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Mitsubishi Lancer Evolution IV, Workshop Manual

The Mitsubishi Lancer Evolution IV Workshop Manual is a comprehensive guide for maintaining and repairing your vehicle. This manual covers all aspects of the car's mechanics and is available for free download from manualshive.com. Ensure your vehicle runs smoothly with this essential manual in hand.

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BASIC BRAKE SYSTEM – 

Master Cylinder and Brake Booster

35A-7

MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY

Master cylinder kit

11

14

13

12

14

13

15

1

4

2

3

6

8

9

5

7

10

12

15

13

14

Brake fluid: DOT3 or DOT4

11

Disassembly steps

1. Reservoir cap assembly
2. Reservoir cap
3. Diaphragm
4. Filter
5. Brake fluid level sensor
6. Float
7. Reservoir stopper bolt

8. Reservoir tank
9. Reservoir seal

A

A

"

10. Piston stopper bolt

11. Gasket

A

B

"

12. Piston stopper ring
13. Primary piston assembly
14. Secondary piston assembly
15. Master cylinder body

Summary of Contents for Lancer Evolution IV

Page 1: ...Pub No S9806CNCP9 WORKSHOP MANUAL EVOLUTION IV EVOLUTION V...

Page 2: ...tains procedures for service mechanics including removal disassembly inspection adjustment reassembly and installation Figures taken from registration documents are given in metric units only All othe...

Page 3: ...MODELS 2 00 1 GENERAL CONTENTS...

Page 4: ...controlled fuel SRGF 97 GSR 16 valves intercooler turbo 4WD 5M T controlled fuel injection MPI LANCER EVOLUTION V Model code Class code Model year Grade Engine model Transmission model Fuel supply sys...

Page 5: ...er Check 5 3 Lash Adjuster Check 5 4 Lash Adjuster Replacement 7 5 Ignition Timing Check 7 6 Idle Speed Check and Idle Mixture Check 7 7 Compression Pressure Check 7 8 Manifold Vacuum Check 8 CRANKSHA...

Page 6: ...ference of all cylinders kg cm2 Max 1 0 Intake manifold vacuum kPa mmHg Min 55 410 Cylinder head bolt shank length mm 99 4 SEALANTS Items Specified sealants Rocker cover Semi drying sealant THREEBOND...

Page 7: ...oil seal installer Pressfitting the camshaft oil seal MD998727 Oil pan remover Removing the oil pan MD998781 Flywheel stopper Securing the flywheel or drive plate MD998776 Crankshaft rear oil seal in...

Page 8: ...pporting the engine assembly during removal and installation of the transmission MD991453 Engine hanger assembly ENGINE ADJUSTMENTS 1 DRIVE BELT TENSION CHECK NOTE Use of the auto tensioner eliminates...

Page 9: ...ed in oil for these reasons gets into the high pressure chamber of the lash adjuster the air in the high pressure chamber is compressed to shrink the lash adjuster excessively while the valve is openi...

Page 10: ...eak down test and bleeding procedures refer to ENGINE WORKSHOP MANUAL If the rocker arm is felt binding and cannot be pushed downward as you push it the lash adjuster is operational Check for other po...

Page 11: ...ection check that the engine oil starter and battery are normal In addition set the vehicle to the pre inspection condition 2 Remove all of the spark plugs 3 Disconnect the crank angle sensor connecto...

Page 12: ...ace b If the compression does not rise after oil is added the cause is a burnt or defective valve seat or pressure is leaking from the gasket 9 Connect the crank angle sensor connector 10 Install the...

Page 13: ...djustment Refer to P 11 4 D Under Cover Installation 1 2 25 2 5 Unit Nm kgf m Removal steps AA 1 Drive belt 2 Crankshaft pulley REMOVAL SERVICE POINT AA DRIVE BELT REMOVAL 1 Align the hole in the auto...

Page 14: ...ng Belt Removal and Installation Refer to P 11 21 22 2 2 Unit Nm kgf m 10 1 0 9 0 9 3 4 0 35 20 2 0 88 9 0 12 15 1 2 1 5 1 5 3 4 6 2 14 15 17 16 13 12 11 10 9 8 7 Removal steps 1 Breather hose connect...

Page 15: ...side 26 3 mm REMOVAL SERVICE POINT AA CAMSHAFT SPROCKET REMOVAL INSTALLATION SERVICE POINTS AA CAMSHAFT INSTALLATION 1 Apply engine oil to the cams and journals of the camshaft 2 Mount the camshaft o...

Page 16: ...entire periphery of the oil seal lip 2 Pressfit the oil seal as shown DA CAMSHAFT SPROCKET INSTALLATION As you did during removal secure the camshaft sprocket with the special tool and tighten bolt t...

Page 17: ...ne Oil Draining and Supplying A 6 8 mm B 6 10 mm Identification of bolt location Semi drying sealant THREEBOND 1207D 4 mm Bolt hole Groove 8 A B B 8 B B B 3 7 8 6 4 5 1 2 39 4 0 39 44 4 0 4 5 7 0 7 26...

Page 18: ...AIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration BA OIL RETURN PIPE GASKET INSTALLATION Install the gasket with the printed por...

Page 19: ...oil 5 Crankshaft front oil seal removal steps D Timing belt and timing belt B Refer to P 11 21 D Crank angle sensor Refer to GROUP 16 1 Crankshaft sprocket B 2 Key CA 3 Crankshaft front oil seal Crank...

Page 20: ...seal case as shown in the illustration BA FLYWHEEL ASSEMBLY INSTALLATION Use the special tool to hold the flywheel in the same manner as removal and install the bolt Tighten the bolts to the specific...

Page 21: ...ation 6 Accelerator Cable Adjustment O ring Delivery pipe Engine oil 12 15 1 2 1 5 5 9 0 9 5 0 5 3 0 3 10 1 0 19 14 15 3 16 18 10 17 8 9 8 11 8 7 20 1 2 Unit Nm kgf m 18 6 3 13 12 4 Removal steps 1 Ce...

Page 22: ...8 0 0 2 0 90_ 90_ 22 22 23 10 mm 10 mm Removal steps 21 PCV hose connection 22 Rocker cover 23 Semi circular packing 24 Starter 25 Oil return pipe CA 26 Oil return pipe gasket 27 Vacuum tank solenoid...

Page 23: ...face 2 Install so that the shapes of the cylinder head holes match the shapes of the respective cylinder head gasket holes BA CYLINDER HEAD BOLT INSTALLATION 1 When installing the cylinder head bolts...

Page 24: ...head bolt will be loosened 2 If it is more than 90_ remove the head bolt and repeat the procedure from step 1 CA OIL RETURN PIPE GASKET INSTALLATION Install the gasket with the printed portion toward...

Page 25: ...ng belt KA 6 Tensioner pulley 7 Tensioner arm JA 8 Auto tensioner 9 Idle pulley 10 Crankshaft position sensor AB IA 11 Oil pump sprocket AC HA 12 Crankshaft bolt AD 13 Crankshaft sprocket 14 Sensing b...

Page 26: ...aution The camshaft sprocket on the exhaust side can turn very easily because of the valve spring tension Use care not to allow your fingers to get caught by the sprocket 3 Loosen the lock nut of the...

Page 27: ...AL AG CRANKSHAFT SPROCKET B REMOVAL If it is difficult to remove the sprocket use the special tool AH CAMSHAFT SPROCKET BOLT LOOSENING Use a wrench to hold the hexagonal part of the camshaft and then...

Page 28: ...worn down and rubber exposed tooth width reduced 8 Missing tooth AUTO TENSIONER 1 Check the auto tensioner for possible leaks and replace as necessary 2 Check the rod end for wear or damage and replac...

Page 29: ...et with a tool damages the sprocket BA ENGINE SUPPORT BRACKET LEFT INSTALLATION Coat the bolts illustrated with sealant before tightening Specified sealant THREEBOND 1207F or equivalent CA SEALANT APP...

Page 30: ...ontacting surface 2 Install the spacer with the chamfered end toward the oil seal Mounting in the reverse direction can damage the oil seal lip FA COUNTERBALANCE SHAFT SPROCKET INSTALLATION GATIMING B...

Page 31: ...IA OIL PUMP SPROCKET INSTALLATION 1 Block the counterbalance shaft in the same way as at the disassembly to prevent it from turning 2 Install the oil pump sprocket 3 Apply a proper amount of engine oi...

Page 32: ...TE Even if the timing marks on the sprocket and the rocker cover are brought into alignment the exhaust camshaft is forced back by the valve spring tension It is stabilized at a position one tooth bef...

Page 33: ...ection 7 Fit the timing belt over the exhaust side camshaft sprocket and secure it at the illustrated position using a paper clip 8 Turn the intake side camshaft sprocket as shown to a position where...

Page 34: ...p sprocket and exhaust camshaft sprocket are all offset one tooth from the corresponding timing marks in the counterclockwise direction 14 Using the special tool turn the tensioner pulley in the illus...

Page 35: ...becomes 3 5 Nm 0 36 kgf m then secure it by tightening the retaining bolt 20 Remove the special tool attached in step 16 21 Rotate the crankshaft clockwise 2 turns Then leave it intact 15 minutes 22...

Page 36: ...15 Intercooler 6 Strut Tower Bar Installation 7 Hood Installation O ring Delivery pipe 1 2 3 4 5 6 7 8 9 10 11 18 12 Engine oil 5 0 5 Unit Nm kgf m 10 12 1 0 1 2 17 16 14 13 10 12 1 0 1 2 15 3 0 3 17...

Page 37: ...sion inspection Refer to P 11 4 AA 23 Drive belt AB 24 A C compressor AC 25 Power steering oil pump D Transmission assembly 26 A C relay box 27 A C receiver bracket mounting bolt 28 Oil pressure hose...

Page 38: ...e compressor from the compressor bracket with the hose still attached NOTE Place the removed A C compressor where it will not be a hindrance when removing and installing the engine assembly and tie it...

Page 39: ...ne mount bracket while adjusting the position of the engine 2 Support the engine with the garage jack 3 Remove the chain block and support the engine assembly with the special tools CA HIGH PRESSURE F...

Page 40: ...LUBRICANTS 2 ENGINE OIL COOLER 2 12 1 ENGINE LUBRICATION CONTENTS...

Page 41: ...EMOVAL AND INSTALLATION Pre removal and Post installation Operation 1 Engine Oil Removal and Refilling 2 Front Bumper Removal and Installation Refer to GROUP 51 3 Unit Nm kgf m 12 1 2 39 44 4 0 4 5 29...

Page 42: ...tion Sensor TPS Adjustment 30 2 Fixed SAS Adjustment 30 3 Basic Idle Speed Adjustment 30 4 Fuel Pressure Measurement 30 5 MPI System Components Layout 31 6 Intake Air Temperature Sensor Check 32 7 Eng...

Page 43: ...n switch ST D Vehicle speed sensor D A C switch D Power steering fluid pressure switch D Alternator FR signal Engine ECU L1 Oxygen sensor L2 Air flow sensor L3 Intake air tem peraturesensor L4 L5 L6 C...

Page 44: ...3 0 At 80_C 0 30 0 42 Coolant temperature sensor resistance k At 20_C 2 1 2 7 At 80_C 0 26 0 36 Fuel pressure kPa kgf cm2 When vacuum hose is connected 230 2 35 kPa kgf cm2 When vacuum hose is disconn...

Page 45: ...ustment of idle switch and throttle position sensor TPS MD998464 Test harness 4 pin square Inspection of oxygen sensor MD998463 Test harness 6 pin square D Inspection of idle speed control servo D Ins...

Page 46: ...ressure gauge set Red harness White harness MB991223 Inspection test herness set D Pin contact pressure inspection harness D Market tester contact probe for general connectors Measurement of terminal...

Page 47: ...ster Misfire Evolution V only 1 2 METHOD OF READING AND ERASING DIAGNOSIS CODES 1 Use the special tool to earth No 1 terminal diagnosis control terminal of the diagnosis connector 2 To check ABS syste...

