Mitsubishi Lancer Evolution 2003 User Manual

2003

Body Repair

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GROUP INDEX

MITSUBISHI

LANCER

EVOLUTION VIII

TECHNICAL

INFORMATION

MANUAL

FOREWORD

This manual has been prepared as an introduction to the specifications, features, construction, functions, and other areas of the new 2003 LANCER EVOLUTION VIII. It includes Technical Information and Body Repair Service. The Body Repair sections immediately follow Group 55 - Heater, Air Conditioning and Ventilation.

Please read this manual carefully so that it will be of assistance for your service and sales activities. Please note the following service manuals are also available and should be used in conjunction with this manual.

General . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . . . .

Engine Electrical. . . . . . . . . . . . . . . .

Engine and Emission Control . . . . .

Clutch. . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transaxle . . . . . . . . . . . . . . .

Propeller Shaft . . . . . . . . . . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . .

SERVICE MANUAL MSSP-206B-2003 PARTS CATALOG BUM6K103A

No part of this publication may be reproduced, stored in any retrieval system of transmitted, in any form or by any means, including but not limited to electronic, mechanical photocopying, recording or otherwise, without the prior written permission of Mitsubishi Motors Corporation.

!2003 Mitsubishi Motors Corporation All Rights, Reserved Printed in USA MSSP-260B-2003

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tire . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . .

Service Brakes . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . .

Body. . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . .

Interior and Supplemental

General . . . . . . . . . . . . . . . . . . . . . . .

Restraint System (SRS) . . . . . . . . . .

Chassis Electrical . . . . . . . . . . . . . . .

Heater, Air Conditioning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

and Ventilation . . . . . . . . . . . . . . . . .

GROUP 52B

SUPPLEMENTAL

RESTRAINT

SYSTEM (SRS)

CONTENTS

52B-1

GENERAL DESCRIPTION. . . . . . . . . 52B-2

SYSTEM OPERATION. . . . . . . . . . . . 52B-7

SRS-ECU . . . . . . . . . . . . . . . . . . . . . . 52B-10

52B-2

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

GENERAL DESCRIPTION

M2521000100132

CAUTION

• Driver and front passenger air bags and seat belt pre-tensioners deploy and operate in all head-on collisions that exceed the threshold to activate the SRS system.

• The specific value is the equivalent impact when a vehicle collides against a concrete (fixed) wall at approximately 25 km/h (16 mph) or more.

• The SRS and pre-tensioner may not work under the following conditions:

• A head-on collision is less than the specific value.

• A vehicle collides on its rear end.

• A vehicle rolls over or is in a similar position.

DRIVER'S AIR BAG

SEAT BELT PRE-TENSIONER

PASSENGER'S (FRONT) AIR BAG

Driverís and front passengerís air bags and seat belts with pre-tensioner are standard, increasing the passive safety level.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

The SRS is designed to supplement the front seat belts. It eliminates or reduces or injury to the front passenger(s) by deploying air bag(s) in case of a head-on collision.

AC211587

SEAT BELT WITH PRE-TENSIONER

The seat belts with pre-tensioner work simultaneously with the SRS. The pre-tensioner takes up seat belt slack immediately when a collision takes place by that restraining the front passengers sooner than the SRS. This prevents the passengers from moving forwards.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

CONSTRUCTION DIAGRAM

VEHICLES IDENTIFICATION CODE CHART PLATE

DRIVER'S AIR BAG MODULE

GENERAL DESCRIPTION

PASSENGER'S (FRONT) AIR BAG MODULE

52B-3

SRS WARNING LIGHT

RADIATOR

CLOCK SPRING

DATA LINK CONNECTOR (FOR SCAN TOOL)

SRS-ECU

The SRS and seat belt tightening systems consist of driverís/passenger air bag modules, SRS-ECU, two front impact sensors, SRS warning light, clock spring, and seat belt pre-tensioner. Air bags are located in the center of the steering wheel and above the glove box. Each air bag has a safing folded air bag and an inflators the system and has a safing G sensor and an analogue G sensor. On all air bag modules, the inflator does not contain sodium azide. The front impact sensor is assembled on the headlight support panel to monitor collision upon frontal impact. The warning light on the instrument panel indicates the operational status of the SRS. A clock spring is installed in the steering column.

FRONT IMPACT SENSOR

SEAT BELT WITH PRE-TENSIONER

AC211592

The SRS-ECU detects the impact produced at the time of a collision from the safing and analog G sensors and supplies squib ignition current to the air bag modules. The SRS-ECU has the following functions: This triggers the air bag modules.

• Power supply backup function (backup condenser) that deploys or operates the air bag module and seat belt pretensioner within specific period, in case of power failure upon impact.

• Voltage raising function (DC-DC converter circuit).

• Diagnostic test mode to improve safety and reliability.

