Mitsubishi Lancer Evolution-VI Workshop Manual
WORKSHOP MANUAL
EVOLUTION-VI
Pub. No. S9806CNCP9-A
General . . . . . . . . . . . . . . . . . . . . . . . .
.
.
00
EVOLUTION-VI
WORKSHOP MANUAL
SUPPLEMENT
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Use the following manuals in
combination with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
N9806CNCP9-A
WORKSHOP MANUAL
S9806CNCP9
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Interior and Supplemental
Restraint System (SRS) . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Heater, Air Conditioner and
V entilation . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
11
13
21
22
26
27
33
35
37
42
51
52
54
55
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
The EVOLUTION -VI is sold exclusively through
RALLIART Inc. Since the EVOLUTION-VI is a rallybased model, it will not be warranted and will not be
homologated for general production. Therefore, any
service matters on the EVOLUTION-VI should be
inquired to RALLIART Inc. as usual.
E Mitsubishi Motors Corporation March 1999
WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air
bag) or to the driver and passenger (from rendering the SRS inoperative).
(2) SRS components should not be subjected to heat over 93_C, so remove the SRS-ECU, air
bag module and clock spring before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) 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.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
GENERAL
CONTENTS
00-1
HOW TO USE THIS MANUAL 3. . . . . . . . . . . . . .
Scope of Maintenance, Repair and Servicing
Explanations 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definition of Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of Tightening Torque 3. . . . . . . . . . . . . . . .
Explanation of Manual Contents 4. . . . . . . . . . . . . . .
HOW TO USE
TROUBLESHOOTING/INSPECTION SERVICE
POINTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Contents 6. . . . . . . . . . . . . . . . . . . . .
Diagnosis Function 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use the Inspection Procedures 10. . . . . . .
Connector Measurement Service Points 11. . . . . . .
Connector Inspection 12. . . . . . . . . . . . . . . . . . . . . . . .
Inspection Service Points for a Blown Fuse 13. . .
Points to Note for Intermittent Malfunctions 13. . . .
MODELS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS BEFORE SERVICE 15. . . . . . .
SUPPORT LOCATIONS FOR LIFTING AND
JACKING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Garage Jack 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Stands 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single-post and Double-post Lift 19. . . . . . . . . . . . . .
SPECIAL HANDLING INSTRUMENTS FOR
TOWING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE TEST 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE 22. . . . . . . . . . . . . . . . . . .
GENERAL – How to Use This Manual
HOW TO USE THIS MANUAL
00-3
SCOPE OF MAINTENANCE, REPAIR
AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components.
For detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
“On-vehicle Service” is procedures for performing
inspections and adjustments of particularly
important locations with regard to the construction
and for maintenance and servicing, but other
inspection (for looseness, play, cracking, damage,
etc.) must also be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection
or the value to which the part or assembly is
corrected and adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a
part or assembly on inspection and means the
maximum or minimum value within which the part
or assembly must be kept functionally or in strength.
It is a value established outside the range of
standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
CAUTION
Indicates the presentation of information particularly
vital to the worker during the performance of
maintenance and servicing procedures in order to
avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of
component or vehicle function or performance, etc.
INDICATION OF TIGHTENING TORQUE
The tightening torque shown in this manual is a
basic value with a tolerance of ±10% except the
following cases when the upper and lower limits
of tightening torque are given.
(1) The tolerance of the basic value is within ±10%.
(2) Special bolts or the like are in use.
(3) Special tightening methods are used.
00-4
GENERAL – How to Use This Manual
EXPLANATION OF MANUAL CONTENTS
Maintenance and Servicing Procedures
The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures.
D Removal steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
D Disassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.
Indicates procedures to be performed
before the work in that section is started,
and procedures to be performed after
the work in that section is finished.
Component Diagram
A diagram of the component parts is
provided near the front of each section
in order to give a reader a better understanding of the installed condition of
component parts.
Indicates (by symbols) where lubrication is necessary.
D Installation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order of
removal steps.
D Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassemby is possible in reverse
order of disassembly steps.
Classifications of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail.
AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained.
: Grease
(multipurpose grease unless there is a
brand or type specified)
: Sealant or adhesive
: Brake fluid or automatic transmission fluid
: Engine oil, gear oil or air conditioner com-
pressor oil
: Adhesive tape or butyl rubber tape
GENERAL – How to Use This Manual
00-5
Indicates the
group title.
Indicates the
section title.
Indicates the
group number.
Indicates the
page number.
Denotes non-reusable part.
Denotes tightening torque.
For bolts and nuts which do not
have a tightening torque listed,
refer to the “Tightening torque”.
Repair kit or set parts
are shown. (Only very
frequently used parts
are shown.)
Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.
indicates that there is
a continuity between the terminals.
indicates terminals to
which battery voltage is applied.
The title of the page (following
the page on which the diagram
of component parts is presented) indicating the locations of
lubrication and sealing procedures.
00-6
GENERAL – How to Use Troubleshooting/Inspection Service Points
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS
Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline
described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems
still follow this outline.
TROUBLESHOOTING CONTENTS
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis
flow is different from that given below, or if additional explanation is required, the details of such
differences or additions will also be listed.
Diagnosis method
Gathering information
from the customer.
Check trouble symptom.
Reoccurs Does not reoccur.
Read the diagnosis code
No diagnosis code
or communication
with MUT-II not
possible
Refer to the INSPECTION
CHART FOR TROUBLE
SYMPTOMS (Refer to
applicable group.)
Diagnosis code
displayed.
Refer to the INSPECTION CHART FOR DIAGNOSIS
CODES (Refer to applicable group.)
Diagnosis code
displayed.
After taking note of the
malfunction code, erase
the diagnosis code
memory
Recheck trouble symptom.
Read the diagnosis codes.
Read the diagnosis code
Diagnosis code
displayed.
No diagnosis
code
INTERMITTENT MALFUNCTIONS (Refer to P.00-13.)
No diagnosis
code
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS
If verification of the trouble symptoms is difficult, procedures for checking operation and verifying
trouble symptoms are shown.
3. DIAGNOSIS FUNCTION
Details which are different from those in the “Diagnosis Function” section on the next page are listed.
GENERAL – How to Use Troubleshooting/Inspection Service Points
4. INSPECTION CHART FOR DIAGNOSIS CODES
5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-10 for how
to read the inspection procedures.)
6. INSPECTION CHART FOR TROUBLE SYMPTOMS
If there are trouble symptoms even though the results of inspection using the MUT-II show that all
diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means
of this chart.
7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM
Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection
Chart for Trouble Symptoms. (Refer to P.00-10 for how to read the inspection procedures.)
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgement values have been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors, inspection items and standard values have been provided
in this chart as reference information.
00-7
10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE
When there are inspection procedures using an oscilloscope, these are listed here.
DIAGNOSIS FUNCTION
MUT-II
METHOD OF READING DIAGNOSIS CODES
WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and take a
reading of the diagnosis codes.
Caution
Turn off the ignition switch before connecting or
disconnecting the MUT-II.
00-8
GENERAL – How to Use Troubleshooting/Inspection Service Points
WHEN USING THE WARNING LAMP
Diagnosis connector
1. Use the special tool to earth No.1 terminal (diagnosis
control terminal) of the diagnosis connector.
2. To check ABS system, remove the valve relay.
NOTE
That is because the valve relay is off and the warning
lamp remains illuminated if there is a fault in the ABS
system.
MB991529
3. Turn on the ignition switch.
4. Read out a diagnosis code by observing how the warning
lamp flashes.
Applicable systems
System name Warning lamp name
MPI Engine warning lamp
AYC A YC warning lamp
ABS ABS warning lamp
Indication of diagnosis code by warning lamp
When the diagnosis code No.24 is output When no diagnosis code is output*
On
Off
1.5 secs.
Pause
time 3
secs.
Tens
signal
0.5 sec.
Place
division
2 secs.