Page 48: ...n sensor TPS No increase in fuel injection amount during acceleration due to the throttle position sensor signal Engine coolant temperature sensor Controls as if the engine coolant temperature is 80_C...

Page 49: ...k D Engine speed is 500 r min or more Set conditions D Sensor output frequency is 3 Hz or less for 4 seconds D Malfunction of the air flow sensor D Improper connector contact open circuit or short cir...

Page 50: ...G Check the harness wire between the engine ECUand the intake air temper ature sensor connector NG Repair OK Replace the engine ECU OK Check the following connector A 25 NG Repair NG Code No 14 Thrott...

Page 51: ...tch ON D Engine speed is approx 50 r min or more Set conditions D The sensor output voltage increases from 1 6 V or less corresponding to an engine coolant temperature of 40_C or more to 1 6 V or more...

Page 52: ...the harness wire between the crank angle sensor and the earth and repair if necessary Code No 23 Camshaft position sensor system Probable cause Range of Check D Ignition switch ON D Engine speed is a...

Page 53: ...en the engine ECU and the vehicle speed sensor connector NG Repair OK Check trouble symptom OK Check the following connectors A 19 B 62 NG Repair NG Check the harness wire between the engine ECU and t...

Page 54: ...switch ON OK 3 7 4 3V Altitude 0 m 3 2 3 8 V Altitude 1 200 m NG Measureattheairflowsensorcon nector A 25 D Disconnect the connector and measure at the harness side D Voltage between 1 and earth Igni...

Page 55: ...Check the harness wire between the detonationsensor and earth and repair if necessary Code No 41 Injector system Probable cause Range of Check D Engine speed is approx 50 1 000 r min D The throttle p...

Page 56: ...Check the spark plugs and spark plug cables D Check the compression pressure OK Check trouble symptom OK Check the following connectors A 110 A 111 NG Repair NG Check the harness wire between the eng...

Page 57: ...alternator connec tor D Connect the connector UsetestharnessMB991519 D Voltage between 4 blue clip and earth Engine Idling Radiator fan Stopped Headlamp OFF ON Brake lamp OFF ON Rear defogger switch...

Page 58: ...e engine stalls when the accelerator pedal is depressed or while it is being used Driving Hesitation Sag Hesitation is the delay in response of the vehicle speed engine speed that occurs when the acce...

Page 59: ...ensor 80 95_C D Lamps electric cooling fan and all accessories OFF 2 500 r min 46 86 Hz all accessories OFF D Transmission Neutral Engine is raced Frequency increases in response to racing 13 Intake a...

Page 60: ...rpm When engine coolant temper ature is 20_C 1 300 1 500 rpm When engine coolant temper ature is 40_C 1 150 1 350 rpm When engine coolant temper ature is 80_C 750 950 rpm 25 Barometric pressure Igniti...

Page 61: ...ion 4 D Lamps electric cooling fan and all accessories OFF D Transmission Neutral D Idle position switch ON D Engine Idling A C switch OFF ON Increases by 10 70 steps D Engine Idling When A C switch i...

Page 62: ...80_C 3 8 5 6 ms Injector drive time 3 D Engine coolant temperature 80 95_C Engine is idling 0 9 2 1 ms drive time 3 80 95_C D Lamps electric cooling fan and all accessories OFF 2 500 r min 0 7 1 9 ms...

Page 63: ...from battery voltage to 17 Stepper motor coil A2 for warming up from battery voltage to 0 6 V and from 0 6 V to battery voltage 5 Stepper motor coil B1 V to battery voltage 18 Stepper motor coil B2 6...

Page 64: ...ng after warming up When steering wheel is stationary Battery voltage When steering wheel is turned 0 3 V 38 Control relay Ignition switch OFF Battery voltage Ignition switch ON 0 3 V 39 Fuel pump rel...

Page 65: ...engine coolant temperature is 0_C 3 2 3 8 V When engine coolant temperature is 20_C 2 3 2 9 V When engine coolant temperature is 40_C 1 3 1 9 V When engine coolant temperature is 80_C 0 3 0 9 V 84 Thr...

Page 66: ...13 Body earth Engine ECU earth Continuity established 0 26 Body earth 60 12 Oxygen sensor heater EVOLUTION V only 11 18 at 20_C 72 92 Intake air temperature sensor 5 3 6 7 k When intake air temperatur...

Page 67: ...al 4G9 engine for the inspection 7 3 INJECTOR Observing waveforms displayed on the oscilloscope allows you to visually check the conditions of injector drive signals actually output from the engine EC...

Page 68: ...time invalid injection time Invalid injection time corrects operation time lag caused by a power supply voltage drop Solenoid coil counter emf When the signal from the engine ECU turns OFF counter emf...

Page 69: ...er and to terminal 6 yellow clip when the waveform is observed with no 4 cylinder 3 For the power supply voltage observe the waveform of the injector control signal at the same time Refer to P 13 26 f...

Page 70: ...all there should normally be a voltage drop of about 10 V Resistance of resistor is too small Resistance of injector is too large Point B Spike when plunger is fully open Refer to abnormal waveform ex...

Page 71: ...lever should be 0 45 mm 2 FIXED SAS ADJUSTMENT EVOLUTION IV Turn down one turn after the fixed SAS has touched the throttle lever EVOLUTION V Turn down 1 1 4 turns after the fixed SAS has touched the...

Page 72: ...il and power transistor unit L sensor and barometric pressure sensor Injector B Camshaft position sensor M ISC servo D Control relay and fuel pump relay P Oxygen sensor K Coolant temperature sensor E...

Page 73: ...hanged replace the air flow sensor assembly 7 ENGINE COOLANT TEMPERATURE SENSOR CHECK The engine coolant temperature sensor is located as shown on the left Standard value 2 1 2 7 k at 20_C 0 26 0 36 k...

Page 74: ...ctively Caution Make sure of the correct connections if a wrong connection is made a broken oxygen sensor results 6 Connect a digital voltmeter between terminal no 2 special tool black clip and termin...

Page 75: ...tor and Clip as illustrated below 4 From here on use the same procedure as with the conventional 4G9 engine for the check MD998741 MD998706 MB991607 Main hose Battery Injector Clip MD998746 Return hos...

Page 76: ...and terminal 5 and across terminal 4 and terminal 5 of fuel pump relay No 2 Jumper wire Continuity across terminals 2 and 5 Continuity across terminals 4 and 5 Connected No Yes Disconnected Yes No 4 I...

Page 77: ...o GROUP15 Intercooler 2 Fuel Leakage Check O ring 9 0 9 8 3 6 11 12 O ring 10 13 1 0 1 3 Engine oil 1 2 3 4 5 6 7 8 9 10 11 12 Unit Nm kgf m 4 Removal steps 1 Injector connector 2 PCV hose connection...

Page 78: ...Accelerator Cable Adjustment 3 4 2 6 1 7 19 1 9 5 Unit Nm kgf m 5 0 5 Removal steps 1 Accelerator cable connection 2 Throttle position sensor connector 3 Idle speed control servo connector 4 Vacuum h...

Page 79: ...14 1 ENGINE COOLING CONTENTS SERVICE SPECIFICATIONS 2 LUBRICANT 2 ON VEHICLE SERVICE 2 Coolant Replacement 2 THERMOSTAT 3 WATER PUMP 5 WATER HOSE AND WATER PIPE 6 RADIATOR 7...

Page 80: ...ICANT Items Brand Quantity dm3 Coolant capacity in condenser tank MITSUBISHI GENUINE DIA QUEEN SUPER LONG LIFE COOLANT 6 6 ON VEHICLE SERVICE COOLANT REPLACEMENT CYLINDER BLOCK DRAIN PLUG Unit Nm kgf...

Page 81: ...Hose Assembly Removal and Installation Refer to GROUP 15 Intercooler 4 3 5 1 Unit Nm kgf m 13 1 3 Removal steps AA BA 1 Radiator lower hose connection 2 Control wiring harness connection 3 Water inle...

Page 82: ...t fitting 2 Align the mating marks on the radiator hose and hose clamp and then connect the radiator hose INSPECTION THERMOSTAT CHECK 1 Immerse the thermostat in water and heat the water while stirrin...

Page 83: ...5 24 2 4 8 22 8 14 Bolt specifications 8 24 Screw diameter length mm 1 2 4 3 2 22 2 2 8 70 Unit Nm kgf m Removal steps 1 Alternator brace 2 Water pump 3 Water pump gasket AA 4 O ring INSTALLATION SER...

Page 84: ...15 AIR CONTROL VALVE 6 2 10 8 Semi drying sealant THREEBOND 1207F 5 7 f3mm 6 9 1 3 Unit Nm kgf m 24 2 4 48 4 9 10 1 0 14 11 12 13 1 3 41 4 2 13 1 3 10 1 0 24 2 4 41 4 2 13 4 Removal steps AA CA 1 Rad...

Page 85: ...adiator removal steps 1 Drain plug 2 Radiator cap 3 Overflow hose 4 Reserve tank 5 Reserve tank bracket AA AA 6 Radiator upper hose AA AA 7 Radiator lower hose 8 Radiator assembly 9 Lower insulator 10...

Page 86: ...of the water inlet or outlet fitting 2 Align the mating marks on the radiator hose and hose clamp and then connect the radiator hose Caution Fit the clamp on the hose at the same position as before I...

Page 87: ...ENGINE COOLING Radiator 14 9 Battery voltage Terminal number 1 2 3 4 When deenergized When energized Radiator fan motor relay HI...

Page 88: ...stem Check 3 3 Wastegate Actuator Check 4 4 Wastegate Solenoid Valve Check 4 5 Air Bypass Valve Check 4 6 Secondary Air Control System Check 5 7 Secondary Air Control Solenoid Valve Check 5 8 Secondar...

Page 89: ...oval and installation of oxygen sensor ON VEHICLE SERVICE 1 TURBOCHARGER BOOST PRESSURE CHECK Caution Carry out driving tests in a location where full throttle acceleration is possible with utmost saf...

Page 90: ...e way joint between the hose and solenoid valve 2 Connect a hand vacuum pump to the three way joint 3 Disconnect the hose black from the intake pipe nipple connected to the turbocharger compressor hou...

Page 91: ...1 OPERATION CHECK 1 Connect a hand vacuum pump to nipple A of the solenoid valve 2 Using jumper wires connect the solenoid valve terminal to battery terminals 3 Disconnecting and reconnecting the jump...

Page 92: ...se white stripe yellow stripe from the solenoid valve 2 Disconnect the harness connector 3 Connect a hand vacuum pump to nipple A of the solenoid valve 4 Using jumper wires connect the solenoid valve...

Page 93: ...ve to check for air passage Vacuum Air blowing direction Air passage 0 kPa vacuum notapplied A B No 40 kPa 300 mmHg or more A B Yes or more B A No 9 VACUUM TANK CHECK 1 Connect a hand vacuum pump to n...

Page 94: ...al steps 1 Vacuum hose connection 2 Air bypass valve assembly 3 Breather hose connection 4 Vacuum hose connection 5 Air intake hose assembly AA 6 Air bypass hose 7 Air hose connection AA 8 Air hose D...

Page 95: ...0 12 1 0 1 2 24 2 4 22 2 2 2 3 8 7 6 4 5 12 15 1 2 1 5 Removal steps 1 Control harness connection 2 Vacuum pipe hose assembly 3 Air pipe assembly AA 4 Gasket 5 Air hose 6 Air control valve 7 Engine ha...

Page 96: ...12 1 0 1 2 12 15 1 2 1 5 35 3 6 9 0 9 30 3 1 35 3 6 20 2 0 22 2 2 20 2 0 14 14 16 7 5 17 15 2 1 3 4 6 7 7 19 20 18 8 9 12 10 11 13 Removal steps 1 Center cover 2 Ignition coil connector connection 3 O...

Page 97: ...se being careful not to damage the O ring Caution Be careful not to let any engine oil get into the delivery pipe 2 Check to be sure that the high pressure hose turns smoothly If it does not turn smoo...