52B-4

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS SYSTEM CIRCUIT DIAGRAM

IGNITION SWITCH (IG1)

No.3

No.2

7.5A

COMBINATION METER (SRS WARNING LIGHT)

CONNECTOR LOCK SWITCH*

DRIVER'S AIR BAG MODULE

OFF

PASSENGER'S (FRONT) AIR BAG MODULE

SEAT BELT PRE-TENSIONER (LH)

SEAT BELT PRE-TENSIONER (RH)

OFF

CONNCTOR LOCK SWITCH*

CLOCK SPRING

CONNECTOR LOCK SWITCH*

OFF

FRONT AIR BAG SAFING G-SENSOR

AIR BAG DRIVE CIRCUIT

GENERAL DESCRIPTION

BACK UP CAPACITOR

DC-DC CONVERTER

WARNING LIGHT DRIVE CIRCUIT

AIR BAG DRIVE CIRCUIT

MICRO PROCESSOR

POWER SOURCE CIRCUIT FOR SIDE-AIRBAG

SCAN TOOL INTERFACE CIRCUIT

CONNECTOR LOCK DETECTION CIRCUIT

FRONT AIR BAG ANALOG G-SENSOR

DATA LINK CONNECTOR (FOR SCAN TOOL)

OFF

CONNECTOR LOCK SWITCH*

(LH) (RH)

FRONT IMPACT SENSOR

NOTE *: CONNECTOR LOCKED: ON CONNECTOR UNLOCKED: OFF

FRONT IMPACT SENSOR INTERFACE CIRCUIT

AC211582

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

GENERAL DESCRIPTION

CAUTION LABELS

Labels to indicate cautions regarding the handling and the services of SRS air bag air attached on the position shown in the following illustration.

52B-5

PASSENGER'S (FRONT) AIR BAG MODULE

COVER

SRS-ECU

CLOCK SPRING

SUN VISOR

GLOVE BOX

FRONT IMPACT SENSOR

SEAT BELT WITH

STEERING JOINT COVER

PRE-TENSIONER (DRIVER'S AND FRONT PASSENGER'S SEATBELT)

AC211604

52B-6

LABEL CONTENTS

AWARNING: SRS

BEFORE REPLACING STEERING WHEEL, READ SERVICE MANUAL. THIS AIR BAG MODULE CANNOT BE REPAIRED. DO NOT DISASSEMBLE OR TAMPER.

BCAUTION: SRS CLOCK SPRING

THIS IS NOT A REPAIRABLE PART. IF DEFECTIVE, REPLACE ENTIRE UNIT ACCORDING TO THE SERVICE MANUAL INSTRUCTIONS. TO RE-CENTER: ROTATE CLOCKWISE UNTIL TIGHT. THEN ROTATE IN OPPOSITE DIRECTION ROUGHLY 3 TURNS AND ALIGN ARROWS >><<.

CWARNING FLAMMABLE/EXPLOSIVE SRS AIR BAG MODULE

TO AVOID SERIOUS INJURY:

• DO NOT REPAIR, DISASSEMBLE OR TAMPER.

• AVOID C ONTA CT WIT H F LAM E OR ELECTRICITY.

• DO NOT DIAGNOSIS/USE NO TEST EQUIPMENT OR PROBES.

• STORE BELOW 200°F (93°C).

• BEFORE DOING ANY WORK INVOLVING MODULE, READ SERVICE MANUAL

FOR IMPORTANT FURTHER DATA.

DCAUTION:

DO NOT DISASSEMBLE OR DROP. IF DEFECT REFER TO SERVICE MANUAL.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

GENERAL DESCRIPTION

EWARNING

DEATH or SERIOUS INJURY can occur

• Children 12 and under can be killed by the air bag.

• The BACK SEAT is the SAFEST place for children.

• NEVER put a rear-facing child seat in the front.

• Sit as far back as possible from the air bag.

• ALWAYS use SEAT BELTS and CHILD RESTRAINTS.

FAIR BAG SYSTEM INFORMATION

THIS VEHICLE HAS AN AIR BAG SYSTEM WHICH WILL SUPPLEMENT THE SEAT BELT IN CERTAIN FRONTAL COLLISIONS. THE AIR BAG IS NOT A SUBSTITUTE FOR THE SEAT BELT IN ANY TYPE OF COLLISION. THE DRIVER AND ALL OTHER OCCUPANTS SHOULD WEAR SEAT BELTS AT ALL TIME. WARNING! IF THE "SRS" WARNING LIGHT DOES NOT ILLUMINATE FOR SEVERAL SECONDS WHEN IGNITION KEY IS TURNED TO "ON" OR THE ENGINE IS STARTED, OR IF THE WARNING LIGHT STAYS ON WHILE DRIVING, TAKE THE VEHICLE TO YOUR NEAREST AUTHORIZED DEALER IMMEDIATELY. ALSO, IF VEHICLE'S FRONT END IS DAMAGED OR IF THE AIR BAG HAS DEPLOYED, TAKE THE VEHICLE FOR SERVICE IMMEDIATELY. THE AIR BAG SYSTEM MUST BE INSPECTED BY AN AUTHORIZED DEALER TEN YEARS AFTER THE VEHICLE MANUFACTURE DATE SHOWN ON THE CERTIFICATION LABEL LOCATED ON THE LEFT FRONT DOOR-LATCH POST OR DOOR FRAME. READ THE "SRS" SECTION OF YOUR OWNER'S MANUAL BEFORE DRIVING FOR IMPORTANT INFORMATION ABOUT OPERATION AND SERVICE OF THE AIR BAG SYSTEM. WHEN YOU ARE GOING TO DISCARD YOUR GAS GENERATOR OR VEHICLE, PLEASE SEE YOUR DEALER.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SYSTEM OPERATION

