Mitsubishi Electric Lancer Evolution-VII Workshop Manual
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Mitsubishi Electric Lancer Evolution-VII Workshop Manual

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Table of Contents

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WORKSHOP MANUAL
EVOLUTION-VII
Pub. No. S0105CT9A

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Summary of Contents for Mitsubishi Electric Lancer Evolution-VII

  • Page 1 WORKSHOP MANUAL EVOLUTION-VII Pub. No. S0105CT9A...
  • Page 2 WIRING AND PIPING DIAGRAM CONTENTS WIRING AND PIPING DIAGRAM ..

  • Page 3: Wiring And Piping Diagram

    WIRING AND PIPING DIAGRAM - Wiring and Piping Diagram WIRING AND PIPING DIAGRAM Pole antennas are routed in some parts of closed-section structures of the body construction. These pole antennas must be removed before body panels in these areas can be replaced. Pole antenna (Vehicles with pole antennas) Antenna feeder-line...
  • Page 4 BODY COLOUR CONTENTS BODY COLOUR CODE ....BODY COLOURING ..... . BUMPER .
  • Page 5 BODY COLOUR - Body Colour Code/Body Colour Charts BODY COLOUR CODE 1. The body colour code is imprinted on the plate, which is mounted on the front deck. 2. The body colour code is imprinted at the areas indicated in the illustration. Body colour code BODY COLOUR CHARTS Check the vehicle’s body colour code, and then use this body colour chart to determine the refinishing...

  • Page 6: New Colour Numbers

    BODY COLOUR - Body Colour Charts NEW COLOUR NUMBERS Example (Body colour code T10) Item Content Identification code C: The colour number is indicated. Manufacture center code M: Japan (Automobile Engineering Center) T: Japan (Truck and Bus Engineering Center) System colour code W (N): White H (A, U): Silver/Gray X (J): Black...
  • Page 7 BODY COLOUR - Body Colouring BLACK PAINT Headlamp support : Black (AC10657) Door sash Front door Rear door : Black (AC10790) Wheel house : Black (AC10657)
  • Page 8 SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS...
  • Page 9 SYNTHETIC-RESIN PARTS - Location of Synthetic-resin Parts LOCATION OF SYNTHETIC-RESIN PARTS The following shows the main locations of synthetic-resin parts.

  • Page 10: Location Of Synthetic-Resin Parts

    SYNTHETIC-RESIN PARTS - Location of Synthetic-resin Parts Part number Material Abbreviation of Heat-resistant material temperature (_C) Outside mirror Acrylonitrile Rear spoiler Butadiene styrene Roof antenna Acrylonitrile Ethylene butadiene Headlamp Polycarbonate Front bumper bezel Polycarbonate + PC + ABS 125 - 135 Rear door outside handle Acrylonitrile butadiene styrene Front door outside handle...
  • Page 11 NOTES...
  • Page 12 CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS ... . UNDERCOAT APPLICATION LOCATIONS . . . FLOOR ........UPPER BODY .

  • Page 13: Upper Body

    CORROSION PROTECTION - Body Sealing Locations BODY SEALING LOCATIONS NOTES REGARDING REPAIR WORK In places where the sealant can be directly seen on surfaces such as the drip rails, pillars, or clinch, and where the appearance of the paint surface is important, apply sealant or wipe away sealant after ▄...
  • Page 14 CORROSION PROTECTION - Body Sealing Locations...
  • Page 15 CORROSION PROTECTION - Body Sealing Locations Front door Hood Rear door Trunk lid...
  • Page 16 CORROSION PROTECTION - Undercoat Application Locations UNDERCOAT APPLICATION LOCATIONS In order to provide resistance to rust, corrosion, chipping, and vibration, an undercoat is applied to certain areas of the underbody. After completing body repairs, restore this undercoat if necessary. * Mark the areas indicated with asterisks to make sure no undercoat adheres to these areas. : Undercoat (Film thickness of at least 0.5 mm)
  • Page 17 NOTES...
  • Page 18 WELDED PANEL REPLACEMENT CONTENTS HEADLAMP SUPPORT ....ROOF ........FENDER SHIELD .
  • Page 19 NOTES...

  • Page 20: Headlamp Support

    WELDED PANEL REPLACEMENT - Headlamp Support HEADLAMP SUPPORT Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

  • Page 21: Fender Shield

    WELDED PANEL REPLACEMENT - Fender Shield FENDER SHIELD Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
  • Page 22 WELDED PANEL REPLACEMENT - Fender Shield (With the upper frame extension outer removed)
  • Page 23 WELDED PANEL REPLACEMENT - Fender Shield 17 points, left side only 5 points, left side only <LHD> 4 points, left side only <RHD(Right side)> <RHD>...

  • Page 24: Front Pillar

    WELDED PANEL REPLACEMENT - Front Pillar FRONT PILLAR Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

  • Page 25: Center Pillar

    WELDED PANEL REPLACEMENT - Front Pillar NOTE ON REPAIR WORK REMOVAL Weld points As the front pillar reinforcement lower and side sill outer Front pillar reinforce- reinforcement front are welded at the side sill, cut the side ment lower outer panel at the position shown in the illustration where the weld points of the reinforcement can be seen, remove, and then remove the weld points of the front pillar reinforcement lower.

  • Page 26: Center Pillar

    WELDED PANEL REPLACEMENT - Center Pillar CENTER PILLAR Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
  • Page 27 C-10 WELDED PANEL REPLACEMENT - Center Pillar NOTE ON REPAIR WORK Weld Center pillar points reinforcement REMOVAL 1. As the center pillar reinforcement and side sill outer reinforcement center are welded at the side sill, cut the side outer panel at the position shown in the illustration where the weld points of the reinforcement can be seen, remove, and then remove the weld points of the center pillar reinforcement.
  • Page 28 C-11 WELDED PANEL REPLACEMENT - Center Pillar <The following service procedures are only applied to RS-II.> 5. When attaching the center pillar inner, attach the center Center pillar silencer pillar silencer protector to the center pillar inner, and seal protector the holes of the center pillar silencer protector with butyl tape.
  • Page 29 C-12 WELDED PANEL REPLACEMENT - Side Sill SIDE SILL Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
  • Page 30 C-13 WELDED PANEL REPLACEMENT - Side Sill NOTE ON REPAIR WORK INSTALLATION 1. Release the side outer panel from the new parts and remove unnecessary front pillar reinforcement lower, front pillar reinforcement lower extension, and center pillar reinforcement from side sill outer reinforcement.

  • Page 31: Quarter, Outer

    C-14 WELDED PANEL REPLACEMENT - Quarter, Outer QUARTER, OUTER Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
  • Page 32 C-15 WELDED PANEL REPLACEMENT - Quarter, Outer NOTE ON REPAIR WORK Left side only INSTALLATION 1. When attaching the quarter outer, apply sealant to the areas indicated in the illustration. For RS-II, attach the rear pillar silencer protector, and fill the gaps with butly tape.
  • Page 33 C-16 WELDED PANEL REPLACEMENT - Quarter, Outer <The following service procedures are only applied to RS-II.> 2. After attaching the quarter outer, seal the holes and flanges with bolts and plate tape, and fill foam material from hole shown in the illustration. Foam material Type Brand Used...
  • Page 34 C-17 WELDED PANEL REPLACEMENT - Roof ROOF Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPAIR WELDS...

  • Page 35: Rear End Panel

    C-18 WELDED PANEL REPLACEMENT - Rear End Panel REAR END PANEL Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded...

  • Page 36: Rear Floor

    C-19 WELDED PANEL REPLACEMENT - Rear Floor REAR FLOOR Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
  • Page 37 C-20 WELDED PANEL REPLACEMENT - Rear Floor (Vehicles with ACD) Right side only NOTE For details on the weld points with the rear end panel refer to REAR END PANEL on P.C-18. NOTE ON REPAIR WORK Rear seat back REMOVAL reinforcement 1.

  • Page 38: Quarter, Inner

    C-21 WELDED PANEL REPLACEMENT - Quarter, Inner QUARTER, INNER Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
  • Page 39 C-22 WELDED PANEL REPLACEMENT - Quarter, Inner Left side (Vehicles with ACD) (With the side sill outer reinforcement rear removed.)

  • Page 40: Front Door Outer Panel

    C-23 WELDED PANEL REPLACEMENT - Front Door Outer Panel FRONT DOOR OUTER PANEL Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded...

  • Page 41: Rear Door Outer Panel

    C-24 WELDED PANEL REPLACEMENT - Rear Door Outer Panel REAR DOOR OUTER PANEL Symbol Operation description Spot welding MIG plug welding ( : indicates two panels to be welded : indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded...
  • Page 42 BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND MEASUREMENT TYPE B (ACTUAL-MEASUREMENT METHODS ......DIMENSIONS) .
  • Page 43 BODY DIMENSIONS - Body Dimensions and Measurement Methods BODY DIMENSIONS AND MEASUREMENT METHODS Projecteddimension 1. Type A (projected dimensions) Height Indicates the dimension when a measurement location Probe is projected onto a plane. The difference in height of the measurement points should be taken into consideration when measuring.
  • Page 44 BODY DIMENSIONS - Body Dimensions and Measurement Methods NOTES...
  • Page 45 BODY DIMENSIONS - Type A (Projected Dimensions) <EVOLUTION- > TYPE A (PROJECTED DIMENSIONS) UNDER BODY 1,239 1,010 1,232 1,225 1,461 1,232 1,157 1,028 1,641...
  • Page 46 BODY DIMENSIONS - Type A (Projected Dimensions) 1,335 1,230 1,545 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of under cover mounting hole Front edge of center bearing mounting bolt Notch of front sidemember inner Front edge of center bearing mounting bolt Centre of crossmember mounting hole - 18...
  • Page 47 BODY DIMENSIONS - Type A (Projected Dimensions) INSTALLATION OF SUSPENSION 1,110 1,186 18 19 1,127 1,073 1,025...
  • Page 48 BODY DIMENSIONS - Type A (Projected Dimensions) Centre of vehicle ° ′ 4°24′ Centre of vehicle 3°12′ 1° 22 23 14 15 1,257 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of crossmember mounting hole - 18 Trailing arm mounting position Centre of front fioor sidemember positioning hole...
  • Page 49 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY 1,250 1,010 1,232 1,463 1,170 1,241 1,225 1,028 1,649...
  • Page 50 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of under cover mounting hole Front edge of center bearing mounting bolt Notch of front sidemember inner Front edge of center bearing mounting bolt Centre of crossmember mounting hole - 18 Centre of rear seat crossmember positioning hole...
  • Page 51 B-10 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) INSTALLATION OF SUSPENSION 1,186 1,137 1,075 1,025...
  • Page 52 B-11 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of crossmember mounting hole - 18 Trailing arm mounting position Centre of crossmember mounting hole - 14 Control link mounting position Front edge of crossmember mounting bolt (Left Front edge of differential support mounting bolt side)
  • Page 53 B-12 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) FRONT BODY 1,091 1,508 Body centre point 1,390 1,437 1,532 1,040 1,382 1,050...
  • Page 54 B-13 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of front end crossmember upper drain hole Centre of hood hinge mounting hole Centre of harness clip mounting hole Corner of roof panel Centre of intercooler pipe mounting hole Centre of front end crossmember outer positioning...
  • Page 55 B-14 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) SIDE BODY 1,127 1,174 1,084 1,100 1,067 1,094 1,124 1,041 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Front pillar positioning notch (Upper section) Quarter panel positioning notch (Upper section) Front pillar positioning notch (Lower section) Quarter panel positioning notch (Lower section) Side roof rail positioning notch (Front section)

  • Page 56: Rear Body

    B-15 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) REAR BODY 1,271 Body centre point 1,200 1,269 1,104 1,562 1,018 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Corner of roof panel Centre of rear combination lamp mounting hole - 10 Centre of rear window moulding mounting hole Centre of rear end trim mounting hole...
  • Page 57 B-16 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) INTERIOR 1,112 1,145 1,235 1,297 1,289 1,379 1,395 1,368 1,407 1,388 1,072 1,100 1,085 1,016 1,136 1,041 Body centre point 1,106...
  • Page 58 B-17 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Body centre point 1,266 1,268 1,266 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Front pillar positioning notch (Upper section) Quarter panel positioning notch (Lower section) Front pillar positioning notch (Lower section) Centre of rear end trim mounting hole - 8.5 Side roof rail positioning notch (Front section)
  • Page 59 NOTES...
  • Page 60 BODY CONSTRUCTION CONTENTS BODY COMPONENTS ....UNDER BODY ......DOOR .
  • Page 61 BODY CONSTRUCTION - Body Components BODY COMPONENTS : Anticorrosion steel plates : High-tensile steel panels...
  • Page 62 BODY CONSTRUCTION - Body Components Headlamp support panel 42. Rear combination lamp housing Hood lock stay 43. Side roof rail inner Front end crossmember 44. Front pillar inner upper Front end upper bar 45. Front pillar inner lower Headlamp support panel side 46.
  • Page 63 BODY CONSTRUCTION - Body Main Cross-sectional Views BODY MAIN CROSS-SECTIONAL VIEWS Front pillar Roof panel Roof panel reinforcement upper Side outer Map lamp panel bracket Front roof rail Side roof rail inner Cowl top Front end crossmember upper reinforcement panel Front cross- member...
  • Page 64 BODY CONSTRUCTION - Body Main Cross-sectional Views Front pillar rein- Roof panel Front pillar forcement upper inner upper Rear roof rail Side outer panel Rear pillar Center pillar Center pillar inner seatbelt inner reinforcement Side Side outer outer Center pillar panel panel reinforcement...
  • Page 65 BODY CONSTRUCTION - Maintenance, Serviceability MAINTENANCE, SERVICEABILITY Fender Shield Positioning holes, marks, and notches have been provided at the following overlapped areas to improve operation performance when replacing panels.
  • Page 66 BODY CONSTRUCTION - Maintenance, Serviceability Side Structure Panel positioning notches have been provided at the door opening section to improve operation performance when replacing panels. Panel positioning notch Side Outer Panel Spare parts are provided in the following cut form with the adoption of the pillar integral type side outer panel.
  • Page 67 BODY CONSTRUCTION - Body Construction Characteristics BODY CONSTRUCTION CHARACTERISTICS FRONT BODY Headlamp Support 1. By adopting a steel sheet with variable thickness* for the front end crossmember outer, the steel sheet thickness on the right side of the vehicle has been increased to improve safety in collision and body rigidity.
  • Page 68 BODY CONSTRUCTION - Body Construction Characteristics Fender Shield 1. The cross section of the front sidemember has been increased and a steel sheet with variable thickness* has been adopted for the front sidemember inner to increase the thickness of the cabinet side in the aim to improve safety in collision, body rigidity, and realize lightweight.
  • Page 69 A-10 BODY CONSTRUCTION - Body Construction Characteristics Front Sidemember Reinforcement Right side 1. Front sidemember inner 10. Pipe nut 2. Front sidemember bulkhead A 11. Front sidemember rear 3. Front sidemember outer 12. Dash crossmember extension 4. Engine mount bracket 13.
  • Page 70 A-11 BODY CONSTRUCTION - Body Construction Characteristics Left side 1. Suspension crossmember support bracket 12. Front sidemember outer 2. Dash crossmember extension 13. Front sidemember bulkhead A 3. Front sidemember rear 14. Pipe 4. Pipe nut 15. Square head bolt 5.
  • Page 71 A-12 BODY CONSTRUCTION - BODY CONSTRUCTION - Body Construction Characteristics Body Construction Characteristics Front Deck Strut house gussetandupper frame to front pillar brace have been added to improve body rigidity. 1. Strut tower bar bracket 9. Clutch pedal support bracket 2.
  • Page 72 A-13 BODY CONSTRUCTION - Body Construction Characteristics SIDE BODY Side Structure 1. Front pillar reinforcement lower extension 24. Quarter inner extension rear 2. Front pillar inner lower extension 25. Quarter corner panel 3. Front pillar reinforcement lower 26. Rear combination lamp housing 4.
  • Page 73 A-14 BODY CONSTRUCTION - Body Construction Characteristics Side Structure Reinforcement 1. The thickness of the reinforcements of the front pillar and center pillar has been increased to improve collision safety. 2. The front pillar reinforcement upper, side outer panel, and front roof rail have been joined to improve twisting rigidity.
  • Page 74 A-15 BODY CONSTRUCTION - Body Construction Characteristics REAR BODY Rear Deck A rear shelf extension has been added to form closed surface structure. Then, the rear shelf and the rear floor have been joined to improve the torsion rigidity of the seat back plate. 1.
  • Page 75 A-16 BODY CONSTRUCTION - Body Construction Characteristics ROOF The cross section of the roof bow has been made large to improve safety in collision. 1. Roof panel 4. Front roof bow 2. Rear roof rail 5. Map lamp bracket 3. Rear roof bow 6.
  • Page 76 A-17 BODY CONSTRUCTION - Body Construction Characteristics UNDER BODY Front Floor The cross section of the front floor sidemember has been made large to improve safety in collision. 1. Installment panel center bracket 8. Front floor sidemember reinforcement 9. Front floor sidemember reinforcement front 2.
  • Page 77 A-18 BODY CONSTRUCTION - Body Construction Characteristics Rear Floor 1. Rear floor pan 11. Rear floor sidemember 2. Seat back plate extension 12. Fuel tank rear bracket (Vehicles with AYC) 3. Jack bracket 13. Differential/fuel support bracket front (Vehicles 4. Spare tire bracket with mechanical LSD) 5.
  • Page 78 A-19 BODY CONSTRUCTION - Body Construction Characteristics Rear Floor Sidemember Reinforcement 1. Trailing arm outer bracket 12. Muffler hanger center 2. Rear floor sidemember support 13. Rear floor sidemember reinforcement front 3. Trailing arm inner bracket 14. Muffler hanger rear 4.
  • Page 79 A-20 BODY CONSTRUCTION - Body Construction Characteristics DOOR The front and back of the side door beam has been made large to cope with the force from the front and sides during collision. Front door 14 15 Rear door 1. Front door hinge panel 11.
  • Page 80 A-21 BODY CONSTRUCTION - Silencer Application Locations SILENCER APPLICATION LOCATIONS Silencers (MD - 12 and melting sheets) are attached to the top of the floor to reduce vibration and insulate against the heat from exhaust gas. NOTE MD - 12 is a high performance sheet composed of asphalt applied with mica and thermosetting resin for improving anti-vibration performance.
  • Page 81 A-22 BODY CONSTRUCTION - Locations Using Urethane Foam and Foam Material LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL 1. Urethane foam is inserted into the center pillar to prevent the penetration of noise. 2. By filling the top of the front pillar, bottom of the front pillar, center pillar, side roof rail, rear pillar and inside the wheel house arch with foam acoustic material, penetration of noise is prevented.
  • Page 82 A-23 BODY CONSTRUCTION - Locations Using Urethane Foam and Foam Material Rear pillar inner Roof panel Foam acoustic Side outer material panel Side roof rail inner Foam acoustic material <RS-II> <RS-II> Rear door hinge reinforcement Center Foam acoustic lower Side outer panel pillar inner material Urethane...
  • Page 83 A-24 BODY CONSTRUCTION - Stiffener and Dump Sheet Application Locations STIFFENER AND DUMP SHEET APPLICATION LOCATIONS Stiffener is pasted to the inside of the side outer panel, and dump sheets are pasted on the inside of the front doors to increase surface rigidity, thus improving soundproof qualities with the anti-vibration effects.
  • Page 84 BODY REPAIR CONTENTS BODY CONSTRUCTION ........... BODY DIMENSIONS .
  • Page 85 NOTES...
  • Page 86 INDEX - In order of connector No. INDEX In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page A A-01 Side turn signal lamp (RH) B-135,139 B-6,8 A-02 Side turn signal lamp (LH) B-134,138 B-6,8 A-03 Wheel speed sensor (Front:LH) B-203,211,217,225,233,243 B-6,8...
  • Page 87 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page A A-45 Condenser fan motor B-177,183 B-7,9 A-46 Condenser fan motor B-177,183 B-7,9 A-47 A/C compressor B-178,184 B-7,9 A-48 Power steering oil pressure switch B-90,98 B-7,9 B B-01...
  • Page 88 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page B B-108 Back-up lamp switch B-142,143 B-12,16 B-110 Engine coolant temperature gauge unit B-148,152 B-12,16 B-112 EGR solenoid valve B-91,99 B-12,16 B-114 Ignition coil 1 B-82,83 B-12,16 B-115...
  • Page 89 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-10 Outside/Inside air selection damper B-175,181 B-18,24 control motor and potentiometer C-14 Blower motor B-174,180 B-18,24 C-16 Resistor B-174,180 B-18,24 C-21 SRS-ECU B-248,249,250,251 B-18,24 C-22 Diagnosis connector...
  • Page 90 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-46 Control wiring harness and floor wiring B-224,244 B-25 harness (LH) combination <ACD> <RHD> C-101 Spare connector (for front fog lamp B-258 B-20,26 switch) C-102 J/C (2)
  • Page 91 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-130 Instrument panel wiring harness and B-84,87,92,95,100,142,143,148,150, B-21,27 control wiring harness combination 152,154,157,175,178,198,200,201, 204,205,206,212,213,216,219,228, 229,232,235,237,252,254,255,256, C-131 Blower switch B-174,180 B-21,27 C-132 Front wiring harness (LH) and instru- B-74,78,92,100,105,108,113,117,119, B-21,27 ment panel wiring harness combination...
  • Page 92 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-207 Air bag module (squib) <Driver’s side> B-248,250 B-22,28 C-208 Instrument panel wiring harness and B-54,55,126,129,256 B-22,28 J/B combination C-209 Instrument panel wiring harness and B-54,55,87,95,104,105,107,108,110, B-22,28 J/B combination...
  • Page 93 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page C C-223 Fuel pump relay 1 B-54,55,87,95 B-23,29 C-224 Power window relay B-54,55,158,159,165 B-23,29 C-225 No connection B-54,55,78 B-23,29 C-226 ETACS-ECU B-54,55,105,108,112,113,116,117,118, B-23,29 119,120,121,122,123,125,126,128, 129,134,136,137,138,140,141,158, 164,165, 170,171,172,173,188,189 C-227...
  • Page 94 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page D D-27 Fuel gauge unit (Sub) B-148,152,156 B-31,33 D-28 Seat belt pretensioner (LH) B-249,251 B-31,33 D-29 Floor wiring harness (RH) and fuel B-93,101 B-31,33 wiring harness combination D-30 Floor wiring harness (RH) and fuel...
  • Page 95 C-10 INDEX - In order of connector No. Connector Parts name Circuit diagram page Wiring diagram page F F-08 Spare connector <for rear speaker B-197 B-38,39 (RH)> F-09 Rear combination lamp (RH) B-111,115,129,134,138,142,144,145 B-38,39 F-10 Trunk lid latch switch B-119,123 B-38,39 F-12 Licence plate lamp (RH)
  • Page 96 C-11 INDEX - In order of parts name INDEX In order of parts name Parts name Connector Circuit diagram page Wiring diagram page 4WD-ECU <ACD> C-43 B-201,209,212,213,214,215,216,218, B-19,25 219,220,221,222,223,224,226,227, 228,230,231,232,234,236,237,238, 240,241,242,244, 246,247 4WD-ECU <ACD> C-44 B-201,209,212,213,216,217,219,220, B-19,25 221,224,225,227,228,229,232,234, 235,237,238,239,242,244,245,247 A A/C compressor A-47 B-178,184 B-7,9...
  • Page 97 C-12 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page C Column switch C-203 B-104,107,112,116,125,128,137,141, B-22,28 187,191 Combination meter C-01 B-84,87,95,103,106,118,122,126,129, B-18,24 135,139,148,149,152,153,156,157, 198,206,214,222,230,240,248,250, 256, 258 Combination meter C-02 B-110,115,118,122,126,129,135,139, B-18,24 148,149,152,153,156,157,198,206, 248, 250,256,258 Condenser fan motor A-45 B-177,183...
  • Page 98 C-13 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page D Door switch (Rear:LH) D-08 B-120,121 B-30,32 Door switch (Rear:RH) D-06 B-120,121 B-30,32 Dual pressure switch A-36 B-178,184 B-7,9 E EGR solenoid valve B-112 B-91,99 B-12,16...
  • Page 99 C-14 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page F Floor wiring harness (RH) and J/B C-217 B-54,55,108,115,116,121,123,138, B-29 combination <RHD> 164, 173,185 Floor wiring harness (RH) and rear door D-02 B-160,166,171,173 B-30,32 wiring harness (RH) combination Fog lamp switch...
  • Page 100 C-15 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page G G sensor (Lateral) D-33 B-200,208,213,221,229,239 B-31,33 G sensor (Longitudinal) D-32 B-200,208,213,221,229,239 B-31,33 H Hazard warning switch C-03 B-136,140 B-18,24 Headlamp (HI:LH) A-16 B-103,106 B-6,8 Headlamp (HI:RH)
  • Page 101 C-16 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page Instrument panel wiring harness and C-42 B-216,234 B-19 control wiring harness combination <ACD> <LHD> Instrument panel wiring harness and C-147 B-209,210,215,223,224,225,231,241, B-27 control wiring harness combination 242,244 <RHD>...
  • Page 102 C-17 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page Instrument panel wiring harness and C-211 B-54,55,78,92,100,105,108,113,117, B-22,28 J/B combination 119,123,125,128,137,141,150,154, 158,164,170,172,174,180,185,188, 189,204,205,219,227,237,247,248, 250,252,254 Instrument panel wiring harness and C-213 B-54,55,78,82,83,84,87,92,95,100, B-22,28 J/B combination 104,105,107,108,110,112,113,115, 116,117,119,120,121,123,125,126, 128,129,135,136,137,139,140,141,...
  • Page 103 C-18 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page K Key reminder switch C-202 B-253,255 B-22,28 Licence plate lamp (LH) F-13 B-110,114 B-38,39 Licence plate lamp (RH) F-12 B-110,114 B-38,39 Luggage compartment lamp F-04 B-119,123 B-38,39...
  • Page 104 C-19 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page P Purge control solenoid valve B-23 B-91,99 B-11,15 R Radiator fan relay A-09X B-73,102,176,182 B-6,8 Rear combination lamp (LH) F-16 B-110,114,126,134,138,143,144,145 B-38,39 Rear combination lamp (RH) F-09 B-111,115,129,134,138,142,144,145 B-38,39...
  • Page 105 C-20 INDEX - In order of parts name Parts name Connector Circuit diagram page Wiring diagram page S SRS-ECU C-41 B-249,251 B-19,25 Starter B-18 B-79 B-11,15 Starter B-19 B-79 B-11,15 Steering wheel sensor C-230 B-202,210,218,226,236,246 B-23,29 Stop lamp switch C-103 B-144,145,198,206,212,220,228,238 B-20,26 T Throttle position sensor...

  • Page 106: Table Of Contents

    ELECTRICAL WIRING CONTENTS WIRING HARNESS CONFIGURATION SINGLE PART INSTALLATION DIAGRAMS ......POSITION ......OVERALL WIRING DIAGRAM RELAY .
  • Page 107 IGNITION SYSTEM STOP LAMP L.H. drive vehicles ..... . . L.H. drive vehicles ..... . R.H.
  • Page 108 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT PRETENSIONER L.H. drive vehicles ..... . L.H. drive vehicles ..... . R.H.
  • Page 109 WIRING HARNESS CONFIGURATION DIAGRAMS WIRING HARNESS CONFIGURATION DIAGRAMS OVERALL WIRING DIAGRAM L.H. drive vehicles Control wiring Instrument panel Roof wiring Floor wiring harness wiring harness harness harness (RH) Front wiring harness (RH) Rear door wiring harness* Battery wiring Front wiring Front door Floor wiring Fuel wiring...
  • Page 110 WIRING HARNESS CONFIGURATION DIAGRAMS R.H. drive vehicles Control wiring Instrument panel Roof wiring Floor wiring harness wiring harness harness harness (RH) Front wiring harness (RH) Rear door wiring harness* Battery wiring Front wiring Front door Floor wiring Fuel wiring harness harness (LH) wiring harness* harness (LH)

  • Page 111: Engine Compartment

    WIRING HARNESS CONFIGURATION DIAGRAMS ENGINE COMPARTMENT L.H. drive vehicles Connector symbol A-01 A-37 A-36 A-48 A-40 Connector colour code B:Black Y:Yellow L:Blue A-31 G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white A-28 A-47 A-46 A-45 A-01 (2-GR) Side turn signal lamp (RH) A-09X (4) Radiator fan relay A-02 (2-GR)
  • Page 112 WIRING HARNESS CONFIGURATION DIAGRAMS A-02 A-03 A-04X A-05X A-06X A-07X A-08X A-09X A-10X A-11X A-12 A-13 A-43 A-39 A-44 A-25 A-21 A-23 A-16 A-21 (3-GR) Fan controller A-40 (8-B) Front combination lamp (RH) A-23 (1-B) Horn (HI) A-43 (8-B) Front wiring harness (LH) and control A-25 (1-B) Horn (LO) wiring harness combination...
  • Page 113 WIRING HARNESS CONFIGURATION DIAGRAMS ENGINE COMPARTMENT R.H. drive vehicles Connector symbol A-01 A-37 A-36 A-34 A-48 A-40 A-31 Connector colour code A-28 B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange A-47 A-46 A-45 GR:Gray None: Milk white A-01 (2-GR) Side turn signal lamp (RH) A-09X (4) Radiator fan relay A-02 (2-GR)
  • Page 114 WIRING HARNESS CONFIGURATION DIAGRAMS A-02 A-03 A-04X A-05X A-06X A-07X A-08X A-09X A-10X A-11X A-12 A-39 A-44 A-16 A-25 A-21 A-23 A-23 (1-B) Horn (HI) A-40 (8-B) Front combination lamp (RH) A-25 (1-B) Horn (LO) A-44 (2) Intercooler water spray motor A-28 (2-B) Headlamp (HI: RH) A-45 (2-B)

  • Page 115: Engine And Transmission

    B-10 WIRING HARNESS CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION L.H. drive vehicles Connector symbol thru Earth cable B-01 B-27 B-26 B-37 B-34 B-23 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red B-21 B-22 BR:Brown V:Violet O:Orange GR:Gray None: Milk white B-01 (5-GR) Windshield wiper motor B-08X (4) No connection...
  • Page 116 B-11 WIRING HARNESS CONFIGURATION DIAGRAMS B-25 B-24 B-02 B-04 B-05X B-06X B-07X B-08X B-09X B-10X B-11X B-12X B-14 B-03 B-36 B-18 B-19 B-20 B-31 B-18 (1) Starter B-25 (2-B) Injector 3 B-19 (1-B) Starter B-26 (2-B) Injector 2 B-20 (1-B) Oil pressure switch B-27 (2-B) Injector 1...
  • Page 117 B-12 WIRING HARNESS CONFIGURATION DIAGRAMS L.H. drive vehicles Connector symbol -108 thru -142 Earth cable B-123 B-138 B-139 B-140 B-141 B-119 B-121 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red B-122 B-112 B-142 BR:Brown V:Violet O:Orange GR:Gray None: Milk white B-108 (2-B) Back-up lamp switch B-115 (6-B)
  • Page 118 B-13 WIRING HARNESS CONFIGURATION DIAGRAMS B-115 B-118 B-108 B-114 B-116 B-110 B-121 (3-B) Crank angle sensor B-139 (5-B) Electric pump relay <ACD> B-122 (2-GR) Detonation sensor B-140 (4) Fuel pump relay 3 B-123 (34-B) ABS-ECU B-141 (2-B) Fuel pump resistor B-138 (6-B) Resistor B-142 (2-B)
  • Page 119 B-14 WIRING HARNESS CONFIGURATION DIAGRAMS ENGINE AND TRANSMISSION R.H. drive vehicles Connector symbol thru Earth cable B-04 B-27 B-26 B-37 B-34 B-23 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red B-21 B-22 BR:Brown V:Violet O:Orange GR:Gray None: Milk white B-01 (5-GR) Windshield wiper motor B-08X (4) No connection...
  • Page 120 B-15 WIRING HARNESS CONFIGURATION DIAGRAMS B-25 B-24 B-02 B-01 B-05X B-06X B-07X B-08X B-09X B-10X B-11X B-12X B-14 B-03 B-36 B-18 B-19 B-20 B-31 B-18 (1) Starter B-25 (2-B) Injector 3 B-19 (1-B) Starter B-26 (2-B) Injector 2 B-20 (1-B) Oil pressure switch B-27 (2-B) Injector 1...
  • Page 121 B-16 WIRING HARNESS CONFIGURATION DIAGRAMS R.H. drive vehicles Connector symbol -108 thru -142 Earth cable B-119 B-121 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red B-122 B-112 B-142 BR:Brown V:Violet O:Orange GR:Gray None: Milk white B-108 (2-B) Back-up lamp switch B-115 (6-B) Idle speed control servo B-110 (1-B)
  • Page 122 B-17 WIRING HARNESS CONFIGURATION DIAGRAMS B-115 B-139 B-140 B-138 B-141 B-123 B-118 B-114 B-116 B-110 B-108 B-121 (3-B) Crank angle sensor B-139 (5-B) Electric pump relay <ACD> B-122 (2-GR) Detonation sensor B-140 (4) Fuel pump relay 3 B-123 (34-B) ABS-ECU B-141 (2-B) Fuel pump resistor B-138 (6-B)