Page 98: ...9 0 9 12 15 1 2 1 5 2 3 4 29 3 0 20 49 59 5 0 6 0 54 64 5 5 6 5 30 3 1 17 20 1 7 2 0 10 1 0 42 4 2 10 1 0 10 12 1 0 1 2 17 1 7 49 5 0 27 32 2 7 3 3 19 6 10 12 10 11 18 7 8 9 17 16 15 14 13 5 Removal...

Page 99: ...sage holes in turbocharger INSTALLATION SERVICE POINTS AA TURBOCHARGER INSTALLATION 1 Clean the connections between oil pipe oil return pipe and water pipe Caution Ensure that no foreign matter will g...

Page 100: ...eck that there is no oil leak from the turbocharger 4 Check to see if the wastegate valve remains open If any of these faulty symptoms is evident disassemble the turbocharger and replace the defective...

Page 101: ...9 18 9 3 3 9 Main muffler removal steps 1 Bolt 2 Main muffler 3 Hanger Center exhaust pipe removal steps 1 Bolt 4 Spring 5 Heat protector 6 Self locking nut 7 Hanger bracket 8 Center exhaust pipe 9 H...

Page 102: ...TENTS CHARGING SYSTEM 2 ALTERNATOR 2 IGNITION SYSTEM 4 ON VEHICLE SERVICE 4 1 Ignition Coil with Built in Power Transistor Check 4 2 Spark Plug Check Cleaning and Replacement 4 CAMSHAFT POSITION SENSO...

Page 103: ...lation 2 Engine Mount Installation 3 Under Cover Installation 4 Drive Belt Tension Adjustment Refer to GROUP 11 On vehicle Service Unit Nm kgf m 44 4 5 7 3 2 6 1 5 4 24 2 4 22 2 2 9 0 9 12 15 1 2 1 5...

Page 104: ...the holes 2 Remove the drive belt AB DELIVERY PIPE INJECTOR AND PRESSURE REGULATOR ASSEMBLY REMOVAL After the mounting points have been loosened slightly move the corresponding part to allow for a sp...

Page 105: ...NT Check the plug gap and replace if the limit is exceeded Caution 1 Do not attempt to adjust the gap of the platinum plug 2 Cleaning the platinum plug can damage platinum tips If a cleaning is needed...

Page 106: ...9 4 0 3 0 3 2 3 4 1 Removal steps 1 Camshaft position sensor 2 Center cover AA 3 Power steering oil pump 4 Power steering oil pump bracket 5 Crank angle sensor REMOVAL SERVICE POINT AA POWER STEERING...

Page 107: ...SSION CONTROL CONTENTS ENGINE CONTROL SYSTEM 2 SERVICE SPECIFICATIONS 2 EMISSION CONTROL SYSTEM 2 ON VEHICLE SERVICE 2 System Configuration Diagram 2 Vacuum Hose Piping Circuit Diagram 3 CANISTER 3 CA...

Page 108: ...TEM SERVICE SPECIFICATIONS Items Standard value Idle speed rpm 850 50 EMISSION CONTROL SYSTEM MPI ON VEHICLE SERVICE SYSTEM CONFIGURATION DIAGRAM Canister Check valve Throttle body Fuel pressure contr...

Page 109: ...ck valve Throttle body Fuel pressure regulator Wastegate solenoid valve Secondary air valve Bypass valve Front of vehicle Wastegate actuator Vacuum hose color B Black L Blue R Red W White Y Yellow CAN...

Page 110: ...I 17 4 CATALYTIC CONVERTER REMOVAL AND INSTALLATION Unit Nm kgf m 3 2 1 5 4 49 5 0 5 0 5 19 1 9 49 5 0 49 5 0 34 3 5 13 1 3 Removal steps 1 Spring 2 Heat protector 3 Front exhaust pipe 4 High temperat...

Page 111: ...21 1 CLUTCH CONTENTS SERVICE SPECIFICATIONS 2 LUBRICANTS 2 ON VEHICLE SERVICE 2 1 Clutch Pedal Inspection and Adjustment 2 2 Bleeding 3 CLUTCH PEDAL 4 CLUTCH CONTROL 5 Clutch Master Cylinder 6...

Page 112: ...d MITSUBISHI genuine brake fluid DIA QUEEN BRAKE FLUID SUPER 4 As required Push rod assembly Rubber grease Boot Release cylinder push rod MOLYKOT BR 2 PUS ON VEHICLE SERVICE 1 CLUTCH PEDAL INSPECTION...

Page 113: ...e C 6 13 mm Standard value D 70 mm or more 7 If the clutch pedal free play and the distance between the clutch pedal and the toeboard when the clutch is disengaged do not agree with the standard value...

Page 114: ...ion 13 5 Unit Nm kgf m 13 1 3 1 13 4 11 12 2 7 6 8 9 10 6 3 5 24 2 4 13 1 3 12 1 2 Removal steps 1 Clutch master cylinder installation nut 2 Master cylinder member bracket installation bolt 3 Clevis p...

Page 115: ...l Adjustment Refer to P 21 2 Specified grease MOLYKOT BR 2 PLUS 5 Unit Nm kgf m 13 1 3 6 6 4 6 7 8 2 3 1 5 0 5 15 1 5 19 1 9 Release cylinder push rod Release fork Clutch master cylinder removal steps...

Page 116: ...lutch fluid DIA QUEEN BRAKE FLUID SUPER 4 Grease Rubber grease 5 2 2 1 4 2 2 8 3 Unit Nm kgf m 13 1 3 Disassembly steps 1 Piston stopper ring 2 Piston assembly 3 Push rod assembly 4 Boot 5 Reservoir c...

Page 117: ...MANUAL TRANSMISSION 22A MANUAL TRANSMISSION OVERHAUL 22B 22 1 MANUAL TRANSMISSION CONTENTS...

Page 118: ...SEMBLY 7 TRANSFER ASSEMBLY 10 WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES 1 Thoroughly review this manual especially GROUP 52B Supplemental Restraint System SRS...

Page 119: ...2 SPECIAL TOOLS Tool Number Name Use MB990635 or MB991113 Steering linkage puller Tie rod end and lower arm disconnection Recommended tool MZ203826 by Anzen Jidosha or MZ203827 by Banzai Engine lifter...

Page 120: ...2 8 4 Tighten the filler plug to the specified torque Tightening torque 32 Nm 3 3 kgf m 3 TRANSFER OIL CHECK 1 Remove the oil filler plug 2 Oil level should be at the lower portion of the filler plug...

Page 121: ...removal steps BA 1 Shift knob BA 2 Spring washer BA 3 Nut D Front floor console Refer to GROUP 52 4 Snap pin 5 Select cable connection Shift lever side 6 Clip 7 Shift cable connection Shift lever sid...

Page 122: ...s should face the snap pins 3 Move the shift lever to all positions and check that the operation is smooth BA NUT SPRING WASHER SHIFT KNOB INSTALLATION 1 Screw in the nut all the way by hand turn back...

Page 123: ...A 6 SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 1 2 3 4 5 7 8 9 10 3 9 6 Unit Nm kgf m 14 1 4 10 1 0 Disassembly steps 1 Bolt 2 Select lever 3 Bushing 4 Return spring 5 Collar 6 Bolt 7 Cap 8 Shift...

Page 124: ...r Installation 5 Transfer Oil Supplying Refer to P 22A 3 6 Transmission Oil Supplying Refer to P 22A 3 7 Shift Lever Operation Check 8 Speedometer Operation Check 1 2 3 4 5 6 7 8 8 Unit Nm kgf m 49 5...

Page 125: ...e rod end connection 13 Lower arm ball joint connection AA D Clutch release bearing connection 14 Centermember assembly AB 15 Drive shaft LH connection AB 16 Drive shaft RH connection D Strut assembly...

Page 126: ...ibly prying can cause the release bearing to be damaged AB DRIVE SHAFT LH DRIVE SHAFT RH DISCONNECTION 1 To disconnect the left hand drive shaft insert a lever as shown and pry out the shaft from the...

Page 127: ...l MITSUBISHI genuine Dia Queen Super hypoid gear oil GL 5 Unit Nm kgf m 2 69 7 0 1 Removal steps D Drive shaft Refer to P 22A 9 D Output shaft Refer to P 22A 9 1 Front propeller shaft Refer to GROUP 2...

Page 128: ...D ADHESIVES 5 LUBRICANTS 6 SNAP RINGS SPACERS AND THRUST PLATES FOR ADJUSTMENT 6 TORQUE SPECIFICATIONS 9 SPECIAL TOOLS 10 TRANSMISSION 13 INPUT SHAFT 20 OUTPUT SHAFT 27 REVERSE IDLER GEAR 35 SPEEDOMET...

Page 129: ...MANUAL TRANSMISSION OVERHAUL General Information 22B 2 GENERAL INFORMATION SECTIONAL VIEW Without Front Limited Slip Differential Front LSD...

Page 130: ...MANUAL TRANSMISSION OVERHAUL General Information 22B 3 SECTIONAL VIEW With Front Limited Slip Differential Front LSD...

Page 131: ...51 1 Z7A1 B 30 36 4 875 Available GEAR RATIO TABLE A B 1st 2 785 2nd 1 950 3rd 1 407 1 444 4th 1 031 1 096 5th 0 761 0 825 Reverse 3 416 Transfer gear ratio 0 3018 SERVICE SPECIFICATIONS Items Allowab...

Page 132: ...s however the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool A flat and thin gasket scraper may be lightly hammered in between the joined s...

Page 133: ...ential oil seal lip area Transmission oil O rings SNAP RINGS SPACERS AND THRUST PLATES FOR ADJUSTMENT Part name Thickness mm Identification symbol Part No Spacer For adj stment of inp t shaft end pla...

Page 134: ...5 MD748468 3 98 6 MD748469 4 02 7 MD748470 4 06 8 MD748471 4 10 9 MD748472 Spacer For adj stment of o tp t shaft preload 0 86 86 MD720938 For adjustment of output shaft preload 0 89 89 MD720939 0 92 9...

Page 135: ...nap ring For adj stment of o tp t shaft 3rd speed gear 2 81 None MD746594 For adjustment of output shaft 3rd speed gear clearance 2 85 Blue MD746595 2 89 Brown MD746596 2 93 Yellow MD746597 2 97 Green...

Page 136: ...0 8 MD748364 0 9 MD748365 1 0 MD748366 1 1 MD748367 TORQUE SPECIFICATIONS TRANSMISSION Items Nm kgf m Under cover mounting bolt 6 9 0 7 Interlock plate bolt 30 3 1 Clutch housing transmission case mou...

Page 137: ...transfer oil seal MB990891 Bushing remover installer base Installation of transfer oil seal MB990928 Installer adapter Installation of input shaft oil seal MB990932 Installer adapter Removal of diffe...

Page 138: ...extension housing oil seal MD998364 Camshaft oil seal installer Installation of gear bearing and sleeve MD998800 Oil seal installer Installation of differential oil seal and transfer cover oil seal M...

Page 139: ...8821 Installer adapter 44 Installation of 4th speed gear 5th speed gear sleeve and 5th reverse speed synchronizer hub MD998824 Installer adapter 50 Installation of 1st 2nd speed synchronizer hub 2nd s...

Page 140: ...2 3 4 5 6 7 8 9 10 11 Unit Nm kgf m 18 1 9 69 7 0 69 7 0 18 1 9 69 7 0 3 9 0 4 32 3 3 32 3 3 3 Disassembly steps 1 Transfer JA 2 O ring 3 Roll stopper bracket 4 Insulator washer 5 Shift cable bracket...

Page 141: ...7 Unit Nm kgf m 18 1 9 30 3 1 48 4 9 3 9 0 7 44 4 5 Disassembly steps 12 Interlock plate bolt 13 Gasket GA 14 Control housing 15 Neutral return spring FA 16 Under cover 17 Reverse idler gear shaft bol...

Page 142: ...ly steps CA 28 Spring pin 29 1st 2nd speed shift rail 30 1st 2nd speed shift fork CA 31 Spring pin AA CA 32 Spring pin AB BA 33 3rd 4th speed shift rail AB BA 34 3rd 4th speed shift fork AB BA 35 5th...