Units
signal
0.5 sec.
On
Off
0.5 sec.
NOTE
*: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to
be output.
Earth terminal
WHEN USING THE VOLTMETER
Use the special tool to connect the diagnosis output terminals
and the earth terminal of the diagnosis connector to a voltmeter
and take a reading of the diagnosis codes from the movement
Full-auto air conditioner terminal
of the needle.
Voltmeter connection terminals
MB991529
System name Positive connection
terminal
Full-auto air
conditioner
11 4 or 5
Negative connection terminal
GENERAL – How to Use Troubleshooting/Inspection Service Points
Diagnosis result display method when using a voltmeter
00-9
Example of diagnosis code voltage wave pattern for
diagnosis code No. 24
0.5 sec.
Units
signal
12V
0 V
1.5 secs.
Pause
time 3
secs.
Tens
signal
0.5 sec.
Place
division
2 secs.
Normal voltage wave pattern
0.5 sec.
12 V
0 V
METHOD OF ERASING DIAGNOSIS CODES
WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and erase the diagnosis code.
Caution
Turn off the ignition switch before connecting or disconnecting the MUT-II.
WHEN NOT USING THE MUT-II
(1) Turn the ignition switch to OFF.
(2) After disconnecting the battery cable from the battery (–) terminal for 10 seconds or more, reconnect
the cable.
(3) After the engine has warmed up, run it at idle for about 15 minutes.
INPUT SIGNAL INSPECTION POINTS <VEHICLES
MUT-II
WITH ETACS-ECU>
WHEN USING THE MUT-II
1. Connect the MUT-II to the diagnosis connector.
Earth terminal
ET ACS terminal
MB991529
Caution
The MUT-II should be connected or disconnected after
turning the ignition switch to the OFF position.
2. If buzzer of the MUT-II sounds once when the each switch
is operated (ON/OFF), the ETACS-ECU input signal for
that switch circuit system is normal.
WHEN USING VOLTMETER
1. Use the special tool to connect a voltmeter between
the earth terminal (No. 4 or 5) and the ETACS terminal
(No. 9) of the diagnosis connector.
2. If the voltmeter indicator deflects once when the each
switch is operated (ON/OFF), the ETACS-ECU input signal
for that switch circuit system is normal.
00-10
GENERAL – How to Use Troubleshooting/Inspection Service Points
HOW TO USE THE INSPECTION PROCEDURES
The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors,
components, the ECU and the harnesses between connectors, in that order. These inspection procedures
follow this order, and they first try to discover a problem with a connector or a defective component.
1. Comments on the diagnosis code or trouble
CHECKING PROCEDURE 4
symptom above.
D Indicator does not turn on or off even if control
mode switch is pressed.
D Indicator switch should not be illuminated is
illuminated.
In the above cases, the ECS switch circuit is defective or the indicator
circuit is defective.
MUT-II Data list
17 Control mode selection switch
OK: Voltage changes between approx. 0V → approx.
2.5V → approx. 5V when the switch is operated.
NG
ECU switch component inspection (Refer to P.3-44.)
OK
Measure at switch connector A-44
D Disconnect the connector, and measure at the harness
side.
D Voltage between terminal 6 – earth and terminal 8 –
earth
OK: Approx. 5V
OK
Check the following connector. A-44
OK
Check trouble symptom.
Replace the ECS-ECU.
OK
4. Indicates voltage and resistance to be measured at a particular
NG
OK
NG
5. Inspect the contact condition at each connector terminal.
Probable cause
2. Indicates inspection carried out using the
MUT-II.
Indicates the operation and inspection procedures.
Indicates the OK judgement conditions.
3. Detailed inspection procedures (methods)
such as component inspection and circuit
inspection are listed on a separate page, and
are given here for reference.
connector.
(Refer to Connector Measurement Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Indicates operation and inspection procedures, inspection terminals
and inspection conditions.
Indicates the OK judgement conditions.
Repair
(Refer to Connector Inspection Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Caution
After carrying out connector inspection, always be sure to
reconnect the connector as it was before.