  • Page 123: Dash Panel

    B-18 WIRING HARNESS CONFIGURATION DIAGRAMS DASH PANEL L.H. drive vehicles Connector symbol thru C-01 C-02 C-32 C-03 C-04 C-05 C-29 C-36 C-26 C-24 C-45 C-23 C-22 C-42 C-41 C-21 C-01 (21) Combination meter C-14 (2) Blower motor C-02 (21-L) Combination meter C-16 (4) Resistor C-03 (4)
  • Page 124 B-19 WIRING HARNESS CONFIGURATION DIAGRAMS C-08 C-10 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet C-16 C-44 C-43 C-14 O:Orange GR:Gray None: Milk white C-26 (22-B) J/C (4) C-43 (22-Y) 4WD-ECU <ACD> C-29 (22-B) J/C (5) C-44 (26-Y) 4WD-ECU <ACD>...
  • Page 125 B-20 WIRING HARNESS CONFIGURATION DIAGRAMS L.H. drive vehicles Connector symbol -101 thru C-101 C-138 C-142 C-102 C-103 C-104 C-141 C-108 -146 C-137 C-135 C-134 C-133 C-132 C-131 C-130 C-129 C-128 C-101 (1) Spare connector (for front fog lamp C-110 (16) Instrument panel wiring harness and front switch) door wiring harness (RH) combination...
  • Page 126 B-21 WIRING HARNESS CONFIGURATION DIAGRAMS C-107 C-109 C-110 C-111 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange C-115 C-118 C-122 C-126 C-112 C-146 GR:Gray None: Milk white C-128 (22-L) Instrument panel wiring harness and C-134 (11-GR) Instrument panel wiring harness and floor control wiring harness combination wiring harness (LH) combination C-129 (10-GR) Instrument panel wiring harness and...
  • Page 127 B-22 WIRING HARNESS CONFIGURATION DIAGRAMS L.H. drive vehicles Connector symbol -201 thru -230 STEERING COLUMN C-207 C-206 Connector colour code B:Black Y:Yellow C-205 C-204 C-230 C-203 C-202 C-201 L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white C-201 (6) Ignition switch C-209 (14) Instrument panel wiring harness and J/B...
  • Page 128 B-23 WIRING HARNESS CONFIGURATION DIAGRAMS JUNCTION BLOCK (Front view) (Rear view) C-208 C-209 C-210 C-226 C-211 C-225 C-224 C-213 C-223 C-222 C-214 C-221 C-215 Dedicated fuse C-220 C-219 C-218 C-216 C-228 C-227 C-214 (5) Defogger relay C-222 (4) Intercooler water spray relay C-215 (5) Blower relay C-223 (4)
  • Page 129 B-24 WIRING HARNESS CONFIGURATION DIAGRAMS DASH PANEL R.H. drive vehicles Connector symbol C-10 C-28 C-05 C-03 C-04 C-32 thru C-46 C-24 C-14 C-16 C-44 C-43 C-35 C-41 C-21 C-01 (21) Combination meter C-14 (2) Blower motor C-02 (21-L) Combination meter C-16 (4) Resistor C-03 (4)
  • Page 130 B-25 WIRING HARNESS CONFIGURATION DIAGRAMS C-01 C-08 C-02 C-26 C-36 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet C-22 C-23 C-34 O:Orange GR:Gray None: Milk white C-26 (22-B) J/C (4) C-41 (22-Y) SRS-ECU C-28 (13) J/C (5) C-43 (22) 4WD-ECU <ACD>...
  • Page 131 B-26 WIRING HARNESS CONFIGURATION DIAGRAMS R.H. drive vehicles Connector symbol -101 C-109 C-107 C-108 C-141 C-104 C-131 thru -147 C-136 C-135 C-134 C-133 C-132 C-115 C-118 C-122 C-126 C-130 C-129 C-128 C-147 C-101 (1) Spare connector (for front fog lamp C-111 (25) Front wiring harness (RH) and instrument switch)
  • Page 132 B-27 WIRING HARNESS CONFIGURATION DIAGRAMS C-101 C-142 C-138 C-137 C-110 C-111 C-146 C-112 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange C-102 C-103 GR:Gray None: Milk white C-130 (25) Instrument panel wiring harness and C-136 (16) Front wiring harness (LH) and control control wiring harness combination wiring harness combination C-131 (6)
  • Page 133 B-28 WIRING HARNESS CONFIGURATION DIAGRAMS R.H. drive vehicles Connector symbol -201 thru -230 STEERING COLUMN C-207 C-206 Connector colour code B:Black C-201 C-202 C-203 C-230 C-204 C-205 Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white C-201 (6) Ignition switch C-209 (14) Instrument panel wiring harness and J/B...
  • Page 134 B-29 WIRING HARNESS CONFIGURATION DIAGRAMS JUNCTION BLOCK (Front view) (Rear view) C-209 C-208 C-210 C-226 C-211 C-225 C-213 C-224 C-214 C-223 C-215 C-222 C-221 Dedicated fuse C-227 C-228 C-220 C-217 C-219 C-218 C-214 (5) Defogger relay C-222 (4) Intercooler water spray relay C-215 (5) Blower relay C-223 (4)
  • Page 135 B-30 WIRING HARNESS CONFIGURATION DIAGRAMS FLOOR AND ROOF L.H. drive vehicles Connector symbol D-01 D-26 D-02 D-03 D-04 D-05 D-06 D-23 D-22 D-21 D-20 D-19 D-18 D-34 D-15 D-33 D-32 D-30 D-29 D-01 (3) Door switch (Front: RH) D-08 (3) Door switch (Rear: LH) D-02 (8) Floor wiring harness (RH) and rear door...
  • Page 136 B-31 WIRING HARNESS CONFIGURATION DIAGRAMS D-27 D-08 D-09 D-10 D-12 D-28 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray D-13 None: Milk white D-18 (1) Cigarette lighter D-29 (1) Floor wiring harness (RH) and fuel wiring D-19 (1-B) Cigarette lighter harness combination...
  • Page 137 B-32 WIRING HARNESS CONFIGURATION DIAGRAMS FLOOR AND ROOF R.H. drive vehicles Connector symbol D-01 D-26 D-02 D-03 D-04 D-05 D-06 D-23 D-22 D-21 D-20 D-19 D-18 D-34 D-15 D-33 D-32 D-30 D-29 D-01 (3) Door switch (Front: RH) D-09 (5-GR) Fuel pump and fuel gauge unit (Main) D-02 (8) Floor wiring harness (RH) and rear door...
  • Page 138 B-33 WIRING HARNESS CONFIGURATION DIAGRAMS D-27 D-08 D-09 D-10 D-12 D-28 Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white D-13 D-18 (1) Cigarette lighter D-29 (1) Floor wiring harness (RH) and fuel wiring D-19 (1-B) Cigarette lighter harness combination...
  • Page 139 B-34 WIRING HARNESS CONFIGURATION DIAGRAMS DOOR L.H. drive vehicles Driver’s side Connector symbol E-02 Front door E-08 E-07 E-05 E-04 Rear door E-12 E-11 E-10 E-02 (3) Remote controlled mirror (LH) E-08 (6-B) Door lock actuator (Front: LH) E-04 (2) Spare connector <for front door speaker E-10 (6-GR) Power window motor (Rear: LH)
  • Page 140 B-35 WIRING HARNESS CONFIGURATION DIAGRAMS Passenger’s side E-13 E-16 Front door E-21 E-20 E-19 E-18 Rear door Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray None: Milk white E-25 E-24 E-23 E-16 (3-B) Door lock key cylinder switch (RH) E-21 (2) Spare connector <for front door speaker E-18 (6-B)
  • Page 141 B-36 WIRING HARNESS CONFIGURATION DIAGRAMS DOOR R.H. drive vehicles Driver’s side Connector symbol E-07 E-13 Front door E-18 E-21 E-20 Rear door E-25 E-24 E-23 E-02 (3) Remote controlled mirror (LH) E-08 (6-B) Door lock actuator (Front: LH) E-04 (2) Spare connector <for front door speaker E-10 (6-GR) Power window motor (Rear: LH)
  • Page 142 B-37 WIRING HARNESS CONFIGURATION DIAGRAMS Passenger’s side E-17 E-19 E-02 Front door E-08 E-05 E-04 Rear door Connector colour code B:Black Y:Yellow L:Blue G:Green R:Red BR:Brown V:Violet O:Orange GR:Gray E-12 E-11 E-10 None: Milk white E-13 (3) Remote controlled mirror (RH) E-21 (2) Spare connector <for front door speaker E-17 (3-B)

  • Page 143: Luggage Compartment

    B-38 WIRING HARNESS CONFIGURATION DIAGRAMS LUGGAGE COMPARTMENT L.H. drive vehicles Connector symbol F-01 F-04 F-05 F-06 F-08 F-19 F-21 F-09 F-10 F-16 F-12 F-13 F-29 F-28 F-27 F-26 F-25 F-24 F-23 F-14 F-01 (2) Spare connector <for rear speaker (LH)> F-16 (6-B) Rear combination lamp (LH) F-04 (2)
  • Page 144 B-39 WIRING HARNESS CONFIGURATION DIAGRAMS LUGGAGE COMPARTMENT R.H. drive vehicles Connector symbol F-01 F-04 F-05 F-08 F-19 F-21 F-06 F-09 F-10 F-16 F-12 F-29 F-13 F-28 F-27 F-26 F-25 F-24 F-23 F-14 F-01 (2) Spare connector <for rear speaker (LH)> F-16 (6-B) Rear combination lamp (LH) F-04 (2)
  • Page 145 B-40 SINGLE PART INSTALLATION POSITION - Relay SINGLE PART INSTALLATION POSITION RELAY Name Symbol Name Symbol A/C compressor relay Fuel pump relay 2 Blower relay L.H. drive vehicles Fuel pump relay 3 Condenser fan relay (HI) R.H. drive vehicles Condenser fan relay (LO) Horn relay Defogger relay Ignition coil relay <R.H.
  • Page 146 B-41 SINGLE PART INSTALLATION POSITION - Relay/ECU Power window Fuel relay pump relay 1 Defogger relay Intercooler water spray relay Fuel pump Blower relay relay 2 Rear fog lamp relay Name Symbol Name Symbol 4WD-ECU <AYC> L.H. drive vehicles Front-ECU R.H.
  • Page 147 B-42 SINGLE PART INSTALLATION POSITION - ABS-ECU ABS-ECU Fan controller Front-ECU ETACS- Column switch <incorporating column-ECU> Immobilizer- Heater control unit <without manual A/C> or A/C-ECU Ignition key cylinder <with manual A/C> Engine-ECU SRS-ECU...
  • Page 148 B-43 SINGLE PART INSTALLATION POSITION - ECU/Sensor 4WD-ECU Glove box Door check (front door: RH side) 4WD-ECU Power window main switch (incorporating ECU) Power window motor (Front) <incorporating ECU> Power window motor (Rear) <incorporating ECU> SENSOR Name Symbol Name Symbol Air flow sensor Oxygen sensor Air thermo sensor <A/C>...
  • Page 149 B-44 SINGLE PART INSTALLATION POSITION - Sensor Intake manifold Throttle position sensor Detonation sensor Crank angle sensor Transfer Vehicle speed sensor Crankshaft sprocket...
  • Page 150 B-45 SINGLE PART INSTALLATION POSITION - Sensor Oxygen sensor Engine coolant temperature sensor Camshaft position sensor Air flow sensor Steering wheel sensor Parking brake lever G sensor G sensor (Lateral) Air thermo sensor (Longitudinal) Oxygen sensor (rear) Wheel speed sensor (front) Pressure sensor Wheel speed sensor (rear)

  • Page 151: Solenoid Valve

    B-46 SINGLE PART INSTALLATION POSITION - Solenoid Valve SOLENOID VALVE Name Symbol Name Symbol EGR solenoid valve Hydraulic unit (incorporating solenoid valve) <ACD> (incorporating solenoid valve) <ACD> Fuel pressure solenoid valve Purge control solenoid valve Hydraulic unit (incorporating solenoid valve) <ABS>...
  • Page 152 B-47 Solenoid Valve/Inspection SINGLE PART INSTALLATION POSITION - Connector and Spare connector Hydraulic unit Proportioningvalve (for ACD control) Direction valve (RH, LH) Proportion- ing valve (for AYC control) INSPECTION CONNECTOR AND SPARE CONNECTOR Name Symbol Name Symbol Diagnosis connector Spare connector (for front fog lamp relay) Engine speed detection connector Spare connector (for front fog lamp switch) Spare connector (for front fog lamp)

  • Page 153: Fusible Link And Fuse

    B-48 Inspection Connector Spare SINGLE PART INSTALLATION POSITION - connector/Fusible Link and Fuse <L.H. drive vehicles> <R.H. drive vehicles> Spare connector Spare connector (for front fog lamp (for front fog lamp switch) switch) 10029AU Diagnosis connector FUSIBLE LINK AND FUSE Name Symbol Name...

  • Page 154: Earth Cable

    B-49 SINGLE PART INSTALLATION POSITION - Fusible Link and Fuse/Earth Cable <L.H. drive vehicles> Multi-purpose fuses Dedicated fuses (No.1-19,25) Dedicated fuses (No.21) <R.H. drive vehicles> Dedicated fuses (No.21) Multi-purpose fuses EARTH CABLE...
  • Page 155 B-50 - Earth SINGLE PART INSTALLATION POSITION EARTH L.H. drive vehicles R.H. drive vehicles NOTE Same earth numbers are used in the circuit diagram.
  • Page 156 B-51 - Earth SINGLE PART INSTALLATION POSITION Door check (front door: RH side) Front deck crossmember <L.H. drive vehicles> <L.H. drive vehicles> <R.H. drive vehicles> Windshield wiper (driver’s side) Rear seat back hook (LH) Rear seat back hook (RH)
  • Page 157 B-52 - Earth SINGLE PART INSTALLATION POSITION Transmission assembly Heat protector Air duct <L.H. drive vehicles> <R.H. drive vehicles>...
  • Page 158 B-53 NOTES...
  • Page 159 B-54 CIRCUIT DIAGRAMS CIRCUIT DIAGRAMS H1J00X08AA...
  • Page 160 B-55 CIRCUIT DIAGRAMS Front side Rear side ETACS-ECU To instrument panel wiring harness To instrument C-208 C-210 panel wiring harness C-209 C-225 C-211 C-226 Power window relay C-213 Blower relay Fuel pump C-223 relay (1) Defogger C-224 C-215 C-214 relay C-222 Inter cooler water spray...
  • Page 161 B-56 CIRCUIT DIAGRAMS L.H. drive vehicles H1J00X06AA...
  • Page 162 B-57 CIRCUIT DIAGRAMS H1J00X06AB...
  • Page 163 B-58 CIRCUIT DIAGRAMS J/C <L.H. drive vehicles> (CONTINUED) H1J00X06BA...
  • Page 164 B-59 CIRCUIT DIAGRAMS H1J00X06BB...
  • Page 165 B-60 CIRCUIT DIAGRAMS J/C <L.H. drive vehicles> (CONTINUED) H1J00X06CA...
  • Page 166 B-61 CIRCUIT DIAGRAMS H1J00X06CB...
  • Page 167 B-62 CIRCUIT DIAGRAMS R.H. drive vehicles H1J00X09AA...
  • Page 168 B-63 CIRCUIT DIAGRAMS H1J00X09AB...
  • Page 169 B-64 CIRCUIT DIAGRAMS J/C <R.H. drive vehicles> (CONTINUED) H1J00X09BA...
  • Page 170 B-65 CIRCUIT DIAGRAMS H1J00X09BB...
  • Page 171 B-66 CIRCUIT DIAGRAMS J/C <R.H. drive vehicles> (CONTINUED) H1J00X09CA...
  • Page 172 B-67 CIRCUIT DIAGRAMS H1J00X09CB...

  • Page 173: Centralized Junction

    B-68 CIRCUIT DIAGRAMS CENTRALIZED JUNCTION FUSIBLE LINK Circuit Type Housing colour Rated capacity Multi-purpoes fuses No. 15, 16, 17, 19, 20 Screwed type Yellow Cooling circuit and manual air conditioner circuit Connector type ABS circuit Connector type Yellow Ignition switch Connector type Green Power window circuit...
  • Page 174 B-69 CIRCUIT DIAGRAMS DEDICATED FUSE Power supply Rated Identification Circuit circuit capacity (A) colour Battery/alternator Blue Spare connectors (Fusible link No 6) (Fusible link No. 6) Horn relay Yellow Engine control relay and ignition control relay A/C compressor Blue ABS-ECU, 4WD-ECU, high-mounted stop lamp and rear combination lamp Green Condenser fan motor...
  • Page 175 B-70 CIRCUIT DIAGRAMS (Relay box in engine compartment) 2 3 4 5 6 7 8 9 10 Front of vehicles 17 18 (in junction block) <L.H. drive vehicles> 23 24 <R.H. drive vehicles> 23 24...
  • Page 176 B-71 CIRCUIT DIAGRAMS MULTI-PURPOSE FUSE (In junction block) Power supply Rated Identification Circuit circuit capacity (A) colour Ignition Ignition coil switch switch Brown Column switch, combination meter, ETACS-ECU, SRS-ECU, vehicle speed sensor and ACD mode changeover switch Brown ETACS-ECU and SRS-ECU Brown A/C compressor relay, A/C-ECU, blower relay, condenser fan relay, defogger relay, front-ECU,...
  • Page 177 B-72 CIRCUIT DIAGRAMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...
  • Page 178 B-73 CIRCUIT DIAGRAMS CENTRALIZED RELAY (relay box in engine compartment) Connector Name Connector Name A-04X Spare connector (for front fog lamp relay) B-05X Engine speed detection connector A-05X Horn relay B-06X A-06X Condenser fan relay (LO) B-07X A-07X Condenser fan relay (HI) B-08X A-08X B-09X...

  • Page 179: Power Distribution System

    B-74 CIRCUIT DIAGRAMS POWER DISTRIBUTION SYSTEM H1J01X08AA...
  • Page 180 B-75 CIRCUIT DIAGRAMS H1J01X08AB...
  • Page 181 B-76 CIRCUIT DIAGRAMS POWER DISTRIBUTION SYSTEM (CONTINUED) H1J01X08BA...
  • Page 182 B-77 CIRCUIT DIAGRAMS H1J01X08BB...
  • Page 183 B-78 CIRCUIT DIAGRAMS POWER DISTRIBUTION SYSTEM (CONTINUED) H1J01X08CA...

  • Page 184: Starting System

    B-79 CIRCUIT DIAGRAMS STARTING SYSTEM H1J02X06AA...
  • Page 185 B-80 CIRCUIT DIAGRAMS STARTING SYSTEM (See P.B-79.) OPERATION TROUBLESHOOTING HINTS When the ignition switch is turned to the ST position, 1. Starter motor does not turn over at all. the starter contacts (magnet switch) turns ON and Check starter (coil). the starter motor starts turning over.
  • Page 186 B-81 CIRCUIT DIAGRAMS NOTES...

  • Page 187: Ignition System

    B-82 CIRCUIT DIAGRAMS IGNITION SYSTEM L.H. drive vehicles H1J03X08AA...

  • Page 188: R.h. Drive Vehicles

    B-83 CIRCUIT DIAGRAMS IGNITION SYSTEM R.H. drive vehicles H1J03X07AA...

  • Page 189: Charging System

    B-84 CIRCUIT DIAGRAMS CHARGING SYSTEM H1J04X04AA...
  • Page 190 B-85 CIRCUIT DIAGRAMS CHARGING SYSTEM (See P.B-84.) OPERATION TROUBLESHOOTING HINTS 1. Charging indicator lamp does not illuminate When engine is stationary when the ignition switch is turned to ON When the ignition switch is turned to the ON position, before the engine starts. position, current flows the alternator L terminal Check multi-purpose fuse No.(2).
  • Page 191 B-86 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM L.H. drive vehicles...
  • Page 192 B-87 CIRCUIT DIAGRAMS H1J05X17AB...

  • Page 193: Engine Control System L.h. Drive Vehicles

    B-88 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <L.H. drive vehicles> (CONTINUED)
  • Page 194 B-89 CIRCUIT DIAGRAMS...
  • Page 195 B-90 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <L.H. drive vehicles> (CONTINUED)
  • Page 196 B-91 CIRCUIT DIAGRAMS...
  • Page 197 B-92 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <L.H. drive vehicles> (CONTINUED)
  • Page 198 B-93 CIRCUIT DIAGRAMS H1J05X17DB...

  • Page 199: R.h. Drive Vehicles

    B-94 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM R.H. drive vehicles...
  • Page 200 B-95 CIRCUIT DIAGRAMS...
  • Page 201 B-96 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <R.H. drive vehicles> (CONTINUED)
  • Page 202 B-97 CIRCUIT DIAGRAMS...
  • Page 203 B-98 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <R.H. drive vehicles> (CONTINUED)
  • Page 204 B-99 CIRCUIT DIAGRAMS...
  • Page 205 B-100 CIRCUIT DIAGRAMS ENGINE CONTROL SYSTEM <R.H. drive vehicles> (CONTINUED)
  • Page 206 B-101 CIRCUIT DIAGRAMS H1J05X16DB...

  • Page 207: Cooling System

    B-102 CIRCUIT DIAGRAMS COOLING SYSTEM H1J06X03AA...
  • Page 208 B-103 CIRCUIT DIAGRAMS HEADLAMP L.H. drive vehicles H1J08X20AA...

  • Page 209: Headlamp L.h. Drive Vehicles

    B-104 CIRCUIT DIAGRAMS HEADLAMP <L.H. drive vehicles> (CONTINUED)
  • Page 210 B-105 CIRCUIT DIAGRAMS...

  • Page 211: R.h. Drive Vehicles

    B-106 CIRCUIT DIAGRAMS HEADLAMP R.H. drive vehicles H1J08X19AA...
  • Page 212 B-107 CIRCUIT DIAGRAMS H1J08X19AB...
  • Page 213 B-108 CIRCUIT DIAGRAMS HEADLAMP <R.H. drive vehicles> (CONTINUED) H1J08X19BA...
  • Page 214 B-109 CIRCUIT DIAGRAMS NOTES...
  • Page 215 B-110 CIRCUIT DIAGRAMS TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER L.H. drive vehicles H1J08X23AA...
  • Page 216 B-111 CIRCUIT DIAGRAMS H1J08X23AB...

  • Page 217: Tail Lamp, Position Lamp, Licence Plate Lamp And Lighting Monitor Buzzer L.h. Drive Vehicles

    B-112 CIRCUIT DIAGRAMS TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <L.H. drive vehicles> (CONTINUED) H1J08X23BA...
  • Page 218 B-113 CIRCUIT DIAGRAMS H1J08X23BB...
  • Page 219 B-114 CIRCUIT DIAGRAMS TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER R.H. drive vehicles H1J08X21AA...
  • Page 220 B-115 CIRCUIT DIAGRAMS H1J08X21AB...
  • Page 221 B-116 CIRCUIT DIAGRAMS TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER <R.H. drive vehicles> (CONTINUED) H1J08X21BA...
  • Page 222 B-117 CIRCUIT DIAGRAMS H1J08X21BB...

  • Page 223: L.h. Drive Vehicles

    B-118 CIRCUIT DIAGRAMS ROOM LAMP AND LUGGAGE COMPARTMENT LAMP L.H. drive vehicles H1J08X26AA...
  • Page 224 B-119 CIRCUIT DIAGRAMS H1J08X26AB...

  • Page 225: Room Lamp And Luggage Compartment Lamp L.h. Drive Vehicles

    B-120 CIRCUIT DIAGRAMS ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <L.H. drive vehicles> (CONTINUED) H1J08X26BA...

  • Page 226: R.h. Drive Vehicles

    B-121 CIRCUIT DIAGRAMS ROOM LAMP AND LUGGAGE COMPARTMENT LAMP R.H. drive vehicles H1J08X24AA...
  • Page 227 B-122 CIRCUIT DIAGRAMS ROOM LAMP AND LUGGAGE COMPARTMENT LAMP <R.H. drive vehicles > (CONTINUED) H1J08X24BA...
  • Page 228 B-123 CIRCUIT DIAGRAMS H1J08X24BB...
  • Page 229 B-124 CIRCUIT DIAGRAMS REAR FOG LAMP L.H. drive vehicles H1J08X28AA...
  • Page 230 B-125 CIRCUIT DIAGRAMS H1J08X28AB...

  • Page 231: Rear Fog Lamp L.h. Drive Vehicles

    B-126 CIRCUIT DIAGRAMS REAR FOG LAMP <L.H. drive vehicles> (CONTINUED) H1J08X28BA...

  • Page 232: R.h. Drive Vehicles

    B-127 CIRCUIT DIAGRAMS REAR FOG LAMP R.H. drive vehicles H1J08X29AA...
  • Page 233 B-128 CIRCUIT DIAGRAMS REAR FOG LAMP <R.H. drive vehicles> (CONTINUED)
  • Page 234 B-129 CIRCUIT DIAGRAMS...

  • Page 235: Headlamp Leveling System

    B-130 CIRCUIT DIAGRAMS HEADLAMP LEVELING SYSTEM L.H. drive vehicles...
  • Page 236 B-131 CIRCUIT DIAGRAMS...

  • Page 237: R.h. Drive Vehicles

    B-132 CIRCUIT DIAGRAMS HEADLAMP LEVELING SYSTEM R.H. drive vehicles...
  • Page 238 B-133 CIRCUIT DIAGRAMS...
  • Page 239 B-134 CIRCUIT DIAGRAMS TURN-SIGNAL LAMP AND HAZARD WARNING LAMP L.H. drive vehicles H1J09X15AA...
  • Page 240 B-135 CIRCUIT DIAGRAMS H1J09X15AB...

  • Page 241: Turn-Signal Lamp And Hazard Warning Lamp L.h. Drive Vehicles

    B-136 CIRCUIT DIAGRAMS TURN-SIGNAL LAMP AND HAZARD WARNING LAMP <L.H. drive vehicles> (CONTINUED) H1J09X15BA...
  • Page 242 B-137 CIRCUIT DIAGRAMS H1J09X15BB...

  • Page 243: R.h. Drive Vehicles

    B-138 CIRCUIT DIAGRAMS TURN-SIGNAL LAMP AND HAZARD WARNING LAMP R.H. drive vehicles H1J09X13AA...
  • Page 244 B-139 CIRCUIT DIAGRAMS H1J09X13AB...
  • Page 245 B-140 CIRCUIT DIAGRAMS TURN-SIGNAL LAMP AND HAZARD WARNING LAMP <R.H. drive vehicles > (CONTINUED) H1J09X13BA...
  • Page 246 B-141 CIRCUIT DIAGRAMS H1J09X13BB...

  • Page 247: Back-Up Lamp

    B-142 CIRCUIT DIAGRAMS BACK-UP LAMP L.H. drive vehicles...

  • Page 248: R.h. Drive Vehicles

    B-143 CIRCUIT DIAGRAMS BACK-UP LAMP R.H. drive vehicles...

  • Page 249: Stop Lamp

    B-144 CIRCUIT DIAGRAMS STOP LAMP L.H. drive vehicles H1J09X17AA...

  • Page 250: R.h. Drive Vehicles

    B-145 CIRCUIT DIAGRAMS STOP LAMP R.H. drive vehicles H1J09X18AA...

  • Page 251: Horn

    B-146 CIRCUIT DIAGRAMS HORN...
  • Page 252 B-147 CIRCUIT DIAGRAMS METER AND GAUGE (See P.B-148,152.) OPERATION TROUBLESHOOTING HINTS 1. Fuel gauge does not operate, or registers <Fuel gauge> incorrectly. When the ignition switch is at the “ON” position, (1) The fuel gauge indicates “F” when the fuel the fuel gauge is activated.
  • Page 253 B-148 CIRCUIT DIAGRAMS METER AND GAUGE L.H. drive vehicles...
  • Page 254 B-149 CIRCUIT DIAGRAMS...

  • Page 255: Meter And Gauge L.h. Drive Vehicles

    B-150 CIRCUIT DIAGRAMS METER AND GAUGE <L.H. drive vehicles> (CONTINUED) H1J10X08BA...
  • Page 256 B-151 CIRCUIT DIAGRAMS NOTES...

  • Page 257: R.h. Drive Vehicles

    B-152 CIRCUIT DIAGRAMS METER AND GAUGE R.H. drive vehicles...
  • Page 258 B-153 CIRCUIT DIAGRAMS...
  • Page 259 B-154 CIRCUIT DIAGRAMS METER AND GAUGE <R.H. drive vehicles> (CONTINUED) H1J10X06BA...
  • Page 260 B-155 CIRCUIT DIAGRAMS FUEL WARNING LAMP (See P.B-156.) OIL PRESSURE WARNING LAMP (See P.B-157.) BRAKE WARNING LAMP (See P.B-157.) OPERATION TROUBLESHOOTING HINTS <Fuel warning lamp> 1. No warning lamps illuminate. Check multi-purpose fuse No.(2). When the ignition switch is at the “ON” position, 2.

  • Page 261: Fuel Warning Lamp

    B-156 CIRCUIT DIAGRAMS FUEL WARNING LAMP H1J10X10AA...

  • Page 262: Oil Pressure Warning Lamp

    B-157 CIRCUIT DIAGRAMS OIL PRESSURE WARNING LAMP BRAKE WARNING LAMP H1J10X10AB...
  • Page 263 B-158 CIRCUIT DIAGRAMS POWER WINDOWS L.H. drive vehicles H1J11X10AA...
  • Page 264 B-159 CIRCUIT DIAGRAMS H1J11X10AB...

  • Page 265: Power Windows L.h. Drive Vehicles

    B-160 CIRCUIT DIAGRAMS POWER WINDOWS <L.H. drive vehicles> (CONTINUED) H1J11X10BA...
  • Page 266 B-161 CIRCUIT DIAGRAMS H1J11X10BB...
  • Page 267 B-162 CIRCUIT DIAGRAMS POWER WINDOWS <L.H. drive vehicles> (CONTINUED) H1J11X10CA...
  • Page 268 B-163 CIRCUIT DIAGRAMS H1J11X10CB...

  • Page 269: R.h. Drive Vehicles

    B-164 CIRCUIT DIAGRAMS POWER WINDOWS R.H. drive vehicles H1J11X14AA...
  • Page 270 B-165 CIRCUIT DIAGRAMS H1J11X14AB...
  • Page 271 B-166 CIRCUIT DIAGRAMS POWER WINDOWS <R.H. drive vehicles> (CONTINUED) H1J11X14BA...
  • Page 272 B-167 CIRCUIT DIAGRAMS H1J11X14BB...
  • Page 273 B-168 CIRCUIT DIAGRAMS POWER WINDOWS <R.H. drive vehicles> (CONTINUED) H1J11X14CA...
  • Page 274 B-169 CIRCUIT DIAGRAMS H1J11X14CB...

  • Page 275: Central Door Locking System

    B-170 CIRCUIT DIAGRAMS CENTRAL DOOR LOCKING SYSTEM L.H. drive vehicles H1J11X12AA...
  • Page 276 B-171 CIRCUIT DIAGRAMS H1J11X12AB...

  • Page 277: R.h. Drive Vehicles

    B-172 CIRCUIT DIAGRAMS CENTRAL DOOR LOCKING SYSTEM R.H. drive vehicles H1J11X15AA...
  • Page 278 B-173 CIRCUIT DIAGRAMS H1J11X15AB...
  • Page 279 B-174 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER L.H. drive vehicles...
  • Page 280 B-175 CIRCUIT DIAGRAMS...

  • Page 281: Heater And Manual Air Conditioner L.h. Drive Vehicles

    B-176 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER <L.H. drive vehicles> (CONTINUED)
  • Page 282 B-177 CIRCUIT DIAGRAMS...
  • Page 283 B-178 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER <L.H. drive vehicles> (CONTINUED)
  • Page 284 B-179 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER (See P.B-174,180.) OPERATION TROUBLESHOOTING HINTS <Blower motor control> <Blower motor control> When the ignition switch is turned “ON”, the 1. Blower motor is energized at one switch position blower relay is energized. If the blower switch and not energized at another.

  • Page 285: R.h. Drive Vehicles

    B-180 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER R.H. drive vehicles...
  • Page 286 B-181 CIRCUIT DIAGRAMS...
  • Page 287 B-182 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER <R.H. drive vehicles> (CONTINUED)
  • Page 288 B-183 CIRCUIT DIAGRAMS...
  • Page 289 B-184 CIRCUIT DIAGRAMS HEATER AND MANUAL AIR CONDITIONER <R.H. drive vehicles> (CONTINUED)

  • Page 290: Defogger

    B-185 CIRCUIT DIAGRAMS DEFOGGER H1J13X19AA...
  • Page 291 B-186 CIRCUIT DIAGRAMS WINDSHIELD WIPER AND WASHER L.H. drive vehicles...
  • Page 292 B-187 CIRCUIT DIAGRAMS...

  • Page 293: Windshield Wiper And Washer L.h. Drive Vehicles

    B-188 CIRCUIT DIAGRAMS WINDSHIELD WIPER AND WASHER <L.H. drive vehicles> (CONTINUED) H1J13X17BA...

  • Page 294: R.h. Drive Vehicles

    B-189 CIRCUIT DIAGRAMS WINDSHIELD WIPER AND WASHER R.H. drive vehicles H1J13X16AA...
  • Page 295 B-190 CIRCUIT DIAGRAMS WINDSHIELD WIPER AND WASHER <R.H. drive vehicles> (CONTINUED)
  • Page 296 B-191 CIRCUIT DIAGRAMS...

  • Page 297: Remote Controlled Mirror

    B-192 CIRCUIT DIAGRAMS REMOTE CONTROLLED MIRROR L.H. drive vehicles H1J13X22AA...

  • Page 298: R.h. Drive Vehicles

    B-193 CIRCUIT DIAGRAMS REMOTE CONTROLLED MIRROR R.H. drive vehicles H1J13X21AA...

  • Page 299: Clock

    B-194 CIRCUIT DIAGRAMS CLOCK H1J14X12AA...

  • Page 300: Cigarette Lighter And Ashtray Illumination Lamp

    B-195 CIRCUIT DIAGRAMS CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LAMP H1J14X13AA...

  • Page 301: Audio System

    B-196 CIRCUIT DIAGRAMS AUDIO SYSTEM...
  • Page 302 B-197 CIRCUIT DIAGRAMS...

  • Page 303: L.h. Drive Vehicles

    B-198 CIRCUIT DIAGRAMS L.H. drive vehicles...
  • Page 304 B-199 CIRCUIT DIAGRAMS...
  • Page 305 B-200 CIRCUIT DIAGRAMS ABS <L.H. drive vehicles> (CONTINUED)
  • Page 306 B-201 CIRCUIT DIAGRAMS...
  • Page 307 B-202 CIRCUIT DIAGRAMS ABS <L.H. drive vehicles> (CONTINUED) H1J15X28CA...
  • Page 308 B-203 CIRCUIT DIAGRAMS H1J15X28CB...
  • Page 309 B-204 CIRCUIT DIAGRAMS ABS <L.H. drive vehicles> (CONTINUED)

  • Page 310: R.h. Drive Vehicles

    B-205 CIRCUIT DIAGRAMS R.H. drive vehicles...
  • Page 311 B-206 CIRCUIT DIAGRAMS ABS <R.H. drive vehicles> (CONTINUED)
  • Page 312 B-207 CIRCUIT DIAGRAMS...
  • Page 313 B-208 CIRCUIT DIAGRAMS ABS <R.H. drive vehicles> (CONTINUED)
  • Page 314 B-209 CIRCUIT DIAGRAMS...
  • Page 315 B-210 CIRCUIT DIAGRAMS ABS <R.H. drive vehicles> (CONTINUED) H1J15X42DA...
  • Page 316 B-211 CIRCUIT DIAGRAMS H1J15X42DB...

  • Page 317: Acd

    B-212 CIRCUIT DIAGRAMS Vehicles without AYC <L.H. drive vehicles>...
  • Page 318 B-213 CIRCUIT DIAGRAMS...
  • Page 319 B-214 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (L.H. drive vehicles)> (CONTINUED)
  • Page 320 B-215 CIRCUIT DIAGRAMS...
  • Page 321 B-216 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (L.H. drive vehicles)> (CONTINUED)
  • Page 322 B-217 CIRCUIT DIAGRAMS H1J15X30CB...
  • Page 323 B-218 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (L.H. drive vehicles)> (CONTINUED) H1J15X30DA...
  • Page 324 B-219 CIRCUIT DIAGRAMS H1J15X30DB...

  • Page 325: Vehicles Without Ayc

    B-220 CIRCUIT DIAGRAMS Vehicles without AYC <R.H. drive vehicles>...
  • Page 326 B-221 CIRCUIT DIAGRAMS...
  • Page 327 B-222 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (R.H. drive vehicles)> (CONTINUED)
  • Page 328 B-223 CIRCUIT DIAGRAMS...
  • Page 329 B-224 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (R.H. drive vehicles)> (CONTINUED)
  • Page 330 B-225 CIRCUIT DIAGRAMS...
  • Page 331 B-226 CIRCUIT DIAGRAMS ACD <Vehicles without AYC (R.H. drive vehicles)> (CONTINUED) H1J15X43DA...
  • Page 332 B-227 CIRCUIT DIAGRAMS H1J15X43DB...
  • Page 333 B-228 CIRCUIT DIAGRAMS ACD AND AYC L.H. drive vehicles...
  • Page 334 B-229 CIRCUIT DIAGRAMS...

