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Pub. No. S9806CNCP9

WORKSHOP MANUAL

EVOLUTION-IV
EVOLUTION-V

Pub. No. S9806CNCP9

Jul. ’98 Printed in Japan

WORKSHOP MANUAL

EVOLUTION-IV

EVOLUTION-V

Содержание Lancer Evolution IV

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Mitsubishi Lancer Evolution IV, Руководство по ремонту

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