...

Page 326: ...enter of crossmember mounting hole Round 18 0 7 4 Center of front floor sidemember positioning hole Round 25 1 10 Center of crossmember mounting hole Round 14 0 6 12 Center of front shock absorber mounting hole Round 110 4 3 13 Center of rear shock absorber mounting hole Round 68 2 7 14 Tip of crossmember mounting bolt left 15 Tip of crossmember mounting bolt right 16 Center of crossmember mountin...

Page 327: ... 6 4 563 22 2 477 18 8 100 3 9 1 257 49 5 175 6 9 3 12 835 32 9 440 17 3 529 20 8 716 28 2 348 13 7 707 27 8 628 24 7 1 523 20 6 23 10 A B VEHICLE CENTER VEHICLE CENTER A B 4 24 11 36 104 4 1 339 13 3 330 13 0 345 13 6 358 14 1 336 13 2 401 15 8 21 18 239 9 4 191 7 5 199 7 8 AB201814AB 12 AB201815AB 13 AB201816 19 21 21 19 AB ...

Page 328: ...EASUREMENT POINT HOLE SHAPE SIZE mm in 1 Center of under cover mounting hole Round 8 0 3 2 Front sidemember inner notch 3 Center of crossmember mounting hole Round 18 0 7 4 Center of front floor sidemember positioning hole Round 25 1 0 5 Tip of center bearing mounting bolt left front side 6 Tip of center bearing mounting bolt right front side 7 Tip of center bearing mounting bolt left rear side 8 ...

Page 329: ...TYPE B ACTUAL MEASUREMENT DIMENSIONS BODY DIMENSIONS 2 9 AB201728AC 1 AB202159 2 AB AB201817AB 3 AB201808AB 4 AB201809 5 6 7 8 5 7 6 8 AB AB202160AB 9 AB201811AB 10 AB201818AB 11 ...

Page 330: ... 18 1 025 40 4 777 30 6 871 34 3 853 33 6 859 33 8 890 35 0 895 35 2 No STANDARD MEASUREMENT POINT HOLE SHAPE SIZE mm in 3 Center of crossmember mounting hole Round 18 0 7 10 Center of crossmember mounting hole Round 14 0 6 14 Tip of crossmember mounting bolt left 15 Tip of crossmember mounting bolt right 16 Center of crossmember mounting hole Round 11 0 4 17 Trailing arm mounting position 18 Cont...

Page 331: ...TYPE B ACTUAL MEASUREMENT DIMENSIONS BODY DIMENSIONS 2 11 AB201819AB 16 3 3 16 AB201820 10 22 AB 10 22 AB201821AB 14 AB201822AB 15 AB201823AB 17 AB201824 18 20 18 20 AB AB201825 23 AB ...

Page 332: ... 2 700 27 6 894 35 2 782 30 8 35 36 314 12 4 901 35 5 547 21 5 732 28 8 No STANDARD MEASUREMENT POINT HOLE SHAPE SIZE mm in 24 Center of front end crossmember upper water draining hole Round 8 0 3 25 Center of harness clip mounting hole Oblong 7 12 0 3 0 5 26 Center of intercooler pipe mounting hole Round 9 0 4 27 Center of front fender mounting hole Round 6 6 0 3 28 Center of front strut mounting...

Page 333: ...ANDARD MEASUREMENT POINT HOLE SHAPE SIZE mm in 34 Center of front bumper reinforcement mounting hole Round 9 0 4 35 Center of headlamp mounting hole Round 6 6 0 3 36 Center of hood latch mounting hole Round 6 6 0 3 No STANDARD MEASUREMENT POINT HOLE SHAPE SIZE mm in AB201826AB 24 36 36 24 AB201827AB 25 AB201828AB 26 AB201829AB 27 AB201830AB 28 AB201831AB 29 AB201832AB 30 31 30 31 AB201833AB 32 AB2...

Page 334: ...itioning notch lower 39 Side roof rail positioning notch front 40 Side sill positioning notch front 41 center pillar positioning notch upper 42 center pillar positioning notch lower 43 Side roof rail positioning notch rear 44 Side sill positioning notch rear 45 Quarter panel positioning notch upper 46 Quarter panel positioning notch lower 47 Center of front door hinge mounting hole upper Round 11 ...

Page 335: ...TYPE B ACTUAL MEASUREMENT DIMENSIONS BODY DIMENSIONS 2 15 AB201836 38 48 AB 48 38 AB202191 42 50 42 50 AB AB201838 46 51 AB 51 46 ...