  • Page 335: Acd And Ayc L.h. Drive Vehicles

    B-230 CIRCUIT DIAGRAMS ACD AND AYC <L.H. drive vehicles> (CONTINUED)
  • Page 336 B-231 CIRCUIT DIAGRAMS...
  • Page 337 B-232 CIRCUIT DIAGRAMS ACD AND AYC <L.H. drive vehicles> (CONTINUED) H1J15X32CA...
  • Page 338 B-233 CIRCUIT DIAGRAMS H1J15X32CB...
  • Page 339 B-234 CIRCUIT DIAGRAMS ACD AND AYC <L.H. drive vehicles> (CONTINUED) H1J15X32DA...
  • Page 340 B-235 CIRCUIT DIAGRAMS H1J15X32DB...
  • Page 341 B-236 CIRCUIT DIAGRAMS ACD AND AYC <L.H. drive vehicles> (CONTINUED)
  • Page 342 B-237 CIRCUIT DIAGRAMS...

  • Page 343: R.h. Drive Vehicles

    B-238 CIRCUIT DIAGRAMS ACD AND AYC R.H. drive vehicles...
  • Page 344 B-239 CIRCUIT DIAGRAMS...
  • Page 345 B-240 CIRCUIT DIAGRAMS ACD AND AYC <R.H. drive vehicles> (CONTINUED)
  • Page 346 B-241 CIRCUIT DIAGRAMS...
  • Page 347 B-242 CIRCUIT DIAGRAMS ACD AND AYC <R.H. drive vehicles> (CONTINUED) H1J15X44CA...
  • Page 348 B-243 CIRCUIT DIAGRAMS H1J15X44CB...
  • Page 349 B-244 CIRCUIT DIAGRAMS ACD AND AYC <R.H. drive vehicles> (CONTINUED) H1J15X44DA...
  • Page 350 B-245 CIRCUIT DIAGRAMS H1J15X44DB...
  • Page 351 B-246 CIRCUIT DIAGRAMS ACD AND AYC <R.H. drive vehicles> (CONTINUED)
  • Page 352 B-247 CIRCUIT DIAGRAMS...

  • Page 353: Supplemental Restraint System (Srs) And Seat Belt Pretensioner

    B-248 CIRCUIT DIAGRAMS SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT PRETENSIONER L.H. drive vehicles...
  • Page 354 B-249 CIRCUIT DIAGRAMS...

  • Page 355: R.h. Drive Vehicles

    B-250 CIRCUIT DIAGRAMS SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT PRETENSIONER R.H. drive vehicles...
  • Page 356 B-251 CIRCUIT DIAGRAMS...

  • Page 357: Immobilizer System

    B-252 CIRCUIT DIAGRAMS IMMOBILIZER SYSTEM L.H. drive vehicles H1J15X26AA...
  • Page 358 B-253 CIRCUIT DIAGRAMS H1J15X26AB...

  • Page 359: R.h. Drive Vehicles

    B-254 CIRCUIT DIAGRAMS IMMOBILIZER SYSTEM R.H. drive vehicles H1J15X25AA...
  • Page 360 B-255 CIRCUIT DIAGRAMS H1J15X25AB...

  • Page 361: Intercooler Water Splay

    B-256 CIRCUIT DIAGRAMS INTERCOOLER WATER SPLAY...
  • Page 362 B-257 CIRCUIT DIAGRAMS...

  • Page 363: Spare Connector

    B-258 CIRCUIT DIAGRAMS SPARE CONNECTOR (FOR FRONT FOG LAMP) H1J15X47AA...
  • Page 364 HOW TO READ THE WIRING DIAGRAMS CONTENTS COMPOSITION AND CONTENTS OF WIRING MARKING FOR CONNECTOR EARTHING . . . DIAGRAMS ....... . WIRE COLOUR CODES .
  • Page 365 HOW TO READ THE WIRING DIAGRAMS - Composition and Contents of Wiring Diagrams COMPOSITION AND CONTENTS OF WIRING DIAGRAMS (1) This manual consists of wiring harness diagrams, installation locations of individual parts, circuits diagrams and index. (2) In each section, all specifications are listed, including optional specifications. Accordingly, some specifications may not be applicable for individual vehicles.
  • Page 366 HOW TO READ THE WIRING DIAGRAMS - How to Read Configuration Diagrams HOW TO READ CONFIGURATION DIAGRAMS The wiring harness diagrams clearly show the connector locations and harness routings at each site on actual vehicles. Denotes connector No. The same connector No. is used throughout the circuit diagrams to facilitate connector location searches.
  • Page 367 HOW TO READ THE WIRING DIAGRAMS - How to Read Circuit Diagrams HOW TO READ CIRCUIT DIAGRAMS The circuit of each system from fuse (or fusible link) to earth is shown. The power supply is shown at the top and the earth at the bottom to facilitate understanding of the current flow. Indicates connector No.
  • Page 368 HOW TO READ THE WIRING DIAGRAMS - How to Read Circuit Diagrams Indicates input/output to/from Indicates a wiring connector which is inside control unit (current flow direction). the equipment and which is not shown in the wiring harness configuration diagram. Input/ Input Output...
  • Page 369 HOW TO READ THE WIRING DIAGRAMS - Markings for Connector Earthing MARKINGS FOR CONNECTOR EARTHING...
  • Page 370 HOW TO READ THE WIRING DIAGRAMS - Markings for Connector Earthing Item Connector/Earthing Symbol Contents Connector The male and female terminals are Male connector Male terminal and terminal indicated as shown. The connector marking with male terminal(s) is called as male connector and indicated by double connector contour linens, while the connector with female...
  • Page 371 HOW TO READ THE WIRING DIAGRAMS - Markings for Connector Earthing Item Connector/Earthing Symbol Contents Connector Direct connection type A connection between a device connection and connector on the harness side marking is either by direct insertion in the device (direct connection type) or by connection with a harness connector on the device side furnished...

  • Page 372: Wire Colour Codes

    HOW TO READ THE WIRING DIAGRAMS - Wire Colour Codes WIRE COLOUR CODES Wire colours are identified by the follow colour codes. Code Wire colour Code Wire colour Black Pink Brown Green Sky blue Gray Silver Blue Violet Light green White Orange Yellow...
  • Page 373 A-10 HOW TO READ THE WIRING DIAGRAMS - Abbreviation Symbols ABBREVIATION SYMBOLS The abbreviation symbols used in wiring diagrams are defined below. 1. Abbreviation symbols used for system name Abbreviation Meaning Abbreviation Meaning symbols symbols Air conditioner Exhaust gas recirculation Anti-skid braking system ETACS Electronic time alarm control system...
  • Page 374 A-11 HOW TO READ THE WIRING DIAGRAMS - HOW TO READ THE WIRING DIAGRAMS - Abbreviation Symbols Abbreviation Symbols Name of switches and Abbreviation Operation relays symbols Dimmer passing Low beams ON switch switch High beams ON PASS Door lock actuator LOCK Door lock UNLOCK...
  • Page 375 A-12 HOW TO READ THE WIRING DIAGRAMS - Abbreviation Symbols Name of switches and Abbreviation Operation relays symbols Windshield wiper MIST Wiper operates once switch switch Wiper operates intermittently Wiper operates at low speed Wiper operates at high speed 4. Other abbreviation symbols Abbreviation Meaning Abbreviation...
  • Page 376 ELECTRICAL WIRING CONTENTS HOW TO READ THE WIRING DIAGRAMS ....... . . ELECTRICAL WIRING .
  • Page 377 NOTES...
  • Page 378 55-1 HEATER, AIR CONDITIONER AND VENTILATION CONTENTS SERVICE SPECIFICATIONS ....Condenser Fan Relay (LO) Check ... . . Condenser Fan Relay (HI) Check .

  • Page 379: Special Tools

    Service Specifications/Lubricants/ 55-2 HEATER, AIR CONDITIONER AND VENTILATION Special Tools SERVICE SPECIFICATIONS Item Standard value Idli Idling speed (rpm): N or P range Idling speed (rpm): N or P range Idling speed (rpm): N or P range 850 ± 50 850 ±...

  • Page 380: Troubleshooting

    55-3 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION TROUBLESHOOTING BASIC FLOW OF TROUBLESHOOTING Refer to Group 00 – How to Use Troubleshooting/Inspection Service Points. INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection procedure Reference page Air conditioner not working at all 55 - 3 Blower motor not working 55 - 4...
  • Page 381 55-4 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION Inspection procedure 2 Blower motor not working Probable cause If the blower motor does not work, the blower motor circuit system may be D Blower motor fault defective. D Harness or connector fault D A/C-ECU fault Check the blower relay.
  • Page 382 55-5 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION From the previous page (1) NG Measure at the blower motor connector C-14. Check the following connectors: C-215, C-210, C-131, C-14. D Disconnect the connector and measure at the harness side. D Ignition switch: ON Repair Check the trouble (2) NG...
  • Page 383 55-6 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION Inspection procedure 4 Rear defogger not working Probable cause If the rear window defogger does not work even though the rear defogger switch D Defogger relay fault is ON (a 20-minute timer operates), the defogger relay system may be defective. D Harness or connector fault D A/C-ECU fault Check the defogger (Refer to Group 54A –...
  • Page 384 55-7 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION Inspection procedure 5 Cold air not coming out from the air outlet Probable cause If cold air does not come out from the air outlet, the amount of refrigerant may D Refrigerant line fault be inappropriate or the compressor circuit system may be defective.
  • Page 385 55-8 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION From the previous page Check the following connectors: C-32, C-111, A-36. Repair Check the trouble symptoms. Check the harness between the dual pressure switch and the Repair A/C-ECU. Check the following connectors: <L.H.D.> A-36, C-111, C-130, C-122, C-32. <R.H.D.>...
  • Page 386 55-9 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION Inspection procedure 7 Condenser fan not working at all Probable cause If the condenser fan does not work at all, the condenser fan circuit system may D Condenser fan motor fault be defective. D Harness or connector fault D Engine-ECU fault Check the condenser fan motor.
  • Page 387 55-10 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION Inspection procedure 8 Condenser fan not working only for LO Probable cause If the condenser fan does not work only for LO, the condenser fan circuit D Condenser fan motor fault system or the condenser fan relay (LO) circuit system may be defective. D Condenser fan relay (LO) fault D Harness or connector fault D Engine-ECU fault...
  • Page 388 55-11 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION Inspection procedure 9 Condenser fan not working only for HI Probable cause If the condenser fan does not work only for HI, the condenser fan circuit system D Condenser fan motor fault or the condenser fan relay (HI) circuit system may be defective. D Condenser fan relay (HI) fault D Harness or connector fault D Engine-ECU fault...
  • Page 389 55-12 Troubleshooting Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION HEATER, AIR CONDITIONER AND VENTILATION CHECK AT THE ENGINE-ECU TERMINAL Terminal no. Check item Check when Normal state Radiator fan: ON 0 - 0.3 V Fan controller output Radiator fan: OFF 0.7 V or more A/C compressor output A/C compressor relay: OFF A/C compressor relay: ON...
  • Page 390 55-13 Troubleshooting HEATER, AIR CONDITIONER AND VENTILATION Termi- Check item Check when Normal state nal no. Ignition switch (IG2) power supply Ignition switch: ON Battery voltage Illumination earth Any time Earth Any time Air thermo sensor When temperature around sensor 25_C (1.5kΩ) 2.2 V Air thermo sensor earth Any time...

  • Page 391: Performance Test

    55-14 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service ON-VEHICLE SERVICE Sufficient or excess Insufficient refrigerant refrigerant REFRIGERANT LEVEL TEST THROUGH Bubbles PERFORMANCE TEST 1. Start the engine. 2. Turn on the A/C switch, and set the A/C control to MAX. COOL.

  • Page 392: Compressor Drive Belt Adjustment

    55-15 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service COMPRESSOR DRIVE BELT ADJUSTMENT Refer to GROUP 11 - On-vehicle Service. DUAL PRESSURE SWITCH CHECK Hood support rod 1. Remove the dual pressure switch connector and connect the high/low pressure side terminals located on the Dual pressure switch harness side as shown in the illustration.
  • Page 393 55-16 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service CHARGING 1. With the handles turned back all the way (valve closed), install the adaptor valve to the low-pressure side of the High-pressure Low-pressure gauge manifold. valve valve 2. Connect the charging hose (blue) to the adaptor valve. 3.
  • Page 394 55-17 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service 12. Turn the vacuum pump adaptor switch to the R134a side to start the vacuum pump. Caution Do not operate the compressor for evacuation. 13. Evacuate to a vacuum reading of 100 kPa or higher (takes approx.
  • Page 395 55-18 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service 24. Fix the engine speed at 1,500 r/min. 25. Tighten the handle of the adaptor valve (valve open) to charge the required volume of refrigerant. Caution If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression.

  • Page 396: Discharging System

    55-19 – – HEATER, AIR CONDITIONER AND VENTILATION HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service On-vehicle Service 8. Start the engine. 9. Operate the air conditioner and set at the lowest Charging valve temperature (MAX. COOL). 10. Fix the engine speed at 1,500 r/min. 11.
  • Page 397 55-20 – – HEATER, AIR CONDITIONER AND VENTILATION HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service On-vehicle Service PERFORMANCE TEST 1. The vehicles to be tested should be in a place that is Low-pressure valve High-pressure valve not in direct sunlight. 2.

  • Page 398: Refrigerant Leak Repair

    55-21 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service REFRIGERANT LEAK REPAIR HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in LOST CHARGE the refrigerant hose lines will greatly reduce the If the system has lost all charge due to a leak: capacity of the entire system.

  • Page 399: Blower Relay Continuity Check

    55-22 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service BLOWER RELAY CONTINUITY CHECK <L.H. drive vehicle> System voltage Terminal No. When current is not supplied When current is supplied Blower fan relay <R.H. drive vehicle> Blower relay A/C COMPRESSOR RELAY CONTINUITY CHECK A/C compressor relay System voltage Terminal No.

  • Page 400: Condenser Fan Relay (Hi) Check

    55-23 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service CONDENSER FAN RELAY (LO) CHECK Condenser fan relay (LO) System voltage Terminal No. When current is not supplied When current is supplied CONDENSER FAN RELAY (HI) CHECK Condenser fan relay (HI) System voltage Terminal No.
  • Page 401 55-24 – HEATER, AIR CONDITIONER AND VENTILATION On-vehicle Service IDLE-UP OPERATION CHECK 1. Set the vehicle in the pre-inspection condition: Engine coolant temperature: 80 – 90 _C Lamps, electric cooling fan and all accessories: OFF 2. Check that the idle speed is within the standard value. Standard value: 850 ±...

  • Page 402: Removal And Installation

    Heater Control Assembly 55-25 HEATER, AIR CONDITIONER AND VENTILATION (A/C-ECU) and A/C Switch HEATER CONTROL ASSEMBLY (A/C-ECU) AND A/C SWITCH REMOVAL AND INSTALLATION Removal steps "BA 1. Air mix door cable connection 4. Air volume adjustment knob "AA 2. Blow vent switching damper cable con- 5.
  • Page 403 Heater Control Assembly 55-26 HEATER, AIR CONDITIONER AND VENTILATION (A/C-ECU) and A/C Switch A AIR MIX DOOR CABLE CONNECTION " <R.H. drive vehicles> MAX.COOL posirion 1. Turn the heater control assembly’s temperatureadjust- ment knob all the way to the HOT side. 2.
  • Page 404 Heater Control Assembly 55-27 HEATER, AIR CONDITIONER AND VENTILATION (A/C-ECU) and A/C Switch DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Switch panel 6. Air mix damper cable AA" 2. Rear window defogger switch 7. Blower switch assembly 3. Air conditioner switch 8.

  • Page 405: Heater Unit And Blower Assembly

    55-28 HEATER, AIR CONDITIONER AND VENTILATION Heater Unit and Blower Assembly HEATER UNIT AND BLOWER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Refrigerant Draining and Refilling (Refer to P.55-16, 19.) Coolant Draining and Refilling (Refer to GROUP 14 – On - vehicle Service.) Instrument Panel Removal and Installation (Refer to GROUP 52A –...
  • Page 406 55-29 HEATER, AIR CONDITIONER AND VENTILATION eater Unit and Blower Assembly DISASSEMBLY AND REASSEMBLY <L.H. DRIVE VEHICLES> Disassembly steps 1. Right-hand foot duct 7. Evaporator 2. Left-hand foot duct 8. Air thermo sensor clip 3. Evaporator cover 9. Air thermo sensor 4.
  • Page 407 55-30 HEATER, AIR CONDITIONER AND VENTILATION eater Unit and Blower Assembly <R.H. DRIVE VEHICLES> Disassembly steps 1. Right-hand foot duct 6. Heater core 2. Left-hand foot duct 7. Expansion valve 3. Left-hand foot duct 8. Evaporator <Rear duct mounted vehicle> 9.
  • Page 408 55-31 HEATER, AIR CONDITIONER AND VENTILATION Heater Unit and Blower Assembly DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Joint duct 4. Hose 2. Resister 5. Blower motor 3. Inside/outside air changeover damper 6. Blower case motor...
  • Page 409 55-32 Resister, Blower Motor, Inside/outside HEATER, AIR CONDITIONER AND VENTILATION Air Changeover Damper Motor RESISTER, BLOWER MOTOR AND INSIDE/OUTSIDE AIR CHANGE OVER DAMPER MOTOR REMOVAL AND INSTALLATION Resister removal steps Inside/outside air changeover damper motor removal steps D Glove box (Refer to GROUP 52A – Instrument Panel.) D Glove box (Refer to GROUP 52A –...
  • Page 410 55-33 Resister, Blower Motor, Inside/outside HEATER, AIR CONDITIONER AND VENTILATION Air Changeover Damper Motor INSPECTION Resister Check Standard values: Test terminals Standard value (Ω) HI - LO (between terminals 2 and 4) 2.54 HI - ML (between terminals 2 and 1) 1.24 HI - MH (between terminals 2 and 3) Blower Motor Check...

  • Page 411: Evaporator And Air Thermo Sensor

    55-34 HEATER, AIR CONDITIONER AND VENTILATION Evaporator and Air Thermo Sensor EVAPORATOR AND AIR THERMO SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Refrigerant Draining and Refilling (Refer to P.55-16, 19.) 12 ± 2 N·m - Pipe coupling O-ring 1, 2 A/C compressor oil: SUN PAG 56 Disassembly steps...
  • Page 412 55-35 HEATER, AIR CONDITIONER AND VENTILATION Evaporator, Air Thermo Sensor AB" EVAPORATOR REMOVAL Dashboard pad <R.H. DRIVE VHEICLESE> 1. When removing the evaporator, cut and fold back the dashboard pad as in the diagram. (The thickness of the pad interferes with the removal of the evaporator.) 2.
  • Page 413 55-36 Compressor HEATER, AIR CONDITIONER AND VENTILATION COMPRESSOR REMOVAL AND INSTALLATION Before Removal After Removal Refrigerant Draining (Refer to P.55-19.) Refrigerant Replenishing (Refer to P.55-16.) Drive Belt Tension Check (Refer to GROUP 11A – Engine Adjustment.) - Pipe coupling 1, 2 O ring A/C compressor oil: SUN PAG 56...
  • Page 414 55-37 Compressor HEATER, AIR CONDITIONER AND VENTILATION AB"DRIVE BELT REMOVAL Due to the adoption of the Serpentine drive system with the automatic tensioner, the following operation is required for removing the drive belt: 1. Insert the 12.7sq. spinner handle into the tool hole of the automatic tensioner and rotate it counterclockwise until the automatic tensioner reaches to the stopper.
  • Page 415 55-38 Compressor Compressor HEATER, AIR CONDITIONER AND VENTILATION HEATER, AIR CONDITIONER AND VENTILATION DISASSEMBLY AND REASSEMBLY 16 ± 1 N·m Cooling temperature switch AA" "CA 3. Self-locking nut dismantling steps 4. Armature 5. Shim 1. Snap ring "BA 6. Snap ring 2.
  • Page 416 55-39 Compressor HEATER, AIR CONDITIONER AND VENTILATION "BA SNAP RING INSTALLATION Field core Rotor Using snap ring pliers, fit the snap ring so that the snap Snap ring ring’s tapered part is on the outside. "CA SELF-LOCKING NUT INSTALLATION Using a special tool, as when removing the nut, secure the armature and tighten the self-locking nut.
  • Page 417 Condenser Assembly and 55-40 HEATER, AIR CONDITIONER AND VENTILATION Condenser Fan Assembly CONDENSER ASSEMBLY AND CONDENSER FAN ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Refrigerant Draining and Refilling (Refer to P.55-16, 19.) D Front Bumper Removal and Installation (Refer to GROUP 51.) Pipe coupling 0.9 N m 5, 6...
  • Page 418 Condenser Assembly and 55-41 HEATER, AIR CONDITIONER AND VENTILATION Condenser Fan Assembly AB" FLEXIBLE DISCHARGE HOSE AND LIQUID PIPE A DISCONNECTION To prevent the entry of dust or other foreign objects, plug the dismantled hose and condenser assembly nipples. Caution As the compressor oil and receiver are highly moisture absorbent, use a non - porous material to plug the hose and nipples.

  • Page 419: Refrigerant Lines

    55-42 Refrigerant Lines HEATER, AIR CONDITIONER AND VENTILATION REFRIGERANT LINES REMOVAL AND INSTALLATION <L.H. DRIVE VEHICLES> Pre-removal and Post-installation Operations Refrigerant Draining and Refilling (Refer to P.55-16, 19.). Radiator Grille Removal and Installation (Refer to GROUP 51.) Air Cleaner Removal and Installation (Refer to GROUP 15.) 13 ±...
  • Page 420 55-43 Refrigerant Lines HEATER, AIR CONDITIONER AND VENTILATION REMOVAL AND INSTALLATION <R.H. DRIVE VEHICLES> Pre-removal and Post-installation Operations Refrigerant Draining and Refilling (Refer to P.55-16, 19.) Radiator Grille Removal and Installation (Refer to GROUP 51.) Air Cleaner Removal and Installation (Refer to GROUP 15.) - Pipe 13 ±...
  • Page 421 55-44 Ducts HEATER, AIR CONDITIONER AND VENTILATION DUCTS REMOVAL AND INSTALLATION Cross-section A - A Clip Instrument panel Air outlet removal steps 5. Defroster nozzle 6. Distribution duct 1. Center air outlet panel 2. Center air outlet Foot duct removal step 3.
  • Page 422 55-45 Ventilation HEATER, AIR CONDITIONER AND VENTILATION VENTILATION REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Rear Bumper Removal and Installation (Refer to GROUP 51.) Cross-section A - A Claw Cross-section B - B Claw 1. Rear ventilation duct RJAK104003 - 1094...
  • Page 423 NOTES...
  • Page 424 54A-1 CHASSIS ELECTRICAL CONTENTS CHASSIS ELECTRICAL ........SMART WIRING SYSTEM (SWS) .
  • Page 425 54A-2 CHASSIS ELECTRICAL CONTENTS ......Speedometer Check ..... . BATTERY Tachometer Check .
  • Page 426 54A-3 SIDE TURN-SIGNAL LAMP ... . SPECIAL TOOL ......HAZARD WARNING LAMP SWITCH .

  • Page 427: Battery

    54A-4 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Battery Battery BATTERY SERVICE SPECIFICATION Item Specification Specific gravity of the battery fluid 1.220 - 1.290 [20_C] ON-VEHICLE SERVICE FLUID LEVEL AND SPECIFIC GRAVITY CHECK Good 1. Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks.

  • Page 428: Battery Testing Procedure

    54A-5 CHASSIS ELECTRICAL - Battery Caution 1. The battery plugs should be removed during charging. 2. The battery electrolyte level may rise and overflow from the battery during charging. 3. Explosions may occur if the battery is brought close to naked flames during charging. 4.

  • Page 429: Ignition Switch And Immobilizer System

    54A-6 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System IGNITION SWITCH AND IMMOBILIZER SYSTEM SPECIAL TOOLS Tool Number Name MB991502 MUT-II Sub as- Checking the immobilizer system sembly MB990784 Ornament remover Instrument panel under cover and column cover removal TROUBLESHOOTING IGNITION SWITCH The ignition switch is controlled by the Smart Wiring System (SWS).

  • Page 430: Chassis Electrical

    54A-7 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE Code No. 11 Problem related to communication with the Probable cause ignition key When the ignition switch is at the ON position, the encrypted codes are not D Malfunction of ignition key transmitted from the ignition key to the immobilizer-ECU.
  • Page 431 54A-8 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS Inspection procedure 1 Diagnosis code No.1610 is generated by the Probable cause engine-ECU. The cause is probably a problem with communication between the engine-ECU D Malfunction of harness or connector and the immobilizer-ECU.
  • Page 432 54A-9 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System Inspection procedure 2 The ignition keys cannot be registered using the MUT-II. Probable cause The ignition key has not been registered with the immobilizer-ECU. Or that there D Malfunction of ignition key is a problem with the immobilizer-ECU.

  • Page 433: Immobilizer-Ecu Check

    54A-10 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System Inspection procedure 4 Immobilizer-ECU power supply and earth circuit system check (1) NG Check the following connectors: Measure at immobilizer-ECU connector C-202-1. <L.H. drive vehicles> C-202 - 1, C-202, C-129, D-108 D Ignition switch: ON <R.H.

  • Page 434: Ignition Switch

    54A-11 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System IGNITION SWITCH REMOVAL AND INSTALLATION Removal steps 1. Lower column cover (Refer to GROUP 5. Steering lock cylinder AA" 52A - Instrument Panel.) 6. Ignition switch 2. Upper column cover (Refer to GROUP 7.
  • Page 435 54A-12 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System INSPECTION IGNITION SWITCH CONTINUITY CHECK With ignition switch installed on the vehicle, disconnect ignition switch connector for inspection. Ignition key Terminal No. position LOCK START KEY REMINDER SWITCH CONTINUITY CHECK With key reminder switch installed on the vehicle, disconnect key reminder switch connector for inspection.
  • Page 436 54A-13 CHASSIS ELECTRICAL - Ignition Switch and Immobilizer System ENCRYPTED CODE REGISTRATION METHOD If using an ignition key that has just been newly purchased, or if the immobilizer-ECU has been replaced, you will need to register the encrypted codes for each ignition key being used into the immobilizer-ECU.

  • Page 437: Combination Meter

    54A-14 CHASSIS ELECTRICAL - Combination Meter COMBINATION METER Caution Never remove pointer of combination meter. This may cause damage of combination meter. SERVICE SPECIFICATIONS Item Standard value Limit value At 40 km/h 37 - 45 – Indication range of speedometer km/h At 80 km/h 75 - 88 –...

  • Page 438: Special Tools

    54A-15 CHASSIS ELECTRICAL - Combination Meter SPECIAL TOOLS Tools Number Name MB991223 Harness set Brief test for fuel gauge and water temperature gauge A: MB991219 A: Inspection har- B: MB991220 ness A: For inspection of connector pin contact C: MB991221 B: LED Harness pressure D: MB991222...
  • Page 439 54A-16 CHASSIS ELECTRICAL - Combination Meter INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection procedure 1 Speedometer inoperative (other meters are operated) Probable cause Failure may occur on engine-ECU system, harnesses, connectors, meter D Engine-ECU fault assembly. D Harness or connector fault D Meter assembly fault MUT-II Self-Diag.
  • Page 440 54A-17 CHASSIS ELECTRICAL - Combination Meter Inspection procedure 3 Fuel gauge inoperative (other meters are operated) Probable cause When speedometer and tachometer are properly operated, harness from power D Fuel gauge unit fault source to combination meter is normal. D Harness or connector fault D Meter assembly fault Replace main fuel gauge unit.
  • Page 441 54A-18 CHASSIS ELECTRICAL - Combination Meter Inspection procedure 4 Water temperature gauge inoperative (other meters are Probable cause operated) When speedometer and tachometer are properly operated, harness from power D Water temperature gauge unit fault source to combination meter is normal. D Harness or connector fault D Meter assembly fault Check water temperature gauge circuit.

  • Page 442: On-Vehicle Service

    54A-19 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Combination Meter Combination Meter Inspection procedure 5 All meters inoperative Probable cause When individual indicators and warning lamps are properly operated, harness D Meter assembly fault from power source (IG1) to combination meter is normal. D Harness or connector fault Check the following connectors: Repair...

  • Page 443: Tachometer Check

    54A-20 CHASSIS ELECTRICAL - Combination Meter TACHOMETER CHECK Engine speed indicator Paper clip 1. Insert paper clip (Zem clip) from harness side of the probe for detection of engine speed to connect engine speed indicator. 2. Compare measured values of individual engine speed Probe for detection of engine speed with tachometer values, and ensure that indication...

  • Page 444: Engine Coolant Temperature Gauge Unit Check

    54A-21 CHASSIS ELECTRICAL - Combination Meter FLOAT HEIGHT OF FUEL GAUGE UNIT Main fuel gauge unit When float is moved to contact float arm on stopper, ensure that Position F (A) and E (B) are within standard value. Standard Value: Float Position Float Position Main fuel gauge unit...

  • Page 445: Combination Meter

    54A-22 CHASSIS ELECTRICAL - Combination Meter COMBINATION METER REMOVAL AND INSTALLATION Removal steps 1. Meter bezel 2. Instrument panel ornament 3. Combination meter INSPECTION COMBINATION METER INTERNAL RESISTANCE CHECK Use circuit tester to measure combination meter internal resistance. Standard Value: Measuring Terminal name Standard...
  • Page 446 54A-23 CHASSIS ELECTRICAL - Combination Meter DISASSEMBLY AND REASSEMBLY Disassembly step 1. Glass 4. Bulb 2. Window plate 5. Meter assembly 3. Circuit board cover...

  • Page 447: Headlamp Assembly

    Outer lens surface should not be rubbed with a sharp-edged tool, etc. Specified wax remover should be used for insistently washing. Authorized Mitsubishi Genuine bulbs should be used. TROUBLESHOOTING Headlamps are controlled smart wiring system (SWS). For troubleshooting, refer to GROUP 54B.
  • Page 448 54A-25 CHASSIS ELECTRICAL - Headlamp Assembly 4. If the fuel tank is not full, place a weight in luggage room of vehicle to simulate weight of a full tank 0.8 kg per litre. 5. There should be no other load in the vehicle other than driver or substituted weight of approximately 75 kg placed in driver’s position.
  • Page 449 54A-26 CHASSIS ELECTRICAL - Headlamp Assembly Limit: (Vertical direction) ± 0.29_ (Horizontal direction) ± 0.5_ NOTE The illustration shows L.H. drive vehicles. For R.H. drive vehicles, it is symmetrical. 3. Alternately turn the adjusting screw to adjust the headlamp Horizontal low beam aiming.
  • Page 450 54A-27 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Headlamp Assembly Headlamp Assembly 2. Check if the high beam shining onto the screen is at the standard value. Lamp centre Standard value: (Vertical and horizontal direction) The center of high intensity zone is on the point of intersection of line (H) and line (V).

  • Page 451: Headlamp Intensity Measurement

    54A-28 CHASSIS ELECTRICAL - Headlamp Assembly HEADLAMP INTENSITY MEASUREMENT 1. Using a photometer, and following its manufacture’s instruction manual. 2. Maintain an engine speed of 2,000 r/min., with the battery in the charging condition 3. Set the headlamps to high beam 4.

  • Page 452: Headlamp Bulb (High Beam)Replacement

    54A-29 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Headlamp Assembly Headlamp Assembly Headlamp Assembly HEADLAMP BULB (HIGH BEAM)REPLACEMENT (1) Disconnect battery. (2) Disconnect connector. (3) Screw out socket to pull out bulb. (4) After bulb is replaced, properly reconnect connector. Caution Do not touch bulb surface bare-handed or with dirty Headlamp bulb...

  • Page 453: Headlamp Assembly

    54A-30 CHASSIS ELECTRICAL - CHASSIS ELECTRICAL - Headlamp Assembly Headlamp Assembly HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION AY2103AU 1. Headlamp leveling switch 2. Air guide panel 3. Headlamp assembly Headlamp removal steps D Front bumper (Refer to GROUP 51) INSPECTION HEADLAMP LEVELING SWITCH CONTINUITY CHECK Switch Position Resistance between the termi- nal 4 and 5 (Ω)

  • Page 454: Side Turn-Signal Lamp

    54A-31 CHASSIS ELECTRICAL - Side Turn-signal Lamp/Room Lamp SIDE TURN-SIGNAL LAMP SPECIAL TOOL Tools Number Name MB990784 Ornament remover Side turn-signal lamp removal SIDE TURN-SIGNAL LAMP REMOVAL SERVICE POINT MB990784 Use special tool, etc. to press and deflect hook to vehicle Side turn-signal lamp front from fender, and unhook the pawls to remove side turn-signal lamp.

  • Page 455: Rear Combination Lamp

    54A-32 CHASSIS ELECTRICAL Rear Combination Lamp REAR COMBINATION LAMP SPECIAL TOOL Tool Number Name MB990784 Ornament remover Rear combination lamp removal TROUBLESHOOTING For troubleshooting on rear combination lamps, refer to GROUP 54B. REAR COMBINATION LAMP REMOVAL AND INSTALLATION 1. Rear fog lamp switch Removal steps 2.
  • Page 456 54A-33 CHASSIS ELECTRICAL Rear Combination Lamp INSPECTION REAR FOG LAMP SWITCH CONTINUITY CHECK Switch position Terminal No. REAR FOG LAMP RELAY CONTINUITY CHECK Battery Voltage Terminal No. De-energized Energized Rear fog lamp relay...

  • Page 457: High-Mounted Stop Lamp

    54A-34 CHASSIS ELECTRICAL High-Mounted Stop Lamp HIGH-MOUNTED STOP LAMP High-mounted ON-VEHICLE SERVICE stop lamp HIGH-MOUNTED STOP LAMP BULB REPLACEMENT Remove socket from trunk compartment, and replace bulb. Caution Do not touch bulb surface bare-handed or with dirty gloves. If dirt is attached on glass surface of the bulb, immediately use alcohol or thinner to remove dirt, and install the bulb after well dried.

  • Page 458: On-Vehicle Service

    54A-35 CHASSIS ELECTRICAL License Plate Lamp LICENSE PLATE LAMP License plate lamp ON-VEHICLE SERVICE LICENSE PLATE LAMP REPLACEMENT Remove socket between rear bumper and body, and remove bulb. Caution Do not touch bulb surface bare-handed or with dirty gloves. If dirt is attached on glass surface of the bulb, immediately use alcohol or thinner to remove dirt, and install the bulb after well dried.