HARNESS INSPECTION
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring manual.
Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses.
For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown
Fuse.”
MEASURES TO TAKE AFTER REPLACING THE ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure
from the beginning.
6. Confirm that there are trouble symptoms. If trouble symptoms have
disappeared, the connector may have been inserted incorrectly and the
trouble symptom may have disappeared during inspection.
If it seems that trouble symptoms still remain, proceed to the next page of
instructions.
7. If trouble symptoms still remain up to this stage, there is a possibility that there is an
open or short circuit in the harness between the connectors, so check the harness.
Alternatively , the cause may be a defective ECU, so try replacing the ECU and check
if the trouble symptom disappears.
GENERAL – How to Use Troubleshooting/Inspection Service Points
CONNECTOR MEASUREMENT SER VICE POINTS
Turn the ignition switch to OFF when connecting disconnecting
the connectors, and turn the ignition switch to ON when
measuring if there are no instructions to be contrary.
00-11
Extra-thin probe
Test bar
Connector
Inspection harness
for connector pin
contact pressure
Harness connector
IF INSPECTING WITH THE CONNECTOR CONNECTED
(WITH CIRCUIT IN A CONDITION OF CONTINUITY)
Waterproof Connectors
Be sure to use the special tool (harness connector). Never
insert a test bar from the harness side, because to do so
will reduce the waterproof performance and result in corrosion.
Ordinary (non-waterproof) Connectors
Check by inserting the test bar from the harness side. Note
that if the connector (control unit, etc.) is too small to permit
insertion of the test bar, it should not be forced; use a special
tool (the extra-thin probe in the harness set for checking
for this purpose.
IF INSPECTING WITH THE CONNECTOR DISCONNECTED
<When Inspecting a Female Pin>
Use the special tool (inspection harness for connector pin
contact pressure in the harness set for inspection).
The inspection harness for connector pin contact pressure
should be used. the test bar should never be forcibly inserted,
as it may cause a defective contact.
<When Inspecting a Male Pin>
Touch the pin directly with the test bar.
Caution
At this time, be careful not to short the connector pins
with the test bars. To do so may damage the circuits
inside the ECU.
00-12
GENERAL – How to Use Troubleshooting/Inspection Service Points
Connector disconnected or improperly
connected
Defective connector contact
Harness wire breakage
at terminal section
Low contact pressure
CONNECTOR INSPECTION
VISUAL INSPECTION
D Connector is disconnected or improperly connected
D Connector pins are pulled out
D Due to harness tension at terminal section
D Low contact pressure between male and female terminals
D Low connection pressure due to rusted terminals or foreign
matter lodged in terminals
MB991219
CONNECTOR PIN INSPECTION
If the connector pin stopper is damaged, the terminal
connections (male and female pins) will not be perfect even
if the connector body is connected, and the pins may pull
out of the reverse side of the connector. Therefore, gently
pull the harnesses one by one to make sure that no pins
pull out of the connector.
CONNECTOR ENGAGEMENT INSPECTION
Use the special tool (connector pin connection pressure
inspection harness of the inspection harness set) to inspect
the engagement of the male pins and females pins. (Pin
drawing force : 1 N or more)
GENERAL – How to Use Troubleshooting/Inspection Service Points
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
Remove the fuse and measure the resistance between the
load side of the fuse and the earth. Set the switches of all
0 Ω
Battery
circuits which are connected to this fuse to a condition of
continuity. If the resistance is almost 0 Ω at this time, there
is a short somewhere between these switches and the load.
If the resistance is not 0 Ω, there is no short at the present
time, but a momentary short has probably caused the fuse
to blow.
00-13
Fuse
Load
switch
Load
Connector
inspection
The main causes of a short circuit are the following.
D Harness being clamped by the vehicle body
D Damage to the outer casing of the harness due to wear
or heat
D Water getting into the connector or circuitry
D Human error (mistakenly shorting a circuit, etc.)