LABEL CONTENTS

GWARNING

CHILDREN CAN BE KILLED OR INJURED BY PASSENGER AIR BAG. THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN 12 AND UNDER. MAKE SURE ALL CHILDREN USE SEAT BELTS OR CHILD SEAT. NOT TO BE REMOVED EXCEPT BY OWNER.

HCAUTION: SRS

FIX STRG. WHEEL AT TIRES STRAIGHT AHEAD BEFORE GEARBOX REMOVAL. OTHERWISE, MAY DAMAGE SRS CLOCK SPRING MAKING SRS SYSTEM IN OPERATIVE. RISKING SERIOUS DRIVER INJURY.

IDANGER SEAT BELT PRETENSIONER

CAUTION THIS ASSEMBLY CONTAINS AN EXPLOSIVE INITIATOR FLAMMABLE MATERIAL TO PREVENT PERSONAL INJURY

• DO NOT IMPACT, DISMANTLE OR INSTALL IT INTO ANOTHER VEHICLE.

• SERVICE OR DISPOSE OF IT AS DIRECTED IN THE REPAIR MANUAL.

JCAUTION:

DO NOT DISASSEMBLE OR DROP.

52B-7

SYSTEM OPERATION

A passengerís (front) air bag module and clock spring are the same as OUTLANDER.

DRIVERíS AIR BAG MODULE

CAUTION

Never disassemble the air bag module.

The driverís air bag module is incorporated into the 3-spoke steering wheel. The driverís air bag module is an assembly part consisting of air bag, module cover, inflator, and its their fasteners. It is installed into the steering wheel. The air bag is made from

AIR BAG MODULE

M2521001000116

SECTION A - A

INFLATOR

MODULE COVER

AIR BAG

AC211615

nylon and inflates by the gas generating from the inflator. As a driver is being pressed to the air bag, it deflates discharging gas from two vents at the rear of the air bag to reduce the shock from the impact. An inflator that does not contain sodium azide is used.

52B-8

SENSOR INTERNAL CIRCUIT

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SYSTEM OPERATION

FRONT IMPACT SENSOR

CAUTION

Never disassemble the front impact sensor.

The front impact sensor is installed in the radiator support panel. In a collision, the contact in the front impact sensor turns ON and an output signal is send to the SRS-ECU. A resistor is connected to the front impact sensor in parallel with the contact for fault diagnosis.

AC206958

SEAT BELT WITH PRE-TENSIONER

BALL

RING GEAR

PINION

SPOOL

PIPE

GAS GENERANT

CAUTION

Never disassemble the seat belt with pre-tensioner.

The seatbelt incorporating the pretensioner automatically winds the seatbelt upon front impact to reduce forward shifting of the passenger. The seat belt pre-tensioner is built into the driver's and passenger's front seat belt retractor.

AC101663

Upon front impact the pretensioner ignites the gas generator and emits gas with the SRS-ECU signal when the front impact sensor, attached to the front of the body, detects an impact that exceeds the permissible limit. The gas pressure shifts the ball in the pipe and the balls comes in contact with the protrusion of the ring gear, The ball is inserted in the ring gear and then interlocked with the pinion. The ring gear rotation forces the pinion to turn the spool toward the belt wind direction to wind the webbing.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SYSTEM OPERATION

SRS AIR BAG SPECIAL CONNECTOR

CLOCK SPRING

SRS-ECU

To en han ce th e Sys te mís r el iabi li ty, a c on nec to r lo ck switch is integrated into the SRS-ECU connector, the air bag module connectors, the clock spring connector, the seat belt pretensioner connectors (black connector "A" shown in the illustration above).