  • Page 459: Hazard Warning Lamp Switch

    54A-36 CHASSIS ELECTRICAL Hazard Warning Lamp Switch HAZARD WARNING LAMP SWITCH SPECIAL TOOL Tool Number Name MB990784 Ornament remover Center panel assembly removal HAZARD WARNING LAMP SWITCH REMOVAL AND INSTALLATION Removal steps 1. Center panel assembly (Refer to 3. Center air outlet panel (Refer to GROUP 52A - Instrument Panel.) GROUP 52A - Instrument Panel.) 2.

  • Page 460: Hazard Warning Lamp Switch

    54A-37 CHASSIS ELECTRICAL Hazard Warning Lamp Switch/Horn/Cigarette Lighter INSPECTION <Except Japan-spec. models> HAZARD WARNING LAMP SWITCH CONTINUITY CHECK Switch Position Terminal No. HORN Horn relay INSPECTION HORN RELAY CONTINUITY CHECK Switch Position Terminal No. De-energized Energized CIGARETTE LIGHTER Spot INSPECTION Element Remove plug and check for wear on spot.

  • Page 461: Column Switch

    54A-38 CHASSIS ELECTRICAL Column Switch COLUMN SWITCH SPECIAL TOOL Tool Number Name MB990784 Ornament remover Column cover removal COLUMN SWITCH REMOVAL AND INSTALLATION Section A - A Pawls Removal steps 1. Lower column cover 2. Upper column cover 3. Lighting switch 4.
  • Page 462 54A-39 CHASSIS ELECTRICAL Column Switch INSPECTION LIGHTING SWITCH CONTINUITY CHECK <FOR R.H. DRIVE> Switch Position Terminal No. Headlamp Tail lamp Passing Dimmer Turn signal lamp RH Turn signal lamp LH NOTE On L.H. drive vehicles, integrated column ECU does not allow lighting switch continuity test.

  • Page 463: Clock

    54A-40 CHASSIS ELECTRICAL Clock CLOCK SPECIAL TOOL Tool Number Name MB990784 Ornament remover Center panel assembly and center air outlet panel removal CLOCK REMOVAL AND INSTALLATION Removal steps 1. Center panel assembly (Refer to 3. Center air outlet panel (Refer to GROUP 52A - Instrument Panel.) GROUP 52A - Instrument Panel.) 2.

  • Page 464: Pole Antenna

    54A-41 CHASSIS ELECTRICAL - Pole Antenna POLE ANTENNA REMOVAL AND INSTALLATION Removal steps 1. Antenna base D Instrument under cover (Refer to AA" 2. Radio plug GROUP 52A - Instrument Panel.) 3. Knob assembly D Instrument panel (Refer to GROUP 4.

  • Page 465: Roof Antenna

    54A-42 CHASSIS ELECTRICAL - Roof Antenna/Defogger ROOF ANTENNA REMOVAL AND INSTALLATION pre-removal and Post-installation Operations D Front Pillar trim, Rear Pillar Trim and Lower/Upper Center Pillar Trim Removal and Installation (Refer to GROUP 52A - Trims.) D Assist Step Removal and Installation (Refer to GROUP 52A - Head Lining.) D Front Room Lamp and Rear Room Lamp Removal and Installation D Head Lining Removal and Installtion (Refer to GROUP 52A - Head Lining.) Removal steps...

  • Page 466: On-Vehicle Service

    54A-43 CHASSIS ELECTRICAL - Defogger ON-VEHICLE SERVICE Normal characteristics of print heater Voltage PRINTED HEATER CHECK (1) With engine running at 2,000 rpm and battery in charging A (Mid point): Approx. 6 V mode, check print heater for normal operation. (2) With defogger switch in “ON”...
  • Page 467 NOTES...
  • Page 468 54B-1 SMART WIRING SYSTEM (SWS) CONTENTS SPECIAL TOOLS ......Diagnosis Code Chart ......Diagnosis Code Inspection Procedures .

  • Page 469: Special Tools

    54B-2 SWS - Special Tools/Troubleshooting SPECIAL TOOLS Tool Number Name MB991502 MUT-II subassem- For SWS inspections (diagnosis code display and input signal check by MUT-II) MB991529 Diagnosis code For checking input signals by voltmeter check harness MB991223 Harness set For checking voltage (continuity and value) at harnesses and connectors A: MB991219 A: Test harness...

  • Page 470: Diagnosis Code Chart

    54B-3 SWS - Troubleshooting INPUT SIGNAL CHECK 1. Check the inputs using MUT-II or a voltmeter. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) 2. The following input signals can be checked using MUT-II or a voltmeter connected to the diagnosis connector.

  • Page 471: Diagnosis Code Inspection Procedures

    54B-4 SWS - Troubleshooting DIAGNOSIS CODE INSPECTION PROCEDURES Code No. 11 ETACS-ECU-related failure Probable cause The ETACS-ECU monitors its own communication data, outputting this diagnosis D ETACS-ECU fault code when data error occurs 15 consecutive times (for 0.6 seconds). The diagnosis code output stops when the ETACS-ECU confirms that its data was transmitted normally 15 consecutive times (for 0.6 seconds).
  • Page 472 54B-5 SWS - Troubleshooting Code No. 13 Front-ECU-related fault or fault in Probable cause connecting to ETACS-ECU This diagnosis code is output when the signal output from the front-ECU to D front-ECU fault ETACS-ECU contains an error for 15 consecutive communication cycles (0.6 D ETACS-ECU fault seconds).
  • Page 473 54B-6 SWS - Troubleshooting Code No. 21 Short circuit in communication lines. Probable cause This diagnostic code is output when the voltage on an SWS communication line D Column switch fault goes LOW for 0.3 seconds. The diagnosis code output stops when the D front-ECU fault ETACS-ECU data line voltage goes HIGH for 0.3 seconds, or when the D Power window main switch fault...

  • Page 474: Trouble Symptom Chart

    54B-7 SWS - Troubleshooting TROUBLE SYMPTOM CHART Trouble symptom Inspection Reference procedure page No communication with MUT-II 54B-10 Buzzers Lights left ON reminder warning function not working normally. 54B-10 Central door locking system not working at all. 54B-11 Central locking Some doors not locking or unlocking.
  • Page 475 54B-8 SWS - SWS - Troubleshooting Troubleshooting DEFECTS FOUND BY INPUT SIGNAL CHECK When a fault is identified in an input signal check, use the following table to investigate the fault. Trouble symptom Inspection Reference procedure page No ignition switch (ACC) signal input to ETACS-ECU. 54B-26 No ignition switch (IG1) signal input to ETACS-ECU.
  • Page 476 54B-9 SWS - Troubleshooting Input Signal Inspection Procedure Nos. by Function When more than one SWS function fails at the same time, run checks based on the following table. (The table lists only input signals and functions in which multiple faults can occur.) Function Driver’s door All doors...

  • Page 477: Inspection Procedures For Trouble Symptoms

    54B-10 SWS - Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure A-1 No communication with MUT-II Probable cause Either the ETACS-ECU power supply circuit system or the harness or connector D Harness or connector fault between the diagnosis connector and ETACS-ECU may be defective. D ETACS-ECU fault Is communication by MUT-II possible when the ignition switch Check the MUT-II diagnosis circuit, and repair if necessary.

  • Page 478: Central Door Locking System Not Working At All

    54B-11 SWS - Troubleshooting Inspection Procedure C-1 Central door locking system not working at all. Probable cause A change in the input signal from the driver’s door lock actuator activates all the D Driver’s door lock actuator fault door lock actuators, causing the ETACS-ECU to lock or unlock all the doors. D ETACS-ECU fault If the central locking is not working normally, the driver’s door lock actuator or D Harness or connector fault...

  • Page 479: Main Switch

    54B-12 SWS - Troubleshooting Inspection Procedure D-1 Power windows not working at all. Probable cause Power windows are not operated with the power window main switch. The power window relay or the ETACS-ECU may be defective. D Power window relay fault D ETACS-ECU fault D Harness or connector fault Check the ignition switch (IG1) input circuit system (Refer to...
  • Page 480 54B-13 SWS - Troubleshooting Inspection Procedure D-2 Driver’s power window not responding to power window Probable cause main switch. Either the power window main switch or the driver’s side power window motor D Power window main switch fault assembly may be defective. The power window lock switch could be ON. D Driver’s side power window motor assembly fault D Harness or connector fault Check the MUT-II input signals.
  • Page 481 54B-14 SWS - Troubleshooting Inspection Procedure D-3 Windows not responding to passenger or rear power Probable cause window switches. Either the power window sub-switches or the passenger’s or rear power window D Power window sub-switch fault motor assembly may be defective. D Passenger’s or rear power window motor assembly fault D Harness or connector fault...
  • Page 482 54B-15 SWS - Troubleshooting Inspection Procedure D-4 Passenger or rear power windows not responding to Probable cause power window main switch. Either the power window main switch or the passenger’s or rear power window D Power window main switch fault motor assembly may be defective.
  • Page 483 54B-16 SWS - Troubleshooting Inspection Procedure D-6 While the window is winding up, it suddenly starts coming Probable cause down again. If the sliding resistance is too great when the window is being raised or if the D The window glass is not properly adjusted. glass encounters an object, the window will return about 150 mm.

  • Page 484: The Windshield Wipers Do Not Work At All

    54B-17 SWS - Troubleshooting Inspection Procedure E-1 The windshield wipers do not work at all. Probable cause Either the windshield wiper motor, the column switch, or the front-ECU may be D Windshield wiper motor fault defective. D Column switch fault D front-ECU fault D Harness or connector fault Perform the inspection procedure for the diagnosis code...
  • Page 485 54B-18 SWS - Troubleshooting Inspection Procedure E-3 The windshield wipers do not respond to any switch Probable cause position. Either the windshield wiper motor, the column switch, or the front-ECU may be D Windshield wiper motor fault defective. D Column switch fault D front-ECU fault D Harness or connector fault Check the MUT-II input signals.

  • Page 486: The Windshield Washer Does Not Work At All

    54B-19 SWS - Troubleshooting Inspection Procedure E-5 The windshield washer does not work at all. Probable cause Either the windshield washer switch input circuit system, the windshield washer D Windshield washer motor fault motor, or the front-ECU may be defective. D Column switch fault D front-ECU fault D Harness or connector fault...

  • Page 487: The Tail Lamps Do Not Work

    54B-20 SWS - Troubleshooting Inspection Procedure F-1 Except for lighting switch “OFF” the headlamps only Probable cause respond to the “low-beam” position. If the headlamps only go onto low-beam regardless of the switch position, the D Column switch fault headlamp fail - safe function is probably activated. D front-ECU fault D Harness or connector fault MUT-II diagnosis code...

  • Page 488: The Headlamps (High-Beam) Do Not Light

    54B-21 SWS - Troubleshooting Inspection Procedure F-3 The headlamps (low-beam) do not light. Probable cause If the (low-beam) headlamp on neither side lights up, either the headlamp switch D Column switch fault input circuit system or the front-ECU may be defective. D front-ECU fault D Harness or connector fault MUT-II diagnosis code...
  • Page 489 54B-22 SWS - Troubleshooting Inspection Procedure F-5 The headlamps (low or high-beam) do not work when the Probable cause passing switch is ON. If the headlamps (low and high-beams) are normal, either the passing switch D Column switch fault input circuit system or the front-ECU may be defective. D front-ECU fault D Harness or connector fault Are the headlamps (low and high-beams) operating normally?

  • Page 490: Rear Fog Lamp Is Not Properly Illuminated

    54B-23 SWS - Troubleshooting Inspection Procedure L-1 Rear fog lamp is not properly illuminated. Probable cause If the tail lamps and the headlamps are normal when the rear fog lamps are not D Fog fog lamp switch inoperative illuminated, failure may occur on the rear fog lamp switch input circuit, the rear D Rear fog lamp relay inoperative fog lamp relay, and the front-ECU or ETACS-ECU.

  • Page 491: The Hazard Warning Lamps Do Not Light Up

    54B-24 SWS - SWS - Troubleshooting Troubleshooting Inspection Procedure H-1 The turn signal lamp do not light. Probable cause The ETACS-ECU controls the turn signal lamps based on input signals from the D Column switch fault following switches. D ETACS-ECU fault D Ignition switch (IG1) D Harness or connector fault D Turn signal lamp left-hand switch...

  • Page 492: The Room Lamps Do Not Come On Or Off Normally

    54B-25 SWS - Troubleshooting Inspection Procedure I-1 The room lamps do not come ON or OFF normally. Probable cause The ETACS-ECU controls the room lamp ON/OFF operation based on input D Door switch fault signals from the following. D Driver’s door lock actuator fault D Ignition switch (ACC) D ETACS-ECU fault D Ignition switch (IG1)
  • Page 493 54B-26 SWS - Troubleshooting Inspection Procedure J-1 No ignition switch (ACC) signal input to ETACS-ECU. Probable cause As the ignition switch (ACC) input signal is used to control the operation of the D ETACS-ECU fault following functions, any abnormality in this signal prevents these functions D Harness or connector fault operating normally.
  • Page 494 54B-27 SWS - Troubleshooting Inspection Procedure J-3 No hazard warning lamp switch signal input to Probable cause ETACS-ECU. As the hazard warning lamp switch input signal is used to control the operation D Hazard warning lamp switch fault of the following functions, any abnormality in this signal prevents these functions D ETACS-ECU fault operating normally.
  • Page 495 54B-28 SWS - Troubleshooting Inspection Procedure J-4 No fog lamp switch signal input to ETACS-ECU. Probable cause When the rear fog lamp switch input signal fault occurs, the rear fog lamp D Rear fog lamp switch inoperative switch signal is not transmitted to the SWS communication line. D ETACS-ECU fault D Harness or connector fault Check the rear fog lamp switch (Refer to GROUP 54A - Rear...
  • Page 496 54B-29 SWS - Troubleshooting Inspection Procedure J-5 No driver’s door switch signal input to ETACS-ECU. Probable cause No door switch signals input to ETACS-ECU. Driver’s door switch D Door switch fault As the driver’s door switch input signal is used to control the operation of the D ETACS-ECU fault following functions, any abnormality in this signal prevents these functions D Harness or connector fault...
  • Page 497 54B-30 SWS - Troubleshooting Inspection Procedure J-6 No driver’s door lock actuator signal input to ETACS-ECU. Probable cause As the driver’s door lock actuator input signal is used to control the operation of D Driver’s door lock actuator fault the following functions, any abnormality in this signal prevents these functions D ETACS-ECU fault operating normally.
  • Page 498 54B-31 SWS - Troubleshooting Inspection Procedure J-7 Column switches: Probable cause D No tail lamp switch signal input to ETACS-ECU. D No headlamp switch signal input to ETACS-ECU. D No dimmer switch signal input to ETACS-ECU. D No passing switch signal input to ETACS-ECU. D No turn signal lamp left-hand switch signal input to ETACS-ECU.
  • Page 499 54B-32 SWS - Troubleshooting Inspection Procedure J-9 No power window main switch signal input to ETACS- Probable cause ECU. The power window main switch input signal is generated to check the individual D Power window main switch fault switch position of the power window main switch, and the communication status D ETACS-ECU fault for ETACS-ECU.
  • Page 500 54B-33 SWS - Troubleshooting Inspection Procedure K-1 When the ignition switch is in the LOCK (OFF) position, Probable cause no functions work normally. Checking of the ETACS-ECU battery power supply circuit Probable cause system. As a fault in this circuit disables ETACS-ECU functions when the ignition switch D ETACS-ECU fault is in the LOCK (OFF) position, any abnormality in this signal prevents the D Harness or connector fault...

  • Page 501: Check At Ecu Terminals

    54B-34 SWS - Troubleshooting CHECKS AT ECU TERMINALS ETACS-ECU Y0795AU NOTE *See the list below for data on the ETACS-ECU terminal 1 - 20 connectors. As the ETACS-ECU connects directly onto the junction box, the voltages cannot be measured. Terminal Check items Checking requirements Normal condition...
  • Page 502 54B-35 SWS - Troubleshooting Terminal Check items Checking requirements Normal condition Driver’s door lock actuator (locking When driver’s door lock locked switch) input Driver’s door lock actuator (unlocking When driver’s door lock unlocked switch) input 37, 38 Back-up lamp switch input When shift lever in reverse position System voltage During diagnosis output (when MUT-II...
  • Page 503 54B-36 SWS - Troubleshooting COLUMN SWITCHES Terminal Check item Checking requirements Normal condition Battery power supply Any time System voltage SWS request signal input Any time 0 - 12 V (pulse signal) SWS communication line Any time 0 - 12 V (pulse signal) Earth Any time...
  • Page 504 54B-37 SWS - SWS - Troubleshooting Troubleshooting Terminal Check item Checking requirements Normal condition Ignition switch (IG2) power supply Ignition switch: ON System voltage Earth Any time POWER WINDOW MAIN SWITCH Y0794AU Terminal Check item Checking requirements Normal condition SWS communication line (with power Power window relay: ON 0 - 12 V (pulse signal) window motor assembly)
  • Page 505 NOTES...
  • Page 506 52A-1 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS INTERIOR ............SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .
  • Page 507 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.

  • Page 508: Special Tool

    52A-3 INTERIOR - Special Tool/Instrument Panel SPECIAL TOOL Tool Number Name Application MB990784 Ornament remover Removal of switches and trims INSTRUMENT PANEL REMOVAL AND INSTALLATION The following bolts and screws are used for installing the instrument panel. Bolts and screws are indicated as marks shown in the illustration in the sections of “Removal and Installation” and “Disassembly and Reassembly.”...
  • Page 509 52A-4 INTERIOR - Instrument Panel <L.H. DRIVE VEHICLE> Caution: SRS 1. Refer to GROUP 52B-SRS Service Precautions and Air bag Module and Clock Spring before removing the passenger side air bag module. 2. Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel. Pre-removal and Post-installation Operation Removal and Installation of Front Pillar Trim (Refer to P.52A-15.)
  • Page 510 52A-5 INTERIOR - Instrument Panel CLIP AND CLAW POSITIONS NOTE : Clip positions : Claw positions Section A - A Section B - B Section C - C Clip Column cover Claw Instrument panel Claw Instrument panel Section D - D Section E - E Section F - F Clip...
  • Page 511 52A-6 INTERIOR - Instrument Panel REMOVAL SERVICE POINT AA" SRS FRONT PASSENGER’S AIR BAG MODULE REMOVAL Insert the flat tipped screw driver into the position shown in the illustration and pull up the screw driver to disengage the claws for removal of the front passenger’s air bag module. Caution 1.
  • Page 512 52A-7 INTERIOR - INTERIOR - Instrument Panel Instrument Panel <R.H. DRIVE VEHICLE> Caution: SRS 1. Refer to GROUP 52B-SRS Service Precautions and Air bag Module and Clock Spring before removing the passenger side air bag module. 2. Do not subject the SRS-ECU to any shocks when removing or installing the instrument panel. Pre-removal and Post-installation Operation Removal and Installation of Front Pillar Trim (Refer to P.52A-15.)
  • Page 513 52A-8 INTERIOR - Instrument Panel CLIP AND CLAW POSITIONS NOTE : Clip location : Claw location Section A - A Section B - B Section C - C Clip Column cover Claw Claw Instrument panel Instrument panel Section D - D Section E - E Section F - F Clip...
  • Page 514 52A-9 INTERIOR - Instrument Panel REMOVAL SERVICE POINT AA" SRS FRONT PASSENGER’S AIR BAG MODULE REMOVAL Insert the flat tipped screw driver into the position shown in the illustration and pull up the screw driver to disengage the claws for removal of the front passenger’s air bag module. Caution 1.

  • Page 515: Front Floor Console

    52A-10 INTERIOR - Front Floor Console FRONT FLOOR CONSOLE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Rear Foor Console (Refer to P.52A - 12.) < L.H. DRIVE VEHICLE> Removal steps 1. Console side cover 7. Shift lever cover 2.
  • Page 516 52A-11 INTERIOR - Front Floor Console REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Rear Floor Console (Refer to P.52A-12.) <R.H. DRIVE VEHICLE> Removal steps 1. Console side cover 7. Shift lever cover 2. Shift lever knob 8.

  • Page 517: Rear Floor Console

    52A-12 INTERIOR - Rear Floor Console REAR FLOOR CONSOLE REMOVAL AND INSTALLATION <Type A> <Type B> Removal steps 1. Console box mat D Rear scuff plate (Refer to P.52A-15.) D Center pillar trim, lower 2. Rear console assembly (Refer to P.52A-15.) D Rear seat cushion assembly D Floor carpet (Refer to P.52A-22.)
  • Page 518 52A-13 INTERIOR - Rear Floor Console DISASSEMBLY AND REASSEMBLY <Type A> <Type B> Disassembly steps 1. Ashtray 6. Console lid 2. Cup holder 7. Lower lid striker 3. Hole lock 8. Hinge bracket 4. Rear floor console 9. Box 5. Console lid assembly 10.
  • Page 519 52A-14 INTERIOR - Rear Floor Console DISASSEMBLY SERVICE POINT Console lid assembly AA" REMOVAL OF CONSOLE LID ASSEMBLY Insert the special tool into the hinges of the console lid assembly and the rear floor console through the ashtray mounting hole to pry for removal. Rear floor console Ashtray...

  • Page 520: Trims

    52A-15 INTERIOR - Trims TRIMS REMOVAL AND INSTALLATION 44 ± 10 N•m NOTE Refer to GROUP42 for more information regarding door trim. Removal steps 1. Front scuff plate 9. Center pillar trim, upper 2. Cowl side trim 10. Rear pillar trim 3.
  • Page 521 52A-16 INTERIOR - Trims CLIP POSITION NOTE : Clip position : Claw position Section A - A Section B - B Section C - C Front scuff plate, Front pillar trim Clip Rear scuff plate Headlining Clip Front pillar trim, Clip Center pillar trim, upper,...

  • Page 522: Headlining

    52A-17 INTERIOR - Trims/Headlining REMOVAL SERVICE POINT Section A – A AA" FRONT PILLAR TRIM REMOVAL Release the clip to pull towards the direction shown in the Front pillar trim Front pillar trim illustration and remove the front pillar trim. Instrument panel HEADLINING...
  • Page 523 52A-18 INTERIOR - Headlining REMOVAL SERVICE POINTS AA" SUNVISOR HOLDER REMOVAL Insert the special tool into sides claws of the sunvisor holder through the both sides of the sunvisor holder to remove the MB990784 hinges. Sunvisor holder MB990784 AB" HEADLINING REMOVAL Bend the headlining to remove from the front passenger’s door.

  • Page 524: Seat

    52A-19 INTERIOR - Seat SEAT FRONT SEAT REMOVAL AND INSTALLATION 44 ± 10 NSm 44 ± 10 NSm 30 ± 5 NSm 30 ± 5 NSm 1. Headrest Front seat assembly removal steps 2. Front seat anchor cover 3. Front seat assembly "AA INSTALLATION SERVICE POINT "AA INSTALLATION OF FRONT SEAT ASSEMBLY...
  • Page 525 52A-20 INTERIOR - Seat DISASSEMBLY AND REASSEMBLY HIGHT ADJUSTER SEAT 12 13 44 ± 10 NSm 12 ± 2 NSm Section A - A Claw 8, 9 9 ± 2 NSm 44 ± 10 NSm Disassembly steps 1. Reclining knob 11.
  • Page 526 52A-21 INTERIOR - Seat RECARO SEAT 22 ± 3 NSm 22 ± 3 NSm Disassembly steps 1. Reclining knob 5. Front seat back assembly 2. Reclining cover 6. Seat rail R.H. 3. Cap 7. Seat rail L.H. 4. Front seat cushion assembly 8.

  • Page 527: Rear Seat

    52A-22 INTERIOR - Seat REMOVAL SERVICE POINT AA" REMOVAL OF HEADREST GUIDE REAR SEAT REMOVAL AND INSTALLATION 22 ± 4 NSm Disassembly steps 1. Rear seat cushion assembly 3. Rear seat hook "BA 2. Rear seatback assembly "AA...
  • Page 528 52A-23 INTERIOR - Seat INSTALLATION SERVICE POINTS "AA INSTALLATION OF REAR SEATBACK Rear seat back ASSEMBLY/REAR SEATBACK SIDE ASSEMBLY assembly L.H., R.H. Press the rear seatback assembly in the direction shown in the illustration and fit the attachment wire into the hook securely to install the rear seatback assembly.
  • Page 529 52A-24 INTERIOR - Seat DISASSEMBLY AND REASSEMBLY Removal steps 1. Rear seat cushion cover 3. Rear seatback cover 2. Rear seat cushion pad 4. Rear seatback pad...

  • Page 530: Seat Belt

    52A-25 INTERIOR - Seat Belt SEAT BELT FRONT SEAT BELT REMOVAL AND INSTALLATION 44 ± 10 NSm 44 ± 10 NSm 44 ± 10 NSm 44 ± 10 NSm Outer seat belt removal steps Inner seat belt removal steps 1. Sash guide cover D Shield cover (Refer to P.52A-20.) 2.

  • Page 531: Rear Seat Belt

    52A-26 INTERIOR - Seat belt REAR SEAT BELT REMOVAL AND INSTALLATION 44 ± 10 NSm 44 ± 10 NSm 44 ± 10 NSm 44 ± 10 NSm Removal steps D Rear seat cushion assembly 1. Inner seat belt (Refer to P.52A-22.) 2.
  • Page 532 52B-1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS GENERAL INFORMATION ....SRS AIR BAG CONTROL UNIT (SRS-ECU) ....... . SRS SERVICE PRECAUTIONS .

  • Page 533: General Information

    52B-2 SRS - SRS - General Information General Information GENERAL INFORMATION To improve safety, the SRS and seat belts with instrument panel indicates the operational status pre-tensioner. These systems enhance collision of the SRS. The clock spring is installed in the safety by restraining the front passengers in case steering column.

  • Page 534: Srs Service Precautions

    52B-3 SRS - SRS Service Precautions SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others NOTE from accidental deployment of the air bag and If any of these components are diagnosed as accidental operation of the seat belt with faulty, they should only be replaced, in pre-tensioner during servicing,...
  • Page 535 52B-4 SRS - SRS Service Precautions SRS-ECU Destination of harness Corrective action Terminal No. Instrument panel wiring harness → Earth Repair or replace each wiring harness harness Instrument panel wiring harness → Combination meter (SRS warning lamp) 9, 10 Instrument panel wiring harness → Front passenger’s air bag module 11, 12 Instrument panel wiring harness →...

  • Page 536: Special Tools

    52B-5 SRS - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub Reading and erasing diagnosis codes assembly Reading trouble period Reading erase times MB991865 Dummy resistor Checking SRS air bag circuit MB991866 Resistor harness MB991613 SRS check Checking SRS electrical circuitry harness MB991223 Harness set...

  • Page 537: Test Equipment

    52B-6 SRS - Special Tools/Test Equipment/Troubleshooting Tool Number Name MB686560 SRS air bag Deploying front passenger’s air bag module adapter harness inside or outside vehicle MR203491or SRS air bag Deploying driver’s air bag module inside MB628919 adapter harness vehicle <RS> TEST EQUIPMENT Tool Name...
  • Page 538 52B-7 SRS - Troubleshooting SRS SYSTEM CIRCUIT DIAGRAM Ignition switch (IG SRS-ECU No.2 No.3 (common fuse) 7.5A 7.5A Combination Meter Connector lock switch* Connector lock switch* Connector lock switch* Driver’s air bag module (squib) C-207 C-22 Clock spring C-204 Diagnosis connector Front pas- senger’s seat Connector lock switch*...
  • Page 539 52B-8 SRS - Troubleshooting CONNECTOR FOR SRS AIR BAG The SRS air bag system connector is yellow or red. To enhance system reliability, a connector lock switch is adopted for the SRS-ECU connector, and each air bag module and clock spring connector, each seat belt with pre-tensioner <the connector A in the following illustration (black)>).
  • Page 540 52B-9 SRS - Troubleshooting WARNING LAMP CIRCUIT CONNECTOR LOCK SWITCH Ignition switch (IG Mechanism to automatically short-circuit the power supply terminal and the earth terminal of the warning lamp circuit when the SRS-ECU connector is disconnected. The structure is the same as that of squib circuit connector lock switch. SRS warning lamp SRS-ECU harness side connector...
  • Page 541 52B-10 SRS - Troubleshooting Code no. Diagnostic item Page Connector lock system 52B-29 SRS-ECU (deployed air bag) system 52B-29 Power supply circuit system (fuse No.2 circuit) 52B-30 Power supply circuit system (fuse No.3 circuit) 52B-32 SRS warning lamp drive circuit system Lamp does not illumi- 52B-33 nate.
  • Page 542 52B-11 SRS - Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No.14, 15, 16, 31, 32, 45, 51, 52, 54, 55, 56, 57, 58, 59 Probable cause System inside SRS-ECU Malfunction is present inside SRS-ECU. See table below for what each code D Malfunction of SRS-ECU tells.
  • Page 543 52B-12 SRS - Troubleshooting Code No.21 Driver’s air bag module (squib) system Possible Cause This code is output when short circuit occurs between terminals of the D Connector engagement faulty or short bar faulty* SRS-ECU driver’s air bag module (squib) circuit. D Short circuit in the clock spring However, SRS warning lamp goes out when a normal operation is resumed D Short circuit between terminals of the driver’s air...
  • Page 544 52B-13 SRS - Troubleshooting <RS> <Clock spring check> Dummy resistor MUT-II self-diag code (MB991865) Resistor harness D Release the clock spring connector (2- pin) C-204. resistance (3Ω) (MB991866) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866). D Insert the resistor harness (MB991866) behind the harness side connector C-204.
  • Page 545 52B-14 SRS - Troubleshooting <RS-II> <Driver’s seat air bag module (squib) check> MUT-II self-diag code Resistor harness D Disconnect the clock spring connector No.1 (connector connected with Dummy resistor (MB991866) the air bag module). (MB991865) D Connect the dummy resistor (MB991865) to the resistor harness resistance (3Ω) (MB991866).
  • Page 546 52B-15 SRS - Troubleshooting From Previous Page Check connector: C- 21, C-204 <Check the circuit between the SRS-ECU and clock spring> Measure at the SRS-ECU connector C- 21 . D Disconnect the SRS-ECU connector C-21. Correct Check the trouble D Release the the clock spring connector C-204. symptoms.
  • Page 547 52B-16 SRS - Troubleshooting Code No.22 Driver’s air bag module (squib) system Possible Cause This code is output when open circuit occurs in the SRS-ECU driver’s air bag D Open in the clock spring module (squib) circuit. D Half open in the circuit due to improper neutral However, SRS warning lamp goes out when a normal operation is resumed positioning of the clock spring (diagnosis code is not cleared.)
  • Page 548 52B-17 SRS - Troubleshooting <RS> <Clock spring check> Dummy resistor MUT-II self-diag code (MB991865) Resistor harness D Release the clock spring connector (2- pin) C-204. resistance (3Ω) (MB991866) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866). D Insert the resistor harness (MB991866) behind the harness side connector C-204.
  • Page 549 52B-18 SRS - Troubleshooting <RS-II> <Driver’s seat air bag module (squib) check> Dummy resistor MUT-II self-diag code Resistor harness D Disconnect the clock spring connector No.1 (connector connected with (MB991865) (MB991866) the air bag module). resistance (3Ω) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866).
  • Page 550 52B-19 SRS - Troubleshooting From Previous Page <Check the circuit between the SRS-ECU and clock Check connector: C-21, C-204 spring> Measure at the C-21 SRS-ECU connector and C-204 clock spring connector. Correct Check the trouble D Disconnect the SRS-ECU connector C-21 and the clock symptoms.
  • Page 551 52B-20 SRS - Troubleshooting Code No.24 Front passenger’s air bag module (squib) Possible Cause system This code is output when short circuit occurs between terminals of the D Connector engagement faulty or short bar faulty* SRS-ECU front passenger’s air bag (squib) circuit. D Short circuit between terminals of the front However, SRS warning lamp goes out when a normal operation is resumed passenger’s air bag (squib) circuit...
  • Page 552 52B-21 SRS - Troubleshooting <Check the front passenger’s air bag module (squib)> Dummy resistor MUT-II self-diag code Resistor harness (MB991865) (MB991866) D Connect the dummy resistor (MB991865) to the resistor harness resistance (3Ω) (MB991866). D Disconnect the front passenger’s air bag module connector C-109 Instrumental panel and insert the resistor harness (MB991866) behind the harness side wiring harness...