Page 143: ...REMOVAL Remove the input shaft output shaft and center differential together ADJUSTMENT BEFORE REASSEMBLY SPACER SELECTION FOR ADJUSTING INPUT SHAFT END PLAY OUTPUT SHAFT PRELOAD DIFFERENTIAL PRELOAD...

Page 144: ...that will provide the standard end play preload value Standard value Input shaft end play 0 0 17 mm Output shaft end play 0 13 0 18 mm Center differential preload 0 05 0 11 mm REASSEMBLY SERVICE POIN...

Page 145: ...NSTALLATION Apply sealant to the illustrated position of the transmission case Specified sealant THREEBOND 1216 Caution Squeeze out the sealant uniformly while making sure that it is not broken or exc...

Page 146: ...mission oil to the O ring of the speedometer gear Transmission oil DIA QUEEN MULTI GEAR OIL 75W 85W IA SELECT LEVER INSTALLATION Apply grease to the control shaft sliding portion of the select lever s...

Page 147: ...KA 3 Thrust plate stopper JA 4 Thust plate AC IA 5 5th speed gear 6 4th speed gear 7 Needle roller bearing AD HA 8 4th speed gear sleeve 9 Synchronizer ring GA 10 Synchronizer spring FA 11 Synchroniz...

Page 148: ...PPER REMOVAL Using a screwdriver pry up the position shown in the illustration and remove the thrust plate stopper AC 5TH SPEED GEAR REMOVAL AD 4TH SPEED GEAR SLEEVE REMOVAL Install the special tool t...

Page 149: ...t shaft front bearing end play will have the standard value Standard value 0 0 12 mm DA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring securely to the illustrated position of the out...

Page 150: ...direction shown 2 When the synchronizer sleeve is installed make sure that the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve GASYNCHRONIZER SPRING I...

Page 151: ...ced against the thrust plate stopper KA THRUST PLATE STOPPER INSTALLATION Install the thrust plate stopper by pressing the special tools with hand Make sure that the stopper is not installed aslant LA...

Page 152: ...nsure that the cage is not deformed SYNCHRONIZER RING 1 Check to ensure that the clutch gear tooth surfaces are not damaged and broken 2 Check to ensure that the cone inside surface is not damaged or...

Page 153: ...k to ensure that the front and rear ends of the sleeve inside surface are not damaged Caution When replacement of either the synchronizer sleeve or hub is necessary make sure that the synchronizer sle...

Page 154: ...se speed synchronizer hub 10 Synchronizer ring LA 11 Synchronizer spring 12 5th speed gear 13 Needle roller bearing KA 14 5th speed gear sleeve JA 15 4th speed gear IA 16 Snap ring AD HA 17 3rd speed...

Page 155: ...AL Mount a special tool on the 4th speed gear and remove the 5th reverse speed synchronizer hub AD 3RD SPEED GEAR REMOVAL Mount a special tool on the 2nd speed gear and remove the 3rd speed gear AE 2N...

Page 156: ...NSTALLATION Make sure that the oil seal is pressed into the position shown in the illustration BA TAPER ROLLER BEARING INSTALLATION CA 1ST SPEED GEAR SLEEVE INSTALLATION 1st speed gear sleeve MD998801...

Page 157: ...caught FA SYNCHRONIZER SLEEVE INSTALLATION 1 Install the synchronizer sleeve in such a way that it will be oriented in the direction shown 2 When the synchronizer sleeve is installed make sure that th...

Page 158: ...utput shaft 3rd speed gear clearance will have the standard value Standard value 0 0 09 mm JA 4TH SPEED GEAR INSTALLATION KA 5TH SPEED GEAR SLEEVE INSTALLATION 2nd speed gear sleeve MD998364 MD998824...

Page 159: ...shown Caution When the hub is installed make sure that the synchronizer ring is not caught NA REVERSE GEAR NEEDLE ROLLER BEARING REVERSE GEAR BEARING SLEEVE INSTALLATION OATAPER ROLLER BEARING INSTAL...

Page 160: ...that when the bearing sleeve and gear are combined and made to rotate they rotate smoothly without looseness and noise 2 Check the cage for deformation SYNCHRONIZER RING 1 Check to ensure that the clu...

Page 161: ...and made to slide they slide smoothly without binding 2 Check to ensure that the front and rear ends of the sleeve inside surface are not damaged Caution When replacement of either the synchronizer s...

Page 162: ...ation 5 4 3 2 1 TFM0807 Disassembly steps 1 Snap ring 2 Thrust washer 3 Reverse idler gear 4 Needle roller bearing 5 Reverse idler gear shaft INSPECTION NEEDLE ROLLER BEARING 1 Check to ensure that wh...

Page 163: ...OVERHAUL Speedometer Gear 22B 36 SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation 4 3 2 1 TFM0593 Disassembly steps 1 e clip 2 Speedometer driven gea...

Page 164: ...10 9 8 7 6 5 4 3 2 1 Unit Nm kgf m 11 1 2 Disassembly steps AA 1 Dust cover 2 Nut 3 Spring washer 4 Washer 5 Select lever bushing 6 Select lever shoe 7 Select lever 8 Select lever bushing AA 9 Dust co...

Page 165: ...kgf m 18 1 9 Disassembly steps AA FA 1 Lock pin 2 Interlock plate 3 Control finger 4 Pin 5 Return spring 6 Stopper plate EA 7 Spring pin DA 8 Spring pin 9 Stopper body 10 Neutral return spring 11 Spac...

Page 166: ...ng sure that the model number stamped side is oriented in the direction shown BA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area Transmission oil DIA QUEEN MULTI GEAR OIL 75W 85W...

Page 167: ...40 DA SPRING PIN INSTALLATION EA SPRING PIN INSTALLATION FA LOCK PIN INSTALLATION Drive in the lock pin in the direction shown in the illustration Control shaft Stopper body Installation direction Sl...

Page 168: ...1 0 Unit Nm kgf m Disassembly steps 1 Clutch release bearing retainer EA 2 Oil seal AA DA 3 Outer race AB CA 4 Outer race BA 5 Bushing AA 6 Cover A AA 7 Cover B 8 Clutch housing NOTE Never remove the...

Page 169: ...NTS AA COVER A COVER B INSTALLATION Install the covers directed as shown in the illustration BA BUSHING INSTALLATION Press fit the bushing to the illustrated position while making sure that the split...

Page 170: ...ng 22B 43 CA OUTER RACE INSTALLATION DA OUTER RACE INSTALLATION EA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area Transmission oil DIA QUEEN MULTI GEAR OIL 75W 85W MB990935 MB99...

Page 171: ...LY AND REASSEMBLY 4 3 2 1 Disassembly steps CA 1 Oil seal BA 2 Needle bearing AA 3 Bushing 4 Transmission case NOTE Never remove the bearing and bushing from the transmission case Only the case when i...

Page 172: ...ide with the air purge groove BA NEEDLE BEARING INSTALLATION Press fit the needle bearing until it is flush with the case while making sure that the model number stamped side is oriented in the direct...

Page 173: ...differential drive gear CA 2 Center differential flange AA BA 3 Taper roller bearing CA 4 Snap ring CA 5 Front output shaft CA 6 Spacer CA 7 Side gear CA 8 Lock pin CA 9 Pinion shaft CA 10 Pinion sha...

Page 174: ...PINION SHAFT LOCK PIN FRONT OUTPUT SHAFT SNAP RING CENTER DIFFERENTIAL FLANGE INSTALLATION 1 Install the side gear in the center differential case with the spacer attached NOTE If a new side gear is...

Page 175: ...ning the mating marks then secure it temporarily with machine screw 8 Measure the backlash between the side gear and the pinion Standard value 0 025 0 150 mm 9 If the measurement deviates from the sta...

Page 176: ...LY 10 2 11 4 8 7 9 5 3 1 6 Apply gear oil to all moving parts before installation 23 2 4 Unit Nm kgf m Disassembly steps FA 1 Air breather 2 Dust seal guard EA 3 Oil seal DA 4 Oil seal AA 5 O ring AA...

Page 177: ...L INSTALLATION 1 Apply transmission oil to the oil seal lip area Transmission oil DIA QUEEN MULTI GEAR OIL 75W 85W 2 By using the special tool install the oil seal DA OIL SEAL INSTALLATION 1 Apply tra...

Page 178: ...MANUAL TRANSMISSION OVERHAUL Transfer 22B 51 FA AIR BREATHER INSTALLATION Apply sealant to the air breather Specified sealant THREEBOND 1501...

Page 179: ...26 1 FRONT AXLE CONTENTS SERVICE SPECIFICATIONS 2 SPECIAL TOOLS 2 AXLE HUB AND KNUCKLE 3...

Page 180: ...B990767 End holder Fixing of hub MB991354 Puller body Removal of drive shaft A B MB990241 A MB990242 B MB990244 Axle shaft puller A Puller shaft B Puller bar A MB991017 B MB990998 C MB991000 A B Front...

Page 181: ...icles with AYC AA 2 Caliper assembly 3 Brake disc 4 Split pin AB AA 5 Drive shaft nut 6 Front hub assembly 7 Dust shield 8 Connection for lower arm ball joint 9 Split pin AC 10 Connection for tie rod...

Page 182: ...ll joint 2 Tie the special tool with a cord not to let it fall off AD DRIVE SHAFT REMOVAL INSTALLATION SERVICE POINT AA DRIVE SHAFT NUT INSTALLATION 1 Install the drive shaft washer in the specified d...

Page 183: ...mit value range and there should be no engagement or feeling of roughness 2 HUB AXIAL PLAY CHECK 1 Measure the hub play in the axial direction Limit 0 05 mm NOTE Measure the hub play while clamping th...

Page 184: ...g 29 6 Differential Carrier Oil Seal Replacement 30 7 Speed Sensor Output Voltage Measurement Vehicles without ABS 31 8 Action When Battery Runs Out 32 REAR HUB ASSEMBLY 33 KNUCKLE 35 DRIVE SHAFT 36 D...

Page 185: ...5 1 9 Nm kgf m When existing clutch plate is installed 2 19 0 2 1 9 Distortion of friction plate and friction disc mm 0 08 Difference in thickness between friction plate friction disc and spring plate...

Page 186: ...pressure measurement vehicles with AYC MB991705 Hose adapter MB990925 Bearing oil seal installer set Pressfitting of oil seal differential MB991115 Oil seal installer Pressfitting of oil seal differen...

Page 187: ...surement of wheel bearing axial play Use MB991000 component of MB990998 for the spacer MB990326 Preload socket D Measurement of wheel bearing rotation starting torque D Measurement of drive pinion pre...

Page 188: ...B MB990938 MB990932 61 0 C MB990939 TROUBLESHOOTING AYC 1 BASIC TROUBLESHOOTING CONDITIONS Before starting the troubleshooting procedure make sure that the following items have been checked okay D Th...

Page 189: ...sensor ST N system short circuit 27 11 33 Steer sensor ST N system 27 12 34 Steer sensor ST 1 ST 2 system short circuit 27 12 41 TPS system open or short circuit 27 13 51 Longitudinal acceleration se...

Page 190: ...h IG2 and AYC ECU OK Replace AYC ECU NG Repair Code No 21 22 23 24 Wheel speed sensor system Probable cause This code is output if any one of three wheel speed sensors fails to provide an input even a...

Page 191: ...symptom OK Check the following connectors B 95 B 52 B 17 A 26 A 50 D 04 D 14 D 19 NG Repair OK Measureat B 95 AYC ECUconnector D Disconnect the connector and measure at the harness side D Resistanceac...

Page 192: ...ector and measure at the harness side D Ignition switch OK D Turn tire at 1 2 to 1 revolution sec D Voltage across 6 7 8 9 and body ground OK 42 mV or more when mea sured with a circuit tester 120 mV...

Page 193: ...the connector and measure at the harness side D Ignition switch ON D Turn tire at 1 2 to 1 revolution sec D Voltage across 6 7 8 9 and body ground OK 42 mV or more when mea sured with a circuit tester...