52B-9

SEAT BELT WITH PRE-TENSIONER (DRIVER'S SIDE)

DRIVER'S AIR BAG MODULE

PASSENGER'S (FRONT) AIR BAG MODULE

SEAT BELT WITH PRE-TENSIONER (FRONT PASSENGER'S SIDE)

AC103223

SQUIB CIRCUIT CONNECTOR LOCK SWITCH

CONNECTOR CONNECTED

SQUIB

ECU-SIDE CONNECTOR

TERMINAL (MALE)

PARTITION PANEL

SECTION A - A

TERMINAL (MALE)

OFF

SRS-ECU

WIRING HARNESS-SIDE CONNECTOR

TERMINAL (FEMALE)

CONNECTOR DISCONNECTED

SQUIB

SECTION B - B

SHORT SPRING

OFF

TERMINAL (MALE)

PARTITION PANEL

SRS-ECU

CONNECTOR CONNECTED

TERMINAL (FEMALE)

PARTITION PANEL

SHORT SPRING

AC006197

52B-10

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS-ECU

CAUTION

When the connector is disconnected, there will be short circuit between the terminals. This is not a fault.

WARNING LIGHT CIRCUIT CONNECTOR LOCK SWITCH

The switch is a mechanism that shorts the power supply termi-

IGNITION SWITCH (IG1)

SRS WARNING LIGHT

SRS-ECU HARNESS-SIDE CONNECTOR

nal to the ground terminal automatically in the warning light circuit, when the connector is disconnected. Its structure is similar to the squib circuit connector shorting mechanism.

The switch is a mechanism that shorts the power supply terminal to the ground terminal automatically in the air bag squib circuit when the connector is disconnected. A "short" spring is integrated inside the connector. This spring prevents static electricity from flowing to the squib by shorting the power supply terminal to the ground terminal (i.e. there is no potential difference between the two terminals).

CONNECTOR LOCK SWITCH*

SHORT SPRING

NOTE *: CONNECTOR LOCKED: ON CONNECTOR UNLOCKED: OFF

OFF

AC006203

SRS-ECU

CAUTION

Never disassemble the SRS-ECU.

The SRS-ECU incorporates an analog G-sensor and safing G-sensor for frontal collisions and a safing Gsensor for side collisions. In frontal collisions, the driverís and passengerís (front) air bags deploy and the seat belt pre-tensioners are activated only when both the analog and safing G-sensors detect simultaneously a collision-induced G of a level exceeding the threshold as in the case with the conventional system. In the case of side collisions, the side-airbag on the side subjected to an impact deploys if the side impact sensor and the SRS-ECUís safing G-sensor detect simultaneously a lateral G of forces above the predetermined level.

M2521007000095

The SRS-ECU is provided with the following capabilities:

• Backup power supply in case of power failure in collisions

• Boosting function in case of battery voltage drop

• Self-diagnosis function to avoid systemís opera-

tion errors and improve its reliability

DIAGNOSTIC FUNCTION

The SRS-ECU has the following functions to make system checking using the scan tool easy.

• Diagnostic trouble code output

• Service data output

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS-ECU

DIAGNOSTIC TROUBLE CODE OUTPUT

The SRS-ECU diagnoses the following items and stores a diagnostic trouble code in the non-volatile

memory (EEPROM* Therefore, the memory is not deleted after a battery terminal is disconnected, (The diagnostic trouble code memory can be deleted by the scan tool.)

CODE NO. MAJOR CONTENTS OF DIAGNOSTICS

1A Front impact sensor (LH) short-circuited

1B Front impact sensor (LH) open-circuited

1C Front impact sensor (LH) short-circuited to power supply

1D Front impact sensor (LH) short-circuited to ground

2A Front impact sensor (RH) short-circuited

2B Front impact sensor (RH) open-circuited

2C Front impact sensor (RH) short-circuited to power supply

2D Front impact sensor (RH) short-circuited to ground

14 Analog G-sensor malfunction

) when a problem is detected.

52B-11

15 Safing G-sensor short-circuited (for frontal collision)

16 Safing G-sensor open-circuited (for frontal collision)

21*

22*

24*

25*

26*

27*

28*

29*

Driver's air bag squib short-circuited

Driver's air bag squib open-circuited

Passenger's (front) air bag squib short-circuited

Passenger's (front) air bag squib open-circuited

Driver's pre-tensioner squib short-circuited

Driver's pre-tensioner squib open-circuited

Passenger's (front) pre-tensioner squib short-circuited

Passenger's (front) pre-tensioner squib open-circuited

31 SRS-ECU capacitor circuit voltage too high

32 SRS-ECU capacitor circuit voltage too low

34*

SRS-ECU connector lock out of order

35 Ignition of the air bag completed

39 Air bag deployed simultaneously

41*

42*

43*

44*

Power supply voltage (IG1 (A) voltage) drops a0bnormally.

Power supply voltage (IG1 (B) voltage) drops abnormally.