  • Page 553: Possible Cause

    52B-22 SRS - Troubleshooting Code No.25 Front passenger’s air bag module (squib) Possible Cause system This code is output when open circuit occurs in the SRS-ECU front passenger’s D Open in the front passenger’s air bag module air bag (squib) circuit. (squib) circuit However, SRS warning lamp goes out when a normal operation is resumed D Connector improper contact...
  • Page 554 52B-23 SRS - Troubleshooting Code No.26 Driver’s seat belt pre-tensioner (squib) Possible Cause system This code is output when short circuit occurs between terminals of the D Connector engagement faulty or short bar faulty* SRS-ECU driver’s seat belt pre-tensioner (squib) circuit. D Short circuit between terminals of the driver’s seat However, SRS warning lamp goes out when a normal operation is resumed belt pre-tensioner (squib) circuit...
  • Page 555 52B-24 SRS - Troubleshooting <Check the driver’s seat belt pre-tensioner (squib)> MUT-II self-diag code Resistor harness D Connect the dummy resistor (MB991865) to the resistor harness Dummy resistor (MB991865) (MB991866) (MB991866). resistance (3Ω) D Disconnect the driver’s seat belt pre-tensioner connector D-28* D-26 and connect to the resistor harness (MB991866) behind the harness side connector.
  • Page 556 52B-25 SRS - Troubleshooting Code No.27 Driver’s seat belt pre-tensioner (squib) Possible Cause system This code is output when open circuit occurs in the SRS-ECU driver’s seat belt D Connector improper contact pre-tensioner (squib) circuit. D Open in the driver’s seat pre-tensioner (squib) However, SRS warning lamp goes out when a normal operation is resumed circuit (diagnosis code is not cleared.)
  • Page 557 52B-26 SRS - Troubleshooting Code No.28 Front passenger’s seat belt pre-tensioner Possible Cause (squib) system This code is output when short circuit occurs between terminals of the D Connector engagement faulty or short bar faulty* SRS-ECU front passenger’s seat belt pre-tensioner (squib) circuit. D Short circuit between terminals of the front However, SRS warning lamp goes out when a normal operation is resumed passenger’s seat belt pre-tensioner (squib) circuit...
  • Page 558 52B-27 SRS - Troubleshooting <Check the front passenger’s seat belt pre-tensioner (squib)> MUT-II self-diag code Resistor harness Dummy resistor D Connect the dummy harness (MB991865) to the resistor harness (MB991866) (MB991865) (MB991866). resistance (3Ω) D Disconnect the front passenger’s seat belt pre-tensioner connector D-28* and D-26* and insert the resistor harness (MB991866) behind...
  • Page 559 52B-28 SRS - Troubleshooting Code No.29 Front passenger’s seat belt pre-tensioner Possible Cause (squib) system This code is output when open circuit occurs in the SRS-ECU front passenger’s D Open in the front passenger’s seat pre-tensioner seat belt pre-tensioner (squib) circuit. (squib) circuit However, SRS warning lamp goes out when a normal operation is resumed D Connector improper contact...
  • Page 560 52B-29 SRS - Troubleshooting Code No.34 Connector Lock System Probable Cause The SRS-ECU connector is mounted with a connector lock switch terminal for D Faulby connector detecting the connected state of the connector. D SRS-ECU inperable SRS-ECU connector is poorly connected. However, when the vehicle condition returns to normal, this code will be automatically erased, and the SRS warning lamp will go out.
  • Page 561 52B-30 SRS - Troubleshooting Code No.41 Power supply circuit system (fuse No.2 Possible Cause circuit) This codes output when the voltage between terminal IG (SRS-ECU, terminal D Harness or connector fault No.16) and earth has been below the standard value for 5 seconds. D SRS-ECU inoperable However, code No.41 is automatically erased and SRS warning lamp goes out when a normal operation is resumed.
  • Page 562 52B-31 SRS - Troubleshooting From Previous Page <Check the circuit between the SRS-ECU and the junction block> Check the harness between the SRS-ECU and junction block, Measure at the SRS - ECU connector C-21. and repair if necessary. D Disconnect the SRS-ECU connector C-21 and measure at the harness side.
  • Page 563 52B-32 SRS - Troubleshooting Code No.42 Power supply circuit system (fuse No.3 Possible Cause circuit) This code is output when the voltage between terminal IG (SRS-ECU, terminal D Harness or connector fault No.13) and earth has been below the standard value for 5 seconds. D SRS-ECU inoperable However, code No.42 is automatically erased and SRS warning lamp goes out when a normal operation is resumed.If code No.41 and 42 are output at the...
  • Page 564 52B-33 SRS - Troubleshooting Code No.43 SRS warning lamp drive circuit system (lamp Possible Cause does not illuminate) This code is output when open circuit has occurred in the SRS warning lamp D Harness or connector fault drive circuit for 5 seconds or more. However, if the code is output due to open D Bulb fault circuit faulty, code No.43 is automatically erased and the SRS warning lamp D SRS-ECU inoperable...
  • Page 565 52B-34 SRS - Troubleshooting Code No.61 Driver’s air bag module (squib) system Possible Cause (short-circuited to power supply) Code No.62 Driver’s air bag module (squib) system (short-circuited to earth) This code is output when the input terminal of the SRS-ECU driver’s air bag D Clock spring fault module (squib) is short-circuited to power supply (code No.61) or short-circuited D Harness or connector fault...
  • Page 566 52B-35 SRS - Troubleshooting <RS> <Check the clock spring and the driver’s air bag module (squib)> Dummy resistor (MB991865) MUT-II self-diag code Resistor harness resistance (3Ω) D Release the clock spring connector (2- pin) C-204. (MB991866) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866).
  • Page 567 52B-36 SRS - Troubleshooting <RS-II> <Driver’s air bag module (squib) check> MUT-II self-diag code Resistor harness Dummy resistor D Disconnect the clock spring connector No.1 (connector connected with (MB991865) (MB991866) the air bag module). resistance (3Ω) D Connect the dummy resistor (MB991865) to the resistor harness (MB991866).
  • Page 568 52B-37 SRS - Troubleshooting From Previous Page YES (when No.61 is output) YES (when No.62 is output) <Check the circuit between the SRS-ECU and <Check the circuit between the SRS-ECU and clock spring> clock spring> Measure at the SRS-ECU connector C-21. Measure at the SRS-ECU connector C-21.
  • Page 569 52B-38 SRS - Troubleshooting Code No.64 Front passenger’s air bag module (squib) Possible Cause system (short-circuited to power supply) Code No.65 Front passenger’s air bag module (squib) system (short-circuited to earth) This code is output when the input terminal of the SRS-ECU front passenger’s D Harness or connector fault air bag module (squib) is short-circuited to power supply (code No.64) or D The harness of the front passenger’s air bag...
  • Page 570 52B-39 S R S - Tr o u b l e s h o o t i n g Code No.66 Driver’s seat belt pre-tensioner (squib) Possible Cause system (short-circuited to power supply) Code No.67 Driver’s seat belt pre-tensioner (squib) system (short-circuited to earth) This code is output when the input terminal of the SRS-ECU driver’s seat belt D Harness or connector fault...
  • Page 571 52B-40 S R S - Tr o u b l e s h o o t i n g Code No.68 Front passenger’s seat belt pre-tensioner Possible Cause (squib) system (short-circuited to power supply) Code No.69 Front passenger’s seat belt pre-tensioner (squib) system (short-circuited to earth) This code is output when the input terminal of the SRS-ECU front passenger’s D Harness or connector fault...
  • Page 572 52B-41 SRS - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Study the trouble symptoms and check according to the inspection procedure chart. Trouble Inspection procedure No(s). Reference page Communication with MUT-II is impossible. 52B-41 SRS warning lamp does not illuminate. See diagnosis code No.43. 52B-33 SRS warning lamp does not go out.

  • Page 573: Srs Maintenance

    52B-42 SRS - SRS Maintenance SRS MAINTENANCE The SRS must be inspected by an authorized dealer 10 years after the date of vehicle registration. SRS WARNING LAMP CHECK Turn the ignition switch to the ON position. Does the SRS warning lamp illuminate for about 7 seconds, and then go out? If yes, SRS system is functioning properly.
  • Page 574 52B-43 SRS - SRS Maintenance AIR BAG MODULES, STEERING WHEEL AND CLOCK <Driver’s side> Inflator SPRING AND SEAT BELT WITH PRE-TENSIONER <RS> 1. Remove the air bag modules, steering wheel and clock spring. (Refer to P.52B-52.) Caution The removed air bag modules should be stored in a clean, dry place with the cover face up.
  • Page 575 52B-44 SRS - SRS Maintenance REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION. (Refer to P.52B-52.) Caution The SRS may not activate if any of the above components is not installed properly, which could result in serious injury or death to the vehicle’s driver or front passenger.

  • Page 576: Post-Collision Diagnosis

    52B-45 SRS - Post-collision Diagnosis POST-COLLISION DIAGNOSIS Whether or not the air bags have deployed, check and service the vehicle after collision as follows: SRS-ECU MEMORY CHECK 1. Connect the MUT-II to the diagnosis connector. (Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.) Caution Refer to that the ignition switch is LOCK(OFF) when...
  • Page 577 52B-46 SRS - Post-collision Diagnosis REPAIR PROCEDURE DEPLOYED DRIVER’S AND FRONT PASSENGER’S AIR BAGS OR OPERATED SEAT BELT PRE-TENSIONER. 1. Replace the following parts with new ones. SRS-ECU (Refer to P.52B-50.) Driver’s air bag module (Refer to P.52B-52.) Front passenger’s air bag module (Refer to P.52B-52.) Seat belt with pre-tensioner (Refer to P.52B-61.) 2.
  • Page 578 52B-47 SRS - Post-collision Diagnosis SRS-ECU SRS-ECU 1. Check the SRS-ECU case and bracket for dents, cracks or deformation. 2. Check the connector for damage, and terminals for deformation. 3. Check the SRS-ECU and bracket for proper installation. Driver’s and passenger’s air bag modules <Driver’s side>...
  • Page 579 52B-48 SRS - Post-collision Diagnosis Steering wheel, steering column and intermediate joint 1. Check the driver’s air bag module for proper installation to the steering wheel. 2. Check the steering wheel for noise, binds or difficult operation and excessive free play. Harness connector (Instrument panel wiring harness, Floor wiring harness) Check the harness for binds, the connector for damage and...

  • Page 580: Individual Component Service

    52B-49 SRS - Individual Component Service/Warning/Caution Labels INDIVIDUAL COMPONENT SERVICE If the SRS components and seat belt with pre-tensioner are to be removed or replaced as a result of maintenance, troubleshooting etc., follow the service procedures that follow. Caution 1. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, driver’s air bag module<RS>, steering wheel - air bag module<RS- >, front passenger’s air bag module, clock spring, and seat belt with pre-tensioner before drying or baking the vehicle after painting.

  • Page 581: Srs Air Bag Control Unit (Srs-Ecu)

    52B-50 SRS - SRS-ECU SRS AIR BAG CONTROL UNIT (SRS-ECU) Caution 1. Disconnect the negative ( - ) battery terminal 3. Do not drop or subject the SRS-ECU to and wait for 60 seconds or more before impact or vibration. starting work.
  • Page 582 52B-51 SRS - SRS-ECU INSTALLATION SERVICE POINTS "AA SRS-ECU INSTALLATION Caution Be sure to install the SRS-ECU properly. Otherwise, the SRS air bags do not activate, which results in serious injury or death of vehicle’s occupants. "BA POST-INSTALLATION CHECK 1. Turn the ignition switch to ON. 2.

  • Page 583: Air Bag Modules And Clock Spring

    52B-52 SRS - Air Bag Modules and Clock Spring AIR BAG MODULES AND CLOCK SPRING Caution 1. Disconnect the negative ( - ) battery terminal 5. Do not store the air bag modules in a place and wait for 60 seconds or more before more than 93_C.
  • Page 584 52B-53 SRS - Air Bag Modules and Clock Spring REMOVAL AND INSTALLATION <Driver’s air bag module, clock spring> Pre-removal Operation Disconnect the Negative ( - ) Battery Terminal. <RS: Steering wheel and air bag module separate type> 41 ± 8 N·m 0.9 ±...
  • Page 585 52B-54 S RS - Air Bag Modules and Clock Spring <RS-II: Steering wheel and air bag module incorporate type> 50 ± 5 N·m Steering wheel - driver’s air bag Steering wheel - driver’s air bag module assembly removal steps module assembly installation steps 1.
  • Page 586 52B-55 SRS - Air Bag Modules and Clock Spring <Front passenger’s air bag module> Removal steps Installation steps D Instrument panel assembly "AA D Pre-installation inspection (Refer to GROUP 52A - Instrument 1. Passenger’s air bag module panel.) D Instrument panel assembly 1.
  • Page 587 52B-56 SRS - Air Bag Modules and Clock Spring STEERING WHEEL REMOVAL " MB990803 AC" CLOCK SPRING REMOVAL Caution Keep the removed clock spring in a clean and dry place. AD" COVER REMOVAL Use the special tool to insert into the notch as shown in the illustration and remove the cover.
  • Page 588 52B-57 SRS - Air Bag Modules and Clock Spring AF" PASSENGER’S AIR BAG MODULE REMOVAL Insert the screwdriver ( - ) into the position specified in the figure and lift the screwdriver upward to release the pawls engaged, and then remove the passenger’s air bag module. Caution 1.
  • Page 589 52B-58 SRS - Air Bag Modules and Clock Spring "CA STEERING WHEEL/STEERING WHEEL - AIR BAG MODULE ASSEMBLY INSTALLATION 1. After checking that centering of the clock spring has been done, install the steering wheel or the steering wheel - air bag module assembly.
  • Page 590 52B-59 SRS - Air Bag Modules and Clock Spring INSPECTION <Driver’s side> Inflator <RS> DRIVER’S AND PASSENGER’S AIR BAG MODULE INSPECTION If any malfunction is found in the following inspection, replace the air bag module(s) with new one(s). Discard the old one(s) after deployment as specified in the service procedure.
  • Page 591 52B-60 SRS - Air Bag Modules and Clock Spring 4. Align the paint mark on the connector No.1 of the SRS check harness (MB991606 or MB991613) with the mark Paint Marking indicated by an arrow on the connector No.3 of the clock spring for connector connection.
  • Page 592 52B-61 S RS - Seat Belt with Pre-tensioner SEAT BELT WITH PRE-TENSIONER Caution: 1. Wait least seconds after 4. Do not place a heavy object on top of the disconnecting the negative ( - ) terminal of seat belt pre-tensioner. the battery before starting any operation.The 5.
  • Page 593 52B-62 S RS - Seat Belt with Pre-tensioner INSTALLATION SERVICE POINTS "AA PRE-INSTALLATION INSPECTION 1. Pre-installation inspection must be carried out even when installing a new seat belt with pre-tensioner. (Refer to Inspections.) Caution If the seat belt with pre-tensioner is discarded, discard it after operating the seat belt pre-tensioner according to the specified procedure.

  • Page 594: Seat Belt Pre-Tensioner

    52B-63 S RS - Seat belt with Pre-tensioner INSPECTION SEAT BELT PRE-TENSIONER If any faulty is discovered by the following inspections, replace the seat belt with pre-tensioner with a new one. Discard the old parts according to the specified procedure after operating the seat belt pre-tensioner.(Refer to P.52B-64.) Caution Do not measure the circuit resistance of the seat belt...

  • Page 595: Air Bag Module And Seat Belt Pre-Tensioner Disposal Procedures

    Air Bag Module and Seat Belt Pre-tensioner 52B-64 SRS - Disposal Procedures AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES Carry out the following procedure of air bag with pre-tensioner or the vehicle with SRS air bag deployment and seat belt pre-tensioner operation and seat belt with pre-tensioner.
  • Page 596 Air Bag Module and Seat Belt Pre-tensioner 52B-65 SRS - Disposal Procedures Driver’s air bag module (1) Remove the steering column cover, lower. (Refer to GROUP 52A – Instrument Panel.) Clock spring (2) Disconnect the clock spring 2-pin connector and 2-pin connector instrument panel wiring harness connector (2-pin, yellow).
  • Page 597 Air Bag Module and Seat Belt Pre-tensioner 52B-66 SRS - Disposal Procedures Front passenger’s air bag module (1) Remove the glove box. (Refer to GROUP 52A – Instrument Panel.) (2) Disconnect the front passenger’s air bag module 2-pin Instrument panel wiring connector (red) and instrument panel wiring harness harness connector...
  • Page 598 Air Bag Module and Seat Belt Pre-tensioner 52B-67 SRS - Disposal Procedures (6) Separate the deployment harnesses as far from the vehicle as possible and connect to the terminals of the battery removed from the vehicle. Then deploy. Caution 1) Before deploying the air bag, see that no one is in and near the vehicle.
  • Page 599 Air Bag Module and Seat Belt Pre-tensioner 52B-68 SRS - Disposal Procedures (5) Close all the doors with the windows fully closed and put a cover over the vehicle to minimize report. Cover Caution The cover is required as the glass, if already damaged, may break.
  • Page 600 Air Bag Module and Seat Belt Pre-tensioner 52B-69 SRS - Disposal Procedures (2) Connect deployment harnesses longer than 6 m to Short-circuited each SRS air bag adapter harness and insulate the Deployment harness connections with plastic tape. Also, connect the deployment harness in the other SRS air bag ends to connect (short-circuit).
  • Page 601 Air Bag Module and Seat Belt Pre-tensioner 52B-70 SRS - Disposal Procedures (7) Separate the deployment harnesses as far from the driver’s side air bag module as possible and connect to the terminals of the battery removed from the vehicle. Then deploy. Caution 1) Before the deployment, see that no one is near around the driver’s air bag module.
  • Page 602 Air Bag Module and Seat Belt Pre-tensioner 52B-71 SRS - Disposal Procedures (4) Release the secured connector of the steering Steering wheel - driver’s air bag Deployment module assembly harness wheel - driver’s air bag module assembly to cut off the connector from the harness with a nipper and etc.
  • Page 603 Air Bag Module and Seat Belt Pre-tensioner 52B-72 SRS - Disposal Procedures Front passenger’s air bag module (1) Remove the front passenger’s air bag module from the vehicle. (Refer to P.52B-52.) Caution Once disconnected, both electrodes of the front passenger’s air bag module connector short automatically to prevent accidental deployment caused by static etc.
  • Page 604 Air Bag Module and Seat Belt Pre-tensioner 52B-73 SRS - Disposal Procedures (6) Disconnect the deployment harnesses as far from the front passenger’s air bag module as possible and connect the harnesses to the battery removed from the vehicle. Caution 1) Before the deployment, see that no one is near the front passenger’s air bag module.
  • Page 605 Air Bag Module and Seat Belt Pre-tensioner 52B-74 SRS - Disposal Procedures (3) Route a thick wire through the holes in the seat belt Seat belt pre-tensioner retractor bracket to secure at the top of the wheel (convex part). (two locations) (4) Connect the seat belt pre-tensioner connector to the the SRS air bag adapter harness with the operation harness attached.
  • Page 606 Air Bag Module and Seat Belt Pre-tensioner 52B-75 SRS - Disposal Procedures DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES Discard the deployed air bag module or the operated seat belt with pre-tensioner paying attention to the following items. 1.
  • Page 607 NOTES...
  • Page 608 51-1 EXTERIOR CONTENTS FRONT BUMPER ....REAR SPOILER ......WINDSHIELD WIPER AND WASHER ADHESIVE .

  • Page 609: Front Bumper

    51-2 EXTERIOR - Front Bumper FRONT BUMPER ADHESIVE Application Brand Front air dam Double-sided tape [10 mm width 1.2 mm thickness] FRONT BUMPER REMOVAL AND INSTALLATION Section A – A Clip Section B – B Clip Fender Section C – C 1,2,3 Clip Removal steps...

  • Page 610: Front Bumper

    51-3 EXTERIOR - Front Bumper DISASSEMBLY AND REASSEMBLY Section A – A Clip Section B – B Clip Section C – C Clip Disassembly steps 1. Front bumper plate 10. Front bumper side blade "CA 2. Front bumper center net 11.
  • Page 611 51-4 EXTERIOR - Front Bumper Section A – A Front bumper face Front bumper lower plate Front air dam Front air dam Double-sided tape: Generic products: 10mm width, 1.2mm thickness DISASSEMBLY SERVICE POINTS AA" RIVET REMOVAL Use the drill (ø4.0 mm) to make a hole in the rivet for removal. Rivet Front bumper...
  • Page 612 51-5 EXTERIOR - Front Bumper "BA RIVET INSTALLATION Riveter Use the recommended tool shown in the illustration to secure the rivet in the following procedure. Bumper face 1. Insert the rivet into the main materials (front bumper face and front bumper side plate.) 2.

  • Page 613: Rear Bumper

    51-6 EXTERIOR - Rear Bumper REAR BUMPER REMOVAL AND INSTALLATION Pre-removal and post-installation operations Removal and installation of rear combination lamp (Refer to GROUP 54A.) Removal and installation of rear end trim, washer tank lid and AYC reservoir tank lid (Refer to GROUP 52A – Trim.) Removal and installation of rear splash shield Section A –...
  • Page 614 51-7 EXTERIOR - Rear Bumper DISASSEMBLY AND REASSEMBLY Disassembly steps 1. License plate bracket 4. Rear bumper side plate 2. Rear bumper center reinforcement 5. Rear bumper face AA" "AA 3. Rivet DISASSEMBLY SERVICE POINTS AA" RIVET REMOVAL Use the drill (ø 4.0 mm) to make a hole in the rivet for removal. Rivet Front bumper...

  • Page 615: Side Air Dam, Molding And Garnish

    51-8 EXTERIOR - Rear Bumper / Side Air Dam, Molding and Garnish REASSEMBLY SERVICE POINTS Riveter "AA RIVET INSTALLATION Bumper face Use the recommended tool shown in the illustration to secure the rivet in the following procedure. 1. Insert the rivet into the main materials (rear bumper face and rear bumper side plate.) 2.

  • Page 616: Side Air Dam Molding Garnish

    51-9 EXTERIOR - Side Air Dam, Molding and Garnish SIDE AIR DAM, MOLDING AND GARNISH REMOVAL AND INSTALLATION Section A – A Section B – B Section D – D Section C – C Clip Clip Clip Clip Section F – F Section E –...
  • Page 617 51-10 EXTERIOR - Side Air Dam, Molding and Garnish REMOVAL SERVICE POINTS AA" ROOF DRIP MOLDING REMOVAL Use the special tool to pry the molding from the rear of the body for removal. Caution Do not use the deformed mold again. MB990449 AB"...
  • Page 618 51-11 EXTERIOR - Side Air Dam, Molding and Garnish 4. Remove strip paper from the pressure sensitive Backing paper double-sided tape. NOTE Affix double-sided tape to the end of strip paper for ease of strip paper removal. (Refer to P.51-9.) 5.

  • Page 619: Rear Spoiler

    51-12 EXTERIOR - Rear Spoiler REAR SPOILER ADHESIVE Application Brand Rear spoiler Double-sided tape [15 mm width 1.2 mm thickness, 30 mm width 1.2 mm thickness] REAR SPOILER REMOVAL AND INSTALLATION 5.2 ± 0.2 N·m 5.2 ± 0.2 N·m 5.2 ± 0.2 N·m 5.2 ±...

  • Page 620: Windshield Wiper And Washer

    51-13 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER SERVICE SPECIFICATIONS Item Standard value Stop position of the windshield wiper arm/blade assembly (distance between the edge of Stop position of the windshield wiper arm/blade assembly (distance between the edge of ±...
  • Page 621 51-14 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WASHER REMOVAL AND INSTALLATION View A Section A - A 3, 4 Clip A NOTE Section B - B indicates the clip A location. indicates the clip B location. 3 ,4 Clip B 13 ±...
  • Page 622 51-15 EXTERIOR - Windshield Wiper and Washer 5.0 ± 1.0 NSm NOTE: Refer to P.51-19 for more information regarding removal and installation of rear washer nozzle. Washer hose removal steps Washer tank and windshield washer motor assembly removal steps D Splash shild <Right side> (Refer to GROUP 42 –...
  • Page 623 51-16 EXTERIOR - Windshield Wiper and Washer REMOVAL SERVICE POINT Windshield wiper motor assembly AA" WINDSHIELD WIPER MOTOR ASSEMBLY REMOVAL 1. Remove the windshield wiper motor assembly mounting bolt. 2. Use the flat-tipped screw driver to disengage the link between the windshield wiper motor assembly and the Link assembly link assembly to remove the windshield wiper motor connection...
  • Page 624 51-17 EXTERIOR - Windshield Wiper and Washer INSPECTIONS WINDSHIELD WIPER MOTOR CHECK Inspection of windshield wiper motor is conducted by removing the harness connector with the motor attached to the vehicle. Operation inspection of windshield wiper motor rotation in a low or high speed Connect the battery to the windshield wiper motor to inspect the operation of motor rotation in a low or high speed.
  • Page 625 51-18 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WASHER NOZZLE INJECTION POSITION CHECK Move the nozzle to adjust the position so that the injection can be done in an area shown in the illustration. Caution On R.H. drive vehicles, the illustration is symmetrical. Unit:mm Windshield washer nozzle perpendicular...
  • Page 626 51-19 EXTERIOR - Windshield Wiper and Washer WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH AND WINDSHIELD INTERMITTENT WIPER INTERVAL ADJUSTING KNOB CHECK <L.H.drive vehicles> (1) Windshield wiper and washer switch, rear wiper and washer switch. Switch position Terminal No. Windshield wiper mist switch ON Windshield intermittent wiper switch ON Windshield low-speed wiper switch ON Windshield high-speed wiper switch ON...

  • Page 627: Marks

    51-20 EXTERIOR - Marks MARKS REMOVAL AND INSTALLATION 1. Three-diamond mark "AA 4. LANCER mark "AA 2. Three-diamond mark "AA 5. RECARO decal <RS- II> "AA 3. Evolution - VII mark INSTALLATION SERVICE POINT "AA ATTACHMENT OF EACH MARK 1. ATTACHED POSITION...
  • Page 628 51-21 EXTERIOR - Marks (2) Three - diamond mark, (3) Evolution - VII mark Section C - C Press line 73 mm 73 mm Press line Vehicle centerline Three - diamond mark Press line Press line View A Vehicle centerline 8.5 mm 23 mm 73 mm...
  • Page 629 51-22 EXTERIOR - Marks (5) RECARO decal <RS - II> <Right> Stationary Application tape terminal RECARO decal terminal window glass 31 mm 15 mm 52 mm 16 mm Stationary window weather strip terminal Stationary <Left> window glass Application tape terminal RECARO decal terminal 28 mm 19 mm...

  • Page 630: Outside Mirror

    51-23 EXTERIOR - Outside Mirror OUTSIDE MIRROR SPECIAL TOOL Tool Number Name Application MB990784 Ornament remover Removal of power remote control outside mirror switch OUTSIDE MIRROR REMOVAL AND INSTALLATION Section A - A Claw 7.4 ± 1.4 N·m Outside mirror removal steps Remote control outside mirror switch removal steps 1.
  • Page 631 51-24 EXTERIOR - EXTERIOR - Outside Mirror Outside Mirror REMOVAL SERVICE POINT Section A – A Mirror AA" MIRROR REMOVAL Tilt the mirror upward, insert the flat-tipped screw driver wrapped around with the protection tape between the notch Flat-tipped screw driver located behind the mirror and pivot plate, and pry off the mirror.
  • Page 632 51-25 EXTERIOR - Outside Mirror CONTINUITY INSPECTION OF POWER REMOTE CONTROL MIRROR SWITCH<RS - II> Switch Switch position Terminal number Left Right Mirror adjustment switch Down Left Right...
  • Page 633 NOTES...
  • Page 634 42-1 BODY CONTENTS HOOD ADHESIVES ............. SPECIAL TOOLS .

  • Page 635: Hood

    42-2 BODY - Hood HOOD ON - VEHICLE SERVICE ADJUSTMENT OF CLEARANCE AROUND HOOD ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER ADJUSTMENT OF HOOD HEIGHT With the marker as guide, turn the hood bumper to adjust the hood height. The hood bumper height changes approx. 3mm (new hood bumper with one complete turn).

  • Page 636: Hood

    42-3 BODY - Hood HOOD REMOVAL AND INSTALLATION 9.0 ± 2.0 N·m Section B - B Section A - A Clip Clip Remarks indicate the clip position. 7. Head lamp weather strip 1. Hood bumper 8. Hood support rod Hood lock release cable removal 9.

  • Page 637: Fender

    42-4 BODY - Hood/Fender REMOVAL SERVICE POINTS "AA HOOD HINGE BOLT INSTALLATION Caution Use the special parts as the aluminum hood uses special coatings on the <hood side> of the hood hinge bolt. FENDER SPECIAL TOOLS Tool Number Name MB990784 Ornament remover Side turn signal lamp removal...

  • Page 638: Fender

    42-5 BODY - Fender FENDER REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Front Bumper Removal and Installation (Refer to Front Deck Garnish Removal and Installation (Refer GROUP 51.) to GROUP 51.) Removal steps D Side air dam (Refer to GROUP 3.
  • Page 639 42-6 BODY - Fender REMOVAL SERVICE POINTS Front of vehicle AA" SIDE TURN SIGNAL LAMP REMOVAL Side turn signal lamp Use the special tool to release the claw part of the fender panel and remove the side turn signal lamp. MB990784 Section A - A MB990784...

  • Page 640: Fuel Filler Door

    42-7 BODY - Fuel Filler Door FUEL FILLER DOOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Rear Seat Removal and Installation. (Refer to GROUP (Driver’s Side), Center Pillar Lower Trim (Driver’s 52A.) Side), Quarter Trim (Driver’s Side) Removal and Front Scuff Plate (Driver’s Side), Rear Scuff Plate Installation (Refer to GROUP 52A –...

  • Page 641: Strut Tower Bar And Rear End Cross Bar

    42-8 BODY - Strut Tower Bar and Rear End Cross Bar STRUT TOWER BAR AND REAR END CROSS BAR REMOVAL AND INSTALLATION 44 ± 5 N·m Strut tower bar Rear end cross bar...

  • Page 642: Window Glass

    42-9 BODY - Window Glass WINDOW GLASS ADHESIVE Items Specified adhesive Windshield 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent Rear window glass SPECIAL TOOLS Tool Number Name MB990480 Window glass Removal and Installation of Window Glass holder MB990784 Ornament remover...
  • Page 643 42-10 BODY - Window Glass HANDLING OF AUTO WINDOW SEALER Keep the sealant in a cool place, not exposed to the direct rays of the sun. Do not place any heavy article on the sealant nor press it, otherwise it will become deformed. Avoid storing the sealant for more than 6 months, because it will lose its sealing effect.

  • Page 644: Windshield

    42-11 BODY - Window Glass WINDSHIELD REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Deck Garnish Removal and Installation Front Pillar Trim Removal and Installation (Refer to GROUP 51-Windshield Wiper and Washer.) (Refer to GROUP 52A.) Headlining Removal and Installation Section A - A Section B - B Seal line center Seal line center...
  • Page 645 42-12 BODY - Window Glass REMOVAL SERVICE POINTS AA" WINDSHIELD AND WINDSHEILD MOLDING REMOVAL 1. In order to protect the body (paint surface), apply cloth tape to all body areas around the installed windshield. 2. Use any of the following methods to cut off adhesive. <Using the piano wire>...
  • Page 646 42-13 BODY - Window Glass 3. Make alignment marks on the windshield and body. MB990480 4. Use the special tool to remove the windshield. 5. Use a knife to cut away remaining adhesive to 2 mm thick or less around the entire circumference of the body flange.
  • Page 647 42-14 BODY - Window Glass INSTALLATION SERVICE POINTS "AAWINDSHIELD SPACER/SPACER/GLASS STOPPER/WINDOW DAM/WINDSHIELD MOLDING/WINDSHIELD INSTALLATION 1. When replacing the windshield, first align it with the body, and then matchmark them. 2. Use isopropyl alcohol to clean the inside edge of the windshield and the body flange.
  • Page 648 42-15 BODY - Window Glass 6. Install the windshield molding. 7. Within thirty minutes after the primer application, fill a sealant gun with the adhesive, and then apply the adhesive evenly around the windshield. NOTE Cut the tip of the sealant gun nozzle into a V shape to simplify adhesive application.

  • Page 649: Rear Window Glass

    42-16 BODY - Window Glass REAR WINDOW GLASS REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Rear Pillar Trim Removal and Installation High Mount Stop Lamp Assembly Removal and (Refer to GROUP 52A.) Installation (Refer to GROUP 54A) Headlining Removal and Installation Rear Shelf Trim Removal and Installation (Refer to GROUP 52A.) Section A - A...
  • Page 650 42-17 BODY - Window Glass REMOVAL SERVICE POINTS AA" REAR WINDOW LOWER MOLDING REMOVAL Pry the rear window lower molding off with the special tool. MB990784 Caution Do not use a deformed molding. AB" REAR WINDOW GLASS REMOVAL Remove the rear window glass in the same manner as for the windshield.
  • Page 651 42-18 BODY - Window Glass Glass stopper and window dam installation position Glass end line Align the window Glass stopper dam end with the seal line mark. 18 mm Align the glass Mark stopper end with the ceramic notch. Seal line 19 mm Ceramic line Ceramic line...

  • Page 652: Doors

    42-19 BODY - BODY - Doors Doors DOORS SERVICE SPECIFICATIONS Items Standard value Door outside handle play mm Front 2.3 ± 2.1 Rear 1.3 ± 1.7 Power window operating current (power supply 14.5 ± 0.5 V, 25_C) A 5 ± 1 Front 9.6 ±...

  • Page 653: Troubleshooting

    42-20 BODY - BODY - Doors Doors Tool Number Name MB991223 Harness set Terminal voltage measurement A: MB991219 A: Test harness A: Connector pin contact pressure check B: MB991220 B: LED harness B: Power circuit check C: MB991221 C: LED harness C: Power circuit check adapter D: MB991222...

  • Page 654: Door Window Glass Adjustment

    42-21 BODY - Doors 3. If the door does not open and close smoothly (1) Adjustment with the striker (inside the vehicle and up and down directions) Change the striker fixing bolt to a temporary bolt, and using the special tool (MB990939) and hammer, gently hit the top of the temporary bolt in the direction to be adjusted.

  • Page 655: Window Malfunction

    42-22 BODY - Doors ADJUSTMENTS AND REPLACEMENT DURING Runchannel POWER WINDOW MALFUNCTION Door sash If the window glass does not rise but automatically descends, adjust and replace the window glass as follows: 1. Remove the door trim and waterproof film. (P.42-27) 2.

  • Page 656: Door Outside Handle Looseness Check

    42-23 BODY - Doors DOOR OUTSIDE HANDLE LOOSENESS CHECK 1. Check that the looseness of the door outside handle satisfies the standard value. Standard value (A): Front 2.3 ± 2.1 mm Rear 1.3 ± 1.7 mm 2. Check the door outside handle and door latch assembly. If faulty, replace.

  • Page 657: Door Inside Handle Looseness Check And Adjustment

    42-24 BODY - Doors DOOR INSIDE HANDLE LOOSENESS CHECK Section B - B AND ADJUSTMENT 1. Check that the door inside handle looseness satisfies the standard value. Standard value (A): Front 9.6 ± 9.2 mm Rear 9.0 ± 9.2 mm 2.

  • Page 658: Door Assembly

    42-25 BODY - Doors DOOR ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Door Adjustment (Refer to P.42-20.) <FRONT DOOR> 27 ± 5 N·m 11 ± 2 N·m 1.5 ± 0.5 N·m 21 ± 4 N·m 11 ± 2 N·m 27 ± 5 N·m 21 ±...
  • Page 659 42-26 BODY - Doors INSTALLATION SERVICE POINTS Striker center Latch center "AA STRIKER INSTALLATION Align the center of the striker and latch within 1.5 mm, and ± +1.5 mm install. - 1.5 mm Striker Latch INSPECTION DOOR SWITCH CONTINUITY CHECK Switch position Terminal No.

  • Page 660: Door Trim And Waterproof Film

    42-27 BODY - Doors DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION <FRONT DOOR> <REAR DOOR> Sealant: 3M ATD Part No. 8625 or equivalent <FRONT DOOR> <REAR DOOR> Removal steps "BA 6. Escutcheon <Vehicles without power windows> 1. Cap "BA 7. Regulator handle <Vehicles without 2.
  • Page 661 42-28 BODY - Doors CLIP AND CLAW POSITIONS <FRONT DOOR> View C View B View A Note Clips positions Claws positions View A View B View C Power window Front door trim switch panel assembly AW0461AU Section B - B Section A - A Power window switch panel assembly...
  • Page 662 42-29 BODY - Doors <REAR DOOR> View C View B View A Note Clips positions Claws positions View B View C View A Rear door trim Power window switch panel assembly AW0461AU Section B - B Section A - A Power window switch panel assembly Clip...
  • Page 663 42-30 BODY - Doors REMOVAL SERVICE POINTS Tapping screw cap AA" DOOR INSIDE HANDLE COVER REMOVAL 1. Insert the driver into the tapping screw cap end of the door inside handle cover and pry the cap the way shown in the illustration to remove the cap, and then unscrew the tapping screw.
  • Page 664 42-31 BODY - Doors INSTALLATION SERVICE POINTS <FRONT DOOR> "AA WATERPROOF FILM INSTALLATION Apply the specified adhesive on the waterproof film as shown in the illustration, and then glue it on the door window glass. Specified sealant: 3M ATD Part No. 8625 or equivalent Waterproof film <REAR DOOR>...

  • Page 665: Door Glass And Regulator

    42-32 BODY - Doors DOOR GLASS AND REGULATOR REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Door Trim and Waterproof Film Removal (Refer to Door Window Glass Adjustment (Refer to P.42-21.) P.42-27.) Door Trim and Waterproof Film Installation (Refer to P.42-27) <REAR DOOR>...
  • Page 666 42-33 BODY - Doors REMOVAL SERVICE POINTS AA" WINDOW REGULATOR ASSEMBLY/POWER MB990480 WINDOW MOTOR ASSEMBLY REMOVAL 1. Loosen the door window glass assembly mounting bolts. 2. Raise the door window glass assembly, and then adhere the special tool on the glass as shown in the illustration to prevent from falling.
  • Page 667 42-34 BODY - BODY - Doors Doors "BA OPERATION CHECK <Vehicles with power window> 1. Install the glass to the window regulator assembly. Caution (1) As fully open position which is programed in the power window-ECU is released (initialized), the window regulator assembly should not be operated until it is installed to the glass.