Page 194: ...n the steering wheel is turned OK Check the following connector B 95 NG Repair NG Voltage alternates between 4 V or more and 0 5 V NG Voltage remains at 0 V Code No 32 Steer sensor ST N system Probabl...

Page 195: ...m about 0 5 V or less to about 3 5 V NG Check the following connectors B 95 B 65 B 98 NG Repair Code No 34 Steer sensor ST 1 ST 2 system Probable cause This code is output if a turning condition is de...

Page 196: ...D Defective AYC ECU NG Replace the acceleration sensor OK Check the trouble symptom OK Checkand repairtheharnessbetween acceleration sensor and ignition switch OK Check the trouble symptom NG Checkand...

Page 197: ...und OK 2 4V to 2 6 V where vehicle in horizontal position NG Check the following connectors B 95 B 52 D 20 Check the acceleration sensor Refer to P 27 52 NG Replace NG Repair Code No 61 Stop lamp swit...

Page 198: ...soutputwhentheproportioningvalvecontrolcircuitisopen orshort circuited D Defective proportioning valve D Defective harness or connector D Defective AYC ECU OK Checkand repairtheharnessbetween proporti...

Page 199: ...ECU NG Checktheharnessbetweendirectional control valve right and AYC ECU NG Repair OK Check the trouble symptom OK Check the following connectors B 96 B 94 D 06 F 30 F 29 NG Repair OK Measure at F 29...

Page 200: ...U NG Checktheharnessbetweendirectional control valve left and AYC ECU NG Repair OK Check the trouble symptom OK Check the following connectors B 96 B 94 D 06 F 30 F 28 NG Repair OK Measure at F 28 dir...

Page 201: ...AYC relay and body ground OK Check the trouble symptom OK Replace AYC ECU NG ChecktheharnessbetweenAYCrelay and AYC ECU NG Repair NG Check the trouble symptom OK Check the following connectors B 96 B...

Page 202: ...between fusible link no 10 and AYC relay OK Check the trouble symp tom OK Replacethe hydraulicunit for a defective accumula tor pressure switch NO Repair the leak OK Check the trouble symptom NG Chec...

Page 203: ...tch connector D Disconnect the connector and measure at the harness side D Ignition switch ON 1 Voltage across 2 and body ground OK Battery voltage 2 Continuity across 1 and body ground OK Conducting...

Page 204: ...cuit between AYC warning lamp and AYC ECU or AYC ECU itself is defective D Blown fuse D AYC warning lamp out D Defective harness or connector D Defective AYC ECU NG Checkand repairtheharnessbetween ig...

Page 205: ...ive Unable to start or accelerate on slippery road surfaces Probable cause The hydraulic oil level is probably low there is an oil leak the hydraulic unit is defective or the torque transfer different...

Page 206: ...nsfer differential NOTE This symptom is limited only when the diagnosis code is correct NG Replace the hydraulic unit NG Replacethetorquetransferdifferential Check the trouble symptom NG Replace AYC f...

Page 207: ...teer sensor ST 1 Engine Idle speed Turn steering wheel slowly 0 V approx 3 V flashing 6 1 FR wheel speed Vehicle stationary 1 V or less Forward vehicle slowly 0 5 V 7 1 FL wheel speed Vehicle stationa...

Page 208: ...31 AYC ECU power supply Ignition switch ON Battery voltage Ignition switch OFF 0 V 35 AYC motor relay Ignition switch ON When motor is energized Battery voltage ON When motor is deenergized 2 V or les...

Page 209: ...No Signal name Normally 2 body ground Longitudinal acceleration sensor ground lateral acceleration sensor ground Conducting 26 body ground ECU ground Conducting 35 body ground AYC motor relay Conduct...

Page 210: ...urn the propeller shaft fully counterclockwise and measure the deviation between the alignment marks Limit 5 mm 4 If the backlash exceeds the limit replace the differential carrier assembly 2 GEAR OIL...

Page 211: ...ug and tighten it to the specified torque 3 GEAR OIL CHANGE 3 1 DIFFERENTIAL 1 Remove the drain plug to discharge the gear oil 2 Fit the drain plug and tighten it to the specified torque Tightening to...

Page 212: ...AX and MIN 4 If the fluid level is lower than MIN add the specified fluid Specified fluid MITSUBISHI DIA QUEEN ATF SPII 5 Reinstall the maintenance lid 5 BLEEDING 1 Lift up the vehicle 2 Remove the ca...

Page 213: ...ose grease 5 Replace the drive shaft circlip with a new one and mount the drive shaft to the differential carrier Refer to P 27 36 6 Check for correct wheel alignment Refer to GROUP 34 On vehicle Serv...

Page 214: ...pe is used 200 mVp p or more 4 If the output voltage is lower than the above value it is probably attributable to the following faults Check or replace the speed sensor as necessary D Excessive cleara...

Page 215: ...uspension it may be open circuited only when the vehicle is run on rough roads and not on ordinary road The speed sensor output voltage waveform should therefore be checked also by rocking the sensor...

Page 216: ...ection AB AA 6 Drive shaft nut AC 7 Rear hub assembly 8 Backing plate Caution Do not disassemble the rear hub assembly REMOVAL SERVICE POINTS AA CALIPER ASSEMBLY REMOVAL Secure the removed caliper ass...

Page 217: ...EL BEARING ROTATION STARTING TORQUE 1 Install the special tool to the rear hub assembly and tighten it to the specified torque 2 Using the special tool measure the wheel bearing rotation starting torq...

Page 218: ...Removal steps 1 Rear speed sensor connection Vehicles with AYC AA 2 Trailing arm connection 3 Lower arm connection AA 4 Toe control arm connection AA 5 Upper arm connection 6 Knuckle Caution Indicates...

Page 219: ...ehicle Service 1 2 3 4 5 6 7 8 9 10 11 Unit Nm kgf m 25 2 6 74 87 7 5 8 9 74 87 7 5 8 9 88 9 0 49 59 5 0 6 0 196 255 20 0 26 0 Removal steps 1 Caliper assembly Refer to P 27 33 2 Brake disc 3 Shoe lin...

Page 220: ...r Caution 1 Be sure to remove the drive shaft from the differential side using a lever Removing it from the BJ side could damage the parts 2 Do not apply the vehicle weight to the wheel bearing with t...

Page 221: ...drive shaft in the direction shown on the left 2 Using the special tool tighten the drive shaft nut to the specified torque Caution Before torquing the drive shaft nut to specification do not apply ve...

Page 222: ...stallation Refer to GROUP 34 3 Lower Arm Assembly Installation Refer to GROUP 35 4 Gear Oil Filling Refer to P 27 28 5 Hydraulic Piping Fluid Filling and Bleeding Refer to P 27 29 1 2 3 4 5 6 7 8 9 10...

Page 223: ...r shown NOTE To ensure both good installation accuracy and ease of installation the rear crossmember mounting holes have different diameters between front and rear This is the reason for specifying th...

Page 224: ...Installation 4 Differential Gear Oil Filling 1 2 3 4 5 6 7 8 9 10 Unit Nm kgf m 29 34 3 0 3 5 88 9 0 108 127 11 0 13 0 3 6 9 7 2 108 127 11 0 13 0 108 127 11 0 13 0 88 9 0 88 9 0 88 9 0 69 7 0 108 12...

Page 225: ...INSTALLATION SERVICE POINTS AA REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY INSTALLATION Tighten the rear crossmember mounting bolts in the numerical order shown NOTE To ensure both good install...

Page 226: ...0 9 9 0 9 49 5 0 3 Disassembly steps 1 Drain plug 2 Packing 3 Filler plug 4 Gasket 5 Vent plug 6 Bleeder screw 7 Cover AA 8 Self locking nut 9 Washer 10 Companion flange 11 Oil seal BA 12 Oil seal AA...

Page 227: ...REAR AXLE Torque Transfer Differential Vehicles with AYC 27 44 GREASE AND SEALANT APPLICATION POINTS Grease Vaseline Semi drying sealant THREEBOND 1281B Semi drying sealant THREEBOND 1281B 3 0 mm...

Page 228: ...NSTALLATION 1 Using the special tool pressfit the oil seal as far as it will go 2 Apply the specified grease to the oil seal lip Specified grease Vaseline BA OIL SEAL INSTALLATION 1 Using the special...

Page 229: ...plate 9 Pressure ring 10 Side gear 11 Pinion gear 12 Pinion shaft 13 Pressure ring 14 Friction plate 15 Friction disc 16 Friction plate 17 Friction disc 18 Friction plate 19 Spring plate AA 20 Differe...

Page 230: ...nd left spring plates 3 Assemble the pressure ring internal parts pinion shaft and pressure ring friction plates and friction discs and using a micrometer measure the overall width NOTE When taking me...

Page 231: ...the specified range disassemble the differential case assembly and repair or replace defective parts INSPECTION 1 DIFFERENTIAL CASE INTERNAL PARTS CONTACT SLIDING SURFACE CHECK 1 Clean the disassembl...

Page 232: ...re ring hole and side gear H Protrusions on outer periphery of pressure ring I Pressure ring inner surface and differential pinion gear spherical surface J Pressure ring V groove and pinion shaft V K...

Page 233: ...12 1 2 12 1 2 18 1 8 34 3 5 34 3 5 Removal steps 1 Dust guard 2 Suction hose and return hose con nection 3 Hydraulic unit hose assembly con nection 4 Hydraulic unit and bracket assem bly mounting bol...

Page 234: ...ON HOSE RETURN HOSE INSTALLATION Fit the suction hose and return hose to the nipple of hydraulic unit as illustrated CA HYDRAULIC UNIT AND BRACKET ASSEMBLY INSTALLATION Hook the hydraulic unit bracket...

Page 235: ...and AYC relay removal 2 Longitudinal acceleration sensor 3 Lateral acceleration sensor 4 AYC relay NOTE For the wheel speed sensor refer to GROUP 35B REMOVAL SERVICE POINT AA STEER SENSOR REMOVAL Remo...

Page 236: ...ENSOR CHECK Refer to GROUP 35B Acceleration Sensor 2 AYC RELAY CONTINUITY CHECK Battery voltage Terminal No 1 3 4 5 When not energized When energized AYC ECU REMOVAL AND INSTALLATION Pre removal and P...

Page 237: ...ROLL STOPPER AND CENTERMEMBER 2 32 1 POWER PLANT MOUNT CONTENTS...

Page 238: ...n torque to specification with the engine weight applied to the body 1 2 3 4 5 Unit Nm kgf m 52 5 3 2 2 34 3 5 34 3 5 93 9 5 69 7 0 93 9 5 2 Removal steps 1 Front crossmember bar vehicles with 17 whee...

Page 239: ...SPENSION CONTENTS SERVICE SPECIFICATIONS 2 SPECIAL TOOLS 2 ON VEHICLE SERVICE 3 Wheel Alignment Check and Adjustment EVOLUTION V 3 STRUT ASSEMBLY 4 LOWER ARM EVOLUTION IV 5 LOWER ARM EVOLUTION V 7 STA...

Page 240: ...tion starting torque Nm kgf cm 2 0 8 8 20 90 EVOLUTION V Same as EVOLUTION IV except for following Items Standard value Camber selectable from 2 options 1_00 30 or 2_00 30 difference between right and...

Page 241: ...wheel less than 30 Select the camber angle as follows If the arrow on the bolt that couples the strut assembly to knuckle faces inboard 1_00 30 If the arrow on the bolt that couples the strut assembl...

Page 242: ...o P 33A 3 1 2 3 4 5 6 7 Unit Nm kgf m 44 4 5 108 127 11 0 13 0 Removal steps 1 Brake hose clamp 2 Front speed sensor bracket Vehicles with ABS 3 Flange nut 4 Strut tower bar 5 Plain washer AA 6 Bolts...

Page 243: ...113 11 5 Molybdenum disulfide base chassis grease SHOWA SHELL SEKIYU SUNLITE MB2 NISSEKI CLAKNOCK FL or equivalent 137 14 0 88 9 0 106 10 8 6 Removal steps 1 Stabilizer link mounting nut AA 2 Lower a...