Page 336: ...2 61 5 No STANDARD MEASUREMENT POINT HOLE SHAPE SIZE mm in 52 Corner of roof panel 53 Center of rear window moulding mounting hole Oblong 7 11 0 3 0 4 54 Rear shelf body center point Body center point 55 Corner of side outer panel 56 Center of rear combination lamp mounting hole Round 10 0 4 57 Center of rear end trim mounting hole Round 8 5 0 3 58 Center of rear end outer panel positioning hole R...

Page 337: ...TYPE B ACTUAL MEASUREMENT DIMENSIONS BODY DIMENSIONS 2 17 AB201839AB 52 AB201840AB 53 AB201841AB 54 AB201842AB 55 56 56 55 AB201843AB 57 AB201844AB 58 ...

Page 338: ...3 1 235 48 6 1 407 55 4 1 145 45 1 1 395 54 9 1 289 50 7 1 112 43 8 1 297 51 1 1 368 53 9 46 AB201764AB 46 38 40 42 44 45 43 41 60 39 37 59 BODY CENTER POINT 683 26 9 1 085 42 7 809 31 9 1 016 40 0 706 27 8 1 136 44 7 848 33 4 1 072 42 2 1 041 41 0 1 100 43 3 AB201766AB 61 62 BODY CENTER POINT 1 266 49 8 63 1 268 49 9 1 266 49 8 678 26 7 664 26 1 ...

Page 339: ...tch rear 44 Side sill positioning notch rear 45 Quarter panel positioning notch upper 46 Quarter panel positioning notch lower 57 Center of rear end trim mounting hole Round 8 5 0 3 59 Center of front seat rail mounting hole Round 14 0 6 60 Center of floor carpet mounting hole Body center point Round 6 0 2 61 Tip of instrument panel bracket center Body center point 62 Center of deck crossmember mo...

Page 340: ...TYPE B ACTUAL MEASUREMENT DIMENSIONS BODY DIMENSIONS 2 20 AB202195 42 AB AB202195 46 AB AB201843AB 57 AB201845AB 59 AB201846AB 60 AB201849AB 61 AB201850AB 63 62 62 63 AB201847AB 64 AB201848AB 65 ...

Page 341: ...NCE SERVICEABILITY 1 6 BODY CONSTRUCTION CHARACTERISTICS 1 8 FRONT BODY 1 8 ROOF 1 13 SIDE BODY 1 14 REAR BODY 1 16 UNDER BODY 1 17 DOOR 1 20 SILENCER APPLICATION LOCATIONS 1 21 LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL 1 22 STIFFENER AND DAMP SHEET APPLICATION LOCATIONS 1 24 THEFT PROTECTION 1 25 ...

Page 342: ... corrosion steel panels High tensile steel panels 1 62 64 69 70 19 2 3 16 17 28 47 29 48 49 81 41 14 15 25 55 38 37 21 18 4 5 6 7 8 9 10 71 23 24 22 72 73 74 75 76 77 26 27 31 32 33 30 46 35 36 34 11 12 20 13 65 78 79 66 39 40 42 44 43 56 57 83 82 61 67 68 58 59 60 63 45 50 51 52 53 54 ...

Page 343: ... 41 QUARTER INNER EXTENSION REAR 42 QUARTER CORNER PANEL 43 REAR COMBINATION LAMP HOUSING 44 SIDE ROOF RAIL INNER 45 ROOF SIDE RAIL REINFORCEMENT CENTER 46 FRONT PILLAR INNER UPPER 47 FRONT PILLAR INNER LOWER 48 CENTER PILLAR INNER 49 SIDE OUTER PANEL 50 REAR WHEEL HOUSE INNER PANEL 51 QUARTER INNER PANEL 52 REAR FLOOR SIDE BRACE 53 QUARTER OUTER EXTENSION LOWER 54 FUEL FILLER DOOR 55 REAR END PAN...

Page 344: ... PILLAR REINFORCEMENT UPPER FRONT PILLAR REINFORCE MENT UPPER B ROOF PANEL B AB200255AC C COWL TOP LOWER PANEL COWL TOP UPPER PANEL COWL TOP INNER PANEL AB200256AC D FRONT END CROSSMEMBER REIFORCEMENT FRONT END CROSS MENBER INNER FRONT END CROSSMENBER OUTER AB201985AB E FRONT PILLAR REINFORCEMENT LOWER FRONT PILLAR INNER LOWER SIDE OUTER PANEL AB200258AC F FRONT FLOOR SIDE SILL INNER SIDE SILL REI...