  • Page 668: Door Handle And Latch

    42-35 BODY - Doors DOOR HANDLE AND LATCH REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Door Trim Removal (Refer to P.42-27.) Door Inside Handle Looseness Check (Refer to P.42-24.) Door Outside Handle Looseness Check (Refer to P.42-23.) Door Trim Installation (Refer to P.42-27.) <REAR DOOR>...
  • Page 669 42-36 BODY - BODY - Doors Doors "BA LOWER SASH INSTALLATION Be sure to install the lower sash to the window rear sash (at door) securely. "CA DOOR INSIDE HANDLE INSTALLATION Clip 1. Install the inside lock cable to the door inside handle Inner cable as follows: Outer cable...
  • Page 670 42-37 BODY - Doors Rear door <Rear door> <Left side> <Left side> Lock Rod position Rod operation Terminal No. View A LOCK LOCK to UNLOCK UNLOCK UNLOCK to LOCK <Right side> Unlock Rod position Rod operation Terminal No. <Right side> LOCK LOCK to UNLOCK Lock...

  • Page 671: Window Glass Runchannel And Door Opening Weatherstrip

    42-38 BODY - Doors WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP REMOVAL AND INSTALLATION <FRONT DOOR> Sectional view of clip position Sectional view of clip position Section A - A Door Door inner opening weatherstrip Door beltline inner weatherstrip removal steps removal steps D Scuff plate (Refer to GROUP 52A.) D Door trim (Refer to P.42-27.)
  • Page 672 42-39 BODY - Doors Sectional view of <REAR DOOR> clip position Sectional view of clip position Section A - A Door Section B - B Door Door inner opening weatherstrip Door beltline inner weatherstrip removal steps removal steps D Scuff plate (Refer to GROUP 52A.) D Door trim (Refer to P.42-27.) D Center pillar lower trim (Refer to 5.
  • Page 673 42-40 BODY - Doors INSTALLATION SERVICE POINTS "AA DOOR OUTER OPENING WATHERSTRIP INSTALLATION The clip colour identifies the left and right weatherstrips so be sure to use the colours as install correctly. Applicable side Identification colour Right door Pink Left door Natural (White)

  • Page 674: Trunk Lid

    42-41 BODY - Trunk lid TRUNK LID REMOVAL AND INSTALLATION Measure of Section A - A length mm Section B - B 8.9 ± 1.9 N·m Trunk lid weatherstrip removal 4. Trunk lid striker steps Trunk lid panel removal steps D Rear end trim <RS- >...
  • Page 675 42-42 BODY - Trunk lid Grease application area REMOVAL SERVICE POINT Trunk lid torsion bar AA" TRUNK LID TORSION BAR REMOVAL Insert the tire lever into the torsion bar, and then pull upward the tire lever to remove the torsion bar as shown in the illustration.
  • Page 676 42-43 BODY - Trunk Lid "BA TRUNK LID WEATHERSTRIP INSTALLATION aligning the trunk lid weatherstrip marking section at the body center to install. Marking section Joint section INSPECTION TRUNK LID LATCH SWITCH CONTINUITY CHECK Switch position Terminal No. Earth Latch open Latch closed Trunk lid latch assembly...
  • Page 677 NOTES...
  • Page 678 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.

  • Page 679: General Information

    37A-2 STEERING - General Information GENERAL INFORMATION The system has been equipped with the MOMO type that combines the steering gear and linkage leather 3-spoke-type steering wheel with built-in into one light-weight and compact assembly. SRS airbag. The steering system uses a vane oil pump with The steering column is equipped with tilt steering a fluid flow control system, so that steering effort mechanism.
  • Page 680 37A-3 STEERING - General Information CONSTRUCTION DIAGRAM <L.H. drive vehicles> Steering wheel Steering column and shaft Reservoir tank Return hose Suction hose Pressure hose Oil pump assembly Steering gear Cooler tube and linkage <R.H. drive vehicles> Steering wheel Steering column and shaft Reservoir tank Return hose Suction hose...

  • Page 681: Service Specifications

    37A-4 STEERING - Service Specifications/Lubricants/Sealant/Special Tools SERVICE SPECIFICATIONS Items Standard value Limit Steering wheel free play mm when engine running 30 or less with engine stopped 0 - 10 Steering angle Inner wheel 31_45’ ± 1_30’ Outer wheel <for reference> 27_15’...
  • Page 682 37A-5 STEERING - Special Tools Tool Number Name MB991006 Preload socket Measurement of the total pinion torque MB990326 Preload socket Measurement of the ball joint turning torque MB990993 Power steering oil Measurement of oil pressure pressure gauge adapter (pump side) MB990994 Power steering oil pressure gauge...
  • Page 683 37A-6 STEERING - Special Tools Tool Number Name MB991197 Bar (long type) Press fitting of rack housing bearing To press in the oil seal for the rack MB991214 Rack installer Rack installation MB990925 Bearing and oil Installation of the oil seal and bearing seal installer set (Refer to GROUP 26 - Special Tools.) MB991120...

  • Page 684: On-Vehicle Service

    37A-7 STEERING - On-vehicle Service ON-VEHICLE SERVICE STEERING WHEEL FREE PLAY CHECK 1. With engine running (hydraulic operation), set front wheels straight ahead. 2. Measure the play on steering wheel circumference before wheels start to move when slightly moving steering wheel in both directions.

  • Page 685: Stationary Steering Effort Check

    37A-8 STEERING - On-vehicle Service 2. Move ball joint stud several times and install nut on stud. MB990326 Measure ball joint turning torque with special tool. Standard value: 1.0 - 3.0 N·m 3. When the turning torque exceeds the standard value, replace tie rod end.

  • Page 686: Power Steering Fluid Level Check

    37A-9 STEERING - On-vehicle Service POWER STEERING FLUID LEVEL CHECK Fluid level change: Within 5 mm 1. Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60_C. 2.

  • Page 687: Oil Pump Pressure Test

    37A-10 STEERING - On-vehicle Service 9. If the level changes more than 5 mm, the air is badly Fluid level change: Within 5 mm bled. So, bleed air again. Caution (1) If the fluid level rises suddenly after the engine is stopped, the bleeding is incomplete.

  • Page 688: Power Steering Oil Pressure Switch Check

    37A-11 STEERING - On-vehicle Service POWER STEERING OIL PRESSURE SWITCH Adapter CHECK Shut-off valve (MB990993) Pressure gauge 1. Disconnect the pressure hose from the oil pump, and (MB990662) then connect the special tools. Temperature 2. Bleed the air, and then turn the steering wheel several gauge times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60_C.

  • Page 689: Steering Wheel

    37A-12 STEERING - Steering Wheel STEERING WHEEL REMOVAL AND INSTALLATION Caution: Before removing the steering wheel and air bag module assembly, refer to GROUP 52B – Service Precautions and Air Bag Module and Clock Spring. Post-installation Operation Checking Steering Wheel Position with Wheels Straight Ahead <RS (standard)>...
  • Page 690 37A-13 STEERING - Steering Wheel REMOVAL SERVICE POINTS AA" STEERING WHEEL REMOVAL <RS (standard)> MB990784 AB" COVER REMOVAL <RS (option), RS-II> Insert the special tool from the indicated position to remove the cover. NOTE MB990784 The special tool can be inserted through the notch behind the position shown.

  • Page 691: Steering Shaft

    37A-14 STEERING - Steering Shaft STEERING SHAFT REMOVAL AND INSTALLATION Caution: Before removing clock spring, refer to GROUP 52B – Service Precautions and Air Bag Module and Clock Spring. Pre-removal Operation Post-installation Operation Steering Wheel Removal (Refer to P.37A-12.) Instrument Under Cover Installation Instrument Under Cover Removal (Refer to GROUP 52A.) (Refer to GROUP 52A.)
  • Page 692 37A-15 STEERING - Steering Shaft DISASSEMBLY AND REASSEMBLY Disassembly steps AA" "AA 1. Special bolt 5. Steering shaft assembly "AA 2. Steering lock bracket 6. Tilt spring "AA 3. Steering lock cylinder assembly 7. Steering column assembly 4. Snap ring DISASSEMBLY SERVICE POINT Left-hand tap Special bolt...

  • Page 693: Power Steering Gear Box And Linkage

    37A-16 STEERING - Power Steering Gear Box and Linkage POWER STEERING GEAR BOX AND LINKAGE REMOVAL AND INSTALLATION Caution: SRS Before removing steering gear box, refer to GROUP 52B. Also, put the front wheels in straight-ahead position. Failure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which results serious driver injury.
  • Page 694 37A-17 STEERING - Power Steering Gear Box and Linkage <R.H. drive vehicles> 15 ± 3 N·m 70 ± 10 N·m 57 ± 7 N·m Removal steps 1. Crossmember 4. Return tube (Refer to GROUP 32.) 5. Pressure hose connection 2. Joint cover grommet 6.
  • Page 695 37A-18 STEERING - Power Steering Gear Box and Linkage TIE ROD SWING RESISTANCE CHECK 1. Swing the tie rod 10 times hardly. 2. With the tie rod end downwards as shown, use a spring scale to measure swing resistance (swing torque). Standard value: 8 - 27 N (1.5 - 4.9 N·m) 3.
  • Page 696 37A-19 STEERING - Power Steering Gear Box and Linkage DISASSEMBLY AND REASSEMBLY <L.H. drive vehicles> Flare nut 22 ± 4 N·m 13 ± 3 N·m Repair kit grease 59 ± 10 N·m 52 ± 2 N·m 15 14 23 ± 2 N·m → - 30_ 11 35 25 ±...
  • Page 697 37A-20 STEERING - Power Steering Gear Box and Linkage <R.H. drive vehicles> Flare nut 13 ± 3 N·m 22 ± 4 N·m Re p ai r k i t g re ase 11 35 17 31 59 ± 10 N·m 29 28 25 ±...
  • Page 698 37A-21 STEERING - Power Steering Gear Box and Linkage Lubrication and Sealing Points Fluid: Automatic transmission fluid DEXRON II Fluid: Automatic transmission fluid DEXRON II Fluid: Automatic transmission fluid DEXRON II Grease: Repair kit grease Sealant: 3M ATD part No. 8661, 8663 or equivalent Fluid: Automatic transmission...
  • Page 699 37A-22 STEERING - Power Steering Gear Box and Linkage DISASSEMBLY SERVICE POINTS AA" RACK SUPPORT COVER REMOVAL MB991204 AB" LOWER OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL With a plastic hammer, lightly tap the pinion and valve assembly in its spline to remove the lower oil seal and pinion and valve assembly from the valve housing.
  • Page 700 37A-23 STEERING - Power Steering Gear Box and Linkage AF" RACK STOPPER/RACK BUSHING/OIL SEAL/ O-RING/RACK ASSEMBLY REMOVAL 1. Remove the rack stopper, rack bushing, oil seal and O-ring together by pulling out the rack gently. 2. Partially bend the oil seal to remove from the rack bushing. Caution Use care not to damage the oil seal press-fitting surface of the rack bushing.
  • Page 701 37A-24 STEERING - Power Steering Gear Box and Linkage REASSEMBLY SERVICE POINTS MB991199 "AA OIL SEAL INSTALLATION MB991197 Gear housing Oil seal "BA NEEDLE BEARING/LOWER BEARING MB990925 Needle MB990925 (MB990938) bearing INSTALLATION (MB990938) MB991202 MB991202 Lower bearing "CA RACK ASSEMBLY INSTALLATION Vent hole 1.
  • Page 702 37A-25 STEERING - Power Steering Gear Box and Linkage "DA OIL SEAL/RACK BUSHING INSTALLATION 1. Apply specified fluid to the outer surface of the oil seal. MB990925 Using the special tool, press in the oil seal until it is flush (MB990927) with the bushing end face.
  • Page 703 37A-26 STEERING - Power Steering Gear Box and Linkage "HA LOWER OIL SEAL INSTALLATION Approx. 1 mm MB990941 Using the special tool, press the oil seal into the valve housing. The upper surface of the oil seal must project outwards about seal 1 mm from the housing end surface.
  • Page 704 37A-27 STEERING - Power Steering Gear Box and Linkage 2. If the total rotation torque or torque fluctuation does not meet the standard values, adjust by returning the rack support cover within a range of 0 to 30_. Caution (1) Adjust around the maximum limit of the standard values.
  • Page 705 37A-28 STEERING - Power Steering Gear Box and Linkage 3. See that the crimped width (A) meets the standard value. Standard value (A): 2.4 - 2.8 mm <When more than 2.8 mm> Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2).

  • Page 706: Power Steering Oil Pump

    37A-29 STEERING - Power Steering Oil Pump POWER STEERING OIL PUMP REMOVAL AND INSTALLATION Caution After temporary tightening all bolts in * part, tighten in specific torque. Pre-removal Operation Post-installation Operation Power Steering Fluid Draining (Refer to P.37A-9.) Power Steering Fluid Supplying and Bleeding (Refer to P.37A-9.) Drive Belt Tension Adjusting (Refer to GROUP 11A –...

  • Page 707: Power Steering Oil Hoses

    37A-30 STEERING - Power Steering Oil Pump/Power Steering Oil Hoses "BA PRESSURE HOSE ASSEMBLY/SUCTION HOSE Suction hose REMOVAL Install the pressure hose assembly and suction hose as illustrated. Pressure hose Marking assembly Notch DISASSEMBLY AND REASSEMBLY 21 ± 3 N·m 39 ±...
  • Page 708 37A-31 STEERING - Power Steering Oil Hoses <L.H. drive vehicles> Pre-removal and Post-installation Operation Power Steering Fluid Draining and Refilling (Refer to P.37A-9.) 18 ± 3 N·m 12 ± 2 N·m 12 ± 2 N·m 12 ± 2 N·m 15 ± 3 N·m 57 ±...
  • Page 709 37A-32 STEERING - Power Steering Oil Hoses <R.H. drive vehicles> Pre-removal and Post-installation Operation Power Steering Fluid Draining and Refilling (Refer to P.37A-9.) 12 ± 2 N·m 18 ± 3 N·m 12 ± 2 N·m 12 ± 2 N·m 12 ± 2 N·m 15 ±...
  • Page 710 37A-33 STEERING - Power Steering Oil Hoses REMOVAL SERVICE POINT AA" EYE BOLT/RETURN TUBE REMOVAL 1. Loosen the crossmember mounting bolts and nuts, and lower the crossmember to a position so that the eye bolts or return tube at the steering gear side can be removed. NOTE In this case, do not remove the crossmember mounting bolts and nuts.
  • Page 711 NOTES...
  • Page 712 36-1 PARKING BRAKES CONTENTS GENERAL INFORMATION ....Parking Brake Switch Check ....Lining Running-In .

  • Page 713: General Information

    36-2 PARKING BRAKES - General Information/Service Specifications/Lubricants GENERAL INFORMATION The parking brake is of a mechanical control type acting on the rear wheels. A lever is used to apply the parking brake. CONSTRUCTION DIAGRAM Parking brake lever Parking brake lever SERVICE SPECIFICATIONS Items Standard value...

  • Page 714: On-Vehicle Service

    36-3 PARKING BRAKES - On-Vehicle Service ON-VEHICLE SERVICE PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 1. Pull the parking brake lever with a force of approx. 200 N and count the number of notches. Standard value: 5 - 7 notches 2.

  • Page 715: Lining Running-In

    36-4 PARKING BRAKES - On-Vehicle Service LINING RUNNING-IN Pull Carry out running-in by the following procedure when replacing the parking brake linings or the rear brake disc rotors, or when brake performance is insufficient. Spring balance Caution Carry out running-in in a place with good visibility, and pay careful attention to safety.

  • Page 716: Parking Brake Lever

    36-5 PARKING BRAKES - Parking Brake Lever PARKING BRAKE LEVER REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Rear Floor Console Assembly and Rear Console Parking Brake Lever Stroke Adjustment Bracket Removal (Refer to GROUP 52A-Floor Console.) (Refer to P.36-3.) Rear Floor Console Assembly and Rear Console Bracket Installation (Refer to GROUP 52A-Floor Console.) Section B - B...

  • Page 717: Parking Brake Cable

    36-6 PARKING BRAKES - Parking Brake Cable PARKING BRAKE CABLE REMOVAL AND INSTALLATION CAUTION If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.

  • Page 718: Parking Brake Drum

    36-7 PARKING BRAKES - Parking Brake Drum PARKING BRAKE DRUM REMOVAL AND INSTALLATION CAUTION If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
  • Page 719 36-8 PARKING BRAKES - Parking Brake Drum REMOVAL SERVICE POINT AA" REAR BRAKE CALIPER ASSEMBLY REMOVAL Remove the rear brake caliper assembly and support it with wire or similar. CAUTION: Brembo disc brake Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.

  • Page 720: Service Brakes

    35A-1 SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM ......... ANTI-SKID BRAKING SYSTEM (ABS) <4WD>...
  • Page 721 35A-2 BASIC BRAKE SYSTEM CONTENTS GENERAL INFORMATION ....Bleeding ........Brake Fluid Level Sensor Check .

  • Page 722: General Information

    35A-3 BASIC BRAKE SYSTEM - General Information GENERAL INFORMATION The brake system offers high dependability and durability along with improved braking performance and brake sensitivity. SERVICE PRECAUTION <VEHICLES WITH BREMBO BRAKING SYSTEM> Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. SPECIFICATIONS Items Specifications...
  • Page 723 35A-4 BASIC BRAKE SYSTEM - General Information CONSTRUCTION DIAGRAM <Vehicles with ABS> Brake booster* Hydraulic unit* Rear disc brake Parking brake Master cylinder* Front disc brake <Vehicles without ABS> Brake booster* Master cylinder and proportioning valves* Rear disc brake Parking brake Front disc brake NOTE For R.H.

  • Page 724: Service Specifications

    35A-5 BASIC BRAKE SYSTEM - Service Specifications SERVICE SPECIFICATIONS Items Standard value Limit Brake pedal height mm 169.1 - 172.1 Brake pedal play mm 3 - 8 Brake pedal to floorboard clearance when the brake pedal is depressed mm 90 or more Brake booster push rod protrusion amount mm 8.98 - 9.23 Proportioning valve...

  • Page 725: Lubricants

    35A-6 BASIC BRAKE SYSTEM - Lubricants/Sealant/Special Tools LUBRICANTS Items Specified Lubricant Quantity Brake fluid DOT3 or DOT4 As required Piston, wheel cylinder body Piston boot, piston seal, shim Repair kit grease Guide pin, lock pin, pin boot <Except for Brembo disc brake> Pad assembly <Brembo disc brake>...

  • Page 726: On-Vehicle Service

    35A-7 BASIC BRAKE SYSTEM - On-vehicle Service ON-VEHICLE SERVICE BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT 1. Turn up the carpet, etc. under the brake pedal. 2. Measure the brake pedal height as illustrated. Standard value (A): 169.1 - 172.1 mm 3.

  • Page 727: Brake Booster Operating Test

    35A-8 BASIC BRAKE SYSTEM - On-vehicle Service 2. If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary: Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod Brake pedal height Installation position of the stop lamp switch, etc.

  • Page 728: Check Valve Operation Check

    35A-9 BASIC BRAKE SYSTEM - On-vehicle Service CHECK VALVE OPERATION CHECK 1. Remove the vacuum hose. (Refer to P.35A-17.) Caution The check valve should not be disassembled from the vacuum hose as they are united as one part. 2. Check the operation of the check valve by using a vacuum pump.

  • Page 729: Bleeding

    35A-10 BASIC BRAKE SYSTEM - On-vehicle Service BLEEDING Caution Specified brake fluid: DOT3 or DOT4 Always use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier.

  • Page 730: Brake Fluid Level Sensor Check

    35A-11 BASIC BRAKE SYSTEM - On-vehicle Service BRAKE FLUID LEVEL SENSOR CHECK The brake fluid level sensor is in good condition if there is no continuity when the float surface is above “MIN” and if there is continuity when the float surface is below “MIN”. DISC BRAKE PAD CHECK AND REPLACEMENT <Except for Brembo disc brake>...
  • Page 731 35A-12 BASIC BRAKE SYSTEM - On-vehicle Service <Brembo disc brake> Caution Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. NOTE The wear indicator contacts the brake disc when the brake pad thickness reaches approximately 2 mm and emit a...

  • Page 732: Disc Brake Rotor Check

    35A-13 BASIC BRAKE SYSTEM - On-vehicle Service (5) Apply repair kit grease to the portions of the pads Front Rear indicated on the left. At this time, make sure that the grease will not be applied to any other surfaces. (6) Mount the pads to the caliper so that its side with the wear indicator is on the outside of the vehicle.

  • Page 733: Brake Disc Thickness Check

    35A-14 BASIC BRAKE SYSTEM - On-vehicle Service BRAKE DISC THICKNESS CHECK Caution: Brembo disc brake Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. 1.
  • Page 734 35A-15 BASIC BRAKE SYSTEM - On-vehicle Service 3. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc. Limit: 0.03 mm or less 4. If the brake disc run-out exceeds the limit, correct it as follows: (1) Chalk phase marks on the wheel stud and the brake disc, which run-out is excessive.

  • Page 735: Brake Pedal

    35A-16 BASIC BRAKE SYSTEM - Brake Pedal BRAKE PEDAL REMOVAL AND INSTALLATION Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-7.) 12 ± 2 N·m 14 ± 3 N·m Removal steps 1. Harness connector 6. Pin assembly 2. Stop lamp switch 7.
  • Page 736 Brake Pedal/Proportioning Valve, 35A-17 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster INSPECTION STOP LAMP SWITCH CHECK 1. Connect an ohmmeter between the stop lamp switch connector terminals. 2. There should be no continuity between the terminals when Continuity No continuity the plunger is pushed in as shown.

  • Page 737: Proportioning Valve, Master

    Proportioning Valve, Master Cylinder 35A-18 BASIC BRAKE SYSTEM - and Brake Booster Master cylinder removal steps 5. Brake pipe connection 8. Master cylinder 1. Clutch hose connection "BA D Push rod protrusion amount check and 2. Brake fluid level sensor connector adjustment 3.

  • Page 738: Master Cylinder

    Proportioning Valve, Master Cylinder Proportioning Valve, Master Cylinder 35A-19 BASIC BRAKE SYSTEM - BASIC BRAKE SYSTEM - and Brake Booster and Brake Booster 2. If the protrusion amount is not within the standard value range, adjust the push rod length by turning the push rod.

  • Page 739: Disc Brake

    35A-20 BASIC BRAKE SYSTEM - Disc Brake DISC BRAKE REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
  • Page 740 35A-21 BASIC BRAKE SYSTEM - Disc Brake INSTALLATION SERVICE POINT <Front> "AA DISC BRAKE ASSEMBLY INSTALLATION MB990998 <Except for Brembo disc brake> 1. In order to measure the brake drag force after pad installation, measure the rotary-sliding resistance of the hub by the following procedure with the pads removed.
  • Page 741 35A-22 BASIC BRAKE SYSTEM - Disc Brake DISASSEMBLY AND REASSEMBLY Front <Except for Brembo disc brake> Clip set 74 ± 10 N·m 7.9 ± 0.9 N·m 74 ± 10 N·m Grease Brake caliper kit Pad set Shim set Seal and boot kit Disassembly steps "AA 1.
  • Page 742 35A-23 BASIC BRAKE SYSTEM - Disc Brake Front <Brembo disc brake> Caution Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. 14 ±...
  • Page 743 35A-24 BASIC BRAKE SYSTEM - Disc Brake Rear <Except for Brembo disc brake> 44 ± 5 N·m 7.9 ± 0.9 N·m Clip set Grease Brake caliper kit Pad set Shim set Seal and boot kit Disassembly steps "AA 1. Guide pin 8.
  • Page 744 35A-25 BASIC BRAKE SYSTEM - Disc Brake Rear <Brembo disc brake> Caution Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. 14 ±...
  • Page 745 35A-26 BASIC BRAKE SYSTEM - Disc Brake LUBRICATION POINTS <Except for Brembo disc brake> Piston seal Grease: Repair kit grease Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off. Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Grease: Repair kit grease...
  • Page 746 35A-27 BASIC BRAKE SYSTEM - Disc Brake DISASSEMBLY SERVICE POINTS Caution: Brembo disc brake Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. AA"...
  • Page 747 35A-28 BASIC BRAKE SYSTEM - Disc Brake "AA LOCK PIN/GUIDE PIN INSTALLATION Lock pin <Front> <Except for Brembo disc brake> Identification mark ”L” As shown in the illustration, align the identification mark on the caliper body and the head mark of the guide pin/lock pin, then install the guide pin/lock pin.

  • Page 748: Braking System

    35B-1 ANTI-SKID BRAKING SYSTEM (ABS) <4WD> CONTENTS GENERAL INFORMATION ....Disc Brake Rotor Check . . . Refer to GROUP 35A Brake Disc Thickness Check SERVICE SPECIFICATIONS .
  • Page 749 ABS-ECU outputs ABS signal to 4WD-ECU. Following system for Lancer EVOLUTION-VII has G sensor (lateral), steering wheel sensor and been modified from Lancer EVOLUTION-VI Tommi parking brake switch have been added to the Makinen Edition.
  • Page 750 35B-3 ABS <4WD> - General Information/Service Specifications CONSTRUCTION DIAGRAM Parking brake switch Steering ABS warning lamp wheel sensor* Hydraulic unit assembly* (integrated with the ABS-ECU) Wheel speed sensor Lateral G sensor Longitudinal G sensor Diagnosis connector* Stop lamp Wheel speed sensor switch* NOTE For R.H.
  • Page 751 35B-4 ABS <4WD> - Special Tools/Troubleshooting SPECIAL TOOLS Tool Number Name MB991502 MUT-II sub For checking of ABS assembly (Diagnosis code display when using the MUT-II) MB991529 Diagnosis code For checking of ABS check harness (Diagnosis code display when using the ABS warning lamp) MB991348 Test harness set...
  • Page 752 35B-5 ABS <4WD> - Troubleshooting ABS WARNING LAMP INSPECTION Check that the ABS warning lamp illuminates as follows. 1. When the ignition key is turned to “ON”, the ABS warning lamp illuminates for approximately 3 seconds and then switches off. 2.
  • Page 753 35B-6 ABS <4WD> - Troubleshooting When not using the MUT-II NOTE If the ABS-ECU function has been stopped because of fail-safe operation, it will not be possible to erase the diagnosis codes. 1. Stop the engine. MB991529 2. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector.
  • Page 754 35B-7 ABS <4WD> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Diagnosis code No. Inspection item Reference page Front right wheel speed sensor (Open circuit or short circuit) 35B-9 Front left wheel speed sensor (Open circuit or short circuit) Rear right wheel speed sensor (Open circuit or short circuit) Rear left wheel speed sensor (Open circuit or short circuit) ABS-ECU power supply system (Abnormal voltage drop or rise) 35B-10...
  • Page 755 35B-8 ABS <4WD> - Troubleshooting Diagnosis code No. Inspection item Reference page Steering wheel sensor (ST-1) system (Open circuit or short circuit) 35B-14 Steering wheel sensor (ST-2) system (Open circuit or short circuit) Steering wheel sensor (ST-N) system (Open circuit or short circuit) NOTE: diagnosis code No.16, 52, 63 1.
  • Page 756 35B-9 ABS <4WD> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES Probable cause Code Nos.11, 12, 13 and 14 Wheel speed sensor (open circuit or short circuit) Code Nos.21, 22, 23 and 24 Wheel speed sensor Code Nos. 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit D Malfunction of wheel speed sensor or short-circuit in the (+) wire or (- ) wire in any one of the four wheel speed sensors.
  • Page 757 35B-10 ABS <4WD> - Troubleshooting Code No.16 ABS-ECU power supply system (abnormal Probable cause voltage drop or rise) This code is output if the ABS-ECU power supply voltage drops below or rises above D Malfunction of battery the rated values. D Malfunction of wiring harness or connector Furthermore, turning the ignition switch to ACC will erase this code.
  • Page 758 35B-11 ABS <4WD> - Troubleshooting Code No.32 Longitudinal G sensor system Probable cause This code is output in the following cases. D Malfunction of longitudinal G sensor D If the longitudinal G sensor output voltage is less than 0.5 V or more than 4.5 V D Malfunction of wiring harness or connector <open circuit or short circuit of longitudinal G sensor circuit>...
  • Page 759 35B-12 ABS <4WD> - Troubleshooting Code Nos.41, 42, 43 and 44 Solenoid valve Probable cause Code No.52 Valve relay problem (stays off) Code No.53 Motor relay problem (stays off) Code No.55 Motor system (seized pump motor) These codes are output if there is an open circuit or short-circuit in the ABS-ECU D Malfunction of wiring harness or connector power supply circuit (power supply circuit for solenoid valve and motor), or the internal D Malfunction of hydraulic unit and ABS-ECU...
  • Page 760 35B-13 ABS <4WD> - Troubleshooting Code No.71 Lateral G sensor system Probable cause This code is output in the following cases. D Malfunction of lateral G sensor D If lateral G sensor output voltage is less than 0.5 V or more than 4.5 V D Malfunction of wiring harness or connector <open circuit or short circuit in the lateral G sensor circuit>...
  • Page 761 35B-14 ABS <4WD> - Troubleshooting Code No.81 Steering wheel sensor (ST-1) system (open Probable cause circuit or short circuit) Code No.82 Steering wheel sensor (ST-2) system (open circuit or short circuit) Code No.83 Steering wheel sensor (ST-N) system (open circuit or short circuit) These codes are output if there is a fault in the steering wheel sensor, an open circuit D Malfunction of steering wheel sensor or short circuit in the steering signal line, or the internal circuit in the hydraulic unit...
  • Page 762 35B-15 ABS <4WD> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptoms Inspection procedure Reference page Communication between the MUT-II and the whole system is not 35B-16 possible. Communication between the MUT-II and the ABS-ECU is not possible. 35B-17 When the ignition key is turned to “ON” (engine stopped), the ABS 35B-18 warning lamp does not illuminate.
  • Page 763 35B-16 ABS <4WD> - Troubleshooting INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Communication between the MUT-II and the whole system Probable cause is not possible. The cause may be a malfunction of the power supply circuit or the earth circuit of D Malfunction of diagnosis connector the diagnosis connector.
  • Page 764 35B-17 ABS <4WD> - Troubleshooting Inspection Procedure 2 Communication between MUT-II and the ABS-ECU is not Probable cause possible. The cause may be an open circuit in the ABS-ECU power supply circuit or an open D Blown fuse circuit in the diagnosis output circuit. D Malfunction of wiring harness or connector D Malfunction of hydraulic unit and ABS-ECU Measure at the diagnosis connector C-22 and the ABS-ECU...
  • Page 765 35B-18 ABS <4WD> - Troubleshooting Inspection Procedure 3 When the ignition key is turned to “ON” (engine stopped), Probable cause the ABS warning lamp does not illuminate. The cause may be an open circuit in the lamp power supply circuit, a blown lamp, D Blown fuse or an open circuit between the ABS warning lamp and the earth.
  • Page 766 35B-19 ABS <4WD> - Troubleshooting Inspection Procedure 5 In the inspection by MUT-II service data, the parking brake Probable cause switch is not turned ON or turn OFF. ABS-ECU optimizes the ABS control when pulling the parking brake lever, parking D Malfunction of parking brake switch brake switch signal is used as support.
  • Page 767 35B-20 ABS <4WD> - Troubleshooting Inspection Procedure 6 The neutral position learning of the steering wheel sensor Probable cause is not finished. The diagnosis is difficult because it depends on driving condition and road surface, D Equipment the odd diameter tyre if the diagnosis code displays the normal code, carry out the following check.
  • Page 768 35B-21 ABS <4WD> - Troubleshooting Inspection Procedure 7 Faulty ABS operation Probable cause This varies depending on the driving conditions and the road surface conditions, so D Improper installation of wheel speed sensor problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry D Malfunction of wiring harness or connector out the following inspection.
  • Page 769 35B-22 ABS <4WD> - Troubleshooting DATA LIST REFERENCE TABLE The following items can be read by the MUT-II from the ABS-ECU input data. 1. When the system is normal Item No. Check item Checking requirements Normal value Front-right wheel speed sensor Perform a test run Vehicle speeds displayed on the...
  • Page 770 35B-23 ABS <4WD> - Troubleshooting ACTUATOR TEST REFERENCE TABLE The MUT-II activates the following actuators for testing. NOTE 1. If the ABS-ECU runs down, actuator testing cannot be carried out. 2. Actuator testing is only possible when the vehicle is stationary. ACTUATOR TEST SPECIFICATIONS Activation pattern of Items No.
  • Page 771 35B-24 ABS <4WD> - Troubleshooting CHECK AT ABS-ECU Lock lever Use the following steps to remove the connector cover and measure the terminal voltage. 1. Move the lock lever of the ABS-ECU connector as shown in the illustration, and then disconnect the ABS-ECU connector.
  • Page 772 35B-25 ABS <4WD> - Troubleshooting Terminal No. Check item Checking requirements Normal condition ABS-ECU power Ignition switch: ON System voltage supply supply Ignition switch: START or ACC Solenoid valve power Always System voltage supply Lateral G sensor input Ignition switch: ON 2.4 - 2.6 V (horizontal position) Longitudinal G sensor Always...
  • Page 773 35B-26 ABS <4WD> - Troubleshooting/On-vehicle Service RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS 1. Turn the ignition key to the “LOCK” (OFF) position. 2. Disconnect the ABS-ECU connector. 3. Check the resistance and continuity between the terminals indicated in the table below. 4.
  • Page 774 35B-27 ABS <4WD> - On-vehicle Service 4. Rotate the wheel to be measured at approximately 1/2 - 1 rotation per second, and check the output voltage using a circuit tester or an oscilloscope. Wheel speed Front Front Rear Rear sensor left right left...
  • Page 775 35B-28 ABS <4WD> - On-vehicle Service Symptom Probable causes Remedy Noisy or disturbed waveform Open circuit in sensor Replace sensor Open circuit in harness Correct harness Incorrectly mounted wheel speed sensor Mount correctly ABS rotor with missing or damaged teeth Replace ABS rotor Caution Because the wheel speed sensor cables move together with the front and rear suspension, they...
  • Page 776 35B-29 ABS <4WD> - On-vehicle Service The result should be as shown in the following diagram. Depressed Pedal operation Released MUT-II actuator test (Item No. 01, 02, 03, 04) start Increase in pressure Solenoid valve Steady pressure position 2 seconds Reduction in pressure 1 seconds Lock...
  • Page 777 35B-30 ABS <4WD> - Hydraulic Unit and ABS-ECU HYDRAULIC UNIT AND ABS-ECU REMOVAL AND INSTALLATION <L.H. drive vehicles> Pre-removal Operation Post-installation Operation Strut Tower Bar Removal (Refer to GROUP 42.) Brake Fluid Supplying and Brake Line Bleeding Brake Fluid Draining (Refer to GROUP 35A - On-vehicle Service.) Hydraulic Unit Check (Refer to P.35B-28.) Strut Tower Bar Installation (Refer to GROUP 42.)
  • Page 778 35B-31 ABS <4WD> - Hydraulic Unit and ABS-ECU <R.H. drive vehicles> Pre-removal Operation Post-installation Operation Strut Tower Bar Removal (Refer to GROUP 42.) Brake Fluid Supplying and Brake Line Bleeding Brake Fluid Draining (Refer to GROUP 35A - On-vehicle Service.) Air Intake Hose and Air Cleaner Removal Hydraulic Unit Check (Refer to P.35B-28.) Air Intake Hose and Air Cleaner Installation...
  • Page 779 35B-32 ABS <4WD> - Hydraulic Unit and ABS-ECU REMOVAL SERVICE POINTS Lock lever AA" HARNESS CONNECTOR DISCONNECTION Move the lock lever of the ABS-ECU connector as shown in the illustration, and then disconnect the harness connector. AB" HYDRAULIC UNIT AND ABS-ECU REMOVAL Caution 1.
  • Page 780 35B-33 ABS <4WD> - Wheel Speed Sensor WHEEL SPEED SENSOR REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
  • Page 781 35B-34 ABS <4WD> - Wheel Speed Sensor INSTALLATION SERVICE POINT "AA WHEEL SPEED SENSOR <REAR> Wheeel speed sensor <rear> INSTALLATION Install the wheel speed sensor crossing with the parking brake cable. Parking brake cable INSPECTION CHECK OF RESISTANCE BETWEEN WHEEL SPEED SENSOR TERMINALS Caution The pole piece can become magnetized because of the...
  • Page 782 35B-35 ABS <4WD> - G Sensors and Steering Wheel Sensor G SENSORS AND STEERING WHEEL Parking brake lever SENSOR REMOVAL AND INSTALLATION Refer to GROUP 22 - Sensor, Switch and Relay. Longitudinal G sensor Lateral G sensor Steering wheel sensor...
  • Page 783 NOTES...
  • Page 784 33A-1 FRONT SUSPENSION CONTENTS GENERAL INFORMATION ....Ball Joint Dust Cover Check ....STRUT ASSEMBLY .

