Mitsubishi Outlander 2013 User Manual

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Page 1

GROUP 00

GENERAL

CONTENTS

00-1

HOW TO USE THIS MANUAL. . . . . . 00-2

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS . . . . . . . . . . . . . . . . . . . . . . . 00-5

CONTENTS OF TROUBLESHOOTING . . . 00-5

DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 00-7

HOW TO USE THE INSPECTION PROCEDURES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8

CONNECTOR MEASUREMENT SERVICE POINTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9

CONNECTOR INSPECTION SERVICE POINTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-10

INSPECTION SERVICE POINTS FOR A BLOWN

FUSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11

HOW TO COPE WITH INTERMITTENT

MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 00-12

HOW TO TREAT PAST TROUBLE . . . . . . 00-12

VEHICLE IDENTIFICATION . . . . . . . 00-13

MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13

VEHICLE IDENTIFICATION NUMBER (CHASSIS

NUMBER) . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14

VEHICLE INFORMATION CODE PLATE. . 00-15

MANUFACTURER PLATE . . . . . . . . . . . . . 00-15

ENGINE MODEL STAMPING. . . . . . . . . . . 00-15

GENERAL DATA AND SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-16

VEHICLES WITH AIR CONDITIONER . . . . 00-19

MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-20

SERVICING ELECTRICAL SYSTEM . . . . . 00-21

HOW TO SHIFT LOCK FORCED RELEASE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-21

HOW TO PERFORM CHASSIS NUMBER (CHASSIS NO.) WRITING FOR ENGINE-ECU, KOS-ECU AND

ETACS-ECU . . . . . . . . . . . . . . . . . . . . . . . . 00-21

CODING LIST . . . . . . . . . . . . . . . . . . . . . . . 00-27

INITIALISATION PROCEDURE FOR LEARNING

VALUE IN MPI ENGINE . . . . . . . . . . . . . . . 00-36

LEARNING PROCEDURE FOR IDLING IN MPI

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-37

PRE-INSPECTION CONDITION . . . . . . . . . 00-37

PRECAUTIONS FOR INSTALLATION OF ON-VEHICLE RADIO TRANSMISSION EQUIPMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-37

ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 00-38

FORM−IN−PLACE GASKET (FIPG) . . . . . . 00-38

BOLTS AND NUTS WITH STABILIZER FOR

COEFFICIENT OF FRICTION. . . . . . . . . . . 00-39

APPLICATION OF ANTI-CORROSION AGENTS AND

UNDERCOATS . . . . . . . . . . . . . . . . . . . . . . 00-39

VEHICLE WASHING . . . . . . . . . . . . . . . . . . 00-39

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-39

SRS SERVICE PRECAUTIONS . . . . . 00-42

PRECAUTIONS BEFORE SERVICE. 00-18

ABOUT THE DESCRIPTION OF THE IGNITION

SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-18

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-19

SUPPORT LOCATIONS FOR LIFTING AND

JACKING . . . . . . . . . . . . . . . . . . . . . . 00-44

TOWING AND HOISTING. . . . . . . . . . 00-46

Page 2

00-2

HOW TO USE THIS MANUAL

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.

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.

GENERAL

M1001000103357

DANGER, WARNING, AND CAUTION

DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows:

• If a DANGER is not followed, the result is severe bodily harm or even death.

• If a WARNING is not followed, the result could be bodily injury.

• If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.

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 com pleted in a shorter time).

INDICATION OF TIGHTENING TORQUE

Tightening torques (units: N⋅m) are set to take into account the central value and the allowable toler ance. The central value is the target value, and the allowable tolerance provides the checking range for tightening torques.

MODEL INDICATIONS

The following abbreviations are used in this manual for identification of model types. 2000:Indicates models equipped with the 1,998 mL

<4B11> petrol engine.

2400:Indicates models equipped with the 2,360 mL

<4B12> petrol engine.

2WD:Indicates the 2-wheel drive vehicles. 4WD:Indicates the 4-wheel drive vehicles. A/C:Indicates the air conditioner. CVT: Indicates the continuously variable transmis-

sion.

DOHC:Indicates an engine with the double overhead

camshaft.

INVECS: Indicates the (Mitsubishi) intelligent and

innovative vehicles electronic control system.

MIVEC:Indicates the Mitsubishi innovative valve tim-

ing and lift electronic control system.

MPI:Indicates the multi point injection.

Page 3

GENERAL

HOW TO USE THIS MANUAL

EXPLANATION OF MANUAL CONTENTS

Indicates the

Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the "Standard Parts tightening-torque Table"

section title.

Indicates the group title.

00-3

Indicates the group number.

>>A<<

>>B<<

35A-19

Indicates the page number.

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 the reader a better understanding of the installed condition of component parts.

Mark denotes nonreusable part.

Repair kit or parts sets are shown. (Only very frequently used parts are shown.)

Maintenance and servicing procedures

The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures.

Removal steps : The part designation number corresponds to the number in the illustration to indicate remov al steps.

Disassembly steps : The part designation number corresponds to the number in the illustration to indicate disas sembly steps.

Installation steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of re moval steps.

Reassembly steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if reassembly is possible in reverse order of dis assembly steps.

AC311238

Page 4

00-4

GENERAL

HOW TO USE THIS MANUAL

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.

<<A>> : Indicates that there are essential points for removal or disassembly. >>A<< : Indicates that there are essential points for installation or reassembly.

BRAKE CALIPER ASSEMBLY

35A-21

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described

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.

Symbols for lubrication, sealants and adhesives

Symbols are used to show the locations for lubrication and for application of sealants and adhesives. These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol.

Indicates (by symbols) where lubrication is necessary.

: Grease (Multi-purpose grease unless there is a brand or type specified) : Sealant or adhesive : Automatic transmission fluid, brake fluid, power steering fluid or air conditioning compressor oil : Engine oil or gear oil : Adhesive tape or butyl rubber tape

AC509265

Page 5

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-5

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS

CONTENTS OF TROUBLESHOOTING

M1001013300824

CAUTION

During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) discon nected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.

WARNING

Since the radiator fan rotates during CAN bus line diagnostics, make sure that no one is servicing the engine compartment before diagnosing the CAN bus line. Since the CAN communication stops when diagnosing the CAN bus line, the ETACS-ECU detects the time-out of the engine-ECU, and activates the radiator fan to prevent overheating as fail-safe.

Troubleshooting of electronic control systems for which the M.U.T.-III can be used follows the basic outline described below. Even in systems for which the M.U.T.-III cannot be used, some of these sys tems still follow this outline.

1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed.

Page 6

00-6

Diagnosis method

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Gathering information from the customer.

Coding data check*

Reoccurs

CAN bus diagnosis*

Read the diagnosis code. Read the diagnosis code.

No diagnosis code or communication with M.U.T.-III not possible

Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group).

Diagnosis code displayed. (Past trouble)*

How to treat past trouble*

Diagnosis code displayed. (Current trouble)*

Check trouble symptom.

CAN bus diagnosis chart*

After taking note of the malfunction code, erase the diagnosis code memory.

Recheck trouble symptom.

Read the diagnosis codes.

Diagnosis code displayed.

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group).

Diagnosis code displayed. (Current trouble)*

Does not reoccur

Diagnosis code displayed. (Past trouble)*

How to treat past trouble*

No diagnosis code.

INTERMITTENT MALFUNCTIONS*

No diagnosis code.

AC508911

• *1: For how to diagnose CAN bus lines, refer to GROUP 54C .

• *2: For the CAN bus diagnosis chart, refer to GROUP 54C .

• *3: When the M.U.T.-III detects a diagnosis code, its display informs users whether a mechanical problem

currently exists or whether it existed before. The message for the former state identifies it as an "Active" and the message for the latter identifies it as a "Stored".

• *4: For how to treat past trouble, refer to P.00-12.

• *5: For how to cope with intermittent malfunctions, refer to P.00-12.

• *6: For coding data, refer to P.00-27.

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

If verification of the symptom(s) is difficult, proce-

4. DIAGNOSIS CODE CHART

Diagnostic trouble codes and diagnostic items are shown.

dures for checking operation and verifying symptoms are shown.

5. DIAGNOSIS CODE PROCEDURES

Indicates the inspection procedures corresponding to

3. DIAGNOSIS FUNCTION

Details specific to individual systems are described.

each diagnosis code (Refer to How to Use Inspection Procedures

P.00-8).

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GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-7

6. TROUBLE SYMPTOM CHART

If there are trouble symptoms even though the M.U.T.-III does not find any diagnosis codes, Inspec tion procedures for each trouble symptom will be found by means of this chart.

7. SYMPTOM PROCEDURES

Indicates the inspection procedures corresponding to each symptom classified in the Symptom Chart (Refer to How to Use Inspection Procedures

P.00-8).

8. DATA LIST REFERENCE TABLE

Inspection items and normal judgement values have been provided in this chart as reference information.

9. ACTUATOR TEST TABLE

The Actuator Test item numbers, inspection items, and judgement values have been provided in this chart as reference information.

10. CHECK AT ECU TERMINALS

Te rm in al n um b er s fo r the ECU connectors, inspection items, and judgement values have been provided in this chart as reference information.

11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE

When there are inspection procedures using an oscilloscope, these are described here.

DIAGNOSIS FUNCTION

M1001013401040

The diagnosis function retrieves diagnosis code and data list by M.U.T.-III and enables the performance of the actuator test.

• DIAGNOSIS CODE

• Data list output

• Actuator test

• Diagnosis deletion using M.U.T.-III

• Freeze frame data

• Status indication by diagnosis code

• ECU information display

NOTE: If a diagnosis code is set, the "status indication by diagnosis code" informs users whether a mechanical problem currently exists (current trouble) or whether it existed before but normal operation has been restored (past trouble).

HOW TO READ DIAGNOSIS CODE

CAUTION

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

Connect the M.U.T.-III to the 16-pin diagnosis connector, and read the diagnosis code.

NOTE: .

•

For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Ensure that the ignition switch is at the "LOCK" (OFF) position.

2. Start up the personal computer.

3. Connect special tool V.C.I.-Lite USB cable (MB992747/MB992748) or M.U.T.-III USB cable (MB991827) to V.C.I.-Lite (MB992744) or V.C.I. (MB991824) and the personal computer.

4. Connect V.C.I.-Lite main harness A (MB992745) or M.U.T.-III main harness A (MB991910) to the V.C .I .- Li te o r V.C .I.

5. Connect the V.C.I.-Lite main harness A or M.U.T.-III main harness A to the diagnosis connector of the vehicle.

NOTE: When the V.C.I.-Lite is connected to the diagnosis connector, the V.C.I.-Lite indicator lamp will be illuminated in a green colour.

6. Turn the V.C.I. power switch to the "ON" position. <When using the V.C.I.>

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col our.

ACB05017

Page 8

00-8

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

7. Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.

8. Read the diagnosis code.

9. Disconnecting the M.U.T.-III is the reverse of the connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF) position.

ERASING DIAGNOSIS CODE

CAUTION

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Connect the M.U.T.-III to the diagnosis connector, and erase the diagnosis code. The procedure is the same as "How to Read Diagnosis Code

HOW TO USE THE INSPECTION PROCEDURES

M1001013500862

The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, the wiring harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.

Explains about the basic operation of the components.

Start of diagnosis procedure

Describes inspection procedure.

Explains about technical details.

Describes the conditions for that diagnosis code being set.

Describes possible causes(s) for that diagnosis code.

AC701738

CURRENT TROUBLE

Indicates that the status is "Active" and the trouble is currently present. Carry out troubleshooting as described in the applicable inspection procedure.

Page 9

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-9

PAST TROUBLE

Indicates that the status is "Stored" and the trouble is historic. Since the trouble may still be present, set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", observe the applicable inspection procedure with particular emphasis on connector(s) and wiring harness.

HARNESS CHECK

Check for an open or short circuit in the harness between the terminals which are faulty according to the connector measurements. Carry out this inspec tion while referring to the Electrical Wiring Manual. Here, "Check the wiring harness between the power supply and terminal xx" also includes checking for blown fuse. For inspection service points when there is a blown fuse, refer to "Inspection Service Points for a Blown Fuse P.00-11."

MEASURES TO TAKE AFTER REPLACING THE ECU

If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection proce dure from the beginning.

IF INSPECTING WITH THE CONNECTOR CONNECTED <WATERPROOF CONNECTORS>

CAUTION

Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.

Special tool

AC105597

Use the special tools such as test harness, harness connector or check harness.

IF INSPECTING WITH THE CONNECTOR CONNECTED <ORDINARY

(NON-WATERPROOF) CONNECTORS>

CONNECTOR MEASUREMENT SERVICE POINTS

M1001013600405

CAUTION

During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) disconnected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.

Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary.

MB992006

AC105598

Inspect by inserting a test probe from the harness side. If the connector is too small to insert a test probe (e.g. control unit connector), do not insert it forcibly. Use special tool extra fine probe (MB992006).

Page 10

00-10

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A FEMALE PIN>

CAUTION

• Use special tool inspection harness (MB991219). If the test bar is inserted forcibly, it will cause a poor contact.

•

If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.

MB991219

AC105599

Use inspection harness (MB991219) of special tool harness set (MB991223).

Tou ch t he p in d ir ec tl y wi th t he t es t ba r.

CONNECTOR INSPECTION SERVICE POINTS

M1001013700286

VISUAL INSPECTION

•

Connector disconnected or improperly connected

Stretched or broken wires

IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A MALE PIN>

CAUTION

• Be careful not to short the connector pins with the test bars. To do so may damage the circuits inside the ECU.

•

If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.

AC105600

Harness wire breakage at terminal section

Low contact pressure

Good

Bad

AC300896

Connector is disconnected or improperly connected

• Connector pins are pulled out

• Due to harness tension at terminal section

• Low contact pressure between male and female

terminals

• Low connection pressure due to rusted terminals or foreign matter lodged in terminals

Page 11

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-11

CONNECTOR PIN INSPECTION

AC300898

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be per

fect even if the connector body is connected, and the pins may pull out of the reverse side of the connec

tor. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

CONNECTOR ENGAGEMENT INSPECTION

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

M1001013800261

CAUTION

A diagnosis code may be stored due to a blown fuse.

Battery

Fuse

Short-circuit Load switch

occurrence

section

MB991219

AC300899

Use special tool inspection harness (MB991219) (connector pin connection pressure inspection har

ness of the inspection harness set) to inspect the engagement of the male pins and female pins. (Pin drawing force: 1 N or more)

Load

AC300900

Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Close the switches of all circuits which are connected to this fuse. 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. The main causes of a short circuit are the following.

• Harness being clamped by the vehicle body

• Damage to the outer casing of the harness due to

wear or heat

• Water getting into the connector or circuitry

• Human error (mistakenly shorting a circuit, etc.)

Page 12

00-12

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

M1001013900268

weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trou

ble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these con ditions 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 gen erates diagnosis codes or trouble symptoms).

• Gently shake the connector up, down and to the left and right.

• Gently shake the wiring harness up, down and to the left and right.

• Gently rock each sensor and relay, etc. by hand.

• Gently shake the wiring harness at suspensions

and other moving parts.

NOTE: If determining the cause is difficult, the drive recorder function of the M.U.T.-III can also be used. (For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual).

AC300901

Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascer

tained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the cus

tomer for details about the driving conditions,

HOW TO TREAT PAST TROUBLE

M1001014100470

Since the trouble may still be present even the status is "Stored", set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", carry out the following procedure.

1. Establish from the customer whether a fuse or connector has been replaced or disconnected.

2. If yes, erase the diagnosis code, and then check that no diagnostic code is reset. If no diagnosis code is reset, the diagnosis is complete.

3. If no, follow the applicable Diagnosis Code Chart. Then check the wiring harness and connector, and refer to "How to Cope with Intermittent Malfunction

P.00-12 ."

Page 13

GENERAL

VEHICLE IDENTIFICATION

00-13

MODELS

M1001000306758

VEHICLES FOR RUSSIA (EASTERN EUROPE COUNTRIES)

<2000>

Model code Seating

capacity

GF2W XTSHL6Z 5-persons 4B11 (1,998 mL)

XTSHZL6Z W1CJA (Electronic control 4WD,

<2400>

Model code Seating

capacity

GF3W XTHHZL6Z 5-persons 4B12 (2,360 mL)

Engine model Transmission model Fuel supply

F1CJA (Front wheel drive 2WD,

DOHC MIVEC petrol engine

Engine model Transmission model Fuel supply

DOHC MIVEC petrol engine

INVECS-III CVT with sport mode)

W1CJA (Electronic control 4WD, INVECS-III CVT with sport mode)

MODEL CODE

system

MPI

system

MPI

12345678910

No. Item Content

1 Development GF OUTLANDER

2 Engine type 2 2.0L MPI (4B11)

3 2.4L MPI (4B12)

3 Vehicle type W Station wagon

4 Body style X 4-door with tailgate

5 Transmission type T CVT

6 Trim level (Price class) S INFORM <2000 − 2WD>

H INVITE <2000 − 4WD>, INSTYLE <2400>

7 Engine specification H MIVEC (DOHC)

8 Special feature None 2WD

Z 4WD

9 Steering wheel location L Left handle

10 Destination 6Z Vehicles for Russia

ACB04331

Page 14

00-14

GENERAL

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER (CHASSIS NUMBER)

M1001005602730

AC905326

CODE CHART

1234 5 6 78 910 11

The vehicle identification number (chassis number) is stamped or scratched on the toeboard inside the engine compartment.

ACB04342

No. Item Content

1 Country J Japan

2 Make M Mitsubishi Motors Corporation

3 Destination B Vehicles for Europe, left handle drive

4 Body style X 4-door with tailgate

5 Transmission type T CVT

6 Development order GF OUTLANDER

7 Engine type 2 2.0L MPI (4B11)

3 2.4L MPI (4B12)

8 Vehicle type W Station wagon

9 Model year D 2013 year

10 Plant Z Okazaki

11 Serial number 000001 to 999999

Page 15

GENERAL

VEHICLE IDENTIFICATION

00-15

VEHICLE INFORMATION CODE PLATE

M1001005403308

MODEL

AC905413

The vehicle information code plate is riveted to the back of the hood.