Page 345: ...RCE MENT UPPER B FRONT PILLAR REINFORCEMENT UPPER AB202122AB G SUNROOF SIDE OUTER PANEL FRONT PILLAR INNER UPPER FRONT PILLAR REINFORCEMENT UPPER AB201986 H CENTER PILLAR REINFORCEMENT CENTER PILLAR SEATBELT REINFORCEMENT CENTER PILLAR INNER SIDE OUTER PANEL AB AB201988AB SIDE OUTER PANEL REAR PILLAR INNER I AB200264AC SIDE OUTER PANEL QUARTER INNER PANEL REAR WHEEL HOUSE INNER PANEL J AB201989AB ...

Page 346: ...SERVICEABILITY M4010003000120 FENDER SHIELD A positioning hole marking and cut out has been added on the front fender shield front upper frame inner front side member gusset rear and dash panel to improve assembling workability when replacing the panel AB202152AB ...

Page 347: ...g to improve assembling workability when replacing the panel SIDE OUTER PANEL The extra parts are supplied in 4 different cut forms as a result of employing the integrated side frame side outer panel AB200202AB PANEL POSITIONING NOTCH AB202025AB AB202024 CENTER PILLAR OUTER FRONT PILLAR OUTER SIDE SILL OUTER QUARTER OUTER AB ...

Page 348: ...e vehicle has been increased to improve safety in collision and body rigidity NOTE Steel sheets with different thickness welded to form one steel sheet AB201017AB 10 1 4 2 5 3 6 7 8 9 11 1 FRONT END UPPER BAR 2 SENSOR BRACKET 3 HEADLAMP SUPPORT PANEL 4 HOOD LOCK STAY 5 FRONT END CROSSMEMBER INNER REINFORCEMENT 6 A C CONDENSER BRACKET 7 RADIATOR BRACKET 8 FRONT END CROSSMEMBER INNER 9 FRONT END CRO...

Page 349: ...o be directly installed with the cowl top lower panel and the body rigidity of the suspension attachment holder has been increased to improve operational stability and quietness AB202153AB 9 10 8 7 6 4 3 5 2 RIGHT SIDE LEFT SIDE 9 1 11 8 10 5 7 6 4 2 12 11 1 A 1 HEADLAMP SUPPORT PANEL SIDE 2 FRONT FENDER SHIELD 3 ENGINE MOUNT REINFORCEMENT 4 UPPER FRAME BULKHEAD FRONT 5 FRONT UPPER FRAME INNER 6 U...

Page 350: ...TER 4 ENGINE MOUNT BRACKET 5 FRONT SIDEMEMBER INNER REINFORCEMENT LOWER 6 FRONT SIDEMEMBER GUSSET REAR 7 FRONT SIDEMEMBER INNER REINFORCEMENT REAR 8 TIE DOWN REINFORCEMENT 9 DASH PANEL EXTENSION 10 PIPE SUPPORT REAR 11 PIPE NUT 12 FRONT SIDEMEMBER REAR 13 DASH CROSSMEMBER EXTENSION 14 SUSPENSION CROSSMEMBER SUPPORT BRACKET 15 SUSPENSION CROSSMEMBER BRACKET INNER 16 PIPE 17 SQUARE HEAD BOLT 18 RETA...

Page 351: ...RCEMENT INNER UPPER 8 TIE DOWN REINFORCEMENT 9 FRONT SIDEMEMBER REINFORCEMENT INNER 10 FRONT SIDEMEMBER GUSSET REAR 11 FRONT SIDEMEMBER OUTER 12 FRONT SIDEMEMBER BULKHEAD REAR 13 FRONT SIDEMEMBER INNER REINFORCEMENT 14 FRONT SIDEMEMBER REINFORCEMENT OUTER 15 FRONT SIDEMEMBER BULKHEAD A 16 FRONT SIDEMEMBER INNER 17 PIPE SUPPORT FRONT 18 RETAINER 19 SQUARE HEAD BOLT 20 PIPE 21 SUSPENSION CROSSMEMBER...

Page 352: ...ine AB201020AB 6 8 10 9 11 1 12 2 3 13 14 4 5 7 1 STRUT TOWER BAR BRACKET 2 COWL TOP LOWER PANEL 3 COWL TOP LOWER REINFORCEMENT 4 COWL TOP UPPER REINFORCEMENT CENTER 5 COWL TOP INNER PANEL 6 COWL TOP UPPER PANEL 7 PEDAL SUPPORT BRACKET 8 CLUTCH PEDAL SUPPORT BRACKET 9 UPPER FRAME EXTENSION INNER 10 UPPER FRAME EXTENSION OUTER 11 UPPER FRAME TO FRONT PILLAR BRACE 12 STRUT HOUSE GUSSET 13 COWL TOP L...