  • Page 785: General Information

    33A-2 FRONT SUSPENSION - General Information GENERAL INFORMATION The front suspension is a McPherson strut with coil spring. The shock absorber is gas-filled hydraulic double-acting type. COIL SPRING Item RS <Vehicles with steel wheels>, RS <Vehicles with aluminium wheels> RS-II Wire diameter average diameter...

  • Page 786: Service Specifications

    33A-3 FRONT SUSPENSION - Service Specifications/Special Tools SERVICE SPECIFICATIONS Items Standard value Toe-in At the centre of tyre tread mm 0 ± 2 Toe-angle (per wheel) 0_00’ ± 05’ Toe-out angle on turns (inner wheel when outer wheel at 20_) 22_00’...

  • Page 787: On-Vehicle Service

    33A-4 FRONT SUSPENSION - Special Tools/On-vehicle Service Tools Number Name MB990800 Ball joint remover & Lower arm ball joint dust cover press-in installer MB990651 Lower arm pillow ball bushing removal and press-fitting MB990816 Bushing remover & installer base MB991576 Base MB990635, Steering linkage...

  • Page 788: Ball Joint Dust Cover Check

    33A-5 FRONT SUSPENSION - On-vehicle Service Tightening torque: 52 ± 2 N·m 3. Confirm that the toe-in is at the standard value. 4. Use a turning radius gauge to check that the steering angle is at the standard value. Standard value: Inner wheels 31_45’...

  • Page 789: Strut Assembly

    33A-6 FRONT SUSPENSION - Strut Assembly STRUT ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation Wheel alignment check and adjustment (Refer to P.33A-4.) 44 ± 5 N·m 167 ± 9 N·m Removal steps 1. Front wheel speed sensor harness 3. Knuckle connection bracket <Vehicles with ABS or ACD>...
  • Page 790 33A-7 FRONT SUSPENSION - Strut Assembly DISASSEMBLY AND REASSEMBLY 60 ± 10 N·m Disassembly steps 1. Dust cover 6. Dust cover AA" "AA 2. Self-locking nut 7. Coil spring 3. Strut insulator assembly 8. Lower spring pad 4. Upper spring seat assembly 9.
  • Page 791 33A-8 FRONT SUSPENSION - Strut Assembly AB" STRUT ASSEMBLY REMOVAL To discard the strut assembly, place the assembly horizontally with its piston rod extended. Then drill a hole approx. 3 mm in diameter at the location shown in the illustration and discharge the gas.

  • Page 792: Lower Arm Assembly

    33A-9 FRONT SUSPENSION - Lower Arm Assembly LOWER ARM ASSEMBLY REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
  • Page 793 33A-10 FRONT SUSPENSION - Lower Arm Assembly REMOVAL SERVICE POINT Wooden block AA" LOWER ARM AND CROSSMEMBER DISCONNECTION Lift the transmission with a transmission jack, and then withdraw the front mounting bolt on the left lower arm assembly. Mounting Bolt Transmission jack INSPECTION Pillow ball bushing...
  • Page 794 33A-11 FRONT SUSPENSION - Lower Arm Assembly LOWER ARM BALL JOINT DUST COVER REPLACEMENT MB990800 Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: Dust cover 1. Remove the dust cover. 2. Apply multipurpose grease to the lip and inside of the dust cover.

  • Page 795: Stabilizer Bar

    33A-12 FRONT SUSPENSION - Lower Arm Assembly/Stabilizer Bar 3. Use the special tools to press in the bushing until its outer tube is flush with the lower arm assembly surface. MB990651 MB991576 Outer tube Lower arm assembly MB991816 STABILIZER BAR REMOVAL AND INSTALLATION Caution 1.
  • Page 796 33A-13 FRONT SUSPENSION - Stabilizer Bar Pre-removal Operation Post-installation Operation Steering Wheel and Air Bag Module Assembly Front Exhaust Pipe Installation (Refer to GROUP Removal (Refer to GROUP 37A.) 15.) Clock Spring Removal (Refer to GROUP 52B.) Centermember Installation (Refer to GROUP 32.) Crossmember Bar Removal (Refer to P.33A-15.) Crossmember Bar Installation (Refer to P.33A-15.) Centermember Removal (Refer to GROUP 32.)
  • Page 797 33A-14 FRONT SUSPENSION - Stabilizer Bar REMOVAL SERVICE POINTS MB991406, MB990635 or AA" TIE ROD END AND KNUCKLE DISCONNECTION MB991113 Caution 1. To prevent the ball joint thread from damage, the tie rod end mounting nut must be only loosened but not Cord removed from the ball joint.

  • Page 798: Crossmember Bar

    33A-15 FRONT SUSPENSION - Crossmember Bar CROSSMEMBER BAR <RS (Vehicles with aluminium wheels), RS-II> REMOVAL AND INSTALLATION 49 ± 10 N·m Crossmember bar...
  • Page 799 NOTES...
  • Page 800 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.

  • Page 801: General Information

    32-2 POWER PLANT MOUNT - General Information GENERAL INFORMATION Inertia principal axes system is incorporated into Upper installation of roll mount reduces engine the engine mount system. rolling, and increase of insulator bore also reduces idle vibration. CONSTRUCTION DIAGRAM <Engine mount, Transmission mount> Engine mount Transmission mount <Engine roll stopper, Centermember, Crossmember: L.H.

  • Page 802: Special Tool

    32-3 POWER PLANT MOUNT - General Information/Special Tool <Engine roll stopper, Centermember, Crossmember: R.H. drive vehicles> Rear roll mount bracket Rear roll stopper Crossmember Front roll mount bracket Front roll stopper Crossmember bar Centermember SPECIAL TOOL Tool Number Name MB990635 Steering linkage Tie rod end disconnection MB991113 or...

  • Page 803: Engine Mounting

    32-4 POWER PLANT MOUNT - Engine Mounting ENGINE MOUNTING REMOVAL AND INSTALLATION Caution *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to Raise the engine and transmission assembly until...

  • Page 804: Transmission Mounting

    32-5 POWER PLANT MOUNT - Transmission Mounting TRANSMISSION MOUNTING REMOVAL AND INSTALLATION Caution *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal Operation Post-installation Operation Under Cover Removal (Refer to GROUP 51 - Front...

  • Page 805: Engine Roll Stopper, Centermember

    32-6 POWER PLANT MOUNT - Engine Roll Stopper, Centermember ENGINE ROLL STOPPER, CENTERMEMBER REMOVAL AND INSTALLATION Caution *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) <L.H.
  • Page 806 32-7 POWER PLANT MOUNT - Engine Roll Stopper, Centermember <R.H. drive vehicles> ± 10 N·m 5 N·m * ± ± 10 N·m 7 N·m * ± 7 N·m * ± 5 N·m * ± 10 N·m ± 10 N·m ± ±...

  • Page 807: Crossmember

    32-8 POWER PLANT MOUNT - Crossmember CROSSMEMBER REMOVAL AND INSTALLATION Caution 1. Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B - Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so that they are facing straight forward, and remove the ignition key.
  • Page 808 32-9 POWER PLANT MOUNT - Crossmember <L.H. drive vehicles> ± 10 N·m 2 N·m ± ± 7 N·m ± 3 N·m 5 N·m* ± 4 N·m ± ± 4 N·m 7 N·m* ± ± 4 N·m ± 10 N·m 5 N·m ±...
  • Page 809 32-10 POWER PLANT MOUNT - Crossmember <R.H. drive vehicles> 2 N·m ± ± 3 N·m 9 N·m ± ± 7 N·m ± 5 N·m* ± 4 N·m 11 12 4 N·m ± ± 4 N·m ± 7 N·m* 10 N·m ±...
  • Page 810 32-11 POWER PLANT MOUNT - Crossmember REMOVAL SERVICE POINTS Wooden block AA" LOWER ARM ASSEMBLY REMOVAL Lift the transmission with a transmission jack, and then withdraw the front mounting bolt on the left lower arm assembly. Mounting bolt Transmission jack AB"TIE ROD END AND KNUCKLE DISCONNECTION Cord Caution...
  • Page 811 NOTES...
  • Page 812 31-1 WHEEL AND TYRE CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Tyre Inflation Pressure Check .

  • Page 813: General Information

    31-2 WHEEL AND TYRE - General Information/Service Specifications GENERAL INFORMATION The wheels and tyres of the following specifications have been established. SPECIFICATIONS Items RS (standard) RS (option), RS-II Wheel Type Steel type Aluminium type Size 15 × 6JJ 17 × 8JJ Amount of wheel offset mm Pitch circle...
  • Page 814 31-3 WHEEL AND TYRE - Troubleshooting TROUBLESHOOTING Symptom Probable cause Remedy Reference page Rapid wear at Under-inflation Adjust the tyre 31-6 shoulders or lack of rotation pressure. Rapid wear at Over-inflation or centre lack of rotation Cracked treads Under-inflation Adjust the tyre 31-6 pressure.
  • Page 815 31-4 WHEEL AND TYRE - Troubleshooting WHEEL BALANCE ACCURACY PURPOSE This section contains tips and procedures for Check your balancer’s calibration approximately achieving accurate wheel balance. Steering wheel every 100 balances. Your wheel balancer’s vibration and /or body shake can result if any of instruction manual should include calibration these procedures are not carefully observed.
  • Page 816 31-5 WHEEL AND TYRE - Troubleshooting If the imbalance is 5 g or less, the zero If the imbalance is within specification, the static calibration is OK. Rebalance the wheel, then balance calibration is correct. Go to Step 5 go to Step 4 to check static balance. to check the dynamic balance.

  • Page 817: On-Vehicle Service

    31-6 WHEEL AND TYRE - On-vehicle Service/Wheel and Tyre ON-VEHICLE SERVICE TYRE INFLATION PRESSURE CHECK NOTE For information on tyre inflation pressure, refer to the label attached near the driver’s side door striker. TYRE WEAR CHECK Measure the tread depth of tyres. Limit: 1.6 mm If the remaining tread depth is less than the limit, replace the tyre.
  • Page 818 27B-1 REAR AXLE CONTENTS GENERAL INFORMATION ....Wheel Bearing Axial Play Check ....Wheel Bearing Rotary-sliding Resistance Check SERVICE SPECIFICATIONS .

  • Page 819: General Information

    27B-2 REAR AXLE - General Information GENERAL INFORMATION The rear axle consists of rear hubs, wheel bearings, ABS rotors for detecting the wheel speeds are drive shafts, and rear differential and, it has the press-fitted to the B.J. outer wheels in vehicles following features.

  • Page 820: Service Specifications

    Vehicles with Gear oil Hypoid gear oil 0.55 mechanical MITSUBISHI Genuine Gear Oil Part No. 8149630 MITSUBISHI Genuine Gear Oil Part No. 8149630 EX, CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD (GL-5, SAE 80W - 90) or equivalent Vehicles with...

  • Page 821: Sealants

    27B-4 REAR AXLE - Lubricants/Sealants/Special tools Item Specified lubricants Quantity Vehicles with Hydraulic piping fluid ATF-SP ACD and ACD and Torque transfer mechanism oil Vaseline As required seal lips B.J. joint Repair kit grease 85 ± 10 g T.J. joint Repair kit grease 105 ±...
  • Page 822 27B-5 REAR AXLE - Special Tools Tool Number Name MB991115 Oil seal installer Press-fitting of oil seal (AYC differential: used in combination with MB990938) MD998812 Installer cap Press-fitting of oil seal (torque transfer mechanism of vehicles with AYC) MD998813 Installer100 MD998829 Installer adapter...
  • Page 823 27B-6 REAR AXLE - Special Tools Tool Number Name MB990685 Torque wrench Measurement of the starting torque of wheel bearing MB990326 Preload socket MB991113 or Steering linkage Disconnection of ball joint MB990635 puller MB990641 Lower arm bush Removal and press-fitting of differential (A) remover &...
  • Page 824 27B-7 REAR AXLE - Special Tools Tool Number Name MB990850 End yoke holder Removal of the self-locking nut Adjustment of the drive pinion turning torque MB990339 Bearing puller Drive pinion rear bearing inner race removal MB990648 Bearing remover MB990835 Drive pinion setting Adjustment of drive pinion height gauge set A: MB990836...

  • Page 825: Rear Axle Troubleshooting

    27B-8 REAR AXLE - Special Tools/Troubleshooting <AYC> Number Name O.D. MB990551 – MB990989 Base – Base Base MB990990 Tool A MB990991 Tool B Tool Tool MB990992 Tool C Toolbox Brass bar Installer adapter Bar (one-touch type) O.D. mm O.D. mm Tool number Tool number MB990926...
  • Page 826 27B-9 REAR AXLE - Troubleshooting <AYC> ERASING THE DIAGNOSIS CODES Connect the MUT-II to the 16-pin diagnosis connector and erase the diagnosis code. (Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.) Caution Turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting the MUT-II.
  • Page 827 27B-10 REAR AXLE - Troubleshooting <AYC> Diagnosis Diagnosis items Reference page code No. Stop lamp switch system open-circuit Refer to GROUP 22 GROUP 22. ACD mode changeover switch stuck Parking brake switch system short-circuit or not re- turned ABS monitor system open-circuit or defective Proportioning valve <AYC>...
  • Page 828 27B-11 REAR AXLE - Troubleshooting <AYC> INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No. 71 Proportioning valve system Probable cause Thiscodeisoutputwhenthe proportioningvalve controlcircuit isopen- orshort-circuited. D Defective proportioning valve D Defective harness or connector D Defective 4WD-ECU <Vehicles with ACD + AYC> Measure at proportioning valve con- Replace the hydraulic unit.
  • Page 829 27B-12 REAR AXLE - Troubleshooting <AYC> Code No. 72 Directional control valve (right) system Probable cause This code is output when the directional control valve (right) control circuit is open- D Defective directional control valve (right) or short-circuited. D Defective harness or connector D Defective 4WD-ECU <Vehicles with ACD + AYC>...
  • Page 830 27B-13 REAR AXLE - Troubleshooting <AYC> Code No. 73 Directional control valve (left) system Probable cause This code is output when the directional control valve (left) control circuit is open- D Defective directional control valve (left) or short-circuited. D Defective harness or connector D Defective 4WD-ECU <Vehicles with ACD + AYC>...
  • Page 831 27B-14 REAR AXLE - REAR AXLE - Troubleshooting <AYC> Troubleshooting <AYC> INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference procedure No. page Communication between MUT-II and the whole system is not possible. Refer to GROUP 22 GROUP 22. Communication between MUT-II and 4WD-ECU is not possible. 3 ACD mode indicator lamps do not light up when the ignition key is turned to “ON”...
  • Page 832 27B-15 REAR AXLE - Troubleshooting <AYC> INSPECTION PROCEDURE 6 Rear tires are noisy during low-speed cornering. Probable cause Vehicle skews. The hydraulic unit or torque transfer differential is probably defective. D Defective hydraulic unit D Defective torque transfer differential NOTE This symptom is limited only when the diagnosis code is correct.

  • Page 833: On-Vehicle Service

    Specified gear oil: Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No. 8149630 EX, CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD (GL-5, SAE 80W - 90) or equivalent 4. Fit the filler plug and tighten it to the specified torque.

  • Page 834: Gear Oil Change

    27B-17 REAR AXLE - On-vehicle Service <Vehicles with AYC> Filler plug Differential part 1. Remove the filler plug. 2. Check that the gear oil level is within the specified range from the bottom end of the filler plug hole. 3. If the gear oil level exceeds the standard value, add the specified gear oil up to the bottom end of the filler plug hole.
  • Page 835 REAR AXLE - On-vehicle Service On-vehicle Service Specified gear oil: Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No. 8149630 EX, CASTROL HYPOY LS (GL-5, SAE 90), Gear oil SHELL-LSD (GL-5, SAE 80W - 90) or equivalent Quantity: 0.55 L 4.

  • Page 836: Fluid Level Check

    27B-19 REAR AXLE - On-vehicle Service FLUID LEVEL CHECK 1. Remove the maintenance lid located in the luggage compartment. 2. <Not using MUT-II> If the vehicle has been run, leave it for 90 min. or more in an ordinary temperature (10_C – 30_C) to allow the accumulator internal pressure to drop.

  • Page 837: Ayc Operation Check

    27B-20 REAR AXLE - On-vehicle Service 6. Remove the cap of the left bleeder screw on the torque transfer differential and connect a vinyl hose. 7. Gradually turn the steering wheel clockwise from the straight-ahead position. At this time, loosen the left bleeder Bleeder screw and check that fluid is discharged with air.

  • Page 838: Oil Pressure Check

    27B-21 REAR AXLE - On-vehicle Service 5. Operate the MUT-II, drive the torque transfer differential (item No.06 and 07) forcibly. NOTE (1) Drive the clutch operating mode forcibly for 1 minutes, release the operation automatically. Drive can also be cleared forcibly using the Clear key of MUT-II. (2) If the hydraulic unit function has been stopped by fail-safe, the torque transfer differential cannot be forcibly driven.

  • Page 839: Wheel Bearing Axial Play Check

    27B-22 REAR AXLE - On-vehicle Service 8. If the measured value exceeds the standard value, replace the hydraulic unit. 9. Connect the hydraulic unit and the hydraulic unit hose assembly, and connect the torque transfer differential and hydraulic unit hose assembly, tighten the flare nut in specified torque.

  • Page 840: Hub Bolt Replacement

    27B-23 REAR AXLE - On-vehicle Service 3. If the limit value is exceeded, loosen the flange nut and then tighten it to the specified torque 225 ± 25 N·m and check the rear hub rotary sliding resistance again. 4. Replace the rear hub assembly if an adjustment cannot be made to within the limit.

  • Page 841: Action When Battery Runs Out

    27B-24 REAR AXLE - On-vehicle Service Torque transfer mechanism part MD998829 1. Remove the drive shaft. (Refer to P. 27B-29.) 2. Remove the oil seal from the differential carrier. 3. Using the special tool, drive a new oil seal all the way into position.

  • Page 842: Rear Hub Assembly

    27B-25 REAR AXLE - Rear Hub Assembly REAR HUB ASSEMBLY REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
  • Page 843 27B-26 REAR AXLE - Rear Hub Assembly REMOVAL SERVICE POINTS AA" REAR BRAKE CALIPER REMOVAL Suspend the rear brake caliper from the body with wire, etc. to prevent it from falling. Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
  • Page 844 27B-27 REAR AXLE - Rear Hub Assembly INSPECTION MB991000 (MB990998) MB991017 MB990326 WHEEL BEARING ROTATION STARTING TORQUE CHECK 1. Tighten special tools in rear hub assembly to the specified torque. 2. Hold rear hub assembly in a vice by way of wooden block.

  • Page 845: Knuckle

    27B-28 REAR AXLE - Knuckle KNUCKLE REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.

  • Page 846: Drive Shaft

    27B-29 REAR AXLE - Drive Shaft DRIVE SHAFT REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.

  • Page 847: Differential Carrier

    27B-30 REAR AXLE - Drive Shaft REMOVAL SERVICE POINTS AA" REAR BRAKE CALIPER REMOVAL Suspend the rear brake caliper from the body with wire, etc. to prevent it from falling. Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.

  • Page 848: Vehicles With Mechanical Lsd

    27B-31 REAR AXLE - Drive Shaft (4) To prevent entry of foreign matter into the differential carrier, use the special tool as a cover. <Vehicles with mechanical LSD (RH)> MB991460 INSTALLATION SERVICE POINTS "AA DRIVE SHAFT INSTALLATION Caution When installing the drive shaft to the differential carrier, be careful that the spline part of the drive shaft does not damage the oil seal.
  • Page 849 27B-32 REAR AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY Caution (1) On the vehicles with ABS or ACD, when the drive shaft is disassembled or reassembled, be careful not to interfere with the rotor for wheel speed sensor installed to the B.J. outer race to prevent the rotor from damage.
  • Page 850 27B-33 REAR AXLE - Drive Shaft DISASSEMBLY SERVICE POINTS AA" T.J. CASE/SPIDER ASSEMBLY REMOVAL 1. Wipe off grease from the spider assembly and the inside of the T.J. case. 2. Always clean the spider assembly when the grease contains water or foreign material. Caution Do not disassemble the spider assembly.
  • Page 851 27B-34 REAR AXLE - Drive Shaft "BA T.J. BOOT BAND (SMALL)/T.J. BOOT BAND (LARGE) INSTALLATION Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot bands securely. Standard value (A): 90±3 mm INSPECTION Check the drive shaft for damage, bending or corrosion.
  • Page 852 27B-35 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> DIFFERENTIAL CARRIER <VEHICLES WITH MECHANICAL LSD> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Differential Gear Oil Draining (Refer to P.27B-17.) Drive Shaft Installation (Refer to P. 27B-29.) Lower Arm Assembly Removal (Refer to GROUP Rear Stabilizer Installation (Refer to GROUP 34.) 34.) Lower Arm Assembly Installation (Refer to GROUP...
  • Page 853 27B-36 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> REMOVAL SERVICE POINTS AA" PROPELLER SHAFT DISCONNECTION Suspend the removed propeller shaft from the body with a wire to prevent bending. AB"REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY REMOVAL 1. Using a jack, support the differential carrier from its underside.
  • Page 854 27B-37 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> BUSHING REPLACEMENT <Differential mount bracket> 1. Remove and press fit the bush with special tool. (About removal and press fitting the bush of the differential support arm, refer to P. 27B-57.) 2.

  • Page 855: 26. Differential Carrier

    27B-38 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> DISASSEMBLY Disassembly steps D Inspection before disassembly 15. Companion flange AA" AF" 1. Filler plug 16. Drive pinion front shim (For adjusting 2. Drain plug preload of drive pinion) 3. Differential cover assembly 17.
  • Page 856 27B-39 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> DISASSEMBLY SERVICE POINTS AA" INSPECTION BEFORE DISASSEMBLY MB990909 and 1. Remove the cover. MB991116 2. Hold the special tool in a vise, and install the differential carrier assembly to the special tool. DRIVE GEAR BACKLASH 1.
  • Page 857 27B-40 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 2. Insert the brass between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive MB990939 gear so that the revolution torque (approximate 2.5 - 3.0 N·m) is applied to the drive pinion.
  • Page 858 27B-41 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> AB" DIFFERENTIAL CASE ASSEMBLY/ SIDE BEARING SPACER/SIDE BEARING OUTER RACE REMOVAL Use the handle of a hammer to remove the differential case assembly, side bearing spacers and side bearings. Caution When taking out the differential case assembly, be careful not to drop and damage the side bearing spacers or the side bearing outer races.
  • Page 859 27B-42 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> AF" DRIVE PINION ASSEMBLY/COMPANION FLANGE MB990810 REMOVAL 1. Make the mating marks to the drive pinion and companion flange. Caution Do not make mating marks on the contact surfaces Companion of the companion flange and propeller shaft.
  • Page 860 27B-43 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> REASSEMBLY 36 ± 5 N·m 49 ± 9 N·m Final drive gear set 37 ± 2 N·m 84 ± 4 N·m 186 ± 29 N·m 64 ± 4 N·m Reassembly steps 1.
  • Page 861 27B-44 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> Lubrication and Adhesive Points 2 - 3mm (bead diameter) Vent plug Adhesive: 3M Stud Locking Sealant: 3M ATD Part No.8661, 8663 4170 or equivalent or equivalent REASSEMBLY SERVICE POINTS "AA OIL SEAL PRESS-FITTING MB990938 MB991115...
  • Page 862 27B-45 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> "BA DRIVE PINION REAR BEARING OUTER RACE PRESS-FITTING MB990938 MB990935 "CA DRIVE PINION FRONT BEARING OUTER RACE PRESS-FITTING MB990938 MB990932 "DA DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures: 1.
  • Page 863 27B-46 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 4. Clean the side bearing hub. Notch MB990392 5. Place special tool between the side bearing hub of the (MB990835) gear carrier, and position the notch as shown in the illustration.
  • Page 864 27B-47 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 3. Measure the drive pinion turning torque (without the oil MB990326 MB990685 seal). Standard value: Bearing division Turning torque 0.88 - 1.17 N · Caution Take care not to fit gear oil on the bearing. 4.
  • Page 865 27B-48 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 7. Measure the drive pinion turning torque (with oil seal) MB990326 MB990685 to verify that the drive pinion turning torque complies with the standard value. Standard value: Bearing Companion flange lubrication Turning torque division None (With anti-rust agent)
  • Page 866 27B-49 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> "HA BEARING CAP INSTALLATION/FINAL DRIVE GEAR BACKLASH ADJUSTMENT Adjust drive gear backlash as follows: 1. Assemble the differential case with the side bearing outer race to the gear carrier. 2. Press the differential case to one side to measure the clearance of the side bearing outer race and the gear carrier.
  • Page 867 27B-50 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> 11. Measure the drive gear runout. Limit: 0.05 mm 12. When drive gear runout exceeds the limit, remove the differential case and then the drive gears, moving them to different positions and reinstall them. 13.
  • Page 868 27B-51 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> REMOVAL SERVICE POINT AA" SCREWS REMOVAL 1. Check out the alignment marks. 2. Loosen a uniform amount little by little the screws securing differential case A to B. 3. Separate differential case B from differential case A and remove their components.
  • Page 869 Friction disc it in the specified direction and order into differential case Specified gear oil: Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No. 8149630 EX, CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD (GL-5, SAE 80W - 90) or equivalent NOTE...
  • Page 870 27B-53 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> INSPECTION Friction disc DIFFERENTIAL CASE INTERNAL PARTS CONTACT/ SLIDING SURFACE CHECK 1. Clean the disassembled parts with cleaning oil and dry them with compressed air. 2. Check each plate, disc, and pressure ring for the following: A.
  • Page 871 27B-54 REAR AXLE - Differential Carrier <Vehicles with mechanical LSD> FRICTION PLATE AND FRICTION DISC DISTORTION CHECK Apply a dial indicator to the friction plate or disc on a surface plate and, turning the friction plate or disc, measure the distortion (flatness).

  • Page 872: Vehicles With Ayc

    27B-55 REAR AXLE - Differential Carrier <Vehicles with AYC> DIFFERENTIAL CARRIER <VEHICLES WITH AYC> REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Hydraulic Piping Fluid Draining Drive Shaft Installation (Refer to P. 27B-29.) Differential Gear Oil Draining (Refer to P. 27B-17.) Rear Stabilizer Installation (Refer to GROUP 34.) Lower Arm Assembly Removal (Refer to GROUP Lower Arm Assembly Installation (Refer to GROUP...
  • Page 873 27B-56 REAR AXLE - Differential Carrier <Vehicles with AYC> REMOVAL SERVICE POINT AA" PROPELLER SHAFT DISCONNECTION Suspend the removed propeller shaft from the body with a wire to prevent bending. INSTALLATION SERVICE POINTS Upper stopper "AA LOWER STOPPER/UPPER STOPPER INSTALLATION Install the lower and upper stopper as shown in the illustration.
  • Page 874 27B-57 REAR AXLE - Differential Carrier <Vehicles with AYC> BUSHING REPLACEMENT <Differential support member> 1. Remove and press fit the bush with special tool. 2. Press fit th bush so that the hollow of the bush is on the position shown as the illustration. 3.
  • Page 875 27B-58 REAR AXLE - Differential Carrier <Vehicles with AYC> TORQUE TRANSFER DIFFERENTIAL <VEHICLES WITH AYC> DISASSEMBLY AND REASSEMBLY Caution 1. The differential carrier assembly is non-maintainable. 2. No foreign matter should be allowed inside and at the joints of the differential carrier assembly. 10 N m 29 N m 1 N m...
  • Page 876 27B-59 REAR AXLE - Differential Carrier <Vehicles with AYC> Lubrication and Adhesive Points Sealant: 3M ATD Part Grease: Vaseline No.8661, 8663 or equivalent Sealant: 3M ATD Part No.8661, 8663 or equivalent DISASSEMBLY SERVICE POINT AA" SELF-LOCKING NUT REMOVAL MB990850...
  • Page 877 27B-60 REAR AXLE - Differential Carrier <Vehicles with AYC> ASSEMBLY SERVICE POINTS MD998829 "AA OIL SEAL PRESS-FITTING 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 MD998812 MD998813...
  • Page 878 27B-61 REAR AXLE - Hydraulic Unit <Vehicles with ACD+AYC> HYDRAULIC UNIT <VEHICLES WITH ACD+AYC> REMOVAL AND INSTALLATION Caution (1) When connecting the return hose and suction hose, do not apply lubricant. (2) No foreign matter should be allowed in the hydraulic piping and joints. Pre-removal Operation Post-installation Operation Trunk Side Trim Removal (Refer to GROUP 52A.)

  • Page 879: Hydraulic Unit

    27B-62 REAR AXLE REAR AXLE - Hydraulic Unit <Vehicles with ACD+AYC> - Hydraulic Unit <Vehicles with ACD+AYC> REMOVAL SERVICE POINTS Hose AA" HYDRAULIC UNIT HOSE ASSEMBLY REMOVAL 1. Disconnect the hydraulic unit side pipe and hose. Pipe 2. Put down the differential support arm, remove the Hydraulic unit hydraulic unit hose assembly.
  • Page 880 26-1 FRONT AXLE CONTENTS GENERAL INFORMATION ....ON-VEHICLE SERVICE ..... Wheel Bearing Axial Play Check .

  • Page 881: General Information

    26-2 FRONT AXLE - General Information GENERAL INFORMATION The front axle consists of front hubs, knuckles, ABS rotors for detecting the wheel speeds are wheel bearings and drive shafts, and it has the press-fitted to the B.J. outer wheels in vehicles following features.

  • Page 882: Service Specifications

    26-3 FRONT AXLE - Service Specifications/Lubricants/Special Tools SERVICE SPECIFICATIONS Item Standard value Limit Wheel bearing axial play mm 0.06 Wheel bearing rotation starting torque N·m Wheel bearing rotation starting torque N·m 1 03 or less 1.03 or less Setting of T.J. boot length mm 85 ±...
  • Page 883 26-4 FRONT AXLE - Special Tools Tool Number Name MB990685 Torque wrench Measurement of wheel bearing rotation starting torque MB990326 Preload socket Measurement of wheel bearing rotation starting torque A: MB991017 A,B:Front hub Provisional holding of the wheel bearing Measurement of wheel bearing rotation B: MB990998 remover and starting torque...

  • Page 884: On-Vehicle Service

    26-5 FRONT AXLE - On-vehicle Service ON-VEHICLE SERVICE WHEEL BEARING AXIAL PLAY CHECK 1. Remove the disc brake caliper and suspend it with a wire. 2. Remove the brake disc from the front hub. 3. Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction.
  • Page 885 26-6 FRONT AXLE - Hub and Knuckle Assembly HUB AND KNUCKLE ASSEMBLY REMOVAL AND INSTALLATION Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.

  • Page 886: Hub And Knuckle Assembly

    26-7 FRONT AXLE - Hub and Knuckle Assembly REMOVAL SERVICE POINTS AA" CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, etc. Caution If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
  • Page 887 26-8 FRONT AXLE - Hub and Knuckle Assembly INSTALLATION SERVICE POINT Washer "AACASTLE NUT INSTALLATION 1. Be sure to install the castle nut washer in the specified direction. 2. Using the special tool, tighten the castle nut. Caution Before securely tightening the castle nuts, make sure 245±29 N·m there is no load on the wheel bearings.
  • Page 888 26-9 FRONT AXLE - Hub and Knuckle Assembly DISASSEMBLY AND REASSEMBLY 10 N·m Disassembly steps 1. Knuckle 2. Front hub assembly...

  • Page 889: Drive Shaft

    26-10 FRONT AXLE - Drive Shaft DRIVE SHAFT REMOVAL AND INSTALLATION Caution 1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly.
  • Page 890 26-11 FRONT AXLE - Drive Shaft REMOVAL SERVICE POINTS MB991113 MB990635 AA" TIE ROD END DISCONNECTION Caution 1. Loosen the nut only; do not remove it from the ball Cord joint. Otherwise ball joint thread will be damaged. 2. The special tool should be suspended by a cord to prevent it from coming off.
  • Page 891 26-12 FRONT AXLE - Drive Shaft AC"OUTPUT SHAFT REMOVAL MB991721 Use the special tool to pull out the output shaft. Caution Do not damage the oil seal of the transmission by the output shaft splines. Output shaft INSTALLATION SERVICE POINTS "AA OUTPUT SHAFT/DRIVE SHAFT INSTALLATION Caution Do not damage the oil seal of the transmission by the...
  • Page 892 26-13 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY Caution (1) On the vehicles with ABS or ACD, when the drive shaft is disassembled or reassembled, be careful not to interfere with the rotor for wheel speed sensor installed to the B.J. outer race to prevent the rotor from damage.
  • Page 893 26-14 FRONT AXLE - Drive Shaft DISASSEMBLY SERVICE POINTS AA" T.J. CASE/SPIDER ASSEMBLY REMOVAL 1. Wipe off grease from the spider assembly and the inside of the T.J. case. 2. Always clean the spider assembly when the grease contains water or foreign material. Caution Do not disassemble the spider assembly.
  • Page 894 26-15 FRONT AXLE - Drive Shaft "BA T.J. BOOT BAND (SMALL)/T.J. BOOT BAND (LARGE) INSTALLATION Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot bands securely. Standard value (A): 85±3 mm INSPECTION Check the drive shaft for damage, bending or corrosion.
  • Page 895 26-16 FRONT AXLE - Drive Shaft (2) The adjusting bolt should not be turned more than once. 6. Install the boot band (small) in order to create clearance as B.J. boot A and B in the illustration. B.J. boot band (small) Projection 7.
  • Page 896 26-17 FRONT AXLE - Drive Shaft 10. Fill the inside of the B.J. boot with the specified amount of the specified grease. Specified grease: Repair kit grease Amount to use: 110±10 g Caution The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
  • Page 897 NOTES...
  • Page 898 25-1 PROPELLER SHAFT CONTENTS GENERAL INFORMATION ....SEALANT ........SERVICE SPECIFICATIONS .