AC700309

AC905471

CODE CHART

No. Item Example Content

1 MODEL GF2WXT

HHZL6Z

2 ENGINE 4B11 Engine model

3 EXT A31A Exterior code

4 TRANS

AXLE

W1CJA 6466

5 COLOUR A31 Body colour code

6 INT 12X Interior code

GF2W: Vehicle model THHZL6Z: Model series

W1CJA: Transmission model 6466: Rear differential final gear ratio (a decimal point is omitted)

MANUFACTURER PLATE

M1001017600678

AC708655

The manufacturer plate is riveted onto the underside of the centre pillar on the right side.

CODE CHART

2 3 4 5 6

AC701126

No. Content

1 WVTA No. (Whole vehicle type approval

number) <Vehicles for Europe>

None <Vehicles for Russia>

2 Chassis No. (Vehicle identification number)

3 Gross vehicle weight

4 Gross combination weight

5 Gross axle weight front

6 Gross axle weight rear

ENGINE MODEL STAMPING

M1001005701165

7 OPT Z34 Equipment code

AC507578

The engine model is stamped on the cylinder block. These engine model numbers are as shown as follows.

Page 16

00-16

GENERAL

GENERAL DATA AND SPECIFICATIONS

Engine model Engine displacement

The engine serial number is stamped near the engine model number.

4B11 1,998 mL

4B12 2,360 mL

Engine number AA0201 to YY9999

GENERAL DATA AND SPECIFICATIONS

1 2

<2000>

Item INTENSE

345

GF2W

M1001000906954

ACB04339

XTSHL6Z XTSHZL6Z

Vehicle dimension mm

Front track 1 1,540 1,540

Overall width 2 1,800 1,800

Front overhang 3 955 955

Wheelbase 4 2,670 2,670

Rear overhang 5 1,030 1,030

Overall length 6 4,655 4,655

Ground clearance (unladen) 7 215 215

Overall height (unladen) 8 1,680 1,680

Rear track 9 1,540 1,540

Vehicle weight kgKerb weight Without full optional parts 1,415 1,480

With full optional parts 1,484 1,559

Gross vehicle weight 1,985 1,985

Gross axle weight rating-front 1,150 1,150

Gross axle weight rating-rear 1,250 1,250

Gross combination weight 3,665 3,665

Seating capacity 5 5

Engine Model No. 4B11 4B11

Type DOHC MIVEC DOHC MIVEC

To ta l d is pl ac em en t mL 1,998 1,998

Max. output <EEC> kW/rpm 107/6,000 107/6,000

Max. torque <EEC> N⋅m/rpm 196/4,200 196/4,200

Fuel system Fuel supply system MPI MPI

Page 17

GENERAL

GENERAL DATA AND SPECIFICATIONS

Item INTENSE

GF2W

XTSHL6Z XTSHZL6Z

Transmission Model code F1CJA W1CJA

Type Front wheel drive 2WD,

INVECS-III CVT with sport mode

Turning radius mBody 5.73 5.73

Wheel 5.3 5.3

<2400>

Item INSTYLE

GF3W

XTHHZL6Z

Vehicle dimension mm

Front track 1 1,540

Overall width 2 1,800

Front overhang 3 955

Wheelbase 4 2,670

Electronic control 4WD, INVECS-III CVT with sport mode

00-17

Rear overhang 5 1,030

Overall length 6 4,655

Ground clearance (unladen) 7 215

Overall height (unladen) 8 1,680

Rear track 9 1,680

Vehicle weight kgKerb weight Without full optional parts 1,495

With full optional parts 1,569

Gross vehicle weight 2,210

Gross axle weight rating-front 1,150

Gross axle weight rating-rear 1,250

Gross combination weight 3,890

Seating capacity 5

Engine Model No. 4B12

Type DOHC MIVEC

To ta l d is pl ac em en t mL 2,360

Max. output <EEC> kW/rpm 123/6,000

Max. torque <EEC> N⋅m/rpm 222/4,100

Fuel system Fuel supply system MPI

Transmission Model code W1CJA

Type Electronic control 4WD, INVECS-III CVT with

sport mode

Turning radius mBody 5.73

Wheel 5.3

Page 18

00-18

PRECAUTIONS BEFORE SERVICE

GENERAL

PRECAUTIONS BEFORE SERVICE

ABOUT THE DESCRIPTION OF THE IGNITION SWITCH

M1001020400038

In this manual, the engine switch of vehicles with KOS and the ignition switch of vehicle without KOS are described as an ignition switch. (However, not "ignition switch", but "engine switch" is described in the GROUP 42B-KOS)

Power supply mode by the engine switch operation

When the engine switch is pressed, the power supply mode changes according to the shift position and brake pedal operation state.

Shift position Brake pedal operation Power supply mode at engine switch operation

P position Released Every time the switch is pressed, the power supply mode

changes from OFF to ACC to ON to OFF.

Depressed While the power supply mode is OFF, the engine is started

when the switch is pressed.

While the power supply mode is ACC, the engine is started when the switch is pressed.

While the power supply mode is ON, the engine is started when the switch is pressed.

Depressed or released When the switch is pressed after the engine is started, the

power supply mode is turned OFF (the engine stops).

Other than P position

Depressed or released When the switch is pressed while the power supply mode is

ACC, the power supply mode is turned ON.

When the switch is pressed while the power supply mode is ON, the power supply mode is turned to ACC.

When the switch is pressed after the engine is started, the power supply mode is turned to ACC.

ENGINE SWITCH INDICATOR

Check that the engine switch indicator is switched as follows in each power supply mode and when an error is detected.

INDICATOR Power supply mode and at

error detection

Indicator

AC904994

NOTE: *: The special operation mode indicates that OSS-ECU is brand new.

OFF Extinguished

ACC Illuminated in orange

ON Illuminated in green

ON (after engine start) Extinguished at 3 seconds after the engine is

System error Flashes in orange

Special operation mode

INDICATOR

started

Flashes in green (when ACC and ON only)

Page 19

GENERAL

PRECAUTIONS BEFORE SERVICE

00-19

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

M1001011601662

SRS AND SEAT BELT WITH PRE-TENSIONER

CAUTION

Items to review when servicing SRS:

1. Be sure to read GROUP 52B − Supplemental

Restraint System (SRS). For safe operation, please follow the directions and heed all warnings.

2. 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. Seri ous injury may result from unintended air bag deployment if work is done on the SRS sys tem immediately after the battery cable is disconnected.

3. Warning/Caution labels must be heeded when

servicing or handling SRS components. Warning labels can be found in the following locations. (Refer to WARNING/CAUTION LABELS

4. Always use the designated special tools and

test equipment.

5. 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 upward. Do not place anything on top of it.

6. Never attempt to disassemble or repair the

SRS components (SRS-ECU, air bag module and clock spring).

7. Whenever you finish servicing the SRS, check

the SRS warning lamp operation to make sure that the system functions properly.

8. Be sure to deploy the air bag before dispos-

ing of the air bag module or disposing of a vehicle equipped with an air bag (Refer to GROUP 52B cedures).

Observe the following when carrying out operations on places 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 compo nents.

2. If heat damage may occur during paint work,

remove the SRS-ECU, the air bag module,

− Air Bag Module Disposal Pro-

clock spring, the front impact sensor, the side impact sensor, and the seat belt pre-ten sioner.

• SRS-ECU, air bag module, clock spring, front impact sensor, the side impact sen sor: 93 °C or more

• Seat belt pre-tensioner: 90 °C or more

VEHICLES WITH AIR CONDITIONER

M1001011300088

CAUTION

Never start the engine with the refrigerant system empty as it will damage the A/C compressor.

Page 20

00-20

GENERAL

PRECAUTIONS BEFORE SERVICE

MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY

M1001012400572

MULTI USE TESTER (M.U.T.-III) sub assembly

Vehicle communication interface (V.C.I.)

MB991824

M.U.T.-III USB cable

MB991827

M.U.T.-III main harness A

MULTI USE TESTER (M.U.T.-III)

Vehicle communication interface-Lite (V.C.I.-Lite)

MB992744

V.C.I.-Lite main harness A

MB992745

V.C.I.-Lite main harness B

Do not use

M.U.T.-III main harness B

Do not use

M.U.T.-III adapter harness

M.U.T.-III trigger harness

MB991910

MB991911

MB991825

MB991826

AC305090

MB992746

V.C.I.-Lite USB cable short

MB992747

V.C.I.-Lite USB cable long

MB992748

ACB05419

• Both the special tool V.C.I. (MB991824) and the special tool V.C.I.-Lite (MB992744) can be used.

CAUTION

For the V.C.I., use MB991827 and MB991910. For the V.C.I.-Lite, use MB992745, MB992747 and MB992748.

• Refer to the "M.U.T.-III OPERATION MANUAL" for instructions on handling the M.U.T.-III.

Page 21

GENERAL

PRECAUTIONS BEFORE SERVICE

00-21

CAUTION

Turn th e i gn i ti on sw it c h t o th e " LO C K" ( O FF ) position before connecting or disconnecting the M.U.T.-III.

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

Connect the M.U.T.-III to the diagnosis connector as shown in the illustration.

SERVICING ELECTRICAL SYSTEM

M1001011900314

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).

AC300693

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.

HOW TO SHIFT LOCK FORCED RELEASE

M1001018100290

If the shift lever cannot be moved from the P position due to discharged battery or similar reasons, release the shift lock by observing the procedure below.

ACB05531

Remove the cover as shown, then insert a straight blade (or flat-tipped screwdriver) into the shift lock release hole, and move the selector lever while pressing the blade down.

HOW TO PERFORM CHASSIS NUMBER (CHASSIS NO.) WRITING FOR ENGINE-ECU, KOS-ECU AND ETACS-ECU

M1001011400814

Follow the procedure below to register the Chassis No. of the ETACS-ECU and the Keyless Operation System (KOS).

Chassis No. is stored in the engine-ECU, ETACS-ECU, and the KOS-ECU. If the Chassis No. is improperly erased, the engine warning lamp or the keyless operation system warning indicator illuminates, and the diag nosis code is displayed. When the engine-ECU, ETACS-ECU, and the KOS-ECU are replaced, follow the procedure below to write the Chassis No.

Page 22

00-22

GENERAL

PRECAUTIONS BEFORE SERVICE

System Select

KOS/IMMO/Keyless

Special Function

ENG Key Code &Chassis No/ VIN Reg

Engine Key Code Registration Completed

Engine Chassis No. Registration

System Select

MPII/GDI/DIESEL

Coding

Chassis No. /VIN Writing

Chassis No. Registration Confirmation

Chassis No. Registration Completed

Result of Chassis No. Registration

System Select

KOS/IMMO/Keyless

Coding

Chassis No. /VIN Writing

Chassis No. Registration Confirmation

Chassis No. Registration Completed

Result of Chassis No. Registration

System Select

ETACS

Coding

Chassis No. /VIN Writing

Chassis No. Registration Confirmation

Chassis No. Registration Completed

Result of Chassis No. Registration

Engine Chassis No. Registration Confirmation

Engine Chassis No. Registration Completed

Result of Engine Chassis No. Registration

ACC00417

NOTE: .

•

Chassis number writing of the OSS ECU and ESL ECU is described in "Keyless Operation System

−

(KOS)". (Refer to GROUP 42B

•

Perform the variant coding of the engine-ECU when the chassis No. or the vehicle identification number is

On-vehicle Service <OSS ECU> .)

registered to the engine-ECU.

Page 23

GENERAL

PRECAUTIONS BEFORE SERVICE

00-23

ENGINE KEY CODE AND CHASSIS NUMBER (CHASSIS NO.) REGISTRA TION STEPS FOR THE ENGINE-ECU <VEHICLES WITHOUT KOS>

CAUTION

• Check that diagnosis code No.P0603 "EEPROM fail" is not set. When diagnosis code No. P0603 "EEPROM fail" is set, the engine-ECU cannot store engine key code and chassis No. even if the engine key code and chassis No. are registered. If this diagnosis code is set, troubleshoot the engine-ECU and repair, and then register the engine key code and chassis No. to the engine-ECU.

•

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

5. Connect the V.C.I.-Lite main harness A or

M.U.T.-III main harness A to the diagnosis connector of the vehicle.

NOTE: When the V.C.I.-Lite is connected to the diagnosis connector, the V.C.I.-Lite indicator lamp will be illuminated in a green colour.

6. Turn the V.C.I. power switch to the "ON" position. <When using the V.C.I.>

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col

our.

7. Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.

8. Select "KOS/IMMO/Keyless" button from the "System Select" screen. Then, select the applicable option code item and push the OK button.

• The display of "Special Function" screen changes, depending on the contents of the option. For vehicles with KOS, select "KOS&Immobi." For vehicles without KOS, select "Immobi&Keyless."

9. Select "Special Function" on the next screen.

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

Connect the M.U.T.-III to the 16-pin diagnosis connector as follows.

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III User's Manual."

1. Ensure that the ignition switch is at the "LOCK" (OFF) position.

2. Start up the personal computer.

3. Connect special tool V.C.I.-Lite USB cable (MB992747/MB992748) or M.U.T.-III USB cable (MB991827) to V.C.I.-Lite (MB992744) or V.C.I. (MB991824) and the personal computer.

4. Connect V.C.I.-Lite main harness A (MB992745) or M.U.T.-III main harness A (MB991910) to the V.C .I .- Li te o r V.C .I.

Option: When Immobi & Keyless is selected

KOS/IMMO/Keyless

ENG Key Code& Chassis No./VIN Reg

AC801055

10.Select "ENG Key Code&Chassis No./VIN Reg." from the "Special Function" screen.

KOS/IMMO/Keyless

ENG Key Code&Chassis No./VIN Reg

Key Co de Re gistra tion to En gine- ECU

OK button

AC509803

11.Push th e O K b ut to n a f t er "K ey Co de Re gi s tr at ion to Engine-ECU" is displayed.

Page 24

00-24

GENERAL

PRECAUTIONS BEFORE SERVICE

12.Push the OK button after "Completed. Press the OK button and move to Chassis No./VIN writing function." is displayed.

***************** *****************

AC700604

13.Enter the Chassis No./VIN of registering vehicle and push the OK button.

14.Push the OK button after "Chassis No./VIN Writing will start. Are you sure?" is displayed.

15.Return to the previous screen and "In Progress" is displayed at the lower-left corner on the screen.

16.Push the OK button after "Completed." is displayed.

CHASSIS NUMBER (CHASSIS NO.) REGISTRATION STEPS FOR THE ENGINE-ECU <VEHICLES WITH KOS>

CAUTION

•

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

Result of Chassis No./VIN Writing

Chassis No./VIN

*****************

AC700605

17.Chassis No./VIN writing result is displayed.

18.Complete the M.U.T.-III.

19.Disconnecting the M.U.T.-III is the reverse of the connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF).

20.Push the OK button after "Completed." is displayed.

21.Terminate the M.U.T.-III.

22.Turn the ignition switch to the LOCK (OFF) position and then disconnect the M.U.T.-III.

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

Connect the M.U.T.-III to the 16-pin diagnosis connector as follows.

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Start up the personal computer.

2. Connect special tool V.C.I.-Lite USB cable (MB992747/MB992748) or M.U.T.-III USB cable (MB991827) to V.C.I.-Lite (MB992744) or V.C.I. (MB991824) and the personal computer.

3. Connect V.C.I.-Lite main harness A (MB992745) or M.U.T.-III main harness A (MB991910) to the V.C .I .- Li te o r V.C .I.

4. Connect the V.C.I.-Lite main harness A or M.U.T.-III main harness A to the diagnosis connector of the vehicle.

Page 25

GENERAL

PRECAUTIONS BEFORE SERVICE

00-25

NOTE: When the V.C.I.-Lite is connected to the diagnosis connector, the V.C.I.-Lite indicator lamp will be illuminated in a green colour.

5. Turn the V.C.I. power switch to the "ON" position. <When using the V.C.I.>

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col

our.

6. Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.

7. Select "MPI/GDI/DIESEL" button from the "System Select" screen.

POWERTRAIN MPI/GDI/DIESEL

• For vehicles without KOS, select " Without immobilizer or OSS equipped model".

CodingMPI/GDI/DIESEL Chassis No./VIN Writing

Current Chassis No./VIN

New Chassis No./VIN

OK button

ACB05859

11.Ente r the cha ssi s num ber in th e New Cha s si s No. frame. Confirm the number and press the OK button.

VIN Writing

Chassis No./VIN Writing

Chassis No./VIN Writing will start. Are you sure?

OK button

ACB05854

8. Select "Coding" on the next screen.

POWERTRAIN MPI/GDI/DIESEL Coding

Chassis No./VIN Writing Chassis No./VIN Information

ACB05856

9. Select "Chassis No./VIN Writing" screen.

CodingMPI/GDI/DIESEL Chassis No./VIN Writing

Select equipment

With immobilizer (except OSS equipped model)

Without immobilizer or OSS equipped model

Please select appropriate equipment.

OK button

ACB05860

12.Following the instruction on the screen, press the OK button to execute the chassis number writing.

Chassis No./VIN Writing

Completed.

OK button

ACB05861

13.Push the OK button after "Completed." is displayed.

MPI/GDI/DIESEL Coding Chassis No./VIN Writing

ACB05857

10.Select whether the vehicle is equipped with immobilizer system or not.

• For vehicles with KOS, select "With immobilizer (except OSS equipped model)".

Chassis No./VIN

Chassis No.

ACB05862

Page 26

00-26

GENERAL

PRECAUTIONS BEFORE SERVICE

14.On the writing result confirmation screen, check that the chassis number is written, and finish the registration.