Page 244: ...BALL JOINT ROTATION STARTING TORQUE Use the conventional procedures except the special tool used and the standard value as given below Standard value 2 0 8 8 Nm 20 90 kgf cm LOWER ARM BALL JOINT DUST...

Page 245: ...rm and Stabilizer Link Ball Joint with a Finger to Check for Possible Cracks or Damage 2 Wheel Alignment Check and Adjustment Refer to P 33A 3 1 2 3 4 5 6 Unit Nm kgf m Molybdenum disulfide base chass...

Page 246: ...tion of the lower arm assembly 2 Should the knuckle be pushed in excessively and grease flow out from the dust cover replace the dust cover with a new one 3 Check that there is no clearance between th...

Page 247: ...er 1 2 3 4 5 Unit Nm kgf m 22 2 2 SHOWA SHELL SEKIYU VARIANT R 2 or equivalent 39 4 0 39 4 0 1 Removal steps 1 Stabilizer link 2 Stabilizer bar bracket AA 3 Fixture AA 4 Bushing 5 Stabilizer bar INSTA...

Page 248: ...llow the conventional procedures STABILIZER LINK DUST COVER REPLACEMENT Replace the dust cover by using the conventional procedure only if it has been inadvertently damaged during servicing After the...

Page 249: ...IAL TOOLS 2 ON VEHICLE SERVICE 3 1 Rear Wheel Alignment Check and Adjustment 3 2 Ball Joint Dust Cover Check 3 REAR SUSPENSION ASSEMBLY 4 UPPER ARM ASSEMBLY 6 TRAILING ARM ASSEMBLY 8 LOWER ARM AND TOE...

Page 250: ...arm ball joint dust cover Molybdenum disulfide base chassis grease SHOWA SHELL SEKIYU SUNLITE MB2 As required Inside and lips of trailing arm ball joint dust cover SHOWA SHELL SEKIYU SUNLITE MB2 NISSE...

Page 251: ...he camber adjusting bolt mounting bolt for the lower arm and rear crossmember Left wheel clockwise camber Right wheel clockwise camber The scale has gradations of approximately 14 2 After adjusting th...

Page 252: ...5 108 127 11 0 13 0 54 5 5 88 9 0 93 9 5 88 9 0 15 8 2 15 29 34 3 0 3 5 25 2 6 34 3 5 25 2 5 69 7 0 Toe control bar EVOLUTION V RS 137 156 14 0 16 0 59 68 6 0 7 0 Removal steps 1 Fuel filler cap 2 Bol...

Page 253: ...MOUNTING BOLT INSTALLATION Tighten the mounting bolts in the numerical order shown NOTE To ensure both good installation accuracy and ease of installation the crossmember mounting holes have differen...

Page 254: ...bly to knuckle coupling 5 Upper arm assembly mounting bolt 6 Stopper 7 Upper arm assembly NOTE Parts marked with K apply only when RH side is removed and installed Caution The part marked with should...

Page 255: ...t cover for cracks or damage by pushing it with a finger 2 If the dust cover is cracked or damaged replace the upper arm assembly NOTE A cracked or damaged dust cover can lead to a damaged ball joint...

Page 256: ...2 Trailing arm assembly to knuckle coupling 3 Trailing arm assembly mounting bolt 4 Stopper 5 Trailing arm assembly Caution The part marked with should be first temporarily tightened then torqued to s...

Page 257: ...cover for cracks or damage by pushing it with a finger 2 If the dust cover is cracked or damaged replace the trailing arm assembly NOTE A cracked or damaged dust cover can lead to a damaged ball join...

Page 258: ...0 93 9 5 2 Lower arm assembly removal steps 1 Lower arm assembly and shock absorber connecting bolt AA 2 Lower arm assembly mounting bolt AA 3 Lower arm assembly Toe control arm assembly removal step...

Page 259: ...ording to the identification mark stamped in the illustrated position INSPECTION 1 TOE CONTROL ARM BALL JOINT TURNING TORQUE CHECK 1 After shaking the ball joint stud several times install the nut to...

Page 260: ...continued use 3 TOE CONTROL ARM BALL JOINT DUST COVER CHECK 1 Check the dust cover for cracks or damage by pushing it with a finger 2 If the dust cover is cracked or damaged replace the toe control a...

Page 261: ...peration D Trunk Room Side Trim Removal and Installation GSR 1 2 3 4 Unit Nm kgf m 44 4 5 88 9 0 Removal steps 1 Cap 2 Shock absorber mounting nuts 3 Bolt 4 Shock absorber assembly Caution The part ma...

Page 262: ...tion Operation D Check the Stabilizer Link Ball Joint Dust Cover for Cracks or Damage by Pushing it with Finger 1 2 3 4 5 Unit Nm kgf m 39 4 0 3 39 4 0 39 4 0 20 2 0 Removal steps 1 Stabilizer link mo...

Page 263: ...l tool to measure the turning torque of the ball joint Standard value 1 7 3 1 Nm 17 32 kgf cm 2 When the measured value exceeds the standard value replace the stabilizer link 3 When the measured value...

Page 264: ...f the dust cover Specified grease SHOWA SHELL SEKIYU VARIANT R 2 or equivalent 3 Wrap plastic tape on the stabilizer link threads as shown in the illustration and then install the dust cover to the st...

Page 265: ...BASIC BRAKE SYSTEM 35A ANTI LOCK BRAKING SYSTEM ABS 35B 35 1 SERVICE BRAKES CONTENTS...

Page 266: ...35A 1 BASIC BRAKE SYSTEM CONTENTS GENERAL 2 Outline of Change 2 ON VEHICLE SERVICE 2 Brake Pedal Check and Adjustment 2 BRAKE PEDAL 4 MASTER CYLINDER AND BRAKE BOOSTER 5 Master Cylinder 7 DISC BRAKE 9...

Page 267: ...the correct brake pedal height is obtained 3 Secure by tightening the lock nut of the operating rod 4 Push the stop lamp switch in the direction of the pedal stroke until it stops The switch will slid...

Page 268: ...rts as required 4 Start the engine depress the brake pedal with approximately 490 N of force and measure the clearance between the brake pedal and the floorboard Standard value 80 mm or more If the cl...

Page 269: ...Operation D Accelerator Pedal Installation D Steering Column Assembly Installation Refer to GROUP 37A Steering Wheel and Shaft D Instrument Under Cover Installation D Brake Pedal Adjustment Refer to...

Page 270: ...Line Bleeding D Brake Pedal Adjustment Refer to P 35A 2 D Air Intake Hose Installation 15 18 Nm 15 Nm Sealant 3M ATD Part No 8661 or equivalent 6 7 3 1 4 2 8 5 4 14 Nm 5 9 1 10 Nm Removal steps 1 Brak...

Page 271: ...l part of the fitting and then secure by using the hose clip BA CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON Calculate clearance A from the B C and D measurements A B C D Sta...

Page 272: ...10 12 15 13 14 Brake fluid DOT3 or DOT4 11 Disassembly steps 1 Reservoir cap assembly 2 Reservoir cap 3 Diaphragm 4 Filter 5 Brake fluid level sensor 6 Float 7 Reservoir stopper bolt 8 Reservoir tank...

Page 273: ...stopper bolt while depressing the piston AB PISTON STOPPER RING DISASSEMBLY Remove the piston stopper ring while depressing the piston INSPECTION D Check the inner surface of master cylinder body for...

Page 274: ...MBLY Front Brake Seal boot kit Shim set Clip set Pad set Brake caliper kit 1 2 3 4 5 6 7 8 9 10 1 2 3 4 3 4 1 2 5 6 5 5 7 9 9 7 9 7 8 6 6 10 2 1 Disassembly steps 1 Pin 2 Cross spring 3 Pad wear indic...

Page 275: ...Clip set Pad set Brake caliper kit 1 2 3 4 5 6 7 8 9 10 2 6 1 6 7 8 9 10 2 1 7 9 7 9 3 4 3 4 2 1 6 5 5 5 Disassembly steps 1 Pin 2 Cross spring 3 Pad wear indicator assembly 4 Pad assembly 5 Shim 6 A...

Page 276: ...spection Procedure for Diagnostic Trouble Codes 3 3 Inspection Chart for Trouble Symptoms 11 4 Inspection Procedure for Trouble Symptoms 12 5 Check at ABS ECU Terminals 15 ON VEHICLE SERVICE 17 Wheel...

Page 277: ...35B 3 14 Wheel speed sensor RL system open or short circuit 35B 3 15 Wheel speed sensor system abnormal output signal 35B 4 16 ABS ECU power supply voltage system abnormal voltage drop or rise 35B 5 2...

Page 278: ...ing sensor or a warped ABS rotor is causing sensor output to drop D Malfunction of wheel speed sensor D Malfunction of wiring harness or connector D Too much gap between the sensor and the rotor D Mal...

Page 279: ...connector D Malfunction of ABS ECU D Malfunction of wheel bearing OK Check the harness wire and repair if necessary D Betweeneachwheelspeedsensor and ABS ECU OK Wheel bearing check NG Replace the ABS...

Page 280: ...motor relay NG Repair OK NG Check the harness wire and repair if necessary D BetweenvalverelayandABS ECU NG Repair OK Check the trouble symptom OK Check the trouble symptom NG Check the harness wire a...

Page 281: ...D Defective ABS ECU OK Check the trouble symptom NG Replace ABS ECU OK Check the trouble symptom NG Checkandrepairtheharnessbetween acceleration sensor longitudinal acceleration and ABS ECU OK Check t...

Page 282: ...turn on and off normally NO Stop lamp switch installation check NG Repair Code No 41 42 43 44 Solenoid valve system Probable cause ABS ECU monitors the solenoid valve energization circuit at all time...

Page 283: ...d and if no diagnosis code other than No 51 is output then the valve relay system is probably defective Make the following checks OK Check the trouble symptom NG Checkandrepairtheharnessbetween genera...

Page 284: ...y OK Check the trouble symptom NG Checkandrepairtheharnessbetween motor relay and hydraulic unit OK Check the trouble symptom NG Checkandrepairtheharnessbetween motor relay and ABS ECU motor monitor t...

Page 285: ...se No 6 and acceleration sensor lateral accelera tion OK Replace ABS ECU OK Check the following connector B 24 NG Repair OK Measureat B 24 ABS ECU connector D Connect the connector D Ignition switch O...

Page 286: ...ce and then switches off 3 35B 13 When the ignition key is turned to START the ABS warning lamp does not illuminate 4 35B 14 Brake operation is abnormal 5 35B 14 Caution 1 If steering movements are ma...

Page 287: ...epair OK Check the trouble symptom NG Check the harness wire and repair if necessary D Between ignition switch and ABS warning lamp OK Check the motor for operation NG Check the harness wire and repai...

Page 288: ...ation meter INSPECTION PROCEDURE 3 After the ignition key is turned to ON the ABS warning lamp blinks once and when turned to START it illuminates When returned to ON the lamp flashes once and then sw...

Page 289: ...easureatvalverelayconnectorA 76 D Disconnect the connector and measure at the harness side D Disconnect ABS ECU connector B 25 D Ignition switch ON D Voltage between 3 and body ground OK Battery volta...

Page 290: ...tput Ignition switch ON after initial check Battery voltage 15 Ground At all times 0 V 17 Acceleration sensor ground At all times 0 V 18 Acceleration sensor lateral acceleration input Ignition switch...

Page 291: ...FF position and ABS ECU connector disconnected 2 Measure the resistance and check for continuity across terminals listed below 3 Fig below shows the arrangement of terminals Terminal No Signal name No...

Page 292: ...sure the output voltage of the wheel speed sensors are different from EVOLUTION V Follow the conventional procedures except these pick out terminals Measurement terminals Front LH Front RH Rear LH Rea...

Page 293: ...sensor 2 Front rotor Refer to GROUP 26 DRIVE SHAFT Rear speed sensor removal steps 3 Rear speed sensor 4 Rear rotor Refer to GROUP 27 REAR AXLE HUB NOTE The front rotor and rear rotor are integrated w...