POINTS TO NOTE FOR INTERMITTENT
MALFUNCTIONS
Intermittent malfunctions often occur under certain conditions,
and if these conditions can be ascertained, determining the
cause becomes simple. In order to ascertain the conditions
under which an intermittent malfunction occurs, first ask the
customer for details about the driving conditions, weather
conditions, frequency of occurrence and trouble symptoms,
and then try to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or some
other factor. If vibration is thought to be the cause, carry
out the following checks with the connectors and components
to confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components
which are indicated by inspection procedures or given as
probable causes (which generates diagnosis codes or trouble
symptoms.)
D Gently shake the connector up, down and to the left and
right.
D Gently shake the wiring harness up, down and to the
left and right.
D Gently rock each sensor and relay, etc. by hand.
D Gently shake the wiring harness at suspensions and other
moving parts.
NOTE
If determining the cause is difficult, the flight recorder function
of the MUT-II can also be used.
00-14
16 valves-intercooler
(4WD-5M/T)
controlled fuel
16
(4WD-5M/T)
turbo)
MODELS
<LANCER EVOLUTION-IV>
GENERAL – Models
Model
code
E-CN9A SNDF ’97 RS 4G63 (2,000-DOHC –-W5M51
Class
code
SRGF ’97 GSR
Model
year
Grade Engine model Transmission
model
turbo)
Applicable serial numbers
E-CN9A: CN9A – 0000001 Y
<LANCER EVOLUTION-V>
Model
code
GF-CP9A SNDF ’98 EVOLUTION-V RS 4G63 (2,000-DOHC –
Class
code
SNGF ’98 EVOLUTION-V
Model
year
Grade Engine model Transmission
GSR
model
W5M51
valves-intercooler
turbo)
Applicable serial numbers
GF-CP9A: CP9A – 0000001 Y
<LANCER EVOLUTION-VI>
Model
code
Class
code
Model
year
Grade Engine model Transmission
model
Fuel supply
system
Electronically
injection (MPI)
Fuel supply
system
MPI
Fuel supply
system
f
GF-CP9A SNDF ’99 EVOLUTION-VI
RS
SNGF ’99 EVOLUTION-VI
GSR
Applicable serial numbers
GF-CP9A: CP9A – 0100001 Y
4G63 (2,000-DOHC –
16 valves-intercooler
W5M51
(4WD-5M/T)
MPI
GENERAL – Precautions Before Service
00-15
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Always use the designated special tools and test equipment.
(3) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
(4) Never attempt to disassemble or repair the SRS components. (SRS air bag control unit, air bag
module and clock spring.) If faulty, replace it.
(5) Warnings labels must be needed when servicing and handling SRS components. Warning labels
are located in the following locations.
D Sun visor
D Glove box
D SRS air bag control unit
D Steering wheel
D Steering gear and linkage
D Air bag module
D Clock spring
(6) Store components removed from the SRS in a clean and dry place.
The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upwards.
(7) Be sure to deploy the air bag before disposing of air bag module or disposing of a vehicle equipped
with an air bag. (Refer to GROUP 52B – Air Bag Module Disposal Procedures.)
(8) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
2. Observe the following when carrying out operations on place where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat over 93_C, so remove the SRS components
before drying or baking the vehicle after painting.
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.
00-16
GENERAL – Precautions Before Service
SERVICING THE ELECTRICAL SYSTEM
Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative
(–) cable from the battery in order to avoid damage caused
by short-circuiting.
Caution
Before connecting or disconnecting the negative (–) cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
APPLICATION OF ANTI-CORROSION AGENTS
AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will cause
a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover when applying
anti-corrosion agents and undercoats.
Approx.
40 cm
PRE-INSPECTION CONDITION
“Pre-inspection condition” refers to the condition that the
vehicle must be in before proper engine inspection can be
carried out. If you see the words “Set the vehicle to the
pre-inspection condition.” in this manual, it means to set the
vehicle to the following condition.
D Engine coolant temperature: 80–90_C
D Lamps, electric cooling fan and all accessories: OFF
D M/T: Neutral
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to note the
following information in order to avoid damage to plastic
components, etc.