SRS warning light circuit open-circuited

SRS warning light circuit malfunction

45 SRS-ECU non-volatile memory (EEPROM) and A/D converter system

46*

Incorrect SRS-ECU

51 Driver's air bag squib activating circuit short-circuited

52 Driver's air bag squib activating circuit open-circuited

52B-12

CODE NO. MAJOR CONTENTS OF DIAGNOSTICS

54 Passenger's (front) air bag squib activating circuit short-circuited

55 Passenger's (front) air bag squib activating circuit open-circuited

56 Driverís seat belt pre-tensioner (squib ignition drive circuit) system detected short

57 Driverís seat belt pre-tensioner (squib ignition drive circuit) system detected open

58 Passengerís seat belt pre-tensioner (squib ignition drive circuit) system detected

short

59 Passengerís seat belt pre-tensioner (squib ignition drive circuit) system detected

open

61 Driver's air bag squib drive circuit (power supply side) short-circuited

62 Driver's air bag squib drive circuit (ground side) short-circuited

64 Passenger's (front) air bag squib drive circuit (power supply side) short-circuited

65 Passenger's (front) air bag squib drive circuit (ground side) short-circuited

66 Driver's pre-tensioner squib (power supply side) short-circuited

67 Driver's pre-tensioner squib (ground side) short-circuited

68 Passenger's (front) pre-tensioner squib drive circuit (power supply side) short-

circuited

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS-ECU

69 Passenger's (front) pre-tensioner squib drive circuit (ground side) short-circuited

NOTE: *1: Electrically Erasable Programmable ROM

: This diagnostic trouble code memory will be automatically cleared from the memory and the SRS warning

* light will be switched off when the system returns to normal condition.

: The diagnostic trouble codes will remain in memory and the SRS warning light will be switched off if the

* system returns to normal condition.

DATA LIST OUTPUT

When the SRS-ECU detects a problem, it stores a diagnostic trouble code and the duration that the problem has lasted in the non-voltage memory. In addition, how often a diagnostic trouble code and duration are cleared by the scan tool are stored in the non-volatile memory as a reference for service work. This data can be read by the scan tool.

No. DATA LIST ITEM APPLICABILITY

92 Number indicating how often the memory is cleared Maximum time to be stored: 250

days

93 How long a problem has lasted (How long from the

occurrence of the problem until the first air bag squib ignition signal)

94 How long a problem has lasted (How long from the first

air bag squib igniting signal until now)

Maximum time to be stored: 9999 minutes (approximately seven days)

GROUP 36

PARKING BRAKE

CONTENTS

GENERAL INFORMATION . . . . . . . . 36-2

36-1

36-2

PARK ING BR AKE

GENERAL INFORMATION

FEATURE

The parking brakes are a mechanical rear wheel brake design and controlled by a lever.

CONSTRUCTION DIAGRAM

M2360000100173

AC211553

GROUP 35B

FOUR-WHEEL

ANTI-LOCK BRAKE

SYSTEM (4ABS)

CONTENTS

35B-1

GENERAL DESCRIPTION. . . . . . . . . 35B-2

SENSORS . . . . . . . . . . . . . . . . . . . . . 35B-6

ACTUATORS . . . . . . . . . . . . . . . . . . . 35B-8

BRAKE MODULATOR (ABS-ECU) . . 35B-9

SYSTEM OPERATION . . . . . . . . . . . . 35B-10

35B-2

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

GENERAL DESCRIPTION

Top comp on ents such as Bremb o! brakes, EBD and sports ABS improve braking power and braking stability.

SPORTS ABS

• 4-wheel independent control optimizes the brake force to each wheel to achieve a balance of improved braking force and braking stability.

• A steering angular velocity sensor was added to monitor the steering angle status. Braking force is altered in response to the steering status to improve the quality of steering when braking in corners.

• The steering angular velocity sensor, lateral Gsensor and longitudinal G-sensor accurately monitor driving conditions and optimize ABS control to match the specific driving conditions.

M2351000100186

EBD (Electronic Brake-force Distribution system)

• Rear brake power is electronically controlled to optimize performance in accordance with road and load conditions and to ensure optimal distribution of braking force between the front and rear brakes.

• Rear brake fluid pressure control employs a brake modulator hydraulic unit solenoid valve that made it possible to eliminate the pressure control valves (proportioning valves).

• Effective use of rear wheel brake force reduces temperature build-up in the front brakes under hard braking conditions.

• Independent control of the left and right rear brakes when braking during cornering achieves a balance of improved vehicle stability and braking force.

SPECIFICATIONS

ITEM LANCER EVOLUTION LANCER

ABS control method 4-sensor, 4-channel 4-sensor, 4-channel

No. of ABS rotor teeth Front 43 43

Rear 43 43

ABS sensor Type Magnet coil type Magnet coil type

Gap between sensor and rotor mm (in)

Front 0.85 (0.033)

<Non-adjustable type>

Rear 0.60 (0.023)

<Non-adjustable type>

0.85 (0.033) <Non-adjustable type>

0.89 (0.035) <Non-adjustable type>

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

CONSTRUCTION DIAGRAM

GENERAL DESCRIPTION

35B-3

7, 10

AC209828

10067AU

AC211546

NAME OF PART NO. OUTLINE OF FUNCTION

Sensor ABS sensor 1 Sends alternating current signals at frequencies which are proportional

to the rotation speeds of each wheel to the ABS-ECU.