Page 353: ... of the roof bow has been made large to improve safety in collision AB202150AB 1 2 3 4 5 6 7 STANDARD ROOF AB201928AB 2 3 8 6 7 1 SUN ROOF 1 ROOF PANEL 2 REAR ROOF RAIL 3 REAR ROOF BOW 4 ROOF BOW FRONT REINFORCEMENT 5 FRONT ROOF BOW 6 MAP LAMP BRACKET 7 FRONT ROOF RAIL 8 ROOF PANEL REINFORCEMENT ...

Page 354: ...T VEHICLES WITH STANDARD ROOF 13 SIDE ROOF RAIL INNER 14 REAR SEAT BACK BRACE 15 REAR SHELF UPPER BRACE 16 REAR SHELF LOWER BRACE 17 REAR PILLAR INNER 18 QUARTER INNER PANEL 19 OIL TANK BRACKET 20 REAR PILLAR REINFORCEMENT 21 REAR FLOOR SIDE BRACE 22 REAR FLOOR BRACE REINFORCEMENT 23 FUEL FILLER NECK BRACKET LH only 24 QUARTER INNER EXTENSION REAR 25 QUARTER CORNER PANEL 26 REAR COMBINATION LAMP H...

Page 355: ...dy rigidity 5 A rear pillar reinforcement has been added and the rear shelf and rear wheel house have been joined to improve the twisting rigidity of the sus pension attaching portion NOTE Steel sheets with different thickness welded to form one steel sheet 43 REAR DOOR HINGE REINFORCEMENT UPPER 44 CENTER PILLAR SEATBELT REINFORCEMENT 45 CENTER PILLAR INNER 46 FRONT PILLAR REINFORCEMENT UPPER B VE...

Page 356: ...improve the torsion rigidity of the seat back plate REAR END PANEL AB201022AB 6 5 7 8 1 2 3 4 1 SEAT BACK PLATE 2 REAR SEAT BACK PANEL 3 REAR SHELF EXTENSION 4 REAR SHELF PANEL 5 REAR SHELF CHILD SEAT BELT REINFORCEMENT 6 REAR SHELF REINFORCEMENT 7 TRUNK LID HINGE REINFORCEMENT 8 SEAT BELT REINFORCEMENT AB201024AB 2 3 1 4 1 REAR END PANEL INNER 2 REAR END PANEL OUTER 3 TRUNK LID LOCK BRACKET SUPPO...

Page 357: ...8 1 INSTRUMENT PANEL CENTER BRACKET REINFORCEMENT 2 FRONT FLOOR CROSSMEMBER FRONT 3 FRONT FLOOR CROSSMEMBER REAR 4 FRONT FLOOR EXTENSION PANEL REAR 5 FRONT FLOOR PAN 6 FRONT FLOOR SIDE SILL INNER 7 FRONT FLOOR SIDEMEMBER REINFORCEMENT REAR 8 FRONT FLOOR SIDEMEMBER 9 FRONT FLOOR SIDEMEMBER REINFORCEMENT FRONT 10 FRONT FLOOR SIDEMEMBER REINFORCEMENT 11 BACKBONE CROSSMEMBER REAR 12 BACKBONE CROSSMEMB...

Page 358: ...AR SEAT BACK REINFORCEMENT 6 TOWING HOOK REINFORCEMENT 7 CROSSMEMBER CENTER SUPPORT 8 REAR FLOOR CROSSMEMBER 9 REAR FLOOR SEAT BELT REINFORCEMENT 10 DIFFERENTIAL FUEL SUPPORT BRACKET REAR 11 REAR FLOOR SIDEMEMBER 12 DIFFERENTIAL FUEL SUPPORT BRACKET FRONT 13 REAR SEAT CROSSMEMBER 14 SEAT CROSSMEMBER REINFORCEMENT 15 FUEL TANK FRONT REINFORCEMENT 16 REAR FLOOR EXTENSION 17 FRONT FLOOR SIDEMEMBER EX...