Page 294: ...NG BRAKES CONTENTS SERVICE SPECIFICATIONS 2 LUBRICANTS 2 SPECIAL TOOLS 2 ON VEHICLE SERVICE 3 1 Parking Brake Lever Stroke Check and Adjustment 3 2 Lining Running in 4 PARKING BRAKE CABLE 5 PARKING BR...

Page 295: ...ption is made only for EVOLUTION IV SERVICE SPECIFICATIONS Items Standard value Limit Parking brake lever stroke operating force approx 196 N 20 kgf 5 7 notches Brake lining thickness mm 2 8 1 0 Brake...

Page 296: ...by both hands Return the adjuster five notches in the direction opposite to the direction of the arrow Reference shoe clearance on one side 0 19 mm 3 Turn the adjusting nut to adjust the parking brak...

Page 297: ...afety 1 Adjust the parking brake stroke to the specified value Standard value 5 7 notches Operating force of approx 196 N 20 kgf 2 Hook a spring balance onto the center of the parking brake lever grip...

Page 298: ...Console and Rear Seat Installation 1 2 3 4 5 6 7 8 9 10 11 12 13 Unit Nm kgf m 49 59 5 0 6 0 Backing plate Brake grease CHUO YUKA AKB100 10 11 9 8 11 11 5 Removal steps AA 1 Rear brake caliper assemb...

Page 299: ...so that the shoe adjusting bolt of left hand wheel is attached towards the front of the vehicle and the shoe adjusting bolt of right hand wheel is towards the rear of the vehicle BA SHOE TO ANCHOR SP...

Page 300: ...se CHUO YUKA AKB100 11 11 5 196 255 20 0 26 0 11 9 8 74 88 7 5 9 0 17 Removal steps 1 Rear brake caliper Refer to P 36 6 2 Rear brake disc 3 Shoe to anchor spring Refer to P 36 6 4 Adjusting screw spr...

Page 301: ...ng removal and tighten the drive shaft nut to the specified torque Tightening torque 196 255 Nm 20 0 26 0 kgf m INSPECTION BRAKE LINING AND BRAKE DRUM WEAR CHECK 1 Measure the thickness of the brake l...

Page 302: ...ICATIONS 2 SPECIAL TOOLS 2 ON VEHICLE SERVICE 2 1 Steering Angle Check 2 2 Oil Pump Belt Tension Check and Adjustment 2 STEERING WHEEL EVOLUTION IV RS 3 POWER STEERING GEAR LINKAGE 3 POWER STEERING OI...

Page 303: ...Installer bar Pressfitting of gear housing oil seal MB991199 Oil seal installer MB991214 Oil seal protector Installation of rack assembly ON VEHICLE SERVICE 1 STEERING ANGLE CHECK Locate front wheels...

Page 304: ...remove the steering wheel from the boss plate 3 Using the special tool remove the boss plate from the steering column POWER STEERING GEAR LINKAGE For removal installation and inspection procedure foll...

Page 305: ...nd MA 5 Dust cover 6 Clip LA 7 Band 8 Bellows KA 9 Tie rod KA 10 Tab washer JA D Pinion total turning torque adjustment 11 Lock nut AA 12 Rack support cover 13 Support spring 14 Rack support IA 15 End...

Page 306: ...ion Do not close the vent hole in the rack with grease 2 Cover rack serrations with special tool 3 Apply the specified fluid on the special tool seal ring and O ring surfaces Specified fluid MITSUBISH...

Page 307: ...0_ to adjust it for the standard value Caution 1 When adjusting set the standard value at its highest value 2 Assure no ratcheting or catching when operating rack towards the axial direction 3 Be sure...

Page 308: ...ation 1 Power Steering Fluid Supplying 2 Drive Belt Tension Adjusting Refer to GROUP 11 On vehicle Service 1 2 3 4 5 6 7 8 9 10 Unit Nm kgf m 49 5 0 59 69 6 0 7 0 10 12 1 0 1 2 39 4 0 49 5 0 18 1 8 12...

Page 309: ...1 Power Steering Fluid Supplying 2 Drive Belt Tension Adjusting 3 Power Steering Fluid Line Bleeding 1 2 3 4 5 6 7 8 9 10 Unit Nm kgf m 22 2 2 11 22 2 2 52 5 3 24 2 4 12 1 2 18 1 8 Removal steps 1 Dri...

Page 310: ...LER REMOVAL AND INSTALLATION Pre removal and Post installation Operation 1 Power Steering Fluid Draining and Refilling 2 Front Bumper Removal and Installation Refer to GROUP 51 1 2 Unit Nm kgf m 12 1...

Page 311: ...42 1 BODY CONTENTS HOOD 2 FENDER 3 TRUNK LID EVOLUTION V 4 BODY CONSTRUCTION Difference between EVOLUTION IV and V 5 TYPE A PROJECTED DIMENSIONS 7 TYPE B ACTUAL MEASUREMENT DIMENSIONS 11...

Page 312: ...od weatherstrip 4 Hood weatherstrip 5 Hood insulator 6 Bumper 7 Hood support rod 8 Hood outlet garnish weatherstrip 9 Hood outlet garnish 10 Hood inlet garnish upper 11 Hood inlet garnish lower Hood l...

Page 313: ...of different kind Be sure to these special washers Pre removal and Post installation Operation 1 Front Bumper Removal and Installation Refer to GROUP 51 2 Front Turn Signal Lamp Removal and Installat...

Page 314: ...ept for followings INSTALLATION SERVICE POINT TRUNK LID TORSION BAR INSTALLATION 1 Torsion bars are color coded as indicated at their center Torsion bar LH ID color Torsion bar RH ID color White green...

Page 315: ...d wide tread tyres For this reason the configuration and the dimensions of the following body sections are also different SIDE BODY Side Structure 1 The quarter panel has a cut out provided at the inn...

Page 316: ...link bracket rear floor sidemember reinforcement and toe control link bracket have been changed in configuration EVOLUTION V EVOLUTION IV EVOLUTION V EVOLUTION IV Upper link bracket Rear floor sidemem...

Page 317: ...anged as follow Those of the other body sections remain unchanged Unit mm 913 10 1 8 7 9 3 2 950 829 714 173 157 329 329 1 232 810 703 544 940 21 6 1 2 3 7 8 10 9 4 21 6 1 indicates that the dimension...

Page 318: ...ay mounting hole f 30 7 Center bearing mounting bolt end 2 Center of suspension crossmember mounting hole Left f 14 Right f 16 8 Center bearing mounting bolt end 3 Rear portion of front floor sidememb...

Page 319: ...icle indicates that the dimension and the measurement point are the same as those for EVOLUTION IV 21 22 69 65 13 12 11 72 71 70 69 21 22 20 20 12 11 13 65 2 3 2 852 700 810 862 829 597 930 290 270 57...

Page 320: ...of strut insulator f 110 65 Trailing arm mounting position 12 Center of suspension crossmember mounting hole f 15 69 Center of rear shock absorber mounting hole f 68 13 Center of suspension crossmembe...

Page 321: ...indicates that the dimension and the measurement point are the same as those for EVOLUTION IV Unit mm UNDER BODY 10 2 3 7 9 6 6 8 1 8 9 7 3 2 1 21 21 10 1 635 1 028 1 231 1 395 1 287 719 544 933 962...

Page 322: ...per stay mounting hole f 30 7 Center bearing mounting bolt end 2 Center of suspension crossmember mounting hole Left f 14 Right f 16 8 Center bearing mounting bolt end 3 Rear portion of front floor si...

Page 323: ...ON INSTALLATION DIMENSIONS indicates that the dimension and the measurement point are the same as those for EVOLUTION IV Unit mm 2 21 2 13 12 22 20 65 21 20 65 22 12 13 1 210 329 1 186 862 930 597 829...

Page 324: ...ole _ Size shape mm 2 Center of suspension crossmember mounting hole Left f 14 Right f 16 21 Center of suspension crossmember mounting hole f 14 12 Center of suspension crossmember mounting hole f 15...

Page 325: ...OLUTION IV 2 FRONT BUMPER EVOLUTION V 4 REAR BUMPER EVOLUTION V 6 AERO PARTS EVOLUTION IV 7 AERO PARTS EVOLUTION V 8 REAR FENDER GARNISH EVOLUTION V 11 WATER SPRAY EVOLUTION IV 12 INTERCOOLER RADIATOR...

Page 326: ...al Tools Front Bumper EVOLUTION IV 51 2 SPECIAL TOOLS Tool Number Name Use MB990784 Ornament remover Removal of front bumper and rear bumper FRONT BUMPER EVOLUTION IV REMOVAL AND INSTALLATION Front bu...

Page 327: ...vehicles without fog lamps 5 Bumper net side 6 Fog lamp cover vehicles without fog lamps 7 Fog lamp 8 Bumper bolt plate AA 9 Clip 10 Bumper upper reinforcement 11 Grille net 12 Bumper lower reinforce...

Page 328: ...EXTERIOR Front Bumper EVOLUTION V 51 4 FRONT BUMPER EVOLUTION V REMOVAL AND INSTALLATION Front bumper assembly...

Page 329: ...cket 2 mark 3 Bumper center stay 4 Bumper center stay vehicles without fog lamps 5 Air guide panel on driver s seat side 6 Bumper net side 7 Fog lamp plate vehicles without fog lamps 8 Fog lamp cover...

Page 330: ...SASSEMBLY SERVICE POINT AA CLIP REMOVAL 1 Using the special tool raise the pin at the center of the clip 2 Remove the clip REAR BUMPER EVOLUTION V REMOVAL AND INSTALLATION 1 2 Rear bumper removal 1 Re...

Page 331: ...pe SUMITOMO 3M 4211 or equivalent width 5 mm Primer SUMITOMO 3M C100 or equivalent 3 2 5 6 2 5 4 Front air dam removal steps 1 Front air dam center 2 Front air dam 3 Brake duct Side air dam removal AA...

Page 332: ...EXTERIOR Aero Parts EVOLUTION IV 51 8 7 8 Rear spoiler removal steps 7 Rear spoiler 8 High mount stop lamp...

Page 333: ...sert bolt mounting locations Double sided adhesive tape SUMITOMO 3M 4211 or equivalent thickness 1 2 mm Primer SUMITOMO 3M 8107 PP parts primer 4 1 Front air dam removal steps 1 Brake duct AA AA 2 Fro...

Page 334: ...5 Double sided adhesive tape Commercially available product thickness 2 0 mm 5 0 5 Rear spoiler removal steps AA AA 5 Rear spoiler 6 High mount stop lamp undercover 7 High mount stop lamp NOTE The co...

Page 335: ...MO 3M 4213 or equivalent thickness 0 8 mm Primer SUMITOMO 3M 8107 PP parts primer Section A A B B 6 4 4 6 3 Rear door garnish removal steps 1 Clip AA AA 2 Rear door garnish assembly 3 Protector 4 Rear...

Page 336: ...AND INSTALLATION 1 2 3 4 5 6 6 1 Water spray switch Removal steps D Front bumper Refer to P 51 3 2 Washer tank 3 Washer motor 4 Water spray motor 5 Water spray hose 6 Water spray nozzle INSPECTION WA...

Page 337: ...mper Removal and Installation Refer to P 51 4 1 2 3 4 5 6 7 8 9 Unit Nm kgf m 2 5 0 25 2 5 0 25 1 5 5 5 5 5 5 4 4 2 2 1 4 4 5 4 4 4 4 5 3 1 2 1 Clamp 2 Water spray nozzle 3 Water spray nozzle bracket...

Page 338: ...e Tape Tape so that the clip faces toward the front of vehicle Connect to intercooler nozzle RH Connect to intercooler nozzle LH Tape so that the clip faces toward the front of vehicle Connect to radi...

Page 339: ...re used both in front and rear on EVOLUTION V INSTALLATION SERVICE POINT AA MARK INSTALLATION Installation positions The dimension up to the cutout in decal A in fig is the same as the dimension from...