CHASSIS NO. WRITING STEPS FOR ETACS-ECU AND KOS-ECU

CAUTION

• Before the chassis No. registration to ETACS-ECU, check that the chassis Nos. of engine-ECU and vehicle are matched.

• Check that diagnosis code No. B2416 "ECU internal error" is not set. When diagnosis code No. B2416 "ECU internal error" is set, the ETACS-ECU and the KOS-ECU cannot store the Chassis No. even if the Chassis No. is written. If this diagnosis code is set, trou bleshoot the immobilizer system or the KOS-ECU and repair, and then write the Chas sis No. to the ETACS-ECU or the KOS-ECU.

•

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

3. Connect V.C.I.-Lite main harness A (MB992745) or M.U.T.-III main harness A (MB991910) to the V.C .I .- Li te o r V.C .I.

4. Connect the V.C.I.-Lite main harness A or M.U.T.-III main harness A to the diagnosis connector of the vehicle.

NOTE: When the V.C.I.-Lite is connected to the diagnosis connector, the V.C.I.-Lite indicator lamp will be illuminated in a green colour.

5. Turn the V.C.I. power switch to the "ON" position. <When using the V.C.I.>

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col our.

6. Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.

7. Select "KOS/IMMO/Keyless" button from the "System Select" screen. Then, select the applicable option code item and push the OK button.

• For vehicles with KOS, select "KOS&Immobi." For vehicles without KOS, select "Immobi&Key less."

8. Select "Coding" on the next screen.

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

Connect the M.U.T.-III to the 16-pin diagnosis connector as follows.

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Start up the personal computer.

2. Connect special tool V.C.I.-Lite USB cable (MB992747/MB992748) or M.U.T.-III USB cable (MB991827) to V.C.I.-Lite (MB992744) or V.C.I. (MB991824) and the personal computer.

System Select

IMMOBI/KOS/Keyless Coding

Chassis No. /VIN Writing

Chassis No. Writing

Please select function.

AC509821

9. Select "Chassis No. /VIN Writing" on "Coding" screen.

IMMOBI/KOS/Keyless Coding Chassis No. Writing

Chassis No. (Engine ECU)

Chassis No. /VIN (Engine ECU)

Write the number displayed on the screen in Immobilizer KOS/ECU.

Press the OK button to execute.

Chassis No. /VIN Writing

Chassis No. Writing

Chassis No. /VIN Writing

00000000000000000

*****************

Chassis No. currently written in Engine ECU is displayed.

Chassis No. /VIN currently written in Engine ECU displayed.

OK button

AC509822AD

10.Push the OK button after the Chassis No./VIN written in the engine-ECU is displayed.

Page 27

GENERAL

PRECAUTIONS BEFORE SERVICE

00-27

11.Push th e O K b ut to n a f t er "C has si s N o. / VI N Writing will start. Are you sure?" is displayed.

12.Push the OK button after "Completed." is displayed.

IMMOBI/KOS/Keyless Coding Chassis No. Writing

Chassis No. Writing

Chassis No. /VIN Writing

Result of chassis No. Writing

Result of chassis No. /VIN Writing

00000000000000000

*****************

AC509823

13.Result of Chassis No./VIN writing is displayed.

14.Resister the other ID code. (Refer to GROUP 42A, On-vehicle service Procedure

<Vehicles without KOS>, GROUP

− ID Codes Registration

42B, On-vehicle service − ID Codes Registration Procedure

<Vehicles with KOS> or GROUP 54A, On-vehicle service − ID Codes Registration Procedure

<Vehicles without KOS>.)

CODING LIST

M1001015001866

CAUTION

With the ETACS functions being customised, if any of the ETACS-ECU variant coding and option coding items are changed, the customised con

tents are reset. In such case, the functions need to be recustomised.

Before troubleshooting, check that the coding data written into the engine-ECU, SRS-ECU and ETACS-ECU are normal. If they are not the same as the initial settings, various functions and systems do not work normally.

VARIANT CODI NG

The coding data can be checked by operating M.U.T.-III.

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Ensure that the ignition switch is at the "LOCK" (OFF) position.

2. Start up the personal computer.

3. Connect special tool V.C.I.-Lite USB cable (MB992747/MB992748) or M.U.T.-III USB cable (MB991827) to V.C.I.-Lite (MB992744) or V.C.I. (MB991824) and the personal computer.

4. Connect V.C.I.-Lite main harness A (MB992745) or M.U.T.-III main harness A (MB991910) to the V.C .I .- Li te o r V.C .I.

5. Connect the V.C.I.-Lite main harness A or M.U.T.-III main harness A to the diagnosis connector of the vehicle.

NOTE: When the V.C.I.-Lite is connected to the diagnosis connector, the V.C.I.-Lite indicator lamp will be illuminated in a green colour.

6. Turn the V.C.I. power switch to the "ON" position. <When using the V.C.I.>

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col

our.

7. Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.

8. On the system selection screen, select "MPI/GDI/DIESEL" to check the engine-ECU data, "SRS-AIR BAG" to check the SRS-ECU data, and "ETACS" to check the ETACS-ECU data.

Page 28

00-28

GENERAL

PRECAUTIONS BEFORE SERVICE

9. Select "Coding."

10.Select "Coding Information & Copy."

11.If th e dis pla ye d c od i ng in fo rma ti o n is d i ffe r en t from the corresponding initial setting in the list, replace the ECU with a correctly coded one. For replacement of the engine-ECU, refer to GROUP 13A

− Engine-ECU . For replacement of the

SRS-ECU, refer to GROUP 52B − SRS Control

. For replacement of the ETACS-ECU, refer

Unit to GROUP 54A − ETACS .

Item name Initial value

Final drive 2WD

Final gear ratio 6.466

Tyre circumference 2155mm

IMMOBILIZER Present

Auto Stop & Go (AS&G) Not present

ABS Not present <Vehicles with ASC>

A.S.C. Not present <Vehicles without ASC>

ENGINE ECU CODING DATA LIST

NOTE: The items to be displayed may differ depending on the version of the M.U.T.-III.

4WD

Present <Vehicles without ASC>

Present <Vehicles with ASC>

EPS Present

ECO indicator Not present

Adaptive cruise control Not present

ECO mode switch Not present

Power window(DR) Not present

Power window(AS) Not present

Power window(RR) Not present

Power window(RL) Not present

Power window(RP) Not present

Sun roof Not present or Present

M/T temperature sensor Not present

Cruise control Not present or Present

Speed limit function

Cruise control option coding Not accept

Speed limit function OP coding Not accept

S/W variation No.1

Not present

SRS-ECU CODING DATA LIST

NOTE: The items to be displayed may differ depending on the version of the M.U.T.-III.

Item name Initial value

DR airbag squib(1st) Present

PS airbag squib(1st) Present

Page 29

GENERAL

PRECAUTIONS BEFORE SERVICE

Item name Initial value

DR airbag squib(2nd) Not present

PS airbag squib(2nd) Not present

DR pretensioner squib Present

PS pretensioner squib Present

PS lap pretensioner squib Present

RH side airbag squib Not present or Present

LH side airbag squib Not present or Present

RH curtain airbag squib Not present or Present

LH curtain airbag squib Not present or Present

DR knee airbag squib Not present or Present

Occupant classification module Not present

DR seat position sensor Not present

Seatbelt warning indicator(CAN) Not present

PS cut off SW Present

DR buckle SW (mecha) Not present

DR buckle SW (hall) Not present

00-29

PS buckle SW (mecha) Not present

PS buckle SW (hall) Not present

Passenger's SRS OFF lamp Present

Passenger's SRS ON lamp Present

LH front G sensor Present

RH front G sensor Present

RH side sensor B-pillar Not present or Present

LH side sensor B-pillar Not present or Present

RH side sensor C-pillar Not present

LH side sensor C-pillar Not present

Roll over sensor Not present

Disposal Present

High volt.cutoff Not present

Emergency call Not present

2nd seat(RH) pretensioner squib Not present

2nd seat(LH) pretensioner squib Not present

Crash parameter flag(#0) ON

Crash parameter flag(#1) OFF

Crash parameter flag(#2) OFF

Crash parameter flag(#3) OFF

Crash parameter flag(#4) OFF

Crash parameter flag(#5) OFF

Crash parameter flag(#6) OFF

Crash parameter flag(#7) OFF

Page 30

00-30

PRECAUTIONS BEFORE SERVICE

GENERAL

ETACS-ECU CODING DATA LIST

NOTE: The items to be displayed may differ depending on the version of the M.U.T.-III.

Item name Initial value

Vehicle line NEW SUV

Model year (Displays the model year)

Handle side LHD

Destination EUR

Transmission CVT <CVT>

Engine type 4B11 D4 MIVEC <4B11>

4B12 D4 MIVEC <4B12>

Smart entry system Not present or Type B

Keyless entry

Immobilizer Type A

WCM/KOS Not present or Present

Panic Alarm

OSS Not present or Present

Present

Disable

KOS LF output Type 3

KOS SW type(Gate/trunk) Gate 2SW

Engine Type for OSS Undefined or Gasoline

Transmission Type for OSS Undefined

TPMS

Not present

TPMS information N/A

TPMS Off mode function Not present

AUDIO

AND

Not present or Present

Destination for HFM EUR

Entertainment Vehicle Line NEW SUV

Entertainment model year (Displays the model year)

Radio Frequency

Number of speaker

EUR

Premium RF or 6 speakers

AUX equipment Not Present

KOS door entry type Switch

Corner sensor control unit Not present or Present

CAMERA Not present

Rear view camera Not present or Present

Nose view camera Not present

Left side view camera Not present

FCM function Not present

FCM type Undefined

Page 31

GENERAL

PRECAUTIONS BEFORE SERVICE

Item name Initial value

ACCS type Undefined

ACCS Not present

ACCS function Not present

Remote engine starter

Present/Chg Ok

IG key illumination W/ getting off

Comfort flasher type Present/Chg Ok

Trailer turn detection Present

Front wiper

Speed Sensitive or Rain Sensitive

After wipe customize Enable(def.D)

Rear wiper mode With Lo control

Rear wiper by reverse customize Enable(d.FR/RR)

Auto fold mirror Keyless/KOS

Manner switch

Auto lamp control

Not present/ChgNg

No/Chg Ng or Hi RLS/Chg Ng

00-31

Coming home lamp customize Enable(def.E)

Welcome lamp customize Enable(d.Small)

Room lamp delay timer/door & H/L Short

Room lamp by H/L Full

Gate/Trunk lamp Mode-2 (cargo)

Head lamp auto cut Enable

Head lamp auto cut mode B-spec

Door Unlock Mode Customize

Customize Enable

Door unlock by IG lock customize Enable(def.D)

Key reminder unlock Disable

Horn chirp by keyless Not Present/ChgNg

Security alarm function NotPresent/ChgNg

Security alarm mode Not present

Pre-alarm Not present

Security alarm sensor Not present

Security alarm siren Not present

Security sensor gain setting Type 1

Siren answer Disable

MiEV REMOTE-ECU

Security type(MiEV REMOTE)

Not present

Not Present

Security alarm(MiEV REMOTE) Not present

Door control(MiEV REMOTE) Not present

Panic Alarm control(MiEV REMOTE) Not present

Position lamp cont.(MiEV REMOTE) Not present

Head lamp control(MiEV REMOTE) Not present

Page 32

00-32

PRECAUTIONS BEFORE SERVICE

GENERAL

Item name Initial value

Horn control(MiEV REMOTE) Not present

Battery reminder(MiEV REMOTE) Not present

Battery charge(MiEV REMOTE) Not present

Pre-A/C control(MiEV REMOTE) Not present

Power window type Type 5(NAFTA)

Power window Dr Not present

Power window As Not present

Power window RR Not present

Power window RL Not present

Multi mode RKE Disable or Enable

Gate/Trunk Gate type

RLS overwipe type Type 2

RLS WS type Type 2 (Green)

RLS

Not present or Present

RLS Communication Type LIN

LDW equipment status Not Present

LDW Parameter status Not parameter

LDW production setup status Not Present

LDW Not present

ORC Present

DRL*1 type

DRL function

DRL not present

NotPresent/ChgNg

Electric Slide door (Left) Not present

Electric Slide door (Right) Not present

Sun roof type Not present or Type S2

Sun roof Not present or Present

Rear S/R unlock output Not present

ETG Not present or Present

Head lamp 4 beams

Head lamp washer Disable or Popup2 w/ washer

Fold mirror Disable or Enable

Front fog lamp mode B spec.

Front fog lamp

Rear fog lamp

Not present or Present

Present/ChgNg

Door lock system B-Spec/exceptUSH

Gate/trunk opener mode Present(Type 1)

Horn type

Dual horn

H/L leveling type Not present or 2 height sensor

Head Lamp Leveling system type NEW SUV

Page 33

GENERAL

PRECAUTIONS BEFORE SERVICE

Item name Initial value

Rear wiper Enable

Wiper washer check bulb

Intelligent/Comfort washer custom Enable(def.D)

ESS by turn lamp Not present

Turn signal bulb 21W+21W+5W or 21/21/21/21/0.36

ESL Not present or Present

Final drive Front Drive <2WD>

T/M oil cooler Not present

S-AWC Not present or Present

TCM Present

Shift lock Present

Transmission control type Def./Not present

Average speed Not available or Available

Coolant temp gauge threshold Normal

Vehicle language status Russian

Present

4WD FF Base <4WD>

00-33

Fuel consumption scale L/100 km

Tire circumference 2155mm

Frost warning threshold EUR

Distance to empty Available

Average fuel consumption Available

Instant fuel consumption Available

Seat belt reminder logic Except EU

Rear door type HINGE

Shift Display Layout LHD

Trip autoreset IG OFF Available

GCC speed alarm indicator Not present

AS&G status Not present

Gear shift reminder Not present

Reverse alarm Not available

Seat belt reminder control type Non AABT

Charging Time Display Not present

Seat belt reminder indicator D&P independent

Key reminder Not available

Brake vacuum warning Not present

GCC speed alarm Not available

Rent-a-car mode IG-OFF always Available

S-AWC Control display Not available

Service reminder schedule table Normal

Display opening type MMC

Page 34

00-34

Item name Initial value

Language mode Available

Fuel tank type Type 0 or Type 1

GSI system Not present

Launch gear block alarm Not present

Service reminder for month 12 month

Service reminder for km 20000km

Service reminder for mile 12500mile

Drive mode Not present or Present

A/C control type EUR

ECO gauge Not present

ECO score Not present

Electric motor switch reminder Not present

Gate/Trunk Gate type

Steering Wheel Switch Not present or Present

Distance to empty(PHEV) Not present

Energy Flow Not present

PRECAUTIONS BEFORE SERVICE

GENERAL

EV ratio Not present

Outside temperature Present

ECO SW(Except for PHEV) Not present

OCM Not present

A/C Present

Indirect lamp Not present

Room lamp Centre Switch Not present

Compressor type

Tem pe ra tu re t yp e Celsius

Option Heater No present

Indirect lamp Type1/No present

Heater Control Panel Type Single LCD or Dual LCD

EPS Present

EPS type Type 1

ABS Not present <Vehicles with ASC>

Vehicle Type for A.S.C. Not present <Vehicles without ASC>

Type 1

Present <Vehicles without ASC>

Type 1 <2.0/2.4L 2WD>

Type 2 <2.0/2.4L 4WD>

Brake Type for A.S.C. Not present <Vehicles without ASC>

Type 1 <Vehicles with ASC>

HBA Type Not present <Vehicles without ASC>

Type 1 <Vehicles with ASC>

Page 35

GENERAL

PRECAUTIONS BEFORE SERVICE

Item name Initial value

ABS Type Not present <Vehicles without ASC>

Type 1 <Vehicles with ASC>

TCL Type Not present <Vehicles without ASC>

Type 9 <2.0L CVT>

Type 10 <2.4L CVT>

A.S.C. Type Not present <Vehicles without ASC>

Type 1 <Vehicles with ASC>

A.S.C. Not present <Vehicles without ASC>

Present <Vehicles with ASC>

HSA Type Not present <Vehicles without HSA>

Type 1 <Vehicles with HSA>

AS&G brake hold Type Not present

Brake prefill Not present

Brake fade support Not present

S-AWC Brake Not present

Enhanced TCL Not present

00-35

TSA Type Not present

ACC Type for A.S.C. Not present

FCM Type for A.S.C. Not present

Engine power Normal

Water separate warning Not present

Cooling fan Relay control

Auto Stop & Go (AS&G) Not present

EV Not present

ETG Buzzer Not present

ETG Answerback Not present

NOTE: .

•

: TPMS is an abbreviation of Tyre Pressure Monitoring System, DRL of Daytime Running Lamp.

•

: The setting can be changed by the option coding. Refer to P.00-35.

OPTION CODING

CAUTION

• If there is any item indicated by the option coding after equipment change, set ETACS-ECU so that the option coding data corresponds with the equipment content. Pay attention to that the concerned functions and systems do not work normally if the setting does not correspond with the equipment.

• With the ETACS functions being customised, if any of the ETACS-ECU option coding items are changed, the customised contents are reset. In such case, the functions need to be recustomised.

The ETACS-ECU option coding data can be checked or changed by operating M.U.T.-III.

• How to check option coding data

1. Connect the M.U.T.-III. Refer to P.00-27.

Page 36

00-36

GENERAL

PRECAUTIONS BEFORE SERVICE

2. Select "MPI/GDI/DIESEL" or "ETACS" on the system selection screen.

3. Select "Coding."

4. Select "Option Coding Information."

5. Check the displayed option coding information.

• How to change option coding data

1. Connect the M.U.T.-III. Refer to P.00-27.

2. Select "MPI/GDI/DIESEL" or "ETACS" on the system selection screen.

3. Select "Coding."

4. Select "Option Coding."

5. Change to correct option coding data.

LIST <Engine-ECU>

Item name

Cruise control

Speed limit function

LIST <ETACS-ECU>

Item name

Auto lamp control

Keyless entry

INITIALISATION PROCEDURE FOR LEARNING VALUE IN MPI ENGINE

M1001011701517

Initialise learning values in the MPI engine when one of the following service operations is performed.