Lateral G-sensor 2 Sends data on vehicleís rate of lateral acceleration to the ABS-ECU.

Longitudinal Gsensor

Steering angular velocity sensor

3Sends data on vehicleís rate of longitudinal acceleration to the ABS-

ECU.

4Sends data on steering wheel angle to the ABS-ECU.

Indicates the ABS-ECU when steering wheel is in straight-ahead position.

Stoplight switch 5 Sends a signal to the ABS-ECU to indicate whether the brake pedal is

depressed or not.

Parking brake switch

6Sends a signal to the ABS-ECU to indicate whether the parking brake

lever is pulled or not.

Actuator Hydraulic unit 7 Drives the solenoid valves according to signals from the ABS-ECU in

order to control the brake hydraulic pressure for each wheel.

ABS warning light

8Illuminates in response to signals from the ABS-ECU when a problem

develops in the system.

Data link connector 9 Outputs the diagnostic trouble codes and allows communication with

the scan tool.

Brake modulator (ABS-ECU) 10 Controls actuators (described above) based on the signals coming from

each sensor.

Controls the self-diagnosis and fail-safe functions.

Controls the diagnostic function (scan tool compatible).

35B-4

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

GENERAL DESCRIPTION

SYSTEM CONFIGURATION DIAGRAM

ABS SENSOR (FL)

ABS SENSOR (RL)

ABS SENSOR (RR)

ABS SENSOR (FR)

LONGITUDINAL G-SENSOR

LATERAL G-SENSOR

STOPLIGHT SWITCH

PARKING BRAKE SWITCH

STEERING ANGULAR VELOCITY SENSOR

ECU POWER SUPPLY

FRONT-RIGHT WHEEL (FR)

ABS-ECU

FR SOLENOID VALVE (OUT)

FR SOLENOID VALVE (IN) FL SOLENOID VALVE (OUT) FL SOLENOID VALVE (IN) RR SOLENOID VALVE (OUT) RR SOLENOID VALVE (IN) RL SOLENOID VALVE (OUT) RL SOLENOID VALVE (IN)

ABS WARNING LIGHT

DATA LINK CONNECTOR

STEERING ANGULAR VELOCITY SENSOR

PARKING BRAKE SWITCH

STOPLIGHT SWITCH

REAR-RIGHT WHEEL (RR)

FRONT-LEFT WHEEL (FL)

ABS SENSOR

HYDRAULIC UNIT

ABS SENSOR

LATERAL G-SENSOR

LONGITUDINAL G-SENSOR

ABS SENSOR

REAR-LEFT WHEEL (RL)

10066AU AC211547

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

GENERAL DESCRIPTION

ABS ELECTRICAL CIRCUIT DIAGRAM

35B-5

FUSIBLE LINK 3 BATTERY

15A

STOPLIGHT

IGNITION SWITCH (IG2)

RELAY BOX

STOPLIGHT SWITCH

7.5A

LATERAL G-SENSOR

JUNCTION BLOCK

LONGITUDINAL G-SENSOR

IGNITION SWITCH (IG1)

7.5A

STEERING ANGULAR VELOCITY SENSOR

HYDRAULIC UNIT

SOLENOID VALVE

7.5A

COMBINATION METER

ANTI LOCK

MOTOR

FUSIBLE LINK 1

15A

ABS-ECU

MOTOR POWER SUPPLY

SOLENOID VALVE POWER SUPPLY

LATERAL G-SENSOR INPUT

STOPLIGHT SWITCH MONITOR

FL FR RL RR

(FL) (FR) (RL) (RR)

ECU POWER SUPPLY

STEERING ANGULAR VELOCITY SENSOR INPUT

ABS SENSOR

LATERAL G-SENSOR INPUT

PARKING BRAKE SWITCH MONITOR

PARKING BRAKE SWITCH

COMMUNICATION LINE

CONTROL LINE

DATA LINK CONNECTOR

AC211548

35B-6

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

SENSORS

ABS SENSOR

FRONT

DRIVESHAFT

ABS SPEED SENSOR

ABS ROTOR

The ABS sensors consist of fixed ABS speed sensors and the ABS rotors that rotate at the same speed as the wheels, that output alternating current signals at frequencies which are proportional to the wheel speed.

M2351001000137

REAR

ABS ROTOR

DRIVESHAFT

ABS SPEED SENSOR

AC211549

• The ABS rotors (43 teeth) are installed to the drive shafts, and the ABS speed sensors are installed to knuckles.

• The gap between the ABS rotors and the ABS speed sensors are non-adjustable at both the front and rear to improve serviceability.