D Spray nozzle distance: Approx. 40 cm or more
D Spray pressure: 3,900 kPa or less
D Spray temperature: 82_C or less
D Time of concentrated spray to one point: within 30 sec.
GENERAL – Precautions Before Service
00-17
MUT-II
sub-assembly
ROM pack
MUT-II
Refer to the MUT-II INSTRUCTION MANUAL for instructions
on handling the MUT-II.
Connect the MUT-II to the diagnosis connector as shown
in the illustration.
Caution
Connection and disconnection of the MUT-II should
always be made with the ignition switch in the OFF
position.
00-18
GENERAL – Support Locations for Lifting and Jacking
SUPPORT LOCATIONS FOR LIFTING AND JACKING
GARAGE JACK
Caution
Do not support the vehicles at locations other than specified supporting points. Neglecting this
will cause damage, etc.
Caution
Never support the rear floor
crossmember.
AXLE STANDS
GENERAL – Support Locations for Lifting and Jacking
00-19
Notch
Rubber
Notch
Rubber
SINGLE-POST AND
DOUBLE-POST LIFT
Notch
Notch
00-20
GENERAL – Special Handling Instruments for Towing
SPECIAL HANDLING INSTRUMENTS FOR TOWING
Towing methods Remarks
If a tow truck is used
Lifting method for 4 wheels – Good
Front wheels lifted – No good
Front wheels lifted – No good
D For 4WD models, the basic principle is that all
four wheels are to be raised before towing.
D The shift lever should be set to 1st gear and
the parking brake should be applied.
D The vehicle must not be towed by placing only
its front wheels or only the rear wheels on a
rolling dolly, because to do so will result in
deterioration of the viscous coupling and result
in the viscous coupling causing the vehicle to
jump forward suddenly.
D If only the front wheels or only the rear wheels
are lifted for towing, the bumper will be damaged.
In addition, lifting of the rear wheels causes
the oil to flow forward, and may result in heat
damage to the rear bushing of the transfer, and
so should never be done.
Rear wheels lifted – No good
Towing by rope or cable – Good
D The front and rear wheels must rotate normally.
D Both running and driving systems must function
normally.
D The shift lever must be set to the neutral position
and the ignition key must be set to “ACC”.
Brake tester
GENERAL – Brake Test
BRAKE TEST
In order to stabilize the viscous coupling’s dragging force,
the brake test should always be conducted after the
speedometer test.
FRONT WHEEL MEASUREMENTS
1. Place the front wheels on the brake tester.
2. Perform the brake test.
Caution
The rear wheels should remain on the ground.
3. If the brake dragging force exceeds the specified value,
jack up the vehicle and manually rotate each wheel to
check the rotation condition of each wheel.
NOTE
If the brake dragging force exceeds the specified value,
the cause may be the effect of the viscous coupling’s
dragging force, so jack up the front wheels and check
the rotation condition of the wheels in this state for no
effect by the viscous coupling’s dragging force.
REAR WHEEL MEASUREMENTS
After placing the rear wheels on the brake tester, follow the
same procedures as for the front wheel measurements.
00-21
00-22
GENERAL – Tightening Torque
TIGHTENING TORQUE
Each torque value in the table is a standard value
for tightening under the following conditions.
(1) Bolts, nuts and washers are all made of steel
and plated with zinc.
(2) The threads and bearing surface of bolts and
nuts are all in dry condition.
The values in the table are not applicable:
(1) If toothed washers are inserted.
(2) If plastic parts are fastened.
(3) If bolts are tightened to plastic or die-cast
inserted nuts.