• At replacing engine assembly

• At replacing injector and at cleaning

• At replacing throttle body and at cleaning

• At replacing detonation sensor

NOTE: *: Initialise CVT related learning value.

INITIALISATION PROCEDURE

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

AUDIO

RLS

Number of speaker

Radio Frequency

Front fog lamp

Rear fog lamp

Horn type

Manner switch

Remote engine starter

AND

Compressor type

DRL function

Wiper washer check bulb

ESS Cancel Function

MiEV REMOTE-ECU

Security type(MiEV REMOTE)

Panic Alarm

Door Unlock Mode Customize

Front wiper

MB992747, MB992748, MB991827

ACB05017

CAUTION

To preve nt d a ma ge to M .U . T.-III, a l wa ys tu rn th e ignition switch to the "LOCK" (OFF) position before connecting or disconnecting M.U.T.-III.

1. After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.

2. Turn the ignition switch to the "ON" position.

3. Select "MPI/GDI/DIESEL" from System select Screen of the M.U.T.-III.

4. Select "Special Function" from MPI/GDI/DIESEL Screen.

5. Select "Learned value reset" from Special Function Screen.

6. Select "All learned value" from Learned value reset Screen

7. Initialise the learning value by pressing the "OK" button.

Page 37

GENERAL

PRECAUTIONS BEFORE SERVICE

00-37

8. After initialising the learning value, the learning value of MPI engine idling is necessary. Learning procedure for idling in MPI engine (Refer to

P.00-37).

LEARNING PROCEDURE FOR IDLING IN MPI ENGINE

M1001011801451

PURPOSE

When the engine-ECU is replaced, or when the learning value is initialised, the idling is not stabilized because the learning value in MPI engine is not com pleted. In this case, carry out the learning method for the idling through the following procedures.

LEARNING PROCEDURE

1. Start the engine and carry out the warm-up for the engine coolant temperature to reach 80 more.

When the engine coolant temperature is 80°C or more, the warm-up is not needed if the ignition switch is in "ON" position once.

2. Place the ignition switch in "LOCK" (OFF) position and stop the engine.

3. After 10 seconds or more, start the engine again.

4. For 10 minutes, carry out the idling under the condition shown below and then confirm the engine has the normal idling.

• Transmission: "P" range

• Operation in lamps, fan and attachments: Not to

be operated

• Engine coolant temperature: 80°C or more

NOTE: When the engine stalls during the idling, check the dirtiness (on the throttle valve) of the throttle body and then perform the service from Procedure 1 again.

°C or

INITIALISATION PROCEDURE FOR THROTTLE VALVE CONTROL SERVO

Disconnecting and reconnecting the battery cables causes the throttle valve closed-position value learned to be erased from the memory. This may prevent the idle speed control from being executed properly. When the battery cables have been discon nected and reconnected, initialise the throttle valve control servo in the following manner.

1. Turn the ignition switch to "ON" and then to "LOCK" (OFF).

2. Keep the ignition switch in "LOCK" (OFF) for at least 10 seconds.

PRE-INSPECTION CONDITION

M1001012100902

"Pre-inspection condition" refers to the condition that the vehicle must be in before proper engine inspec tion can be carried out. If you see the words "Set the vehicle to the pre-inspection condition". In this man ual, it means to set the vehicle to the following condition.

• Engine coolant temperature 80 to 90°C

• Lamps, electric cooling fan and all accessories:

OFF

• M/T: Neutral

• CVT: P range

PRECAUTIONS FOR INSTALLATION OF ON-VEHICLE RADIO TRANSMISSION EQUIPMENT

M1001015500158

The computers (control unit) for various on-vehicle electronic equipment are provided with sufficient pro tective measures against external radio wave interference. However, because the on-vehicle radio transmission equipment may affect adversely the computers (control unit), pay attention to the follow ing precautions for installation.

• Install radio transmission equipment and antenna (including coaxial cables) 200 mm or more away from the computers (control unit) for on-vehicle electronic equipment.

• Because radio wave is radiated from the coaxial cables of the antenna for radio transmission equipment, do not route the cables in parallel with the vehicle wiring harness.

• Install only radio transmission equipment with the frequencies, output, and radio wave types described in the table.

FREQUENCY, OUTPUT, AND RADIO WAVE TYPE OF THE RADIO TRANSMISSION EQUIPMENT

Frequency (MHz)

3.5 50 CW, FM, AM,

144

430

Maximum output power (W)

Modulation

SSB

1,260 2

Page 38

00-38

•

Antenna attachment position

PRECAUTIONS BEFORE SERVICE

ACB05478

Install the antenna for radio transmission equipment

only to the position shown in the figure.

ENGINE OILS

M1001011200230

HEALTH WARNING

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addi

tion, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

RECOMMENDED PRECAUTIONS

The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them. Other precautions:

• Avoid prolonged and repeated contact with oils, particularly used engine oils.

• Wear protective clothing, including impervious gloves where practicable.

• Avoid contaminating clothes, particularly underpants, with oil.

• Do not put oily rags in pockets, the use of overalls without pockets will avoid this.

• Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separately from per sonal clothing.

• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

• Obtain first aid treatment immediately for open cuts and wounds.

GENERAL

• Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After clean ing, the application of preparations containing lanolin to replace the natural skin oils is advised.

• Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.

• Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work.

• If skin disorders develop, obtain medical advice without delay.

FORM−IN−PLACE GASKET (FIPG)

M1001014200132

The engine has several parts to which the form-in-place gasket (FIPG) is used. To sufficiently achieve the aims of this gasket, it is necessary to pay attention to the application amount, procedure, and surface status. If the application amount is too small, a leakage will occur. If the application amount is excessive, the FIPG will overflow and cause a clogging or narrowing of water and oil paths. Therefore, to eliminate the leak from the joint, it is indispensable that the FIPG be applied with a correct amount and without any gap. Because the FIPG used for the engine parts becomes hardened by the reaction with the atmos pheric moisture, it is normally used for the metal flange section.

CAUTION

Reapply the FIPG with care to the followings.

1. Completely remove the old FIPG including the

residue in gaps of parts.

2. Using Mitsubishi genuine parts cleaner

(MZ100387) or equivalent, degrease the FIPG application surface carefully.

3. According to the FIPG application proce-

dures, apply it accurately.

DISASSEMBLY

The parts installed with the FIPG can be disassembled easily without using any special method. However, in some cases, it is necessary to tear the sealant in between the mating surfaces by tapping the parts with a wooden hammer or similar tools. It is acceptable to lightly hit in a smooth, thin gasket scraper into the mating surface, but, in this case, a sufficient caution is required not to damage the mat ing surface. The oil pan FIPG cutter (Special tool: MD998727) is provided. Thus, use this special tool.

Page 39

GENERAL

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

00-39

GASKET SURFACE CLEANING

Use a gasket scraper or wire brush to completely remove all the foreign materials adhering to the gas ket surface. Check that the FIPG application surface is smooth. There must be no grease or foreign mate rial adhesion to the gasket surface. Do not forget to remove the old FIPG remaining in the mounting hole and tapped hole.

APPLICATION PROCEDURE

Apply the FIPG with a specified diameter and without any gap. Completely enclose around the mounting hole. When the FIPG is not hardened, it can be wiped off. Install the parts immediately after applying the FIPG. At the time of installation, prevent the FIPG from adhering to locations other than it is necessary. After the installation, until a sufficient period of time (one hour or more) elapses, do not contact the oil or water to the application area. Also, do not start the engine. Because the FIPG application procedure may differ depending on the application area, apply the FIPG according to the procedure described in the text.

NOTE: The bolts and nuts with stabilizer for coefficient of friction mean that the bolts and nuts with surface treatment to stabilize and reduce the coefficient

of friction, allowing to achieve the stable axial force and to secure the high axial force with low tightening

torque.

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

M1001011000258

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.

VEHICLE WASHING

M1001012000433

Approximately 40 cm or more

BOLTS AND NUTS WITH STABILIZER FOR COEFFICIENT OF FRICTION

M1001014800060

The bolts and nuts with stabilizer for coefficient of friction have been used for the connections such as the suspension arm and crossmember in order to stabilize the axial force and to ensure the high axial force at bolt/nut connections, resulting in improved reliability.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

The Supplemental Restraint System (SRS) and seat belt with pre-tensioner is designed to supplement the driver's and front passenger's seat belts to help reduce the risk or severity of injury to the driver and front passenger by activating and deploying both front air bags in certain frontal collisions. The side-air bag and the curtain air bag are activated when an impact exceeds the threshold upon a side collision, and inflates to protect the heads of the occupants in the front and rear seats.

AC300832

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.

• Spray nozzle distance: Approx. 40 cm or more

• Spray pressure: 3,900 kPa or less

• Spray temperature: 82°C or less

• Time of concentrated spray to one point: within

30 sec.

M1001009801186

The SRS consists of air bag modules, SRS air bag control unit (SRS-ECU), two front impact sensors, two side impact sensors, SRS warning lamp, clock spring, passenger’s air bag cut off switch, passen

ger’s air bag OFF indicator lamp and seat belt pre-tensioner. Front air bags are located in the centre of the steering wheel and above the glove box. Each air bag is made up of a folded air bag and an inflator unit. Side-airbags are located inside the front seat

back assemblies. The curtain air bag module consists of an air bag, an inflator, and the fixing gear relating to those parts, and is installed in the roof side sections (from the driver's and the passenger's front

Page 40

00-40

GENERAL

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

pillars to the rear pillars).The SRS-ECU under the front floor console monitors the system and has a front air bag analogue G-sensor, front air bag ana logue G-sensor and a side (curtain) air bag analogue G-sensor. The front impact sensor is installed on the front end upper bar in the engine room and contains an analogue G-sensor. The side impact sensor is installed in the lower parts of the centre pillars, and contains an analogue G-sensor. The warning lamp on the instrument panel indicates the operational sta tus of the SRS. The clock spring is installed in the

steering column. The passenger’s air bag cut off switch is outside the instrument panel side. The pas senger’s air bag OFF indicator lamp is installed in centre panel assembly. The seat belt pre-tensioner is built into the driver's and passenger's front seat belt retractor. Only authorized service personnel should do work on or around the SRS components. Those service per sonnel should read this manual carefully before start-

ing any such work.

Page 41

GENERAL

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

00-41

SRS warning lamp

ACB05440 ACB05441

Driver's air bag module

Clock spring

Passenger's air bag ON indicator lamp

Passenger's air bag OFF indicator lamp

Curtain air bag module

ACB05561

Knee air bag module

SRS warning lamp

SRS-ECU

Side-airbag module

Passenger's (front) air bag module

Passenger's air bag cut off switch

ACB05560

Seat belt pre-tensioner

Side impact sensor

Front impact sensor

ACB05423

Seat belt pre-tensioner

ACC00250

Page 42

00-42

SRS SERVICE PRECAUTIONS

1. In order to avoid injury to yourself or others

from accidental deployment of the SRS air bag during servicing, read and carefully follow all the precautions and procedures described in this manual.

2. Be sure to use the tester and special tools

specified in this manual (Special tool: refer to tester: refer to ).

3. Never attempt to repair the following

components:

• SRS-ECU

• Driver's air bag module

• Clock spring

• Passenger's (front) air bag module

• Curtain air bag module

• Knee air bag module

• Front seat assembly incorporating side-air-

bag module

GENERAL

• Seat belt with pre-tensioner

• Front impact sensor

•

Side impact sensor

SRS-ECU connector

AC905461

4. Never attempt to repair the wiring harness

connectors of the SRS. If a defective wiring harness is found, repair or replace it by referring to the table follows.

M1001006001095

SRS-ECU

Destination of wiring harness Measures terminal No.

1, 2 Instrument panel wiring harness → knee air bag

module

5, 6 Instrument panel wiring harness → clock spring →

driver's air bag module (squib)

7, 8 Instrument panel wiring harness → passenger's (front)

air bag module (squib)

13 Instrument panel wiring harness → hazard indicator

assembly [air bag OFF indicator lamp (passenger’s

side)]

15 Instrument panel wiring harness → hazard indicator

assembly [air bag ON indicator lamp (passenger’s

side)]

17, 27 Instrument panel wiring harness → front wiring

harness

→ front impact sensor (LH)

18, 28 Instrument panel wiring harness → front wiring

harness

→ front impact sensor (RH)

Repair or replace the instrument panel wiring harness.

Replace the clock spring, or repair or replace the instrument panel wiring harness.

Repair or replace the instrument panel wiring harness.

Repair or replace the wiring harnesses.

22 Floor wiring harness → ETACS-ECU (fuse No. 16) Repair or replace the floor wiring

harness.

23 Instrument panel wiring harness → diagnosis

connector

Repair or replace the instrument panel wiring harness.

24 Instrument panel wiring harness → earth

25,26 Instrument panel wiring harness → passenger’s air

bag cut OFF switch

29, 30 Instrument panel wiring harness → CAN bus line

Page 43

GENERAL

SRS SERVICE PRECAUTIONS

00-43

SRS-ECU

Destination of wiring harness Measures terminal No.

31, 32 Floor wiring harness → front passenger's seat belt

pre-tensioner

36, 37 Floor wiring harness → curtain air bag module (LH)

39, 40 Floor wiring harness → side-airbag module (LH)

41, 42 Floor wiring harness → side impact sensor (LH)

54, 55 Floor wiring harness → driver's seat belt pre-tensioner

56, 57 Floor wiring harness → side-airbag module (RH)

59, 60 Floor wiring harness → curtain air bag module (RH)

64, 65 Floor wiring harness → side impact sensor (RH)

5. Before maintenance, wait for 60 seconds or

more after the disconnection of the battery (

Insulating tape

Battery

terminal. Wrap the disconnected ( with tape for insulation. The condenser inside SRS-ECU keeps a voltage necessary to expand the air bag for a certain period even after the IG power is turned OFF. Therefore, if any operation is performed before the period elapses, it may cause serious damage.

6. If the influence of heat is suspected during

Battery cable

AC300580

painting work, remove the following parts:

• 93°C or higher SRS-ECU, air bag module, clock spring, front impact sensor, side impact sensor

• 90 °C or higher Seat belt with pre-tensioner

7. After the maintenance of the SRS air bag and

seat belt with pre-tensioner is completed, be sure to delete the diagnosis code and check whether the SRS warning lamp lights up (refer to

Repair or replace the floor wiring harness.

−)

−) terminal

Page 44

00-44

SUPPORT LOCATIONS FOR LIFTING AND JACKING

GENERAL

SUPPORT LOCATIONS FOR LIFTING AND JACKING

M1001000701256

SUPPORT POSITIONS FOR A GARAGE JACK

CAUTION

• Be sure to support the specified locations only. Otherwise, deformation of vehicle may occur.

•

Be careful to avoid damage to the front under cover or rear differential carrier assembly.

Front suspension crossmember

ACB04345

Rear suspension crossmember

ACB04346

ACB04347

ACB04348

Page 45

GENERAL

SUPPORT LOCATIONS FOR LIFTING AND JACKING

00-45

SUPPORT POSITIONS FOR AXLE STANDS, SINGLE-POST LIFT OR DOUBLE-POST LIFT

CAUTION

• If rubber attachments with grooves that are too thick are used at the front support positions, the front fender may become bent, so be sure to use rubber attachments with groove thicknesses of 18 mm or less.

• If attachments which are not high enough are used, they may damage areas such as the side step. Be sure to use attachments which are high enough, or remove the side step if not using attach ments.

AXLE STANDS

Notch

Notch

SINGLE-POST LIFT OR DOUBLE-POST LIFT

Rubber

ACB04357

Rubber

Notch

Notch

Rubber

ACB04349

Page 46

00-46

SUPPORT POSITIONS FOR A PLATE TYPE LIFT

Spacer Spacer

GENERAL

TOWING AND HOISTING

Support the notch with a spacer (100-mm width, 100-mm height and 200-mm depth).

TOWING AND HOISTING

WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP <2WD>

CAUTION

SLING TYPE

WHEEL LIFT TYPE

Plate type lift

extended distances provided the parking brake is released. It is recommended that vehicles be towed using the front pickup whenever possible.

ACB04350

M1001000800948

FLAT BED TYPE

AC000070

This vehicle cannot be towed by a wrecker using sling-type equipment; as the bumper may become deformed. If this vehicle is towed, use wheel lift or flat bed equipment.

The vehicle may be towed on its rear wheels for

Page 47

GENERAL

TOWING AND HOISTING

00-47

FRONT TOWING PICKUP <4WD>

CAUTION

SLING TYPE

•

WHEEL LIFT TYPE

FLAT BED TYPE

AC000070

REAR TOWING PICKUP

CAUTION

SLING TYPE

WHEEL LIFT TYPE

FLAT BED TYPE

AC000071

If only the front wheels or only the rear wheels

are lifted for towing, the bumper will be dam aged. In addition, lifting of the rear wheels causes the transfer case oil to flow forward, and may result in heat damage to the rear bushing of the transfer.

• The vehicle must not be towed by placing only its front wheels or only the rear wheels on a rolling dolly. This will result in deteriora tion of the viscous coupling causing the vehicle to jump forward suddenly.

If this vehicle is towed, use flat bed equipment only.

Never lift the rear wheels, otherwise the vehicle becomes unstable while driving.

TOWING WHEN KEYS ARE NOT AVAILABLE

When a locked vehicle must be towed and keys are not available, the vehicle may be lifted and towed from the front, provided the parking brake is released. If not released, the rear wheels should be

placed on a tow dolly.