LATERAL G-SENSOR/LONGITUDINAL G-SENSOR

G-SENSOR OUTPUT CHARACTERISTICS

PARKING BRAKE LEVER

LATERAL G-SENSOR

LONGITUDINAL G-SENSOR

ACCELERATION SPEED (G)

The longitudinal G-sensor detects the acceleration in the lateral direction of the vehicle, and are basically the same as those used conventionally. The lateral G-sensor is used for detecting the acceleration along the sides of the vehicle by changing the installing direction by 90 degree angle. The same sensor as the longitudinal G-sensor is used.

OUTPUT VOLTAGE (V)

4.0

3.5

2.5

1.5

1.0

0 1.01.0 1.51.5

DECELERATION SPEED (G)

AC211550

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

SENSORS

STEERING ANGULAR VELOCITY SENSOR

35B-7

OUTPUT WAVEFORM OF EACH PHOTOINTERRUPTOR

STEERING ANGULAR VELOCITY SENSOR

Y2057AU

SLIT

SLIT PLATE

ST-1

ST-2

ST-N

HLHLH

4˚ 4˚4˚ 4˚

4˚ 4˚

11˚

2˚

θθ

SLIT PLATE

NEUTRAL POSITION DETECTION SLIT

PHOTOINTERRUPTOR (ST-2)

PHOTOINTERRUPTOR (ST-1)

PHOTOINTERRUPTOR (ST-N)

10091AU

The steering angular velocity sensor is installed at the steering column, and is used to output steer angles to the ABS-ECU as signals. It is composed of the slit plate which rotates according to the movements of the steering wheel and a three-set photointerruptor. The slit plate and photointerruptors have a sealed integrated structure to prevent the invasion of foreign particles as well as misoperations by external light. To detect malfunctions of the sensor output circuit, it is equipped with a zener diode for detecting disconnections parallel to the photo-transistor. The

ZENER DIODE (FOR DISCONNECTION DETECTION)

LIGHT-EMITTING DIODE

PHOTO-TRANSISTOR

AC211551

ABS-ECU calculates the steering angle by reading the signals of the steering angular velocity sensor after every certain period of time and calculating the total of the ST-1 signal and ST-2 signal. The steering angle is obtained by taking the neutral position (ST-N output is L center) as 0 degree angle, and if there are changes, the steering angle is added with 2 degree angle for right and -2 degree angle for left. The output of the photointerruptor becomes L (low) when light passes through and H (high) when obstructed.

35B-8

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

ACTUATORS

STOPLIGHT SWITCH

This switch turns on when the brake pedal is depressed, and turns off when the brake pedal is released. The ABS-ECU detects whether the stoplight switch is on or off by means of fluctuations in voltage (ON: system voltage; OFF: Approximately 0 V). This data is used for ABS control.

ACTUATORS

ABS WARNING LIGHT

The ABS-ECU controls the power transistor in ABS-ECU to turn on and causes the ABS warning light to illuminate in the following cases:

• During initial check when the ignition switch is at the "ON" position (for approximately three seconds)

• When a problem develops in the ABS/EBD system

• Poor ABS-ECU connector connection

ABS WARNING LIGHT

AC211552

PARKING BRAKE SWITCH

This switch turns on when the parking brake lever is pulled, and turns off when the parking brake lever is released. The ABS-ECU detects whether the parking brake switch is on or off by means of fluctuations in voltage (ON: less than 1 volt; OFF: system voltage). This data is used for ABS control.

M2351002000099

HYDRAULIC UNIT

The hydraulic unit is basically the same as that of the LANCER.

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

BRAKE MODULATOR (ABS-ECU)

35B-9

BRAKE MODULATOR (ABS-ECU)

The ABS-ECU is basically the same as that of the LANCER except the followings:

DIAGNOSTIC FUNCTIONS

DIAGNOSTIC TROUBLE CODE OUTPUT

DTC ITEM

11 Ope n cir cuit or shor t-ci rcuit in ABS senso r (F R)

12 Open circuit or short-circuit in ABS sensor (FL)

13 Open circuit or short-circuit in ABS sensor (RR)

14 Open circuit or short-circuit in ABS sensor (RL)

16 Abnormal drop or rise in ABS-ECU power supply voltage

21 ABS sensor (FR) system

22 ABS sensor (FL) system

23 ABS sensor (RR) system

24 ABS sensor (RL) system

32 Longitudinal G-sensor system

41 Solenoid valve (FR) system

M2351003000144

42 Solenoid valve (FL) system

43 Solenoid valve (RR) system

44 Solenoid valve (RL) system

51 Valve relay ON problem

52 Valve relay OFF problem

53 Motor relay OFF problem

54 Motor relay ON problem

55 Motor system

63 ABS-ECU abnormality

71 Lateral G-sensor system

81 Steering angular velocity sensor (ST-1) system

82 Steering angular velocity sensor (ST-2) system

83 Steering angular velocity sensor (ST-N) system

35B-10

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS)