(4) If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
Thread size Torque Nm
Bolt nominal
diameter (mm)
M5 0.8 2.5 4.9 5.9
M6 1.0 4.9 8.8 9.8
M8 1.25 12 22 25
M10 1.25 24 44 52
M12 1.25 41 81 96
M14 1.5 72 137 157
Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
M16 1.5 111 206 235
M18 1.5 167 304 343
M20 1.5 226 412 481
M22 1.5 304 559 647
M24 1.5 392 735 853
Flange bolt and nut tightening torque
Thread size Torque Nm
Bolt nominal
diameter (mm)
M6 1.0 4.9 9.8 12
M8 1.25 13 24 28
M10 1.25 26 49 57
M10 1.5 24 44 54
M12 1.25 46 93 103
M12 1.75 42 81 96
Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
ENGINE
CONTENTS
11-1
GENERAL INFORMATION 2. . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . .
Service Specifications 3. . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 5. . . . . . . . . . . . . . . . . . . . . .
New Tightening Method by Use of Bolts
to Be Tightened in Plastic Area 9. . . . . . . . . . . .
Sealants 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Form-In-Place Gasket 10. . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 11. . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR AND IGNITION SYSTEM 14.
TIMING BELT 15. . . . . . . . . . . . . . . . . . . . . . . . .
FUEL AND EMISSION CONTROL PARTS 27
SECONDARY AIR SYSTEM AND INTAKE
MANIFOLD 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD 31. . . . . . . . . . . . . . . . .
WATER PUMP AND WATER HOSE 34. . . . .
ROCKER ARMS AND CAMSHAFT 37. . . . . .
CYLINDER HEAD AND VALVES 43. . . . . . . .
FRONT CASE, COUNTERBALANCE
SHAFT AND OIL PAN 51. . . . . . . . . . . . . . . . .
PISTON AND CONNECTING ROD 59. . . . . .
CRANKSHAFT AND FLYWHEEL 67. . . . . . . .
THROTTLE BODY 73. . . . . . . . . . . . . . . . . . . . .
TURBOCHARGER 75. . . . . . . . . . . . . . . . . . . . .
ALTERNATOR 79. . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR 83. . . . . . . . . . . . . . . . . . . . .
11-2
ENGINE – General Information
GENERAL INFORMATION
Descriptions Specifications
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pentroof + curved top piston type
Total displacement dm
Cylinder bore mm 85.0
Piston stroke mm 88.0
Compression ratio 8.8
V alve timing Intake valve Opens (BTDC) 21°
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type
3
Closes (ABDC) 59°
Exhaust valve Opens (BBDC) 58°
Closes (ATDC) 18°
1,997
ENGINE – Specifications
hol
SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard value Limit
Timing belt
Auto-tensioner rod projection length mm 12 –
11-3
Auto-tensioner rod pushed-in amount [when pushed with a force of 98
– 196 N] mm
Rocker arms and camshaft
Camshaft cam height mm Intake 35.79 35.29
Exhaust 35.49 34.99
Camshaft journal outer diameter mm 26 –
Cylinder head and valves
Cylinder head flatness of gasket surface mm Less than 0.05 0.2
Cylinder head grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
Cylinder head overall height mm 131.9 – 132.1 –
Cylinder head bolt shank length mm – Maximum 99.4
V alve thickness of valve head (margin) mm Intake 1.0 0.5
Exhaust 1.5 1.0
Overall valve length mm Intake 109.5 109.0
Exhaust 109.7 109.2
1.0 or less –
– 0.2
Valve thickness to valve guide clearance
mm
V alve face angle 45° – 45.5° –
Valve spring free length mm 48.3 47.3
Valve spring load/installed height N/mm 294/40.0 –
Valve spring out-of-squareness 1.5° or less Maximum 4°
Valve seat contact width mm 0.9 – 1.3 –
Valve guide inner diameter mm 6.6 –