SAFETY PRECAUTIONS

The following precautions should be taken when towing the vehicle:

1. Do not lift or tow the vehicle by attaching to or wrapping around the bumper.

2. Any loose, protruding, or damaged parts such as hoods, doors, fenders, trim, etc. should be secured or removed prior to moving the vehicle.

3. Refrain from going under a vehicle when it is lifted by the towing equipment, unless the vehicle is adequately supported by safety stands.

4. Never allow passengers to ride in a towed vehicle.

5. Local rules and regulations must be followed when towing a vehicle.

Page 48

GROUP 00E

GENERAL

CONTENTS

00E-1

HOW TO READ WIRING DIAGRAMS 00E-2

COMPOSITION AND CONTENTS OF WIRING

DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 00E-2

HOW TO READ CONFIGURATION DIAGRAMS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E-2

HOW TO READ CIRCUIT DIAGRAMS . . . . 00E-4

MARKINGS FOR CONNECTOR AND EARTHING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E-5

WIRE COLOUR CODE . . . . . . . . . . . . . . . . 00E-7

ABBREVIATION SYMBOLS . . . . . . . . . . . . 00E-8

Page 49

00E-2

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

COMPOSITION AND CONTENTS OF WIRING DIAGRAMS

M1001012800194

In each section, all specifications are listed, including optional specifications. Accordingly, some specifications may not be applicable for individual vehicles.

Section Basic contents

Component locations

Configuration diagrams

Circuit diagrams Circuits from power source to earth are shown completely, classified according to

Locations are shown for each point of relays, ECUs, sensors, solenoid valves, inspection connectors, fusible links, fuses, etc. In the part’s lists, parts are listed in alphabetical order.

Connector locations and harness wiring configurations on actual vehicles are illustrated.

system. There is a main division into power source circuits and circuits classified by system.

• ETACS-ECU The entire circuit for the ETACS-ECU is described, because only the part of the ETACS-ECU needed is normally shown in each circuit diagram.

• J/C The internal circuits for all joint connectors are described, because only the part needed is shown in each circuit diagram.

• Power source circuits Circuits from the battery to fusible link, fuse, ignition switch, etc are shown.

• Circuits classified by system For each system, the circuits are shown from fuse to earth, excluding the power source sections.

HOW TO READ CONFIGURATION DIAGRAMS

M1001006400357

The wiring harness diagrams clearly show the connector locations and harness routings at each site on actual vehicles.

Page 50

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Denotes connector No. The same connector No. is used throughout the circuit diagrams to facilitate connector location search. The first alphabetical symbol indicates the location site of the connector and a number that follows is the unique number. Numbers are usually assigned to part in clockwise order on the diagram.

Example: A-19

E: Roof

Denotes earth point. Same earth number is used throughout circuit diagrams to facilitate search of earth point. Refer to GROUP 70 COMPONENT LOCATIONS

- EARTH MOUNTING LOCATIONS for details of earth points.

Denotes harness name.

Number specific to connector (serial number)

Connector location site symbol A: Engine compartment B: Engine and transmission C: Instrument panel D: Floor

F: Door G: Tailgate

A-19

Front wiring harness (RH)

A-18

00E-3

Denotes a section covered by a corrugated tube.

The mark shows the standard mounting position of wiring harness.

Denotes the colour of the tube (If not specified, it is black). R: Red Y: Yellow

The number of connector pins and the connector colour (except milk white)* are shown for ease of retrieval.

Example: (2-B)

Connector colour (milk white if no colour is indicated)

Number of connector pins

*: Typical connector colours B: Black BR: Brown Y: Yellow V: Violet L: Blue O: Orange G: Green GR: Grey R: Red None: Milk white

A-17

A-16

A-15

A-15 (2) Fog lamp (RH) A-16 (2-GR) Horn (LO) A-17 (2-B) Headlamp (RH) A-18 (2-B) Windshield washer motor A-19 (2-GR) Dual pressure switch

Indicates the device to which the connector is connected.

AC208446

Page 51

00E-4

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

HOW TO READ CIRCUIT DIAGRAMS

M1001006500224

The circuit of each system from the fuse (or fusible link) to earth is shown. The power source is shown at the top and the earth at the bottom to facilitate understanding of how the current flows. The circuit diagrams show the state when switches are not operated.

Indicates power source.

Indicates that terminal is connected via a plate in the relay box.

Each circuit diagram consists of block(s).

Indicates harness junction point numbers for another system. The number corresponds to the junction point number indicated on another circuit diagram.

Indicates equipment which the branched harness wire leads to.

An "X" at the end of a connector number indicates that the connector is connected to a centralized junction that is shown in the section "Centralized Junction."

Indicates that the diagram continues at which belongs to the block in the same circuit.

Indicates the connector symbol. Connectors in the circuit diagram are indicated in numerical order.

RELAY BOX

MOTOR

RELAY

RESISTOR

FUSIBLE

LINK

Indicates shield wire.

SENSOR

Indicates connector number. The same numbers are used in the wiring harness diagram. Connector and connector numbers are shown at the lower part of the page. Connector numbers not enclosed by frame indicate the device incorporated into wiring harness.

FUSIBLE LINK

ECU

SWITCH

SENSOR

MOTOR

SOLENOID VALVE ASSEMBLY

IGNITION SWITCH (IG1)

Indicates that these connectors are the same intermediate connectors.

RESISTOR

Indicates that the diagram comes from which belongs to the block in the same circuit.

Indicates terminal number.

In case two or more connectors are connected to the same device, markings indicating the same connector are connector by a broken line.

Indicates harness junction where wire diameter or colour changes.

Indicates intersections at which the lead wires are not connected.

Indicates intersections at which the lead wires are connected.

Indicates representative vehicle body earth point. (Same number as that of earth point in EARTHING LOCATION).

ACA00087

Indicates a wiring connector which is inside the equipment and which is not shown in the wiring harness configuration diagram.

Example C-15-2

Indicates the connector number shown in

DIODE

the wiring harness configuration diagram.

SENSOR

Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple SI : Silver

SOLENOID VALVE 1

Indicates a connector which is inside the equipment, numbered in order starting from 1.

SOLENOID VALVE 2

Indicates that the terminal is a spare one if the device (sensor in this case) is not provided.

Page 52

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

MARKINGS FOR CONNECTOR AND EARTHING

M1001007900195

00E-5

1, 5

1, 4

SOLENOID VALVE 1

IGNITION SWITCH (IG1)

FUSIBLE

LINK

2, 6

ECU

1, 5

INSPECTION CONNECTOR

RELAY

MOTOR ASSEMBLY

SENSOR

Wire colour code B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue

BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple SI : Silver

ACA00254

Page 53

00E-6

Male terminal

Male connector

Female terminal

Female connector

Device

Intermediate connector

Spare connector, check connector

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Item No. Connector/Earthing Symbol Contents

Connector and terminal marking

−

Male connecto

The male and female terminals are indicated as shown. The connector with male terminal(s) is called as male connector and indicated by two connector

ACX01252

contour lines, while the connector with female terminal(s) is called as female connector and indicated by

Male terminal

single connector contour line.

Connector symbol marking

ACX01251

ACX01253

Female connecto

ACX01255

Female terminal

ACX01256

ACX01254

The symbol indicates the connector is viewed as shown. At a device connection, the connector symbol on the device side is shown. For an

ACX01253

ACX01257

intermediate connector, the male connector symbol is shown. For spare connectors and check connectors, no device is connected, and so the harness-side connector symbol is shown for these connectors. However, a diagnosis connector

ACX01258

is exceptional.

ACX01256

ACX01816

Page 54

GENERAL <ELECTRICAL>

Direct connection type

Intermediate connector

Device earth

HOW TO READ WIRING DIAGRAMS

Item No. Connector/Earthing Symbol Contents

Connector connection marking

Connection between a device and the harness is either by direct insertion in the device (direct connection type) or by connection with a harness

ACX01260

Harness connection type

ACX01261

connector furnished on the device side (harness connection type). The two types are indicated as illustrated.

00E-7

Earth marking

ACX01262

ACX01263

ACX01264

Body earth

ACX01265

Earthing is either by body earth, device earth or control unit interior earth. These are indicated as illustrated.

AC208448

ACX01274

WIRE COLOUR CODE

Wire colours are identified by the following colour codes.

Code Wire colour Code Wire colour Code Wire colour Code Wire colour

B Black L Blue PU Purple V Violet

AC208449

arth in control unit

AC208450

M1001008000195

ACX01276

ACX01278

Page 55

00E-8

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Code Wire colour Code Wire colour Code Wire colour Code Wire colour

BR Brown LG Light green R Red W White

G Green O Orange SB Sky blue Y Yel l ow

GR Grey P Pink SI Silver

− −

If a cable has two colours, the first of the two colour

Example:

<F> 1.25 G B

1234

code characters indicates the basic colour (colour of the cable coating) and the second indicates the marking colour.

ACX01279

No. Meaning

1 <F>: Flexible wire

<T>: Twisted wire

Wire size (mm2)*

3 Basic colour (colour of the cable coating)

4 Marking colour

NOTE: *: No code indicates 0.5 mm2. Cable colour code in parentheses indicates 0.3 mm

ABBREVIATION SYMBOLS

M1001008101667

The abbreviation symbols used in wiring diagrams are defined below.

1. FOR SYSTEM NAME

Abbreviation symbol

4WD 4 wheel-drive vehicles INVECS Intelligent and innovative vehicles

ABS Anti-skid braking system

ASC Active stability control system J/C Joint connector

CAN Controller area network KOS Keyless operation system

CVT Continuously variable transmission MMCS Mitsubishi multi-communication

ETACS Electronic time and alarm control

HSA Hill start assist USB Universal serial bus

Meaning Abbreviation

symbol

SRS Supplemental restraint system

system

Meaning

electronic control system

system

2. FOR COMBINATION METER

Abbreviation symbol

4WD AUTO 4WD automatic indicator display EPS Electric power steering system

4WD-E 4WD ECO indicator lamp F/GA Fuel gauge display

4WD ECO 4WD ECO indicator display FRONT FOG Front fog lamp indicator lamp

Meaning Abbreviation

symbol

Meaning

warning lamp/warning display

Page 56

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

00E-9

Abbreviation symbol

4WD FAILURE

4WD LOCK 4WD lock indicator display KOS Keyless operation system indicator

ABS Anti-skid braking system warning

ASC OFF ASC off indicator display LED Light emitting diode

ASC OPERATION

ASC WARNING

BEAM High beam indicator lamp OSS One touch start system warning

BRAKE Brake warning lamp/warning display REAR FOG Rear fog lamp indicator lamp

CHECK ENGINE

CHG Charging warning lamp/warning

Meaning Abbreviation

symbol

4WD system warning display FUEL

WARNING

LCD Liquid crystal display

lamp/warning display

ASC operation indicator lamp/indicator display

ASC warning display OIL

Check engine warning lamp/warning display

display

LOCK 4WD lock indicator lamp

PRESSURE

SPEED Speedometer

SRS Supplemental restraint system

Meaning

Low fuel warning display

lamp/indicator display

Oil pressure warning lamp/warning display

lamp/warning display

warning lamp/warning display

CRUISE Cruise control system indicator

lamp/indicator display

CVT FAILURE CVT system warning display TA CHO Ta c ho m et er

CVT POSITION

CVT TEMP CVT fluid temperature warning

DRIVER’S SEAT BELT

EACH DOOR Door-ajar warning lamp/warning

CVT shift position indicator display TAI L Ta i l la mp i nd ic at or l am p/ in d ic a to r

display

Driver’s seat belt warning lamp/warning display

display

T/GA Engine coolant temperature gauge

display

TURN (LH)/TURN (RH)

WATER TEMP Engine coolant temperature warning

Turn-signal indicator lamp, hazard warning indicator lamp

lamp/warning display

3. FOR SWITCHES AND RELAYS

Name of switches and relays

Dimmer / passing switch

Abbreviation symbol

LO Low beam ON

HI High beam ON

PASS High beam ON

Operation

Door lock actuator, door lock switch

Front room lamp and rear room lamp

Headlamp manual levelling switch

LOCK Door lock

UNLOCK Door unlock

DOOR Front room lamp ON and rear room lamp ON when a door is

open

0, 1, 2, 3, 4 Lower the optical axis of the headlamp (LO) in steps at each

position

Page 57

00E-10

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Name of switches and relays

Heated seat switch LO Normal heating

Ignition switch LOCK When turned to the LOCK position, no circuits will start

Inhibitor switch P Selector lever is at the P (PARKING) position

Lighting switch AUTO Headlamps or tail lamps automatically illuminate by sensing

Abbreviation symbol

HI Rapid heating

ACC When turned to the ACC (ACCESSORY) or ON position, the

IG1 Even when at the ST (START) position, the power circuit will start

ST Only when turned to the ST (START) position, the power circuit

R Selector lever is at the R (REVERSE) position

N Selector lever is at the N (NEUTRAL) position

D Selector lever is at the D (DRIVE) position

L Selector lever is at the L (LOW) position

HEAD Headlamps ON

TAIL Ta il , p os i ti on , li ce nc e pl at e and illumination lamps ON

Operation

power circuit will start

will start

ambient brightness

FOG Fog lamps (front fog lamp or rear fog lamp) ON

Others (switch or relay) ON Switched ON or relay ON

OFF Switched OFF or relay OFF

Paddle shift switch UP Upshift by one gear

DOWN Downshift by one gear

Power window switch UP Window closes

DOWN Window opens

AUTO UP Window easily closes with one action

AUTO DOWN Window easily opens with one action

Power window lock switch

Rear wiper switch INT Wiper operates intermittently

Remote controlled mirror switch

LOCK Prevents all switches other than the main switch from operating

the power windows

UNLOCK Every switch can open or close the respective window

LH LH mirror operates

RH RH mirror operates

Page 58

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

00E-11

Name of switches and relays

Steering wheel multi-function switch

Steering wheel speed control switch

Sunroof switch OPEN Sunroof slides to open

Turn-signal switch LH LH turn-signal lamps ON

Abbreviation symbol

INFO Switches the information

MODE Switches the mode

CH UP Changes the radio frequency or the music number in the CD

CH DOWN

VOL UP Increases the sound volume

VOL DOWN Decreases the sound volume

ON HOOK On hook the phone

OFF HOOK Off hook the phone

SPEECH Switches to the speech recognition mode

CRUISE Cruise control system ON or OFF

RES + Set the vehicle speed

SET −

CANCEL Cancel the driving at a constant speed

UP Sunroof tilts to up

CLOSE/DOWN Sunroof tilts down or slides to close

Operation

RH RH turn-signal lamps ON

Windshield intermittent wiper interval adjusting knob

Windshield rain sensitive wiper function adjusting knob

Windshield wiper switch

SLOW Lengthen pause time for intermittent operation

FAST Shorten pause time for intermittent operation

−

+ Raises the sensitivity of the lighting control sensor to the amount

AUTO The windshield wiper operates depending on the amount of

MIST Wiper operates once

INT Wiper operates intermittently

LO Wiper operates at low speed

HI Wiper operates at high speed

Lowers the sensitivity of the lighting control sensor to the amount of rainfall.

of rainfall.

rainfall.

4. FOR OTHERS

Abbreviation symbol

2WD Front wheel-drive vehicle IG Ignition

A/C Air conditioner ILL Illumination lamp

Meaning Abbreviation

symbol

Meaning

ACC Accessory IND Indicator lamp

CTR Centre LH Left hand

CPU Central processing unit LIN Local interconnect network

ECU Electronic control unit LO Low

Page 59

00E-12

GENERAL <ELECTRICAL>

HOW TO READ WIRING DIAGRAMS

Abbreviation symbol

GND Earthing OSS One touch start system

HI High RHD Right hand drive vehicles

IC Integrated circuit UHF Ultrahigh frequency

Meaning Abbreviation

symbol

Meaning

Page 60

GROUP 00

GENERAL

CONTENTS

GENERAL

GENERAL <ELECTRICAL>

00-1

Page 61

ENGINE

ENGINE MECHANICAL

ENGINE OVERHAUL

11-1

GROUP 11

CONTENTS

Page 62

GROUP 11A

ENGINE

MECHANICAL

CONTENTS

11A-1

SERVICE SPECIFICATIONS. . . . . . . 11A-2

SEALANTS . . . . . . . . . . . . . . . . . . . . 11A-2

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-3

ON-VEHICLE SERVICE. . . . . . . . . . . 11A-8

DRIVE BELT TENSION CHECK. . . . . . . . . 11A-8

DRIVE BELT AUTO-TENSIONER CHECK 11A-8

IGNITION TIMING CHECK . . . . . . . . . . . . . 11A-10

IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-11

IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A-12

VALVE CLEARANCE CHECK AND ADJUSTMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12

COMPRESSION PRESSURE CHECK. . . . 11A-14

MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-15

CRANKSHAFT PULLEY . . . . . . . . . . 11A-16

REMOVAL AND INSTALLATION . . . . . . . . 11A-16

CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11A-19

REMOVAL AND INSTALLATION . . . . . . . . 11A-19

VALVE STEM SEAL . . . . . . . . . . . . . 11A-30

REMOVAL AND INSTALLATION . . . . . . . . 11A-30

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A-36

REMOVAL AND INSTALLATION . . . . . . . . 11A-36

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-38

CRANKSHAFT OIL SEAL . . . . . . . . . 11A-39

REMOVAL AND INSTALLATION . . . . . . . . 11A-39

CYLINDER HEAD GASKET . . . . . . . . 11A-41

REMOVAL AND INSTALLATION . . . . . . . . 11A-41

TIMING CHAIN . . . . . . . . . . . . . . . . . . 11A-50

REMOVAL AND INSTALLATION . . . . . . . . 11A-50

BALANCER TIMING CHAIN, BALANCER SHAFT AND OIL PUMP MODULE <4B12>

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-56

REMOVAL AND INSTALLATION . . . . . . . . 11A-56

BALANCER SHAFT AND OIL PUMP MODULE

<4B12> . . . . . . . . . . . . . . . . . . . . . . . . 11A-59

REMOVAL AND INSTALLATION . . . . . . . . 11A-59

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-63

REMOVAL AND INSTALLATION . . . . . . . . 11A-63

Page 63

11A-2

ENGINE MECHANICAL

SERVICE SPECIFICATIONS

Item Standard value Limit

Drive belt tension Vibration frequency Hz

(Reference)