Page 340: ...dy on which the marks are mounted 2 Peel off the release paper from the back side of the mark and affix the mark ensuring the specified dimensions are met Caution 1 Perform the procedure in a dust fre...

Page 341: ...RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 The service personnel must thoroughly review this manual and especially its GROUP 52B Supplemental Restraint System SRS before beginning any service o...

Page 342: ...SHOOTING 42 REAR COMBINATION LAMP 42 SIDE TURN SIGNAL LAMP 43 SPECIAL TOOL 43 SIDE TURN SIGNAL LAMP 43 HAZARD WARNING LAMP SWITCH CLOCK 44 SPECIAL TOOL 44 HAZARD WARNING LAMP SWITCH 44 RADIO AND TAPE...

Page 343: ...L and LOWER LEVEL marks 2 Use a hydrometer and thermometer to check the specific gravity of the battery fluid Standard value 1 220 1 290 20_C The specific gravity of the battery fluid varies with the...

Page 344: ...in amperes 4 Determining if charging is completed 1 If the specific gravity of the battery fluid reaches 1 250 1 290 and remains constant for at least one hour 2 If the voltage of each cell reaches 2...

Page 345: ...yattherecommendeddischargerate seeLOAD TEST RATE CHART 3 Read voltage after 15 seconds then remove load 4 Compare the measured value with the minimum voltage see LOAD TEST CHART OK Higher than minimum...

Page 346: ...54 7 While key hole illumination lamp is illuminated ignition key is turned to the ON position but key hole illumination lamp does not switch off However it switch off after 10 seconds 3 54 8 Key remi...

Page 347: ...bulb D Malfunction of connector D Malfunction of harness wire D Malfunction of ETACS ECU D Malfunction of buzzer ECU OK Replace ETACS ECU or buzzer ECU Vehicles with ETACS ECU MUT II Pulse check Driv...

Page 348: ...alfunction of fuse D Malfunction of connector D Malfunction of harness D Malfunction of ETACS ECU D Malfunction of buzzer ECU OK Replace ETACS ECU Vehicles with ETACS ECU MUT II Pulse check Ignition s...

Page 349: ...U or buzzer ECU and repair if necessary OK Check trouble symptom OK Replacethe ETACS ECU or the buzzer ECU OK NG Key reminder switch continuity inspec tion Refer to P 54 12 NG Replace Vehicles with ET...

Page 350: ...uity inspec tion Refer to P 54 12 NG Replace OK Inspect the harness between the key reminder switch and junction block NG Repair OK Replace the ETACS ECU OK Vehicles with ETACS ECU MUT II Pulse check...

Page 351: ...l steps 1 Cowl side trim R H 2 Junction block 3 Buzzer control unit ETACS ECU Ignition switch removal steps 4 Hood lock release handle 5 Driver side lower panel 6 Column cover lower 7 Column cover upp...

Page 352: ...lock cylinder INSPECTION IGNITION SWITCH CONTINUITY CHECK Disconncect the ignition switch connector without removing the ignition switch from the vehicle Then check the continuity between the followi...

Page 353: ...shooting Inspection Service Points DIAGNOSIS FUNCTION DIAGNOSIS CODES CHECK Refer to GROUP 00 How To Use Troubleshooting Inspection Service Points ERASING DIAGNOSIS CODES Refer to GROUP 00 How To Use...

Page 354: ...the immobilizer ECU NG Diagnosis codes check Code No 12 occurs To INSPECTION PROCEDURE FOR DIAGNOSIS CODE No 12 Refer to P 54 14 Code No 11 occurs Check the continuity of the ignition key ring antenn...

Page 355: ...54 being gener ated by the engine ECU NO Check the engine ECU power source and the earth circuit Refer to GROUP 13A Troubleshoot ing YES Check the following connectors B 100 B 65 B 61 NG Repair OK Ch...

Page 356: ...ble cause The cause is probably that a malfunction of the diagnosis line or the immobilizer ECU is not functioning D Malfunction of the diagnosis line D Malfunction of harness or connector D Malfuncti...

Page 357: ...PECTION PROCEDURE 4 OK Check trouble symptoms NG Replace the immobilizer ECU Inspection Procedure 3 Engine does not start cranking but no initial combustion Probable cause If the fuel injectors are no...

Page 358: ...gnition switch IG and immobilizer ECU NG OK Check trouble symptoms NG Check the ignition switch Refer to P 54 20 2 NG Check the following connectors B 65 B 100 NG Repair OK Check trouble symptoms NG C...

Page 359: ...drive vehicles R H drive vehicles 3 4 Immobilizer ECU removal steps 1 Hood lock release handle 2 Driver s side lower cover D Radio and tape player R H drive vehicles D Heater control assembly R H driv...

Page 360: ...ock cylinder inward and then pull the steering lock cylinder toward you INSPECTION IGNITION SWITCH CONTINUITY CHECK 1 Remove the column cover lower and upper 2 Disconnect the wiring connector from the...

Page 361: ...keys that have already been registered 1 Connect the MUT II to the diagnosis connector Caution Turn the ignition switch off before connecting or disconnecting the MUT II 2 Check that the diagnosis co...

Page 362: ...surable up to 9 000 rpm and meters measurable up to 10 000 rpm 325 125 6 000 Meters measurable up to 8 000 rpm 300 7 000 Meters measurable up to 9 000 rpm and meters measurable up to 10 000 rpm 400 10...

Page 363: ...dhesive nut locking No 4171 or equivalent Drying sealant SPECIAL TOOLS Tool Number Name Use A B C D MB991223 A MB991219 B MB991220 C MB991221 D MB991222 Harness set A Test harness B LED harness C LED...

Page 364: ...ity between the terminal No 11 and earth OK Continuity 2 VoltagebetweenterminalNo 51and earth OK 4 7 V or more 3 Voltagebetween the terminal No 22 and earth OK System voltage 1 NG OK Replace the speed...

Page 365: ...m voltage 1 NG Check the following connectors B 08 A 36 B 61 B 64 A 41 A 109 NG Repair OK Check trouble symptom NG Checktheharnessbetweenthe engine ECU and combination meter and repair if necessary 2...

Page 366: ...1 NG Check the following connectors A 19 B 64 NG Repair OK Check trouble symptom NG Check the harness wire between the vehicle speed sensor and multi purpose fuse 4 and repair if necessary 3 NG Check...

Page 367: ...peed rapidly while testing Standard values Vehicle speed km h Speedometer indication allowable errors km h 40 37 45 80 75 88 120 113 132 160 150 176 Limit Pointer fluctuation at vehicle speeds of high...

Page 368: ...GAUGE UNIT CHECK Remove the fuel gauge unit from the fuel tank FUEL GAUGE UNIT RESISTANCE 1 Check that resistance value between the fuel gauge unit terminal and earth terminal is at standard value wh...

Page 369: ...thermistor is immersed in water and goes on when it is taken out of water ENGINE COOLANT TEMPERATURE GAUGE SIMPLE CHECK Remove the engine coolant tempara ture gauge unit connector Connect a test lamp...

Page 370: ...the specified adhesive around the thread of engine coolant temperature gauge unit Then tighten the unit to the specified torque Specified sealant 3M Adhesive Nut Locking No 4171 or equivalent 5 Add en...

Page 371: ...g screw 2 Use a circuit tester to measure the resistance value between the terminals Standard value Unit Measurement terminal Resistance value Power supply Earth 187 18 7 Power supply Engine coolant t...

Page 372: ...ising section intersects vertical line V Headlamp intensity cd Center of high beam high intensity zone 15 000 or more per light Cautions in Handling Headlamp Assembly Each headlamp assembly has a plas...

Page 373: ...unction of the lighting switch input circuit system or a malfunction of ETACS ECU or buzzer ECU When the key reminder warning buzzer is sounding the lighting monitor warning buzzer does not sound even...

Page 374: ...evel D Set the vehicle unladen on a level floor D Place one person approximately 55 kg on the driver s seat 1 Position the tester so that its converging lens faces the high beam lamp f marked center t...

Page 375: ...e charged condition 3 Check that the high beam headlamp intensity at the center of the high intensity zone satisfies the limit value Limit 15 000 cd or more per headlamp Caution 1 Perform intensity me...

Page 376: ...ly POSITION LAMP BULB REPLACEMENT Remove the position lamp by turning it together with the lamp socket then replace its bulb HEADLAMP AND FRONT TURN SIGNAL LAMP REMOVAL AND INSTALLATION CAUTION SRS Be...

Page 377: ...hrust the front turn signal lamp in the direction of the vehicle 3 Unplug the connector and remove the front turn signal lamp INSTALLATION SERVICE POINT AA HEADLAMP INSTALLATION Tighten attaching bolt...

Page 378: ...CHASSIS ELECTRICAL Headlamp 54 38 HEADLAMP RELAY CONTINUITYCHECK Battery voltage Terminal No 1 3 4 5 Not supplied Supplied Headlamp relay...

Page 379: ...a level floor D Place one person approximately 55 kg on the driver s seat D Maintain an engine speed of 2 000 r min to keep the battery in the charged condition 1 Position the tester so that its conv...

Page 380: ...ht 2 Do not mask the outer lenses by taping or in any other way 3 Aiming adjustment must be completed with the aiming adjustment screws turned in the tightening direction FOG LAMP BULB REPLACEMENT 1 R...

Page 381: ...54 41 FOG LAMP REMOVAL AND INSTALLATION 3 1 4 2 1 Front fog lamp switch Fog lamp removal steps 2 Front bumper 3 Fog lamp bezel 4 Fog lamp assembly INSPECTION FOG LAMP SWITCH CONTINUITY CHECK Switch p...

Page 382: ...ION Caution SRS Before removal of air bag module and clock spring refer to GROUP 52B SRS Service Precautions and Air Bag Module and Clock Spring 2 1 3 1 Column switch Rear combination lamp removal ste...

Page 383: ...3 SIDE TURN SIGNAL LAMP SPECIAL TOOL Tool Number Name Use MB990784 Ornament remover Removal of side turn signal lamp SIDE TURN SIGNAL LAMP REMOVAL INSTALLATION Fit the hook side rearward Fender panel...

Page 384: ...r conditioner panel removal HAZARD WARNING LAMP SWITCH REMOVAL AND INSTALLATION 2 1 3 4 Hazard warning lamp switch removal steps 1 Air conditioner panel 2 Switch holder 3 Hazard warning lamp switch Cl...

Page 385: ...er is broken enters the glass antenna Repair the print heater AM FM Wiper motor noise Humming wheez ing Sound becomes faster with the increase of wiper speed and is lost when the wiper is stopped Caus...

Page 386: ...serted between a noise generating power line and earthing line to suppress noise by earthing noise components in AC or pulse signal to the vehicle body 2 Noise Filter The coil allows the passage of DC...

Page 387: ...7 RADIO AND TAPE PLAYER REMOVAL AND INSTALLATION 1 3 2 Removal steps 1 Radio panel 2 Radio and tape player 3 Radio bracket SPEAKER REMOVAL AND INSTALLATION 2 1 3 4 5 Removal steps 1 Door trim 2 Speake...

Page 388: ...val steps 6 Speaker garnish 7 Speaker ANTENNA POLE ANTENNA REMOVAL AND INSTALLATION 1 2 3 5 4 7 6 8 9 Removal steps 1 Pole 2 Radio panel 3 Radio and tape player 4 Hood lock release handle 5 Driver sid...

Page 389: ...drain pipe can be seen 3 Pass the cord through the hole in the end of the drain pipe and wrap it with vinyl tape Caution Wrap it securely so that the cord will not come off 4 Pull out the antenna asse...

Page 390: ...good if it indicates about 6V 3 If 12 V is indicated at A there is a break in the negative terminals from A Move test bar slowly to negative terminal to detect where voltage changes suddenly 0V 4 If...

Page 391: ...ILL IND ILL 54 51 REAR WINDOW DEFOGGER SWITCH VEHICLES WITH AUTOMATIC A C REMOVAL AND INSTALLATION Refer to GROUP Heater Control Assembly INSPECTION DEFOGGER SWITCH CONTINUITY CHECK Switch iti Termin...

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