Valve guide projection from cylinder head upper surface mm 20.5 –
Valve stem projection mm Intake 49.20 49.70
Oversize rework dimensions of valve guide
e mm
Intake 0.02 – 0.05 0.10
Exhaust 0.05 – 0.09 0.15
Exhaust 48.40 48.90
0.05 O.S. 12.05 – 12.07 –
0.25 O.S. 12.25 – 11.27 –
0.50 O.S. 12.50 – 12.52 –
11-4
Items LimitStandard value
ENGINE – Specifications
Intake oversize rework dimensions of valve
guide hole mm
Exhaust oversize rework dimensions of
valve guide hole mm
Front case and oil pan
Oil pump side clearance mm Drive gear 0.08 – 0.14 –
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90°C] 78 or more –
Piston and connecting rod
Piston outer diameter mm 85.0 –
Piston ring side clearance mm No. 1 ring 0.04 – 0.075 –
Piston ring end gap mm No. 1 ring 0.25 – 0.35 0.8
0.3 O.S. 35.30 – 35.33 –
0.6 O.S. 35.60 – 35.63 –
0.3 O.S. 33.30 – 33.33 –
0.6 O.S. 33.60 – 33.63 –
Driven gear 0.06 – 0.12 –
No. 2 ring 0.02 – 0.06 –
No. 2 ring 0.40 – 0.55 0.8
Oil ring 0.10 – 0.40 1.0
Piston pin outer diameter mm 21.0 –
Piston pin press-in load N (Room temperature) 7,350 – 17,200 –
Crankshaft pin oil clearance mm 0.02 – 0.05 0.1
Connecting rod big end side clearance mm 0.10 – 0.25 0.4
Crankshaft and flywheel
Crankshaft end play mm 0.05 – 0.25 0.40
Crankshaft journal outer diameter mm 57.0 –
Crankshaft pin outer diameter mm 44.0 –
Crankshaft journal oil clearance mm 0.02 – 0.04 0.1
Bearing cap bolt shank length mm – Maximum 71.1
Piston to cylinder clearance mm 0.02 – 0.04 –
Cylinder block grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
Cylinder block overall height mm 284 –
Cylinder block inner diameter mm 85.0 –
– 0.2
Cylinder block cylinder mm 0.01 –
Turbocharger
Waste gate actuator operation check kPa 100 113.3
ENGINE – Specifications
Items LimitStandard value
Alternator
Rotor coil resistance Ω Approx. 3 – 5 –
Protrusion length of brush mm – 2
Starter motor
Commutator runout mm 0.05 0.1
Commutator outer diameter mm 32.0 31.4
Commutator undercut mm 0.5 –
TORQUE SPECIFICATIONS
Items Nm
Alternator and ignition system
Oil level gauge guide 13
11-5
Water pump pulley 9
Alternator brace (Alternator side) 21
Alternator brace (Tightened with water pump) 23
Alternator pivot bolt 44
Crankshaft pulley 25
Center cover 3
Spark plug 25
Ignition coil 10
Timing belt
Timing belt cover (Flange bolt) 11
Timing belt cover (Washer bolt) 9
Power steering pump bracket 49
Tensioner pulley 49
Tensioner arm 24
Auto tensioner 24
Idler pulley 48
Crank angle sensor 9
Oil pump sprocket 54
Camshaft bolt 118
Tensioner “B” 19
Counterbalance shaft sprocket 45
11-6
Items Nm
Rocker cover 3.5
Engine support bracket 49
Camshaft sprocket bolt 88
Timing belt rear right cover 11
Timing belt rear left upper cover 11
Fuel and emission control parts
Throttle body 18
Fuel pressure regulator 9
Delivery pipe 11
Vacuum tank bracket 9
Solenoid valve bracket 9
Solenoid valve 9
ENGINE – Specifications
Vacuum hose and vacuum pipe 11
Secondary air intake manifold
Heat protector 13
Vacuum hose and vacuum pipe 11
Air pipe (Heat protector side) 13
Air pipe (Cam position sensor side) 11
Air pipe (Eye bolt) 49
Air pipe (Control valve side) 24
Air control valve 21
Air control valve bracket 24
Intake manifold stay 30
Intake manifold (M8) 19
Intake manifold (M10) 35
Exhaust manifold
Engine hanger 12
Heat protector (Turbocharger side) 14
Oxygen sensor 54
Exhaust fitting bolt 59
Exhaust fitting nut 59
Air outlet fitting 19
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