Ten si on N ( Re fe re nc e) 234 − 421

Valve c le ar anc e (a t c ol d ) mm Intake valve 0.20 ± 0.03

115 − 156

−

M1112000302906

Exhaust valve 0.30 ± 0.03

Basic ignition timing 5° BTDC ± 3°

Ignition timing Approximately

° BTDC

Idle speed r/min 4B11 650 ± 100

4B12 750 ± 100

CO contents % 0.3 or less

HC contents ppm 200 or less

Compression pressure (at engine speed of 200 r/min) kPa

Compression pressure difference of all cylinders kPa

Intake manifold vacuum kPa

4B11 1,470 Minimum 1,000

4B12 1,440 Minimum 1,000

−

Maximum 98

Minimum 60

SEALANTS

M1112000502751

Item Specified sealant

Rocker cover assembly (matching area of the cylinder head assembly and the timing chain case assembly)

Engine oil pan ThreeBond 1217G (MITSUBISHI

Drive plate mounting bolt ThreeBond 1324 or equivalent

Cylinder block (matching area of the cylinder head assembly, cylinder head gasket and the timing chain case assembly)

Timing chain case assembly

ThreeBond 1217G (MITSUBISHI MOTORS GENUINE Part No.1000A923), ThreeBond 1227D, LOCTITE 5900 or equivalent

MOTORS GENUINE Part No.1000A923), ThreeBond 1227D, ThreeBond 1207F (MITSUBISHI MOTORS GENUINE Part No.1000A992), LOCTITE 5970, LOCTITE 5900 or equivalent

ThreeBond 1217G (MITSUBISHI MOTORS GENUINE Part No.1000A923), LOCTITE 5900 or equivalent

Page 64

ENGINE MECHANICAL

SPECIAL TOOLS

Tool Number Name Use

MB992080 a: MB992081 b: MB992082

B992080

Belt tension meter set a: Belt tension meter b: Microphone assembly

Alternator and others belt tension check

11A-3

M1112000603212

DO NOT USE

MB992744

MB992745

MB992746

a. MB992744 b. MB992745 c. MB992746 d. MB992747 e. MB992748

a. Vehicle communication

interface-Lite (V.C.I.-Lite)

b. V.C.I.-Lite main

harness A (for vehicles with CAN communication)

c. V.C.I.-Lite main

harness B (for vehicles without CAN communication)

d. V.C.I.-Lite USB cable

short

e. V.C.I.-Lite USB cable

long

• Checking the ignition timing

• Checking the idle speed

MB992747

MB992748

ACB05421

Page 65

11A-4

ENGINE MECHANICAL

SPECIAL TOOLS

Tool Number Name Us e

MB991955

a: MB991824 b: MB991827 c: MB991910 d: MB991911

MB991824

MB991827

e: MB991825 f: MB991826

M.U.T.-III sub assembly

a: Vehicle communication

interface (V. C. I.) b: M.U.T.-III USB cable c: M.U.T.-III main harness

A (Vehicles with CAN

communication system) d: M.U.T.-III main harness

B (Vehicles without

CAN communication

system) e: M.U.T.-III adapter

harness

For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly.

• Checking the ignition timing

• Checking the idle speed

f: M.U.T.-III trigger

harness

MB991910

CAUTION

DO NOT USE

MB991911

MB991825

MB991826

MB991955

MB990767 Front hub and flange yoke

Holding the crankshaft pulley

holder

B990767

D998719

MD998719 Pin

Page 66

ENGINE MECHANICAL

SPECIAL TOOLS

Tool Number Name Us e

MB992103 Chain tension release bar Camshaft and camshaft

sprocket assembly (exhaust side) removal

B992103

MD998772 Valve sp ri ng c o mp re ss or Valv e sprin g compr essio n

MD99877

MB992090 Retainer holder

attachment

B992090

MB992089 Retainer holder C

11A-5

D998727

MB992085 Valve st em se al p li er s Valv e stem seal remo va l

MD998737 Valve st em s e al i ns tal l er Valv e stem seal press -fit t ing

MD998727 Oil pan FIPG cutter Engine oil pan removal

MB991883 Flywheel stopper Supporting the drive plate

MB991883

Page 67

11A-6

Tool Number Name Us e

MD998718 Crankshaft rear oil seal

ENGINE MECHANICAL

SPECIAL TOOLS

installer

Press-fitting the crankshaft rear oil seal

MB991614

MB991448 Bush remover and installer

base

MB991614 Angle gauge Balancer shaft and oil pump

Press-fitting the crankshaft front oil seal

module bolt installation

Page 68

ENGINE MECHANICAL

SPECIAL TOOLS

Tool Number Name Us e

MB991454 Engine hanger balancer Support of engine assembly

NOTE: .

•

For the engine hanger balancer (MB991454), use a

B991454

MB991527 Hanger

chain only.

•

Engine hanger balancer (MB991454) is a part of the engine hanger assembly (MB991453).

B991527

11A-7

Slide bracket (HI)

Z203830

MB991928

a: MB991929 b: MB991930 c: MB991931 d: MB991932 e: MB991933

B991928

f: MB991934

Engine hanger

a: Joint (50) × 2 b: Joint (90) × 2 c: Joint (140) × 2 d: Foot (standard) × 4 e: Foot (short) × 2 f: Chain and hook

assembly

MB991895 Engine hanger

MB991956 Engine hanger plate

B991956

B992853

MB992853 Engine hanger plate

Page 69

11A-8

ENGINE MECHANICAL

ON-VEHICLE SERVICE

DRIVE BELT TENSION CHECK

M1111003103752

CAUTION

Check the drive belt tension after turning the crankshaft clockwise one turn or more.

Indicator mark

ACC00374

1. Make sure that the indicator mark on the drive belt auto-tensioner is within the area marked with A in the illustration.

2. If the mark is out of the area A, replace the drive belt (Refer to

P.11A-16).

NOTE: The drive belt tension adjustment is not necessary as the drive belt auto-tensioner is adopted.

4. Securely set the tool to the hexagonal part of the auto-tensioner.

5. Check that no binding is present by turning the auto-tensioner in the left and right directions.

6. If there are any problems in the procedure 2 or 5, replace the drive belt auto-tensioner (Refer to

P.11A-50).

7. Install the drive belt (Refer to P.11A-16).

FUNCTION CHECK

The drive belt auto-tensioner can be checked whether it is in good condition by checking its ten

sion.

1. Check the tension of the drive belt (Refer to

P.11A-8).

Belt tension meter set (MB992080)

MB992081

DRIVE BELT AUTO-TENSIONER CHECK

M1111003003476

OPERATION CHECK

1. Stop the engine from the idle state.

2. Check that the drive belt are not protruding from the pulley width of drive belt auto-tensioner.

3. Remove the drive belt (Refer to P.11A-16).

WARNING

Be sure to set the tool to the hexagonal part securely to prevent the tool from falling off because the tension of the auto-tensioner is high.

ACC00375

MB992082

AC507219

2. Connect special tool microphone assembly (MB992082) to special tool belt tension meter (MB992081) of special tool belt tension meter set (MB992080).

3. Press the "POWER" button to turn on the power supply.

4. Press number key "1". Check to ensure that "No. 01" appears on the upper left of the display and that the following numeric values are displayed for individual items ("M", "W", and "S"):

M 000.9 g/m

W 010.0 mm/R

S 0100 mm

NOTE: If numeric values have not been entered (new tool), set them according to the belt specifi cations as shown below. Once you set them, you do not have to set them again. The settings remain undeleted even after battery replacement.

Page 70

ENGINE MECHANICAL

ON-VEHICLE SERVICE

11A-9

NOTE: This operation is to temporarily set the preset data such as the belt specifications, because if the measurement is taken without input of the belt specifications, conversion to tension value (N) cannot be made, resulting in judgement of error.

<Setting procedure> (1) Press down the "MASS" button till the belt

mass select display appears.

(2) Press the "UP" or "DOWN" button to select "01

1.5GT 0.9" and press the "MEASURE" button to decide it.

Check to ensure that "M 000.9 g/m" is displayed.

(3) Press the "WIDTH" button to change to the

belt width input display.

(4) Press number keys "0", "1", "0", and "0"

sequentially, and press the "SELECT" button to apply them. Check to ensure that "W 010.0 mm/R" appears on the display.

(5) Press the "SPAN" button to change to the

span length input display.

(6) Press number keys "0", "1", "0", and "0"

sequentially, and press the "SELECT" button to apply them. Check to ensure that "S 0100 mm" appears on the display.

5. Press "Hz" button twice to change the display to the frequency display (Hz).

CAUTION

• When measuring, make sure that the engine is cold.

• Measure after turning the crankshaft clockwise one turn or more.

• Do not let any contaminants such as water or oil get onto the microphone.

• If strong gusts of wind blow against the microphone or if there is loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

• If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not corre

spond to actual values.

• Do not take the measurement while the vehicle's engine is running.

Gentry tap

10 – 15 mm

with your finger

Crankshaft pulley

MB992080

15˚

A/C compressor pulley

ACB00850

6. Hold special tool MB992080 to the middle of the drive belt between the pulleys (at the place indicated by arrow) where it does not contact the drive belt (approximately 10 − 15 mm away from the rear surface of the belt) so that it is perpendicular to the drive belt (within an angle of

± 15°).

7. Press the "MEASURE" button.

8. Gently tap the middle of the drive belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration.

9. Check that the vibration frequency of the drive belt is within the standard value.

Page 71

11A-10

ENGINE MECHANICAL

ON-VEHICLE SERVICE

Standard value (Reference): 115 − 156 Hz

NOTE: To take the measurement repeatedly, fillip the drive belt again.

10.After the completion of the measurement, press and hold the "POWER" button to turn off the power supply.

11.If no t wi t hi n t he sta n da rd va lu e , r ep la c e th e d ri v e belt auto-tensioner (Refer to

P.11A-50).

1. Check the tension of the drive belt (Refer to

P.11A-8).

CAUTION

• When measuring, make sure that the engine is cold.

• Measure after turning the crankshaft clockwise one turn or more.

IGNITION TIMING CHECK

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

M1111001703242

Crankshaft pulley

Belt tension gauge

A/C compressor pulley

ACB00851

2. Use a belt tension gauge in the middle of the drive belt between the pulleys shown in the figure (at the place indicated by the arrow) to check that the drive belt tension is within the standard value.

Standard value (Reference): 234 − 421 N

3. If not within the standard value, replace the drive belt auto-tensioner (Refer to

P.11A-50).

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Turn the ignition switch to the "LOCK" (OFF) position and then connect the M.U.T.-III to the diagnosis connector.

Equipment side connecto

No.1 Ignition coil

Power supply line (terminal No. 3)

3213

AK604618

3. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

4. Start the engine and let it run at idle.

5. Select item No. 2 on the M.U.T.-III to measure engine idle speed and check that it is approximately 650 r/min<4B11> or 750 r/min<4B12>.

6. Select item No. 11 (actuator test function) on the M.U.T.-III, and set the ignition timing to the basic ignition timing.

7. Check that basic ignition timing is within the standard value.

Standard value: 5° BTDC ± 3°

Page 72

ENGINE MECHANICAL

ON-VEHICLE SERVICE

11A-11

8. If the basic ignition timing is outside the standard value, inspect the MPI system (Refer to GROUP

− Troubleshooting − Inspection chart for

13A trouble symptom

CAUTION

If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this con

dition may damage the engine.

9. Cancel the actuator test function item No. 11, Basic ignition timing set mode, on the M.U.T-III.

10.Check that ignition timing is at the standard value.

Standard value: approximately 10° BTDC

NOTE: .

•

The ignition timing may fluctuate within ± 7°. This is normal.

•

In higher altitude, the ignition timing is more advanced than the standard value by approxi mately 5°.

•

Wait till approximately 1 minute passes after the engine started, and check the ignition tim

ing when the engine stabilized.

11.Remov e t he ti m in g l ig h t.

12.Turn the ignition switch to the "LOCK" (OFF) position and then disconnect the M.U.T.-III.

IDLE SPEED CHECK

M1111003503329

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Turn the ignition switch to "LOCK" (OFF) position.

3. Connect the M.U.T.-III to the diagnosis connector.

Equipment side connecto

No.1 Ignition coil

Power supply line (terminal No. 3)

3213

AK604618

4. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

5. Start the engine and let it run at idle.

6. Check that ignition timing is at the standard value.

Standard value: approximately 10° BTDC

NOTE: .

•

The ignition timing may fluctuate within ±7°. This is normal.

•

In higher altitude, the ignition timing is more advanced than the standard value by approxi mately 5°.

•

Wait till approximately 1 minute passes after the engine started, and check the ignition tim ing when the engine stabilized.

7. Check the idle speed.

Standard value: 650 ± 100 r/min <4B11> 750 ± 100 r/min <4B12>

NOTE: .

•

The idle speed is controlled automatically by the idle speed control system.

•

When using the M.U.T.-III, select item No. 2 and take a reading of the idle speed.

8. If the idle speed is outside the standard value, inspect the MPI system (Refer to GROUP 13A Troubleshooting symptom

− Inspection chart for trouble

9. Remove the timing light.

10.Turn the ignition switch to the "LOCK" (OFF) position and then disconnect the M.U.T.-III.

−

Page 73

11A-12

ENGINE MECHANICAL

ON-VEHICLE SERVICE

IDLE MIXTURE CHECK

M1111002102295

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Turn the ignition switch to "LOCK" (OFF) position.

3. Connect the M.U.T.-III to the diagnosis connector.

Equipment side connecto

No.1 Ignition coil

ACB05017

Power supply line (terminal No. 3)

3213

NOTE: .

•

The ignition timing may fluctuate within ±7°. This is normal.

•

In higher altitude, the ignition timing is more advanced than the standard value by approxi mately 5°.

•

Wait till approximately 1 minute passes after the engine started, and check the ignition tim ing when the engine stabilized.

7. Run the engine at 2,000 − 3,000 r/min for 2 minutes.

8. Set the CO, HC tester.

9. Check the CO contents and the HC contents at idle.

Standard value CO contents: 0.3 % or less HC contents: 200 ppm or less

10.If there is a deviation from the standard value, inspect the MPI system (Refer to GROUP 13D Troubleshooting symptom

− Inspection chart trouble

11.Remo v e th e H C , CO t e st e r an d t im i ng l ig h t.

12.Turn the ignition switch to the "LOCK" (OFF) position and then disconnect the M.U.T-III.

VALVE CLEARANCE CHECK AND ADJUSTMENT

M1111001502182

NOTE: Perform the valve clearance check and adjustment at the engine cold state.

1. Remove all ignition coils.

2. Remove the cylinder head cover.

CAUTION

Turn th e c ra n ks haft a lw ay s c lo c kw is e .

−

AK604618

4. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1.

5. Start the engine and let it run at idle.

6. Check that ignition timing is at the standard value.

Standard value: approximately 10° BTDC

Timing mark

AK604565

3. Turn the crankshaft clockwise, and align the timing mark on the exhaust camshaft sprocket against the upper face of the cylinder head as shown in Figure. Therefore, No.1 cylinder goes to the compression top dead centre.

Page 74

ENGINE MECHANICAL

ON-VEHICLE SERVICE

11A-13

Exhaust valve side

No.1

No.3

No.1 No.2

Intake valve side

AK502387

4. Using a thickness gauge, measure the valve clearance with the arrow shown in Figure. If deviated from the standard value, make note for the valve clearance.

Standard value: Intake valve 0.20 ± 0.03 mm Exhaust valve 0.30 ± 0.03 mm

Timing mark

Wall thickness

AK304938

8. Using a micrometer, measure the thickness of the removed valve tappet.

9. Calculate the thickness of the newly installed valve tappet through the following equation.

A: thickness of newly installed valve tappet

B: thickness of removed valve tappet

C: measured valve clearance

Equation Intake valve: A = B + (C − 0.20 mm) Exhaust valve: A = B + (C − 0.30 mm)

NOTE:

AK604566

5. Turn the crankshaft clockwise 360 degrees, and put the timing mark on the exhaust camshaft sprocket in position shown in Figure. Therefore, No.4 cylinder goes to the compression top dead centre.

Exhaust valve side

No.2 No.4

No.3 No.4

Intake valve side

AK502388

6. Check the valve clearance with the arrow shown in Figure. In the same procedure as 4.

7. If the valve clearance is deviated from the standard value, remove the camshaft and the valve tappet. For the camshaft removal, refer to Camshaft Removal and Installation

P.11A-19.

Under view

Thickness stamp

AK703500AC

The valve tappet ranges 3,000 − 3,690 mm and has 47 types per 0.015 mm. The thickness below a decimal point is stamped on the reverse side of the valve tappet.

10.Install the valve tappet selected through the procedure 9, and put the camshaft in position. For the camshaft installation, refer to Camshaft Removal and Installation

P.11A-19.

11.After in s tal l in g t he ti mi n g ch ai n , m ea su r e the valve clearance using the procedure 3 to 6. Confirm the clearance is within the standard value.

CAUTION

Completely remove all the old liquid gasket, which might be remaining among the compo nents.

12.Remove any liquid gasket remaining on the cylinder head cover, the timing chain case and the cylinder head.

Page 75

11A-14

ENGINE MECHANICAL

ON-VEHICLE SERVICE

13.Using white gasoline and so on, degrease the cylinder head cover, timing chain case and cylinder head.