Page 359: ...MBER EXTENSION 6 DIFFERENTIAL MOUNT BULKHEAD 7 DIFFERENTIAL MOUNT REINFORCEMENT 8 PIPE 9 SQUARE HEAD BOLT 10 RETAINER 11 REAR SUSPENSION BRACKET 12 MUFFLER HANGER CENTER 13 REAR FLOOR SIDEMEMBER REINFORCEMENT FRONT 14 MUFFLER HANGER REAR 15 REAR FLOOR SIDEMEMBER REINFORCEMENT REAR 16 BUMPER STAY REINFORCEMENT 17 REAR FLOOR SIDEMEMBER EXTENSION 18 REAR FLOOR SIDEMEMBER REINFORCEMENT 19 UPPER LINK B...

Page 360: ...EAM 4 FRONT DOOR OUTER PANEL 5 FRONT DOOR OUTSIDE HANDLE REINFORCEMENT 6 FRONT DOOR BELTLINE REINFORCEMENT OUTER 7 FRONT DOOR WINDOW SASH 8 FRONT DOOR BELTLINE REINFORCEMENT INNER 9 FRONT DOOR LATCH REINFORCEMENT 10 FRONT DOOR INNER PANEL 11 REAR DOOR HINGE PANEL 12 REAR DOOR SIDE DOOR BEAM LOWER 13 REAR DOOR SIDE DOOR BEAM UPPER 14 REAR DOOR OUTER PANEL 15 REAR DOOR BELT LINE REINFORCEMENT OUTER ...

Page 361: ...a high performance sheet composed of asphalt applied with mica and thermosetting resin for improving anti vibration performance AB202009 4 0 mm 0 157 in thick MD 12 Place three 1 6 mm 0 063 in melting sheet one on top of another 1 6 mm 0 063 in thick melting sheet 3 2 mm 0 126 in thick melting sheet Place two 1 6 mm 0 063 in melting sheet one on top of another AB NOTE When you use melting sheet s ...

Page 362: ... burn when heated Always observe the following instructions Never use a gas burner or burn the areas using foam materials When cutting the parts using foam materi als ensure to use tools air saw etc that do not generate fire If there is residual foam materials remain ing on the cut section body side then weld after removing the foam materials from periphery of the welding area AB202185 A C B D AB ...

Page 363: ... RIGIDITY FOAM MATERIAL AB201980AB SIDE ROOF RAIL INNER SIDE OUTER PANEL F FOAM ACOUSTIC MATERIAL AB201981AB SIDE OUTER PANEL REAR PILLAR INNER FOAM ACOUSTIC MATERIAL G AB201982AB CENTER PILLAR INNER REAR DOOR HINGE REINFORCEMENT UPPER SIDE OUTER PANEL H FOAM ACOUSTIC MATERIAL AB201983AB SIDE SILL OUTER REINFORCEMENT CENTER CENTER PILLAR REINFORCE MENT URETHANE FOAM I ...

Page 364: ...er on the inner side of the side outer panel and roof panel as well as a damping sheet adhered to the inner side of the front door NOTE The main contents of a stiffener are epoxy resin It comes in a sheet form and contains a mix ture of glass fiber and filler and cures stiffens when heated It is used to improve the rigidity of the outer plate AB201919AB STIFFENER STIFFENER VHIECLES WITH SUNROOF DA...

Page 365: ...outer panel main components and the same data is stamped into replacement parts for the engine and the transaxle CAUTION Cautions regarding panel repairs 1 When repainting original parts do so after first masking the theft protection label After painting be sure to peel off the masking tape 2 The theft protection label for replacement parts is cov ered by masking tape so such parts can be painted ...

Page 366: ... FOR REPLACEMENT PARTS AC211574 AB ENGINE B A AC211575 MANUAL TRANSAXLE B A AB AC101605AB A B FENDER THE ILLUSTRATION INDICATES LEFT OUTER SIDE RIGHT SIDE IS SYMMETRICALLY OPPOSITE AC101606AB A B QUARTER PANEL OUTER THE ILLUSTRATION INDICATES LEFT OUTER SIDE RIGHT SIDE IS SYMMETRICALLY OPPOSITE ...

Page 367: ...01607AB A B FRONT DOOR THE ILLUSTRATION INDICATES LEFT INNER SIDE RIGHT SIDE IS SYMMETRICALLY OPPOSITE AC101608AB A B REAR DOOR THE ILLUSTRATION INDICATES LEFT INNER SIDE RIGHT SIDE IS SYMMETRICALLY OPPOSITE AC211576 HOOD B A AB AC212032 TRUNK LID AB A B AC211577 FRONT BUMPER B A AB AC211578 REAR BUMPER B A AB ...

Page 368: ...NOTES ...

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