SYSTEM OPERATION

SERVICE DATA OUTPUT

SCAN TOOL DISPLAY

ITEM NO. CHECK ITEM DISPLAY TEXT

OR UNIT

FR SNSR 11 Front-right ABS sensor km/h or mph

FL SNSR 12 Front-left ABS sensor

RR SNSR 13 Rear-right ABS sensor

RL SNSR 14 Rear-left ABS sensor

BATT. VOLTAGE 21 ABS-ECU power supply voltage V

29 Parking brake switch ON/OFF

32 Longitudinal G-sensor V

STOPLIGHT SW 36 Stoplight switch ON/OFF

37 Steering angular velocity sensor straight ahead position

ON/OFF

memory

71 Lateral G-sensor V

74 Steering angular velocity sensor (ST-N) OFF/ON

75 Steering angular velocity sensor (ST-1)

76 Steering angular velocity sensor (ST-2)

86 Steering angle

° or OFF (when the steering angle is straight ahead position)

ACTUATOR TEST

NO. ITEM PARTS TO BE ACTIVATED

01 Solenoid valve for front-left wheel Solenoid valves and pump motors in the hydraulic

02 Solenoid valve for front-right wheel

unit (simple inspection mode)

03 Solenoid valve for rear-left wheel

04 Solenoid valve for rear-right wheel

SYSTEM OPERATION

In terms of operation, the system is basically the same as that of the LANCER.

M2351004000114

GROUP 35

SERVICE BRAKES

CONTENTS

SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A

FOUR-WHEEL ANTI-LOCK BRAKE SYSTEM (4ABS) . . . . . . . 35B

35-1

NOTES

GROUP 35A

SERVICE BRAKES

CONTENTS

35A-1

GENERAL DESCRIPTION. . . . . . . . . 35A-2

MASTER CYLINDER . . . . . . . . . . . . . 35A-4

BRAKE BOOSTER ASSEMBLY . . . . 35A-4

FRONT DISC BRAKE. . . . . . . . . . . . . 35A-5

REAR DISC BRAKE . . . . . . . . . . . . . . 35A-6

35A-2

SERVICE BRAKES

GENERAL DESCRIPTION

Top comp on ents such as Bremb o! brakes, EBD and sports ABS improve braking power and braking stability.

FEATURES

Improved braking performance

1. A 8+9-inch tandem vacuum booster is utilized to provide high braking force with a small pedal depression force.

2. Brembo! 17-inch 4-pot front ventilated disc brakes and Brembo! 16-inch 2-pot rear ventilated disc brakes are adopted to provide stable braking force and improved braking feel.

Improved stability

1. Sports ABS (4-wheel anti-lock braking system) is used to prevent slipping caused by the vehicle wheels locking up in order to maintain an appropriate braking distance, and also to maintain a stable vehicle posture and steering performance.

M2350000100183

2. Adoption of an electronic brake-force distribution (EBD) makes it possible to maintain the maximum amount of braking force even when the vehicle's load is unevenly distributed.

3. Front- and rear-wheel X-type brake line layout is used.

4. Ventilated discs improve anti-fading performance.

Improved serviceability

1. A diagnosis function has been adopted for the ABS system in order to make inspection easier.

2. An outer disc method separated hub and rotor is featured to make removal and installation easier.

3. The master cylinder reservoir tank cap is colored white to make identification easier.

4. The ABS-ECU and hydraulic unit are integrated to make them more compact and light weight.

CONSTRUCTION DIAGRAM

BRAKE BOOSTER ASSEMBLY

BRAKE MODULATOR HYDRAULIC UNIT (INTEGRATED WITH THE ABS-ECU)

BRAKE MASTER CYLINDER ASSEMBLY

FRONT DISC BRAKE

PARKING BRAKE LEVER ASSEMBLY

10064AU

REAR DISC BRAKE

AC211387

SERVICE BRAKES

GENERAL DESCRIPTION

SPECIFICATIONS

ITEM SPECIFICATION

Master cylinder

Type Tandem type

I.D. mm (in) 26.9 (1.06)

35A-3

Brake booster

Rear wheel hydraulic control method Electronic brake-force distribution (EBD)

Front brakes Type 4-opposed piston, ventilated disc

Rear brakes Type 2-opposed piston, ventilated disc

Brake fluid DOT3 or DOT4

Type Vacuum type, tandem

Effective dia. of power cylinder mm (in)

Boosting ratio 4.5 <Brake pedal depressing force: 230 N (51.7 lb)>

Disc effective dia × thickness mm (in)

Wheel cylinder I.D. mm (in) 40.0 (1.58) × 2, 46.0 (1.81) × 2

Pad thickness mm (in) 10.0 (0.39)

Clearance adjustment Automatic

Disc effective dia × thickness mm (in)

Wheel cylinder I.D. mm (in) 40.0 (1.58) × 2

Pad thickness mm (in) 9.0 (0.35)

Clearance adjustment Automatic

205 + 230 (8.07 + 9.06)

263 × 32 (10.4 × 1.3)

252 × 22 (9.9 × 0.9)

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