  • Page 899: Propeller Shaft

    General Information/Service Specification/ 25-2 PROPELLER SHAFT - Lubricant/Sealant/Special Tool GENERAL INFORMATION 3 way split 4-joint type propeller shaft with center bearing is adopted. SERVICE SPECIFICATION Items Standard value Limit Propeller shaft runout mm LUBRICANT Items Specified lubricant Quantity Front propeller shaft sleeve Hypoid gear oil SAE 75W-90 or 75W-85W or 80W As required yoke...
  • Page 900 25-3 PROPELLER SHAFT - Propeller Shaft PROPELLER SHAFT REMOVAL AND INSTALLATION Gear Oil: Hypoid gear oil SAE 75W-90 or 75W-85W or 80W conforming to API GL-4 30 ± 4 N·m 30 ± 4 N·m 32 ± 2 N·m Removal steps 1.
  • Page 901 25-4 PROPELLER SHAFT - Propeller Shaft INSTALLATION SERVICE POINT "AA PROPELLER SHAFT ASSEMBLY INSTALLATION When reusing the propeller shaft, align the mating marks made during the removal and install the propeller shaft assembly to the companion flange. Caution Oil seal 1.
  • Page 902 25-5 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY AND REASSEMBLY 187 ± 29 N·m 34 ± 5 N·m 187 ± 29 N·m 34 ± 5 N·m LJ kit LJ boot kit Disassembly steps 1. Bolt 10. Center propeller shaft 2. Front propeller shaft assembly 11.
  • Page 903 25-6 PROPELLER SHAFT - Propeller Shaft Lubrication and Adhesive Points Rubber mount Repair kit grease: Adhesive: 3M Stud Locking 4170 Quantity: 75 ± 5 g or equivalent...
  • Page 904 25-7 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY SERVICE POINTS AA" COMPANION FLANGE REMOVAL Mating marks Make mating marks on the companion flange and center propeller shaft. Then, remove the companion flange. AB" CENTER BEARING ASSEMBLY REMOVAL Center bearing assembly MD998801 AC"...
  • Page 905 25-8 PROPELLER SHAFT - Propeller Shaft 3. Using puller (general service tool), remove the inner race Cage Inner race and cage from the center propeller shaft assembly. 4. Wipe out grease on the outer race, inner race, cage and ball then clean. Puller (General service tool) AE"...
  • Page 906 25-9 PROPELLER SHAFT - Propeller Shaft 4. Apply a little specific sealant to the surface which has groove (for packing) of LJ assembly (allow as shown Rubber packing in the illustration), fix the rubber packing. Specified sealant: 3M Stud Locking 4170 or equivalent 5.
  • Page 907 25-10 PROPELLER SHAFT - Propeller Shaft "DA CENTER BEARING ASSEMBLY/COMPANION Center propeller shaft rear side Companion FLANGE/SELF LOCKING NUT INSTALLATION Center bearing flange assembly 1. Install the center bearing assembly to the rear propeller shaft in the direction shown as the illustration. Self 2.
  • Page 908 22A-1 MANUAL TRANSMISSION CONTENTS MANUAL TRANSMISSION ........MANUAL TRANSMISSION OVERHAUL .
  • Page 909 (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.

  • Page 910: General

    Transmission oil Gear oil SAE 75W-90 or 75W-85W conforming to API GL-4 Transfer Vehicles without ACD or ve- MITSUBISHI Genuine Gear Oil Part No.8149630 EX, 0.55 hicles without ACD and AYC CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD (GL 5 SAE 80W...

  • Page 911: Special Tools

    22A-4 MANUAL TRANSMISSION - Special Tools SPECIAL TOOLS Tool Number Name MB991502 MUT-II Sub as- Diagnosis code checking sembly MB991529 Diagnosis code checking harness G sensor check MB991348 Test harness set MD998330 Oil pressure gauge Hydraulic pressure measurement <ACD> (including (3.0 MPa) MD998331) MB991705...

  • Page 912: Troubleshooting

    22A-5 MANUAL TRANSMISSION - Troubleshooting <ACD> TROUBLESHOOTING <ACD> BASIC TROUBLESHOOTING CONDITIONS Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. NOTE Before starting the troubleshooting procedure, make sure that the following items have been checked okay. Is the appropriate steering wheel installed at the center of the steering column shaft correctly? Are the tire, wheel size, specifications, air pressure, balance, and wear state normal? Is the wheel alignment normal? Has the engine, suspension, etc.
  • Page 913 22A-6 MANUAL TRANSMISSION - Troubleshooting <ACD> INSPECTION CHART FOR DIAGNOSIS CODES Diagnosis Diagnosis items Reference page code No. Power supply voltage (valve power supply) system open circuit or short-circuit 22A-8 Fail-safe relay system <inside 4WD-ECU> open circuit or short-circuit 22A-8 Wheel speed sensor <FR>...
  • Page 914 22A-7 MANUAL TRANSMISSION - Troubleshooting <ACD> Diagnosis Diagnosis items Reference page code No. Electric pump relay system open circuit or short-circuit 22A-29 electric pump malfunction 22A-30 or pressure sensor defect AYC control error Refer to GROUP 27B. ACD control error NOTE Code No.85 is not a code number output due to malfunction, but a code number output when control for the 4WD-ECU to protect the ACD is stopped in excessive driving.
  • Page 915 22A-8 MANUAL TRANSMISSION - Troubleshooting <ACD> INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No.12 Power supply voltage (valve power supply) Probable cause system The power supply circuit opens or short-circuits if the power supply voltage of the D Defective harness or connector 4WD-ECU is below 9 V or above 18 V.
  • Page 916 22A-9 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.21 Wheel speed sensor <FR> system Probable cause Code No.22 Wheel speed sensor <FL> system Code No.23 Wheel speed sensor <RR> system Code No.24 Wheel speed sensor <RL> system A diagnosis code corresponding to the open circuit or short circuit of the wheel D Wheel speed sensor fault speed sensor is output when one wheel speed sensor has detected a vehicle D Rotor fault...
  • Page 917 22A-10 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
  • Page 918 22A-11 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.25 Wrong-diameter tire Probable cause Code No.25 is output as wrong-diameter tire when one of the four vehicle D Tire fault speeds is outside the range of specified values in respect to the average of the D Wheel speed sensor fault four vehicle speed sensors, when the vehicle speed is above 20 km/h with the D Rotor fault...
  • Page 919 22A-12 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
  • Page 920 22A-13 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.26 Wheel speed sensor system (faulty output Probable cause signal) Code No.26 is output as output signal error of the wheel speed sensor when D Tire fault one wheel speed is outside the specified range at the vehicle speed of above D Wheel speed sensor fault 20 km/h.
  • Page 921 22A-14 MANUAL TRANSMISSION - Troubleshooting <ACD> <Vehicles with ACD> Check the installation of the wheel speed sensor. NG→Repair MUT-II Data List D No.01 Vehicle speed sensor <FR> D No.02 Vehicle speed sensor <FL> D No.03 Vehicle speed sensor <RR> D No.04 Vehicle speed sensor <RL> OK: The speed meter display and MUT-II display match.
  • Page 922 22A-15 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.31 Steering wheel sensor <ST-1, ST-2, ST-N> Probable cause system Code No.31 is output when open circuit or short circuit of the steering wheel D Steering wheel sensor fault sensor output line (ST-1, ST-2, or ST-N) occurs. D Harness or connector fault D 4WD-ECU fault MUT-II Diagnosis Code...
  • Page 923 22A-16 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.32, 33 Steering wheel sensor <ST-N> system Probable cause Code No.32 is output when the steering wheel sensor ST-N has been detected D Harness or connector fault at the neutral position in a state where the steering wheel has been determined D Steering wheel sensor fault to have changed above 40_C from steering wheel sensor ST-1 and ST-2.
  • Page 924 22A-17 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.34 Steering wheel sensor <ST-1, ST-2> system Probable cause Code No.34 is output when no change in the steering wheel sensor signal at a D Harness or connector fault vehicle speed of above 15 km/h is detected for a total of more than 15 minutes D Steering wheel sensor fault <ST-1, ST-2>, and turning is detected during this time.
  • Page 925 22A-18 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.41, 42 TPS system Probable cause Code No.41 is output as excessively small output when the TPS output is below D TPS fault 0.2 V In the idling state. D Harness or connector fault Code No.42 is output as excessively large output when the TPS output is more D 4WD-ECU fault than 4.8 V for more than 2 minutes continuously below a vehicle speed of 10...
  • Page 926 22A-19 MANUAL TRANSMISSION - Troubleshooting <ACD> MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.45 Pressure sensor system (Open circuit or Probable cause ground) Code No.45 is output when the output signal from the pressure sensor is below D Harness or connector fault 0.2 V.
  • Page 927 22A-20 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.47 Pressure sensor system (Abnormal power Probable cause supply) Code No.47 is output when the pressure sensor power supply voltage is above D Harness or connector fault 4.0V during pressure sensor power OFF or less than 4.0V during pressure D Pressure sensor fault sensor power ON.
  • Page 928 22A-21 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.51 Longitudinal G sensor system Probable cause Code No.51 is output when the output signal of the longitudinal G sensor is less D Harness or connector fault than 0.5 V or above 4.5 V. D Longitudinal G sensor fault D ABS-ECU fault <Vehicles with ACD and AYC>...
  • Page 929 22A-22 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.52 Longitudinal G sensor system Probable cause Code No.52 is output when the G sensor has exceeded the specified value in a D Harness or connector fault state where the ABS and brake are not operating above the vehicle speed of 10 D Longitudinal G sensor fault km/h.
  • Page 930 22A-23 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.56 Lateral G sensor system Probable cause Code No.56 is output when the output signal of the lateral G sensor is below D Harness or connector fault 0.5 V or above 4.5 V. D Lateral G sensor fault D ABS-ECU fault <Vehicles with ACD and AYC>...
  • Page 931 22A-24 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.57 Lateral G sensor system Probable cause Code No.57 is output when the G sensor has exceeded the specified value in a D Harness or connector fault state where the ABS and brake are not operating above the vehicle speed of 10 D Lateral G sensor fault km/h.
  • Page 932 22A-25 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.61 Stop lamp switch system Probable cause Code No.61 is output when the stop lamp switch is ON for more than 15 D Brake pedal fault minutes when the vehicle speed is above 15 km/h. D Stop lamp switch fault D Harness or connector fault D 4WD-ECU fault...
  • Page 933 22A-26 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.62 ACD mode switch system Probable cause Code No.62 is output when the ACD mode switch is ON for more than 60 D ACD mode switch fault seconds. D Harness or connector fault D 4WD-ECU fault MUT-II Data List D No.63 ACD mode switch...
  • Page 934 22A-27 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.63 Parking brake switch system Probable cause Code No.63 is output when the parking brake switch is ON for more than 15 D Parking brake switch fault minutes with the vehicle speed above 15 km/h. D Harness or connector fault D ABS-ECU fault <Vehicles with ACD and AYC>...
  • Page 935 22A-28 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.65 ABS monitor system Probable cause Code No.65 is output when ABS is detected to be operating for more than 1 D Harness or connector fault minute continuously. D ABS-ECU fault <Vehicles with ACD and AYC> D 4WD-ECU fault <Vehicles with ACD and AYC>...
  • Page 936 22A-29 MANUAL TRANSMISSION - Troubleshooting <ACD> MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.74 Proportional valve <ACD> system Probable cause Code No.74 is output when open circuit or short circuit of the control circuit of D Proportional valve <ACD> fault the proportional valve <ACD> has occurred. D Harness or connector fault D 4WD-ECU fault MUT-II Data List...
  • Page 937 22A-30 MANUAL TRANSMISSION - Troubleshooting <ACD> Code No.82 Electric pump relay system Probable cause Code No.82 is output when the pressure sensor does not reach the specified D Insufficient fluid value even if the 4WD-ECU has output the electric pump motor drive command. D Pressure sensor fault D Electric pump relay fault D Hydraulic unit fault...
  • Page 938 22A-31 MANUAL TRANSMISSION - Troubleshooting <ACD> INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection Reference procedure No. page No communication possible between MUT-II and all systems. 22A-31 No communication possible between MUT-II and 4WD-ECU. 22A-32 ACD mode indicator lamp does not light up when the ignition switch is set to ”ON“ 22A-33 (engine is stopped).
  • Page 939 22A-32 MANUAL TRANSMISSION - Troubleshooting <ACD> Inspection procedure 2 No communication is possible between the MUT-II and Probable cause 4WD-ECU. The diagnostic output circuit, 4WD-ECU power supply circuit, earth circuit, or D Harness or connector fault 4WD-ECU may be faulty. D 4WD-ECU fault Measure at diagnosis connector C-22 and 4WD-ECU Check the following connectors:...
  • Page 940 22A-33 MANUAL TRANSMISSION - Troubleshooting <ACD> Inspection procedure 3 The ACD mode indicator lamp does not light up when the Probable cause ignition switch is turned “ON” (engine stop). The ACD mode indicator lamp circuit or 4WD-ECU may be faulty. D Harness or connector fault D ACD mode indicator lamp assembly fault D 4WD-ECU fault...
  • Page 941 22A-34 MANUAL TRANSMISSION - Troubleshooting <ACD> Inspection procedure 4 More than two ACD mode indicator lamps remain lit even Probable cause after the engine starts The output circuit of the ACD mode indicator lamp may be faulty. D Harness or connector fault D 4WD-ECU fault D ACD mode indicator lamp assembly fault NOTE...
  • Page 942 22A-35 MANUAL TRANSMISSION - Troubleshooting <ACD> DATA LIST REFERENCE TABLE Item Check item Check condition Normal conditions Wheel speed sensor Execute actual driving. The speed meter dis- <FR> play and MUT-II dis- play match. Wheel speed sensor <FL> Wheel speed sensor <RR>...
  • Page 943 22A-36 MANUAL TRANSMISSION - Troubleshooting <ACD> Item Check item Check condition Normal conditions Pressure sensor power Ignition switch: ON Approx.5 V supply Valve power supply Ignition switch: ON System voltage Steering wheel sensor Ignition switch: ON Steering wheel: Turn 1 - 2 V and 2.5 - 4.5 V voltage <ST-1>...
  • Page 944 22A-37 MANUAL TRANSMISSION - Troubleshooting <ACD> ACTUATOR TEST JUDGEMENT VALUE Item Check item Test description Normal state Bleeding <ACD> Input current to the Proportional valve Make sure no air leaks from the bleeder according to the steering angle, and operate screw on the transfer.
  • Page 945 22A-38 MANUAL TRANSMISSION - Troubleshooting <ACD> CHECK AT 4WD-ECU TERMINALS NOTE: 1. * indicates the eliminated terminal when only ACD is installed. 2. * indicates the terminal added when only ACD is installed. Termi- Check item Check condition Normal state nal no.
  • Page 946 22A-39 MANUAL TRANSMISSION - Troubleshooting <ACD> Termi- Check item Check condition Normal state nal no. Longitudinal G sensor Any time 1 V or less earth, lateral G sensor earth ECU earth Any time 1 V or less ECU backup power Any time System voltage supply...

  • Page 947: On-Vehicle Service

    22A-40 MANUAL TRANSMISSION - On-vehicle Service MANUAL TRANSMISSION - On-vehicle Service ON-VEHICLE SERVICE TRANSMISSION OIL CHECK Filler plug hole 1. Remove the oil filler plug. Transmission oil 2. Oil level should be at the lower portion of the filler plug hole.

  • Page 948: Fluid Check

    4. Fill with specified oil till the level comes to the lower portion of oil filler plug hole. Specified transfer oil: MITSUBISHI Genuine Gear Oil Part No.8149630 EX, CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD (GL-5, SAE 80W - 90) or equivalent Quantity: 0.55 L <Vehicles without ACD or vehicles without...

  • Page 949: Bleeding

    22A-42 MANUAL TRANSMISSION - On-vehicle Service BLEEDING <VEHICLES WITH ACD OR VEHICLES WITH ACD AND AYC> 1. Lift up the vehicle. 2. Set the MUT-II to the 16-pin diagnosis connector. Caution Turn the ignition switch to the “LOCK”(OFF) position before connecting or disconnecting the MUT-II. 3.

  • Page 950: Hydraulic Pressure Check

    22A-43 MANUAL TRANSMISSION - On-vehicle Service 4. Set the gear to the 2nd gear or above, operate the MUT-II, and check from the service data (Item No.09) that the wheel speed is within 10 km/h to 20 km/h. NOTE (1) Set the steering wheel to the neutral position (2) The ACD may continue operating (operation sounds can be heard) when the steering wheel is steered, this is not a system fault.

  • Page 951: Wheel Speed Sensor Output Voltage

    22A-44 MANUAL TRANSMISSION - On-vehicle Service (2) If the hydraulic unit function has been stopped by fail-safe, the hydraulic unit cannot be forcibly driven. 6. Check that the generated oil pressure of the hydraulic unit satisfies the standard value. Standard value: 1.0 – 1.6 MPa Caution While the oil pressure is checked, add fluid as necessary to ensure that it is left in the oil reservoir...
  • Page 952 22A-45 MANUAL TRANSMISSION - On-vehicle Service Output voltage: Above 70 mV when measured with the circuit tester Above 200 mVP-P when measured with the oscilloscope 4. If the output voltage is lower than the above values, the following reasons may be suspected. Check or replace the wheel speed sensor.

  • Page 953: Transmission Control

    22A-46 MANUAL TRANSMISSION - Transmission Control TRANSMISSION CONTROL REMOVAL AND INSTALLATION Pre-removal Operation Caution: SRS Strut Tower Bar Removal and Installation (Refer Be careful not to subject the SRS-ECU to any to GROUP 42.) shocks during removal and installation of the Air Cleaner Removal (Refer to GROUP 15.) shift cable and select cable assembly.
  • Page 954 22A-47 MANUAL TRANSMISSION - Transmission Control REMOVAL SERVICE POINT Shift cable, AA" CLIP/SELECT CABLE CONNECTION Clip select cable Claws (TRANSMISSION)/SHIFT CABLE (TRANSMISSION) INSTALLATION Push up the claws of the clip using a screwdriver, etc., and then remove the clip from the bracket together with the cables. INSTALLATION SERVICE POINT "AA CLIP/SELECT CABLE AND SHIFT CABLE ASSEMBLY/SHIFT CABLE CONNECTION/SELECT...
  • Page 955 22A-48 MANUAL TRANSMISSION - Transmission Control SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 2 N·m ± 1 N·m ± Disassembly steps 7. Cap 8. Shift lever 1. Bolt 9. Shift lever bushing 2. Select lever 10. Distance piece 3. Bushing 11. Bushing 4.

  • Page 956: Transfer Assembly

    22A-49 MANUAL TRANSMISSION - Transfer Assembly TRANSFER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.) Side Under Cover Removal and Installation Transmission Oil Draining and Supplying (Refer to P.22A-40.) Transfer Oil Draining and Supplying (Refer to P.22A-40.) Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) Crossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
  • Page 957 22A-50 MANUAL TRANSMISSION - Transfer Assembly 5 N·m ± 9 N·m ± ± 9 N·m 7 N·m* ± 7 N·m* ± 10 N·m ± 10 N·m ± 9. Rear roll stopper connection bolt 14. Dust seal guard 10. Centermember assembly 15.
  • Page 958 22A-51 MANUAL TRANSMISSION - Transfer Assembly AB" DRIVE SHAFT <L.H.>/DRIVE SHAFT <R.H.> <L.H.> DISCONNECTION 1. As shown in the figure, pull out the transfer shaft <L.H.> Transmission side from the transmission using the pry bar. As shown in the illustration, press a hammer, etc. against the driveshaft <R.H.>, and pull out the driveshaft from the transfer assembly using the pry shaft.

  • Page 959: Transmission Assembly

    22A-52 MANUAL TRANSMISSION - Transmission Assembly TRANSMISSION ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Transfer Assembly Removal and Installation (Refer to P.22A-49.) Starter Motor Removal and Installation (Refer to GROUP 16.) Air Cleaner Bracket Removal and Installation (Refer to GROUP 15 - Air Cleaner.) Rear Roll Rod Assembly and Rear Roll Rod Bracket <L.H.
  • Page 960 22A-53 MANUAL TRANSMISSION - Transmission Assembly 7 N·m* ± ± 7 N·m* ± 5 N·m 5 N·m ± 5 N·m ± ± 5 N·m 1.0 N·m ± 5 N·m ± 8. Transmission assembly upper part 13. Transmission assembly lower part coupling bolts coupling bolts 9.
  • Page 961 22A-54 MANUAL TRANSMISSION - Transmission Assembly AB" ENGINE ASSEMBLY SUPPORTING MZ203827 Set the special tool to the vehicle to support the engine assembly. MB991453 AC" CLUTCH RELEASE BEARING SEPARATION 1. Remove the cover from the service hole in the clutch housing.

  • Page 962: 4Wd-Ecu

    22A-55 4WD-ECU <Vehicles with ACD or vehicles MANUAL TRANSMISSION - with ACD and AYC> 4WD-ECU <VEHICLES WITH ACD OR VEHICLES WITH ACD AND AYC> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Cowl Side Trim <R.H.> Removal and Installation. (Refer to GROUP 52A - Trims.) <L.H. drive vehicles> Front floor Console Removal and Installation.
  • Page 963 Sensor, Switch and Relay <Vehicles with ACD 22A-56 MANUAL TRANSMISSION - or vehicles with ACD and AYC> SENSOR, SWITCH AND RELAY <VEHICLES WITH ACD OR VEHICLES WITH ACD AND AYC> REMOVAL AND INSTALLATION Caution Before removing the steering wheel and air bag module assembly, be sure to refer to GROUP 52B Precautions in Servicing and Airbag Module Clock Spring.
  • Page 964 Sensor, Switch and Relay <Vehicles with ACD or 22A-57 MANUAL TRANSMISSION - vehicles with ACD and AYC> INSPECTION ELECTRIC PUMP RELAY CONTINUITY CHECK 1. Using a jumper wire, connect a battery (+) to terminal 13 of the electric pump relay and battery ( - ) to terminal 2.
  • Page 965 NOTES...
  • Page 966 22B-1 MANUAL TRANSMISSION OVERHAUL CONTENTS GENERAL DESCRIPTION ....OUTPUT SHAFT ......SPECIFICATIONS .

  • Page 967: General Description

    22B-2 MANUAL TRANSMISSION OVERHAUL - General Description GENERAL DESCRIPTION SECTIONAL VIEW <W5M51 - 2 - X5B3>...
  • Page 968 22B-3 MANUAL TRANSMISSION OVERHAUL - General Description SECTIONAL VIEW <W5M51 - 2 - X5B1>...
  • Page 969 22B-4 MANUAL TRANSMISSION OVERHAUL - General Description SECTIONAL VIEW <W5M51 - 2 - X5B2>...
  • Page 970 22B-5 MANUAL TRANSMISSION OVERHAUL - General Description SECTIONAL VIEW <W5M51 - 2 - X5B, X5B 4>...

  • Page 971: Specifications

    22B-6 MANUAL TRANSMISSION OVERHAUL - Specifications/Service Specifications SPECIFICATIONS TRANSMISSION MODEL TABLE Transmission Gear ratio Speedometer Final Front LSD Vehicle model Engine model model gear ratio reduction ratio W5M51- 2 - X5B 28/36 4.529 CT9A 4G63 - I/C•T/C Provided W5M51- 2 - X5B1 28/36 4.529 Not provided...

  • Page 972: Sealants

    Sealants SEALANTS TRANSMISSION Items Specified sealants Clutch housing and transmission case contact surface MITSUBISHI genuine sealant Part No MD997740 or equivalent No.MD997740 or equivalent Control housing and transmission case contact surface Under cover and transmission case contact surface Air breather 3M SUPER WEATHERSTRIP No.8001 or...

  • Page 973: Lubricants

    LUBRICANTS TRANSMISSION Items Specified lubricants Drive shaft oil seal lip section MITSUBISHI genuine “DIA-QUEEN” multi gear oil <75W/85W> or equivalent gear oil <75W/85W> or equivalent Input shaft oil seal lip section Control shaft oil seal lip section Select lever shoe MITSUBISHI genuine grease Part No.0101011 or equivalent...

  • Page 974: Snap Rings, Spacers And Thrust

    Snap Rings, Spacers and Thrust 22B-9 MANUAL TRANSMISSION OVERHAUL - Plates for Adjustment SNAP RINGS, SPACERS AND THRUST PLATES FOR ADJUSTMENT SPACERS (FOR ADJUSTMENT OF INPUT SHAFT END PLAY) Thickness mm Identification Part No. Thickness mm Identification Part No. 1.34 MD723600 1.61 MD723609...
  • Page 975 22B-10 Snap Rings, Spacers and Thrust MANUAL TRANSMISSION OVERHAUL - Plates for Adjustment SNAP RINGS (FOR ADJUSTMENT OF OUTPUT SHAFT BEARING CLEARANCE) Thickness mm Identification Part No. Thickness mm Identification Part No. 1.36 Yellow MD748449 1.55 White MD748452 1.40 Green MD748450 1.58 Brown...

  • Page 976: Tightening Torque

    22B-11 MANUAL TRANSMISSION OVERHAUL - Tightening Torque TIGHTENING TORQUE TRANSMISSION Items Tightening torque N•m Under cover mounting bolt 6.9 ± 1 Interlock plate bolt 30 ± 3 Clutch housing and transmission case tightening bolt 44 ± 5 Clutch release bearing retainer mounting bolt 9.8 ±...

  • Page 977: Special Tools

    22B-12 MANUAL TRANSMISSION OVERHAUL - Special Tools SPECIAL TOOLS Tool Number Name MB990887 Arm bush remover Installation of transfer oil seal and installer ring MB990891 Bush remover and Installation of transfer oil seal installer base MB990928 Installer adapter Installation of input shaft oil seal MB990932 Installer adapter Removal of differential case taper roller...
  • Page 978 22B-13 MANUAL TRANSMISSION OVERHAUL - Special Tools Tool Number Name MD998364 Camshaft oil seal Installation of each gear, bearing and sleeve installer MD998800 Oil seal installer Installation of differential oil seal and transfer cover oil seal MD998801 Bearing remover Installation and removal of each gear, bearing and sleeve MD998812 Installer cap...
  • Page 979 22B-14 MANUAL TRANSMISSION OVERHAUL - Special Tools Tool Number Name MD998821 Installer adapter Installation of 4th speed gear, 5th speed gear (44) sleeve and 5th-reverse speed synchronizer MD998824 Installer adapter Installation of 1st-2nd speed synchronizer (50) hub, 2nd speed gear sleeve and 3rd speed gear MD998825 Installer adapter...

  • Page 980: Transmission

    22B-15 MANUAL TRANSMISSION OVERHAUL - Transmission TRANSMISSION DISASSEMBLY AND REASSEMBLY 18 ± 3 N•m 18 ± 3 N•m 32 ± 2 N•m 69 ± 9 N•m 32 ± 2 N•m 3.9 ± 1 N•m 69 ± 9 N•m 69 ± 9 N•m Disassembly steps 1.
  • Page 981 22B-16 MANUAL TRANSMISSION OVERHAUL - Transmission Apply gear oil on all sliding sections before installing. 18 ± 3 N•m 30 ± 3 N•m 44 ± 5 N•m 48 ± 5 N•m 6.9 ± 1 N•m Disassembly steps 11. Interlock plate bolt "EA 19.
  • Page 982 22B-17 MANUAL TRANSMISSION OVERHAUL - Transmission Apply gear oil on all sliding sections before installing. Disassembly steps "CA 27. Spring pin AB" "BA 34. 5th-reverse speed shift rail 28. 1st-2nd speed shift rail AB" "BA 35. 5th-reverse speed shift fork 29.
  • Page 983 22B-18 MANUAL TRANSMISSION OVERHAUL - Transmission DISASSEMBLY SERVICE POINTS 5th-reverse speed shift AA" SPRING PIN REMOVAL fork Shift the 5th-reverse speed shift fork in the direction shown in the illustration, and remove the spring pin. AB" 3RD-4TH SPEED SHIFT RAIL/3RD-4TH SPEED 3rd-4th speed SHIFT FORK/5TH-REVERSE SPEED SHIFT shift rail...
  • Page 984 22B-19 MANUAL TRANSMISSION OVERHAUL - Transmission (3) Set solder (10 mm long, 1.6 mm diameter) on the Solder transmission case at the position shown in the illustration. (4) Install the outer race onto the transmission case. (5) Install the transmission case, and tighten the bolt with the specified torque.
  • Page 985 "EA TRANSMISSION CASE INSTALLATION Apply sealant at the positions of the transmission case shown in the illustration. Sealant Specified sealant: MITSUBISHI genuine sealant Part No.MD997740 or equivalent Caution Evenly squeeze out the agent so that it is not insufficient or excessive.
  • Page 986 "GA CONTROL HOUSING INSTALLATION Apply sealant at the positions of the transmission case shown in the illustration. Sealant Specified sealant: MITSUBISHI genuine sealant Part No.MD997740 or equivalent Caution Evenly squeeze out the agent so that it is not insufficient or excessive.

  • Page 987: Input Shaft

    22B-22 MANUAL TRANSMISSION OVERHAUL - Input Shaft INPUT SHAFT DISASSEMBLY AND REASSEMBLY Apply gear oil on all sliding sections before installing. Disassembly steps "MA 1. Snap ring "EA 12. 3rd-4th speed synchronizer hub 2. Ball bearing 13. Outer synchronizer ring AA"...
  • Page 988 22B-23 MANUAL TRANSMISSION OVERHAUL - Input Shaft DISASSEMBLY SERVICE POINTS MD998801 AA" BALL BEARING REMOVAL Using the special tool, remove the ball bearing from the input shaft. AB" THRUST PLATE STOPPER REMOVAL Using a screwdriver, lift the stopper at the position shown in the illustration, and remove the thrust plate stopper.
  • Page 989 22B-24 MANUAL TRANSMISSION OVERHAUL - Input Shaft REASSEMBLY SERVICE POINTS "AA OIL SEAL INSTALLATION 3.5 mm Oil seal Accurately tap in the oil seal to the dimensions shown in the illustration. "BA BALL BEARING INSTALLATION MD998812 Using the special tool, install the ball bearing onto the input shaft.
  • Page 990 22B-25 MANUAL TRANSMISSION OVERHAUL - Input Shaft Caution (1) Press in so that the synchronizer ring does not bite MD998812 MD998813 MD998801 (2) After assembling, confirm that the 3rd speed gear rotates smoothly. MD998825 "FA SYNCHRONIZER SLEEVE INSTALLATION speed speed (1) Install the synchronizer sleeve onto the input shaft at Identification side...
  • Page 991 22B-26 MANUAL TRANSMISSION OVERHAUL - Input Shaft "IA 5TH SPEED GEAR INSTALLATION MD998812 Using the special tool, install the 5th speed gear onto the MD998813 input shaft. MD998801 Caution MD998825 (1) Press in so that the synchronizer ring does not bite (2) After assembling, confirm that the 4th speed gear rotates smoothly.
  • Page 992 22B-27 MANUAL TRANSMISSION OVERHAUL - Input Shaft INSPECTION INPUT SHAFT (1) There must be no damage, abnormal wear or seizure on the outer diameter of the needle bearing installation section. (2) Check the spline for damage and wear. NEEDLE BEARING (1) When the needle bearing is assembled with the input shaft and gears and rotated, the needle bearing must rotate smoothly without play or abnormal noise.
  • Page 993 22B-28 MANUAL TRANSMISSION OVERHAUL - Input Shaft (2) Assemble the outer ring, inner ring and cone. Press “A” against the gears and check the clearance “A”. Replace Outer ring if “A” is less than the limit value. Cone Limit value: 0.5 mm Caution When replacing, replace the outer ring, inner ring and cone as a set.

  • Page 994: Output Shaft

    22B-29 MANUAL TRANSMISSION OVERHAUL - Output Shaft OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY Apply gear oil on all sliding sections before installing. 19 18 Disassembly steps "PA 1. Snap ring 19. Needle roller bearing AA" "OA 2. Taper roller bearing AE" "GA 20. 2nd speed gear sleeve AB"...
  • Page 995 22B-30 MANUAL TRANSMISSION OVERHAUL - Output Shaft DISASSEMBLY SERVICE POINTS Taper roller MD998801 bearing AA" TAPER ROLLER BEARING REMOVAL Using the special tool, remove the taper roller bearing from the output shaft. AB" REVERSE GEAR BEARING SLEEVE REMOVAL MD998801 Sleeve Install the special tool on the reverse gear, and remove the reverse gear bearing sleeve from the output shaft.
  • Page 996 22B-31 MANUAL TRANSMISSION OVERHAUL - Output Shaft AF" 1ST SPEED GEAR SLEEVE REMOVAL Using the special tool, remove the 1st speed gear sleeve from the output shaft. MD998801 Sleeve AG" TAPER ROLLER BEARING REMOVAL Taper roller MD998801 Using the special tool, remove the taper roller bearing from bearing the output shaft.
  • Page 997 22B-32 MANUAL TRANSMISSION OVERHAUL - Output Shaft "DA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring at the position shown in the illustration. Synchronizer spring "EA 1ST-2ND SPEED SYNCHRONIZER HUB Using the special tool, install the 1st-2nd speed synchronizer speed speed side side hub onto the output shaft in the direction shown in the...
  • Page 998 22B-33 MANUAL TRANSMISSION OVERHAUL - Output Shaft "GA 2ND SPEED GEAR SLEEVE INSTALLATION MD998812 Using the special tool, install the 2nd speed gear sleeve onto the output shaft. MD998814 Sleeve MD998824 MD998364 "HA 3RD SPEED GEAR INSTALALTION MD998812 Using the special tool, install the 3rd speed gear onto the output shaft.
  • Page 999 22B-34 MANUAL TRANSMISSION OVERHAUL - Output Shaft "LA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring at the position shown in the illustration. Synchronizer spring "MA5TH-REVERSE SPEED SYNCHRONIZER HUB Reverse INSTALLATION side speed side Using the special tool, install the 5th-reverse synchronizer hub onto the output shaft in the direction shown in the illustration.
  • Page 1000 22B-35 MANUAL TRANSMISSION OVERHAUL - Output Shaft "PA SNAP RING INSTALLATION Snap ring Select and install the snap ring onto the output shaft so that the output shaft rear bearing clearance is at the standard value. Standard value: 0.01 mm tight to 0.09 mm loose INSPECTION OUTPUT SHAFT Check the spline for damage and wear.

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