CAUTION

The cylinder head cover should be installed within 3 minutes of applying liquid gasket.

4 mm

2 mm

Cylinder head

4 mm

Timing chain case assembly

2 mm

AK701438

14.Apply a 4 mm bead of liquid gasket as illustrated.

Specified sealant:

ThreeBond 1217G or equivalent

2. Disconnect the ignition coil connectors and then remove all of the ignition coils and spark plugs.

Injector connectors

AK502603AD

3. Disconnect the all of the injector connectors.

CAUTION

• Keep away from the spark plug hole when cranking.

• If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

4. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

Compression gauge

Engine front

AC506743

15. Install the cylinder head cover and tighten the tightening bolts using the following procedures.

(1) Temporarily tighten to the following torque in

order shown in the illustration.

Tightening torque: 3.0 ± 1.0 N⋅m

(2) Tighten to the specified torque in order shown

in the illustration.

Specified torque: 5.5 ± 0.5 N⋅m

16.Install the ignition coils.

COMPRESSION PRESSURE CHECK

M1111002604155

1. Before inspection, set the vehicle to the pre-inspection condition.

AK502604AD

5. Set compression gauge to one of the spark plug holes.

6. Crank the engine with the throttle valve fully open and measure the compression pressure.

Standard value (at engine speed of 200

r/min): 1,470 kPa <4B11> 1,440 kPa <4B12>

Limit (at engine speed of 200 r/min): Minimum 1,000 kPa

7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: Maximum 98 kPa

Page 76

ENGINE MECHANICAL

ON-VEHICLE SERVICE

11A-15

8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps from 5 to 7.

(1) If the compression increases after oil is added,

the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is

added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

9. Connect the injector connector.

10.Install the spark plugs and spark plug cables.

Diagnosis connector

MANIFOLD VACUUM CHECK

Diagnosis connector

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

M1111002702587

MB992745, MB991910

MB992744, MB991824

MB992747, MB992748, MB991827

ACB05017

11.Use t he M . U. T.-III t o era se th e d ia gn o si s co d es .

NOTE: This will erase the diagnosis code resulting from the injector connectors being disconnected.

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Turn the ignition switch to "LOCK" (OFF) position.

3. Connect the M.U.T.-III to the diagnosis connector.

Vacuum gauge

PCV valve

Plug

AK502601

4. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose. Plug the PCV valve.

5. Start the engine and check that idle speed is approximately 650 r/min<4B11> or 750 r/min<4B12>.

6. Check the intake manifold vacuum.

Limit: Minimum 60 kPa

7. Turn off the ignition switch.

8. Remove the vacuum gauge and then connect the ventilation hose to the PCV valve.

9. Disconnect the M.U.T.-III.

Page 77

11A-16

ENGINE MECHANICAL

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

M1112001604821

Pre-removal Operation

• Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 Cover

210 N·m 0 N·m 210 N·m

− Under

Post-installation Operation

• Drive Belt Tension Check (Refer to P.11A-8).

• Engine Room Under Cover Front A, B and Engine Room

Side Cover (RH) Installation (Refer to GROUP 51 Cover

− Under

(Engine oil)

Removal steps

<<A>> >>B<< <> >>A<< <> >>A<< <> >>A<<

1. Drive belt

2. Crankshaft pulley centre bolt

3. Crankshaft pulley washer

4. Crankshaft pulley

REMOVAL SERVICE POINTS

<<A>> DRIVE BELT REMOVAL

To i nt ro du ce th e se rp en ti ne d ri ve s ys te m wi th t he auto-tensioner, the following operations will be required.

ACB00863

WARNING

Be sure to set the tool to the hexagonal part securely to prevent the tool from falling off because the tension of the auto-tensioner is high.

L-shaped hexagon wrench

ACC00376

1. Securely set the tool to the hexagonal part of the auto-tensioner.

2. Rotate the auto-tensioner anti-clockwise.

3. Insert the L-shaped hexagon wrench into the auto-tensioner hole to fix the auto-tensioner.

Page 78

ENGINE MECHANICAL

CRANKSHAFT PULLEY

11A-17

CAUTION

To reuse t he dr ive b el t , dr a w an ar r ow i n di ca t in g the rotating direction on the back of the belt using chalk to install the same direction.

4. Remove the drive belt.

<> CRANKSHAFT PULLEY CENTRE BOLT/CRANKSHAFT PULLEY WASHER/CRANKSHAFT PULLEY REMOVAL

MD998719

MB990767

ACB01872

1. Use the following special tools to support the crankshaft pulley:

• Front hub and flange yoke holder (MB990767)

• Pin (MD998719)

2. Loosen the crankshaft pulley centre bolt and remove the crankshaft pulley washer and crankshaft pulley.

INSTALLATION SERVICE POINTS >>A<< CRANKSHAFT PULLEY/CRANK-

SHAFT PULLEY WASHER/CRANKSHAFT PULLEY CENTRE BOLT INSTALLATION

: Wipe clean with a rag. : Wipe clean with a rag and degrease. : Apply a small amount of engine oil.

Crankshaft pulley washer

Crankshaft pulley centre bolt

Engine front

Crankshaft pulley

1. Wipe off the dirt on the crankshaft sprocket, crankshaft and crankshaft pulley as shown in the figure using a rag, and then degrease the areas.

NOTE: Degrease them to prevent drop in the friction coefficient of the pressed area which is caused by oil adhesion.

2. Install the crankshaft pulley.

3. Wipe off the dirt on the crankshaft pulley washer and the crankshaft pulley centre bolt as shown in the figure using a rag.

4. Apply an adequate and minimum amount of engine oil to the thread of the crankshaft pulley centre bolt and the lower area of the flange.

Crankshaft sprocket

Crankshaft

AC606441

MD998719

MB990767

ACB01872

5. Use the following special tools as during removal to support the crankshaft pulley:

Page 79

11A-18

ENGINE MECHANICAL

CRANKSHAFT PULLEY

• Front hub and flange yoke holder (MB990767)

• Pin (MD998719)

6. Tighten the crankshaft pulley centre bolt to the specified torque.

Tightening torque: 210 N⋅m

7. Loosen the crankshaft pulley centre bolt fully.

8. Tighten the crankshaft pulley centre bolt to the specified torque again.

Tightening torque: 210 N⋅m

>>B<< DRIVE BELT INSTALLATION

CAUTION

• To re us e the d r ive b el t, instal l it b y al ignin g the arrow mark on the backside of belt marked at the removal with the rotating direc tion.

Drive belt

•

1. Install the drive belt to each pulley as shown in the figure.

WARNING

Be sure to set the tool to the hexagonal part securely to prevent the tool from falling off because the tension of the auto-tensioner is high.

L-shaped

2. Securely set the tool to the hexagonal part of the auto-tensioner.

3. Rotate the auto-tensioner anti-clockwise and remove the L-shaped hexagon wrench fixing the auto-tensioner.

4. Apply tension to the drive belt while slowly turning the auto-tensioner clockwise.

hexagon wrench

ACC00376

Notched pulley

Flat pulley

AC704717

Check that the notches of the notched pulley and

the notches of the drive belt are fit correctly.

•

Check that the drive belt is installed in the centre of the flat surface of the flat pulley.

Drive belt auto-tensioner pulley

Drive belt

Water pump pulley

Crankshaft pulley

Idler pulley

Alternator pulley

Idler pulley

A/C compressor pulley

ACB00849

Page 80

ENGINE MECHANICAL

CAMSHAFT

11A-19

REMOVAL AND INSTALLATION

M1112023100866

Pre-removal Operation

• Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 Cover

• Air Cleaner Assembly Removal (Refer to GROUP 15 − Air Cleaner

3.0 ± 1.0 N·m 5.5 ± 0.5 N·m

17 ± 3 N·m 30 ± 2 N·m

12 ± 1 N·m

− Under

Post-installation Operation

• Air Cleaner Assembly Installation (Refer to GROUP 15 − Air Cleaner

• Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 Cover

Apply engine oil to all moving parts before installation.

12 ± 1 N·m

3.0 ± 0.5 N·m

− Under

59 ± 5 N·m

(Engine oil)

10 ± 2 N·m

13 ± 1 N·m

V.V.T. sprocket bolt

Engine oil

AC607720

ACB01329

Page 81

11A-20

ENGINE MECHANICAL

CAMSHAFT

<<A>> >>G<<

<>

<<C>>

<<D>> >>F<<

>>E<<

<<E>> >>D<<

<<F>> >>E<<

<<G>> >>B<< <<G>> >>B<<

>>E<<

<<E>> >>D<<

<<E>> >>D<< <<E>> >>D<< <<E>> >>D<<

>>C<<

<<G>> >>B<< <<G>> >>B<<

<<H>> >>A<<

>>A<<

Camshaft removal steps

1. Engine upper cover Ignition coil (Refer to GROUP 16 −

•

Ignition System, Ignition Coil

2. Breather hose

3. PCV hose connection Control wiring harness connection

•

4. Rocker cover assembly

5. Rocker cover gasket No.1 cylinder compression top

•

dead centre setting <only at removal>. Valve clear a n c e adjustment ( Re f e r

•

P.11A-12) <only at installation>.

6. Service hole bolt Camshaft and camshaft sprocket

•

assembly (exhaust side) removal preparatory operation <only at removal>.

7. Camshaft bearing front cap assembly

8. Camshaft bearing

9. Camshaft bearing oil feeding cap (exhaust side)

10. Camshaft bearing cap (exhaust side)

11. Camshaft bearing cap (exhaust side)

12. Camshaft bearing thrust cap (exhaust side)

13. Camshaft and camshaft sprocket assembly (exhaust side)

14. Exhaust camshaft sprocket

15. Camshaft (exhaust side)

16. Camshaft bearing

17. Camshaft bearing oil feeding cap (inlet side)

18. Camshaft bearing cap (inlet side)

19. Camshaft bearing cap (inlet side)

20. Camshaft bearing thrust cap (inlet side)

21. Camshaft and camshaft sprocket assembly (inlet side)

22. Inlet V.V.T. sprocket assembly

23. Camshaft (inlet side)

Oil feeder control valve removal steps

1. Engine upper cover

24. Oil feeder control valve (OCV) inlet

25. O-ring

)

REMOVAL SERVICE POINTS <<A>> ROCKER COVER ASSEMBLY

REMOVAL

Engine front

Loosen the rocker cover assembly mounting bolts in the order of number shown in the figure, and remove the rocker cover assembly.

AC506743

<> NO.1 CYLINDER COMPRESSION TOP DEAD CENTRE SETTING

CAUTION

Never turn the crankshaft anti-clockwise.

Cylinder head upper surface

Paint Timing chain mating mark

markings

Camshaft sprocket timing marks

1. Turn the crankshaft clockwise so that the camshaft sprocket timing marks become horizontal to the cylinder head upper surface, and set the No.1 cylinder to the top dead centre of compression. At this time, check that the crankshaft pulley timing mark is in the "T" mark position of the ignition timing indicator of the timing chain case assembly.

2. Put paint marks on both the camshaft sprocket and valve timing chain at the position of camshaft sprocket timing chain mating mark (circular hole).

Timing chai mating mark

AC506744

Page 82

ENGINE MECHANICAL

CAMSHAFT

11A-21

<<C>> CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL PREPARATORY OPERATION

Precision flat-tipped screwdriver

Service hole

Precision flat-tipped screwdriver

Service hole

Crankshaft pulley

SectionA-A

Ratchet

1. Insert a precision flat-tipped screwdriver through the service hole of the timing chain case, press up the timing chain tensioner ratchet to unlock, and keep the timing chain tensioner with that state.

NOTE: Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.

Timing chain tensioner construction diagram

Timing chain tensioner

Ratchet release hol

Ratchet

Ratchet release hole

AC509155

Page 83

11A-22

)

CAUTION

• When inserting special tool chain tension release bar (MB992103) into the timing chain case assembly inside, pay attention to the position of the valve timing chain to avoid damage to the valve timing chain and timing chain tension side guide. Do not insert the special tool MB992103 beyond its insertion guideline.

• If unlocking the timing chain tensioner is insufficient, the special tool MB992103 cannot be inserted to the insertion guideline. Do not insert the special tool MB992103 forcibly, fol low Step 1 again to unlock the timing chain tensioner and insert the special tool MB992103.

ENGINE MECHANICAL

CAMSHAFT

MB992103

Valve timing chai

Insertion standard line

AC507118

Camshaft sprocket (inlet side

Valve timing chain (tension side)

Timing chain tension side guide

AC508123

MB992103

Timing chain tensioner

Timing chain tension side guide

AC509159

2. With the timing chain tensioner unlocked, insert special tool chain tension release bar (MB992103) from the timing chain case assembly inside along the tension side of the valve timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (A in the figure).

Page 84

ENGINE MECHANICAL

CAMSHAFT

11A-23

NOTE: With the timing chain tensioner unlocked, insert the special tool MB992103 along the ten

sion side of the valve timing chain, according to the special tool MB992103 top shape. The special tool MB992103 can be inserted smoothly to the position where the special tool MB992103 inser

tion guideline aligns with the timing chain case assembly top surface (B in the figure), and the spread timing chain tension side guide can be hold (C in the figure).

3. With the special tool MB992103 inserted up to the insertion guide line, press the special tool MB992103 against the inlet side camshaft sprocket and spread and hold the timing chain tension side guide.

4. Remove the precision flat-tipped screwdriver unlocking the timing chain tensioner.

CAUTION

The valve timing chain may be bitten by other parts. After sagging the valve timing chain, never rotate the crankshaft.

Hexagon part of exhaust

MB992103

Valve timing chain

camshaf

AC506748

5. With the timing chain tension side guide spread, hook the special tool MB992103 over the hexagon part of the camshaft on the exhaust side, and turn the camshaft clockwise to apply slack to the valve timing chain between the camshaft sprockets.

<<D>> CAMSHAFT BEARING FRONT CAP ASSEMBLY REMOVAL

CAUTION

Be careful not to drop the camshaft bearing.

Camshaft bearing front cap assembly

Engine front

AC506745

Loosen the camshaft bearing front cap mounting bolts in the order of number shown in the figure, and remove the camshaft bearing front cap assembly.

<<E>> CAMSHAFT BEARING OIL FEEDING CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING THRUST CAP REMOVAL

CAUTION

When the camshaft bearing cap mounting bolts are loosened at once, the mounting bolts jump out by the spring force and the threads are dam aged. Always loosen the mounting bolts in four or five steps.

Engine front

Camshaft bearing cap

AC506746

Page 85

11A-24

ENGINE MECHANICAL

CAMSHAFT

Loosen the camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

<<F>> CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL

Camshaft and camshaft sprocket assembly

AC508124

1. Raise slightly the transmission side of the camshaft and camshaft sprocket assembly (exhaust side) by using the slack of the valve timing chain, and remove from the cam bearing.

3. Remove special tool chain tension release bar (MB992103) inserted into the timing chain case assembly inside.

CAUTION

The valve timing chain may be bitten by other parts. After removing the camshaft and camshaft sprocket assembly, never rotate the crankshaft.

Rope

Valve timing chain

AC509403

4. After removing the camshaft and camshaft sprocket assembly (exhaust side), hang up the valve timing chain with a rope to prevent the valve timing chain from falling into the timing chain case assembly.

Camshaft and camshaft sprocke assembly

MB992103

Valve timing chain

AC506749

2. Remove the valve timing chain from the camshaft and camshaft sprocket assembly (exhaust side) toward the timing chain case assembly, and remove the camshaft and camshaft sprocket assembly (exhaust side) toward the transmission.

<<G>> SPROCKET/CAMSHAFT REMOVAL

Hexagon part of camshaft

AC700424

Hold the hexagon part of the camshaft with a monkey wrench. Loosen the sprocket mounting bolt and remove the sprocket from the camshaft.

<<H>> OIL FEEDER CONTROL VALVE REMOVAL

CAUTION

After removal of the oil feeder control valve, be careful to prevent dust from getting into the oil passage in the cylinder head.

Page 86

ENGINE MECHANICAL

CAMSHAFT

11A-25

INSTALLATION SERVICE POINTS >>A<< O-RING/OIL FEEDER CONTROL

VALVE I NSTAL LATIO N

CAUTION

When installing the oil feeder control valve, be careful to avoid damage to the O-ring.

Apply engine oil to the O-ring of the oil feeder control valve and install the oil feeder control valve to the cylinder head.

>>B<< CAMSHAFT/SPROCKET INSTALLATION

Hexagon par of camshaft

>>C<< CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (INLET SIDE) INSTALLATION

Paint markings (inlet side)

AC509403

1. Align the inlet side paint mark of the valve timing chain which was put at removal with the paint mark of the inlet side camshaft sprocket, and install the camshaft sprocket to the valve timing chain.

2. Install the camshaft and camshaft sprocket assembly (inlet side) to the cylinder head.

AC611532

1. Use a monkey wrench to secure the hexagon part of the camshaft in the same manner as removal.

V.V.T. sprocket

V.V.T. sprocket bolt

Camshaft

AC607720

2. Apply an adequate and minimum amount of engine oil to the positions shown of the camshaft and inlet V.V.T. sprocket assembly.

3. Install the sprocket to the camshaft.

4. Apply an adequate and minimum amount of engine oil to the inlet V.V.T. sprocket bolt.

5. Tighten the sprocket bolt to the specified torque.

Tightening torque: 59 ± 5 N⋅m

>>D<< CAMSHAFT BEARING THRUST CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING OIL FEEDING CAP INSTALLATION

Engine front

Identification of inlet side and exhaust side

Bearing cap No.

Camshaft bearing cap

E 5

AC506778

1. Install the camshaft bearing caps to the cylinder head.

Page 87

11A-26

ENGINE MECHANICAL

CAMSHAFT

NOTE: Because the camshaft bearing thrust cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the inlet and exhaust sides for correct installation.

2. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps.

Tightening torque: 12 ± 1 N⋅m

>>E<< CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION

CAUTION

• Be careful not to drop the camshaft bearing.

•

When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.

Camshaft bearing front cap assembly

Identification mark

Journal diameter mm

1 40.000 − 40.008 1

2 40.008 − 40.016 2

3 40.016 − 40.024 3

Precision flat-tipped screwdriver

Service hole

Precision flat-tipped screwdriver

Service hole

Crankshaft pulley

SectionA-A

Camshaft bearing identification mark

Ratchet

Camshaft bearing front cap assembly

Identification mark

AC611697

Notch

Identification ma

Oil hole

1. When replacing the camshaft bearing, select a

AC708893

camshaft bearing in relevant size according to the camshaft bearing front cap assembly identification mark in the table below. The camshaft bearing identification mark is stamped at the position shown in the figure.

Timing chain tensioner construction diagram

Timing chain tensioner

Ratchet release hol

Ratchet

Ratchet release hole

AC509155

2. In the same manner as removal, insert the precision flat-tipped screwdriver through the service hole of the timing chain case, press up the ratchet of timing chain tensioner to unlock, and hold the unlocked timing chain tensioner.

NOTE: Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.

Page 88

ENGINE MECHANICAL

)

CAUTION

• If unlocking the timing chain tensioner is insufficient, the special tool MB992103 cannot be inserted to the insertion guideline. Do not insert the special tool MB992103 forcibly, fol low Step 2 again to unlock the timing chain tensioner and insert the special tool MB992103.

CAMSHAFT

MB992103

Insertion standard line

Valve timing chain (exhaust camshaft and camshaft sprocket assembly side)

11A-27

Valve timing chai

AC507118

Camshaft sprocket (inlet side

Valve timing chain (tension side)

Timing chain tensioner

MB992103

Timing chain tension side guide

AC508125

MB992103

Timing chain tension side guide

AC509177

3. With the timing chain tensioner unlocked, insert special tool chain tension release bar (MB992103) from the timing chain case assembly inside along the tension side of the valve timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (A in the figure).

Page 89

11A-28

ENGINE MECHANICAL

CAMSHAFT

NOTE: With the timing chain tensioner unlocked, insert the special tool MB992103 along the ten

sion side of the valve timing chain, according to the special tool MB992103 top shape. The special too MB992103 can be inserted smoothly to the position where the special tool MB992103 inser

tion guideline aligns with the timing chain case assembly top surface, and the spread timing chain tension side guide can be hold.

4. With the special tool MB992103 inserted up to the insertion guide line, press the special tool MB992103 against the inlet side camshaft sprocket (B in the figure) and spread and hold the timing chain tension side guide (C in the figure).

5. Remove the precision flat-tipped screwdriver unlocking the timing chain tensioner.

6. Pull up the camshaft and camshaft sprocket assembly (exhaust side) mounting area of the valve timing chain (D in the figure) to provide allowance for easy installation of the camshaft and camshaft sprocket assembly (exhaust side) to the valve timing chain.

9. Remove the special tool MB992103 inserted into the timing chain case assembly inside.

>>F<< CAMSHAFT BEARING FRONT CAP ASSEMBLY INSTALLATION

CAUTION

When the mounting bolts are tightened with the camshaft bearing front cap tilted, the camshaft bearing front cap is damaged. Install the cam shaft bearing front cap properly to the cylinder head and camshaft.

Engine front

(1)

(2)

Camshaft bearing front cap assembly

AC511062

CAUTION

When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.

Paint markings (exhaust side)

AC506752

7. Align the exhaust side paint mark of the valve timing chain which was put at removal with the paint mark of the exhaust side camshaft sprocket, and install the valve timing chain to the camshaft sprocket.

8. Install the camshaft and camshaft sprocket assembly (exhaust side) to the cylinder head.

1. Install the camshaft bearing front cap to the cylinder head, and temporarily tighten the camshaft bearing front cap to the specified torque in the order shown in the figure (1).

Tightening torque: 17 ± 3 N⋅m

2. Tighten the camshaft bearing front cap to the specified torque again in the order shown in the figure (2).

Tightening torque: 30 ± 2 N⋅m

3. After the camshaft bearing font cap installation, check that the paint markings of the camshaft sprocket and the timing chain and the timing mark of the crankshaft pulley and the "T" mark position of ignition timing indicator are aligned respectively.

>>G<< ROCKER COVER ASSEMBLY INSTALLATION

1. Remove the sealant from the joints between the rocker cover assembly and cylinder head and timing chain case assembly, and degrease the surface where the sealant is applied by white gasoline or the like.

Page 90

ENGINE MECHANICAL

CAMSHAFT

11A-29

CAUTION

After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

Cylinder head

4 mm

Timing chain case assembly

4 m

AC506753

2. Apply sealant to the joint between the cylinder head and timing chain case assembly as shown in the figure and install the rocker cover assembly to the cylinder head.

Specified sealant: ThreeBond 1217G or equivalent

NOTE: Install the rocker cover assembly immediately after the application of sealant.

Engine front

AC506743

3. Tighten the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.

Tightening torque: 3.0 ± 1.0 N⋅m

4. Tighten again the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.

Tightening torque: 5.5 ± 0.5 N⋅m

Page 91

11A-30

ENGINE MECHANICAL

VALVE STEM SE A L

VALVE STEM SEAL

REMOVAL AND INSTALLATION

M1112008101787

CAUTION

* Remove and assemble the marked parts in each cylinder unit.

Pre-removal Operation

• Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 Cover

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle Service, Engine Oil Replacement

• Rocker Cover Assembly Removal (Refer to P.11A-19).

• Engine Oil Pan Removal (Refer to P.11A-36).

• Valve Ti m i n g Chain Removal (Refer to P.11A-50).

− Under

12 ± 1 N·m

17 ± 3 N·m 30 ± 2 N·m

Post-installation Operation

• Valve Ti m i n g C hain Installation (Refer to P.11A-50).

• Engine Oil Pan Installation (Refer to P.11A-36).

• Valve Clearance Ch eck (Refer t o P.11A-12).

• Rocker Cover Assembly Installation (Refer to P.11A-19).

• Engine Oil Refilling (Refer to GROUP 12 − On-vehicle

Service, Engine Oil Replacement

• Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 Cover

12 ± 1 N·m

− Under

14*

15*

16*

17*

18*

14*

15*

16*

17*

18*

Apply engine oil to all moving parts before installation.

AC904692

Page 92

ENGINE MECHANICAL

VALVE STEM SE A L

Removal steps

<<A>> >>F<<

>>E<<

<> >>D<<

>>E<<

<> >>D<<

<> >>D<< <> >>D<< <> >>D<<

<<C>> >>C<< <<D>> >>B<<

<<E>> >>A<<

1. Camshaft bearing front cap assembly

2. Camshaft bearing

3. Camshaft bearing oil feeding cap (exhaust side)

4. Camshaft bearing cap (exhaust side)

5. Camshaft bearing cap (exhaust side)

6. Camshaft bearing thrust cap (exhaust side)

7. Camshaft and camshaft sprocket assembly (exhaust side)

8. Camshaft bearing

9. Camshaft bearing oil feeding cap (inlet side)

10. Camshaft bearing cap (inlet side)

11. Camshaft bearing cap (inlet side)

12. Camshaft bearing thrust cap (inlet side)

13. Camshaft and camshaft sprocket assembly (inlet side) Spark plug (Refer to GROUP 16 −

•

Ignition System, Ignition Coil

14. Val v e tap pe t

15. Val v e s p r i ng r e t a i n er l o c k

16. Val v e sp r i n g r e t a i n e r

17. Val v e sp r i n g

18. Val v e stem seal

REMOVAL SERVICE POINTS <<A>> CAMSHAFT BEARING FRONT

CAP ASSEMBLY REMOVAL

1. Temporarily install the engine oil pan which was removed at the valve timing chain removal (Refer to P.11A-36).

11A-31

MB991527

MB991454

MB991956

MB991454

MB991956

3. Remove special tool engine hanger (MB991928 or MB991895) which was installed for supporting the engine and transmission assembly when the valve timing chain was removed.

CAUTION

Be careful not to drop the camshaft bearing.

Camshaft bearing front cap assembly

MB991527

MB991928

AC506487

MB991895

AC506484

CAUTION

When supporting the engine and transmission assembly with a garage jack, be careful not to deform the engine oil pan.

2. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transmission assembly.

Engine front

AC506745

4. Loosen the camshaft bearing front cap mounting bolts in the order of number shown in the figure, and remove the camshaft bearing front cap assembly.

Page 93

11A-32

ENGINE MECHANICAL

VALVE STEM SE A L

<> CAMSHAFT BEARING OIL FEEDING CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING THRUST CAP REMOVAL

CAUTION

Engine front

Camshaft bearing cap

<<C>> VALVE TAPPET REMOVAL

CAUTION

• Do not use pliers or other tools to remove the valve tappets. Always remove them by hands.

• When reusing the removed valve tappet, it has to be installed in the same position as before. Be sure to put a tab that shows the

original installation position on the valve tap pet when storing it.

Valve tappet

AC509270

Remove all of the valve tappets by hands.

Camshaft bearing cap

AC506746

Loosen the camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

<<D>> VALVE SPRING RETAINER LOCK REMOVAL

MD998772

MB992090

MB992089

AC509271

1. Screw in special tool retainer holder attachment (MB992090) to special tool valve spring compressor (MD998772), and assemble special tool retainer holder C (MB992089).

Page 94

ENGINE MECHANICAL

VALVE STEM SE A L

11A-33

CAUTION

When removing the valve spring retainer lock, leave the piston of the cylinder in the TDC (Top Dead Centre) position. The valve may fall into the cylinder if the piston is not properly in the TDC position.

2. Install special tool MD998772 (with special tools MB992090 and MB992089 attached) to the cylinder head and compress the valve spring. Then, remove the valve spring retainer lock.

<<E>> VALVE STEM SEAL REMOVAL

MB992085

Valve stem seal

AK502782

Use special tool valve stem seal pliers (MB992085) to nip the base of the stem seal (where the outside diameter is larger) securely, and remove it by twisting it to the left and right.

CAUTION

• Valve stem seals cannot be reused.

• Do not damage the wall of the tappet hole

when installing the valve stem seal.

•

Special tool valve stem seal installer (MD998737) must be used to install the valve stem seal. Improper installation of the valve stem seal could result in oil leaking past the valve guide.

MD998737

Valve

Valve stem seal

Valve guide

AC308654

2. Use special tool valve stem seal installer (MD998737) to press-fit a new valve stem seal in the valve guide using the valve stem area as a guide.

>>B<< VALVE SPRING RETAINER LOCK INSTALLATION

INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEAL INSTALLA-

TION

1. Apply a small amount of engine oil to the valve stem seals.

MB992090

MB992089

MD998772

AC509271

Page 95

11A-34

ENGINE MECHANICAL

VALVE STEM SE A L

In the same manner as removal, use special tool valve spring compressor (MD998772) with special tool retainer holder attachment (MB992090) and spe cial tool retainer holder C (MB992089) attached to compress the valve spring, and install the valve spring retainer lock.

>>C<< VALVE TAPPET INSTALLATION

1. Apply a small amount of engine oil to the valve tappets.

CAUTION

• Do not use pliers or other tools to install the valve tappets. Always install them by hand.

•

Be sure to install the valve tappets in the same position as before.

Valve tappet

>>D<< CAMSHAFT BEARING THRUST CAP/CAMSHAFT BEARING

CAP/CAMSHAFT BEARING OIL FEEDING CAP INSTALLATION

Engine front

Identification of inlet side and exhaust side

Bearing cap No.

Camshaft bearing cap

E 5

AC509270

2. Install the valve tappet to the cylinder head by hand.

Camshaft bearing cap

AC506778

1. Install the camshaft bearing caps to the cylinder head.

NOTE: Because the camshaft bearing thrust cap and camshaft bearing cap are the same in shape, check the cap number and additionally its symbol to identify the inlet and exhaust sides for correct installation.

2. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps.

Tightening torque: 12 ± 1 N⋅m

Page 96

ENGINE MECHANICAL

VALVE STEM SE A L

11A-35

>>E<< CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION

CAUTION

• Be careful not to drop the camshaft bearing.

•

When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.

Camshaft bearing front cap assembly

Identification mark

AC611697

Notch

>>F<< CAMSHAFT BEARING FRONT CAP ASSEMBLY INSTALLATION

CAUTION

Engine front

(1)

(2)

Camshaft bearing front cap assembly

AC511062

1. Install the camshaft bearing front cap to the cylinder head, and temporarily tighten the camshaft bearing front cap mounting bolts to the specified torque in the order shown in the figure (1).

Tightening torque: 17 ± 3 N⋅m

Identification ma

Oil hole

AC708893

When replacing the camshaft bearing, select a camshaft bearing in relevant size according to the camshaft bearing front cap identification mark in the table below. Identification mark of the camshaft bearing is painted in the position shown in the figure.

Camshaft Camshaft

Identification mark

Journal diameter mm

bearing identification mark

1 40.000 − 40.008 1

2 40.008 − 40.016 2

3 40.016 − 40.024 3

2. Tighten again the camshaft bearing front cap mounting bolts to the specified torque again in the order shown in the figure (2).

Tightening torque: 30 ± 2 N⋅m

MB991527

MB991454

MB991956

MB991928

MB991527

AC506487

MB991454

MB991956

MB991895

AC506484

Page 97

11A-36

ENGINE MECHANICAL

OIL PAN

3. Install special tool engine hanger (MB991928 or MB991895) which was installed for supporting the engine and transmission assembly when the valve timing chain was removed (Refer to

P.11A-50).

OIL PAN

REMOVAL AND INSTALLATION

M1112002803416

Pre-removal Operation

• Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 Cover

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle Service, Engine Oil Replacement

• Alternator and Others Belt Removal (Refer to P.11A-16).

− Under

4. Remove the garage jack which supports the engine and transmission assembly.

5. Remove the engine oil pan installed temporarily.

Post-installation Operation

• Alternator and Others Belt Installation (Refer to

P.11A-16).

• Engine Oil Refilling (Refer to GROUP 12 − On-vehicle Service, Engine Oil Replacement

• Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 Cover

− Under

39 ± 5 N·m

10 ± 2 N·m

23 ± 6 N·m

31 ± 2 N·m

23 ± 6 N·m

ACC00061

Page 98

ENGINE MECHANICAL

OIL PAN

11A-37

Removal steps

1. A/C compressor and clutch connector connection

<<A>> >>B<<

<> >>A<<

2. A/C compressor and clutch assembly

3. A/C compressor bracket A

4. A/C compressor bracket B

5. Engine oil pan drain plug

6. Engine oil pan drain plug gasket

7. Engine oil pan

REMOVAL SERVICE POINTS <<A>> A/C COMPRESSOR AND CLUTCH

ASSEMBLY REMOVAL

1. Remove the A/C compressor and clutch assembly together with the hose from the bracket.

2. Tie the removed A/C compressor and clutch assembly with a string at a position where they will not interfere with the removal and installation of engine oil pan.

<> ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.

CAUTION

Do not forcibly drive in special tool oil pan FIPG cutter (MD998727) to avoid damage to the engine oil pan seal surface of cylinder block assembly.

Engine oil pan

Crankshaft pulle

AC506757

Engine oil pan

Engine oil filter

AC506758

MD998727

AC102324

2. Insert special tool oil pan FIPG cutter (MD998727) from the engine oil pan removal groove of the cylinder block assembly.

3. Lightly tap the special tool (MD998727) with a hammer to slide the engine oil pan seal surface, cut off the liquid gasket, and remove the engine oil pan.

INSTALLATION SERVICE POINTS >>A<< ENGINE OIL PAN INSTALLATION

1. Remove all the traces of sealant adhering to the engine oil pan and cylinder block assembly using a remover or others. Then, degrease them.

Page 99

11A-38

1mm

2 mm or 3 mm

AC506756

ENGINE MECHANICAL

OIL PAN

Tightening torque: M6: 10 ± 2 N⋅m M8: 29 ± 2 N⋅m

>>B<< A/C COMPRESSOR AND CLUTCH ASSEMBLY INSTALLATION

2. Apply the sealant without any gap to the mating surface of engine oil pan as shown in the figure, and install the engine oil pan to the cylinder block assembly.

Specified sealant: ThreeBond 1217G or equivalent

NOTE: Install the engine oil pan immediately after applying sealant.

CAUTION

After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

3. Tighten the engine oil pan mounting bolts to the specified torque.

A/C compressor and clutch assembly

AC506759

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.

Tightening torque: 23 ± 6 N⋅m

INSPECTION

M1112002900920

• Check the engine oil pan for cracks.

• Check the engine oil pan sealant-coated surface

for damage and deformation.

Page 100

ENGINE MECHANICAL

CRANKSHAFT OIL SEAL

11A-39

REMOVAL AND INSTALLATION

M1112003104286

40 N·m 130 N·m

>>C<<

<<A>> >>B<<

>>B<< >>B<< >>A<<

Crankshaft front oil seal removal steps

Crankshaft pulley (Refer to

•

P.11A-16.)

1. Crankshaft front oil seal

Crankshaft rear oil seal removal steps

Transmission assembly (Refer to

•

GROUP 23A - Transmission Assembly

2. Drive plate bolt

3. Drive plate adapter plate

4. Drive plate

5. Crankshaft rear oil seal

AC506760

REMOVAL SERVICE POINTS <<A>> DRIVE PLATE BOLT REMOVAL

Cylinder block

MB991883

Drive plate

AC506761

Fix the drive plate using the flywheel stopper (Special Tool: MB991883), and loosen the drive plate bolts.

INSTALLATION SERVICE POINTS >>A<< CRANKSHAFT REAR OIL SEAL

INSTALLATION

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.

Mitsubishi Outlander 2013 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual