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P.00-15 - EvoScan

1. 00 39 PRECAUTIONS BEFORE SERVICE 7 991827 608435 N CAUTION prevent damage to scan tool 991958 always turn ignition switch to the LOCK OFF position before con necting or disconnecting scan tool MB991958 1 After the ignition switch is in LOCK OFF position connect scan tool MB991958 to the data link connector 2 Turn the ignition switch to the ON position 3 Select MFI from System select Screen of scan tool MB991958 4 Select Special Function from MFI Screen 5 Select Timing chain maintenance from Special Function Screen 6 Select Learned value Read amp Save from Timing chain maintenance Screen 7 Press to store the initial learning value file NOTE When the initial learning value file is appropriately stored Learned value Save Complete is shown on the screen of the scan tool MB991958 NOTE Calculating the amount of elongation of the timing chain by the ECM takes the time Thus the file cannot be stored for a while after the ECM initialization or replacement 8 Replace the ECM 9 Select Write learned value Changed ECU from Timing chain maintenance Screen 10 Select the initial learning value file stored during Step 7 to write the initial learning value NOTE Use only the initial learning value file stored during Step 7 without using any other files NOTE When
2. 00 43 APPLICATION OF ANTI CORROSION 00 14 AGENTS AND UNDERCOATS 00 43 BOLTS AND NUTS WITH STABILIZER FOR 00 15 COEFFICIENT OF FRICTION 00 43 00 16 FORM4N PLACE GASKET FIPG 00 43 00 7 TOWING AND HOISTING 00 45 00 17 GENERAL DATA AND SPECIFICATIONS 00 49 00 17 00 18 TIGHTENING TORQUE 00 51 00 19 00 9 LUBRICATION AND 00 9 MAINTENANCE 00 52 00 20 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE 00 54 00 20 SCHEDULED MAINTENANCE 0020 TABLE 00 57 00 20 Continued on next page 00 21 00 2 SSS ee ee pa nnt MAINTENANCE SERVICE 00 61 14 TRANSFER OIL CHECK OIL LEVEL PIPE LINE AND 00 70 CONNECTION AND FUEL TANK FILLER 15 RESERVE TANK FLUID FOR ACTIVE TUBE CAP CHECK FOR LEAKS 00 61 CENTER DIFFERENTIAL AND ACTIVE YAW 2 FUEL HOSES CHECK CONDITION 00 61 E SVS TEM CHEVA TUD 3 AIR CLEANER ELEMENT REPLACE 00 61 v tst set rtt 2 16 ENGINE COOLANT CHANGE 00 72 SYSTEM EXCEPT EVAPORATIVE EMISSION RADIATOR BOSE Ben ECCE LEKSAND HEATER HOSE INSPECT 00 74 CLOGGING ess sees ace et 00 61 18 DISK BRAKE PADS AND ROTORS 5 GPARR PLUGS REPLACE INSPECT FOR 00 74 6 INTAKE AND EXHAUST VALVE CLEARANCE Ta PRANE LECTUS INSPECT AND ADJUST gt 00 62 DETE
3. 7 991827 608435 0880 A CAUTION prevent damage to scan tool 991958 always turn ignition switch to the LOCK OFF position before con necting or disconnecting scan tool MB991958 1 After the ignition switch is in LOCK OFF position connect scan tool MB991958 to the data link connector 2 Turn the ignition switch to the ON position 3 Select MFI from System select Screen of scan tool MB991958 4 Select Special Function from MFI Screen 5 Select Timing chain maintenance from Special Function Screen 6 Select Test Limit value readout from Timing chain maintenance Screen 7 Read the value of percentage 96 shown on the screen NOTE The value of percentage shown on the screen is the amount of elongation of the timing chain calculated by the ECM based on the initial learning value and thus is not the actual amount Use this for the reference only SERVICING ELECTRICAL SYSTEM WARNING Battery posts terminals and related accessories con tain lead and lead compounds WASH HANDS AFTER HANDLING 1 Note the following before proceeding with working on the electrical system Never perform unauthorized modifications to any electrical device or wiring Such modifications might lead to a vehicle malfunction over capacity or short circuit that could result in a fire in the vehicle M1001011900433 TSB
4. 55 55 Turning radius m ft 5 9 19 4 5 9 19 4 TSB Revision 5 9 19 4 Each torque value in the table is standard value for tightening under the following conditions 1 Bolts nuts and washers are all made of steel and plated with zinc 2 The threads and bearing surface of bolts and nuts are all in dry condition GENERAL TIGHTENING TORQUE TIGHTENING TORQUE The values in the table are not applicable STANDARD BOLT AND NUT TIGHTENING TORQUE Thread size 1 2 3 inserted nuts used Standard tightening torque 00 51 M1001001100964 If toothed washers are inserted If plastic parts are fastened If bolts are tightened to plastic or die cast If self tapping screws or self locking nuts are Nominal bolt diameter mm Head mark 4 Head mark 7 Head mark 8 2 5 0 5 23 4 in Ib 5 0 1 0 m 44 9 in Ib 6 0 1 0 m 53 9 in Ib 5 0 x 1 0 m 44 9 in Ib 8 5 x1 5 m 76 13 in Ib 10 x2N m 89 17 in Ib 11 2 m 98 17 in Ib 20 4 m 15 3 ft lb 24 4 m 18 x3 ft lb 23 4 m 17 3 ft lb 42 8 m 31 6 ft lb 53 7 m 39 5 ft lb 42 8 N m 31 6 ft lb 80 10 N 59 7 ft lb 93 12 m 68 9 ft lb 70 10 52 7 ft lb 130 20 N m 96 15 ft lb 150 20 N 111 214 ft lb
5. Change in thickness parallelism If the thickness of the disk changes this will cause pedal pulsation shuddering and surging Inset or warping flatness Overheating and improper handling while servicing will cause warping or distortion BRAKE DISK THICKNESS CHECK 1 Using a micrometer measure disk thickness at eight positions approximately 45 degrees apart and 10 mm 0 4 inch in from the outer edge of the disk Standard value 32 0 mm 1 26 inch Front 22 0 mm 0 87 inch Rear Limit 30 0 mm 1 18 inch Front 20 0 mm 0 79 inch Rear NOTE Thickness variation at least 8 positions should not be more than 0 015 mm 0 0006 inch TSB Revision 00 76 006226 00669 GENERAL MAINTENANCE SERVICE A CAUTION SS marks AC201323 AD After a new brake disk is installed always grind the brake disk with on the car type brake lathe If this step is not carried out the brake disk run out exceeds the specified value resulting in judder When the on the car type lathe is used first install M12 flat washer on the stud bolt in the brake disk side according to the figure and then install the adapter If the adapter is installed with M12 flat washer not seated the brake disk rotor may be deformed resulting in inac curate grinding Grind the brake disk with all wheel nuts diagonally and equally tightened to
6. 105 15 78 11 ft lb 195 25 N ft lb m 144 18 230 30 m 170 22 ft lb 150 20 N ft lb m 111 14 290 40 N ft lb m 214 29 335 45 m 247 33 ft lb 210 30 N ft Ib m 155 22 400 60 N ft lb m 295 44 465 65 m 343 48 ft lb 290 40 N ft lb m 214 29 540 80 N ft lb m 398 59 630 90 m 465 66 ft lb 375 55 N ft lb m 277 40 705 105 m 520 77 ft lb TSB Revision 820 120 m 605 88 ft lb 00 52 GENERAL LUBRICATION AND MAINTENANCE FLANGE BOLT AND NUT TIGHTENING TORQUE Thread size Standard tightening torque Head mark 4 Nominal bolt diameter mm Head mark 7 Head mark 8 in Ib 5 0 1 0 N m 44 9 10 2 89 17 12 2 m 107 17 in Ib in Ib 13 x2N m 111 22 24 x4 m 18 3 ft lb 28 x5 m 20 4 ft lb 26 5 m 19 4 ft lb 50 5 m 37 4 ft lb 58 7 m 43 5 ft lb 25 x4 m 18 3 ft lb 46 x8 m 34 6 ft Ip 55 x5 m 41 3 ft lb 47 x9 m 35 6 ft lb 93 12 m 68 9 105 15 m 78 11 ft Ib ft lb 43 8 m 32 6 40 83 12 m 61 9 98 12 N m 72 9 ft Ib ft Ib LUBRICATION AND MAINTENANCE Maintenance and lubrication service recommenda tions have been compiled
7. TSB Revision Permatex Spray Adhesive No 82019 Application GENERAL MAIN SEALANT AND ADHESIVE TABLE 3M three bond No 00 81 Loctite permatex No BODY SEALANTS Sealing of sheet metal joints drip rail floor side panels trunk front panel tail gate hinge 3M AAD Part No 8531 Heavy Drip Check Sealer gray or 3M AAD Part No 8302 Ultrapro Autobody Sealant clear or 3M AAD Part No 8361 Urethane A B Sealant gray or white Miscellaneous body sealants original mounted w adhesive tape Waterproof door film Fender panel Splash shield Mud guard Rear combination lamp AAD Part No 8633 Windo weld Resealant Fuel Tank and Pad 3M AAD Part No 8088 General Trim Adhesive or 3M AAD Part No 8090 Super Trim Adhesive Permatex Spray Adhesive No 82019 Sealant of various flange faces and threaded parts Packing of fuel gauge unit AAD Part No 8730 High Strength Red Threadlock or AAD Part No 8731 Medium Strength Blue Threadlocker Loctite 272 High Strength and High Temperature 27200 Sealing of various threaded parts dust covers Differential carrier packing dust covers and ball joint and linkage Packing and shims of steering box sealing of rack support cover and top cover of steering box housing seal of junction face of knuckle arm flange 3M AAD Part No 8672 Ultrapro High Temp Silicone Gasket
8. 140 5 5 140 5 5 Overall height unladen 1 480 58 3 1 480 58 3 1 480 58 3 I C CI A co N gt 1 545 60 8 1 545 60 8 1 545 60 8 Vehicle weight Curb weight 1 595 3 517 1 620 3 572 1 630 3 594 kg Ib Gross vehicle weight rating Gross axle weight rating front Gross axle weight rating rear 2 060 4 542 1 080 2 381 1 050 2 315 2 060 4 542 1 080 2 381 1 050 2 315 2 060 4 542 1 080 2 381 1 050 2 315 Seating capacity 5 5 5 Engine Model No 4B11 4B11 4B11 Piston displacement cm cu in 1 998 121 9 1 998 121 9 1 998 121 9 Maximum output kW r min HP r min 217 6 500 291 6 500 217 6 500 291 6 500 217 6 500 291 6 500 Maximum torque N m r min ft Ib r min 407 4 000 300 4 000 407 4 000 300 4 000 407 4 000 300 4 000 Fuel system Fuel supply system MFI MFI MFI Transaxle Model No W5M6A W6DGA W6DGA Type 5M T TC SST TC SST Turning radius m ft 5 9 19 4 5 9 19 4 TSB Revision 5 9 19 4 00 50 VEHICLES FOR CANADA GENERAL GENERAL DATA AND SPECIFICATIONS Item CZ4AS AC710509AC NGFZL3M MGFZL3M MPFZL3M Vehicle dimension mm in Overall width 1 810 71 3
9. Compressor type 2 No compressor or Scroll 90cc Temperature type Celsius or Fahrenheit Rear view camera Not present Nose view camera Not present Side view camera Not present Average speed Available Vehicle language status English Fuel amount Not used Fuel consumption scale L 100km Vehicles for USA MPG US Vehicles for CANADA Speed gauge tolerance U S Coolant temp gauge threshold Normal Frost warning threshold U S Distance to empty Available Average fuel consumption Available Instant fuel consumption Available Time traveled Not available Distance traveled Not available Fuel used Not available Trip autoreset IG OFF Available Variable Speed Alarm Not available Rest reminder Available Instant speed Not available Seat belt reminder control type AABT Seat belt reminder flashing Available Seat belt reminder indicator D amp P independent Reverse alarm Not available Key reminder Available Lighting monitor Available GCC speed alarm Not available Condition tone alarm Not available TSB Revision GENERAL 00 33 PRECAUTIONS BEFORE SERVICE Item name Initial value Rent a car mode IG OFF always Available Rent a car mode IG OFF door open Available Service reminder schedule table NAS 20 ACD control display Not used TPMS information 32 psi Horn chirp by keyless
10. diagnosis code displayed Current trouble Read the diagnosis code diagnosis code No diagnosis displayed code or After taking note of the malfunction code erase the diagnosis cod memory diagnosis code displayed Current trouble No diagnosis code communication Current trouble with scan tool Y MB991958 not How to treat past possible trouble i displayed Recheck trouble symptom How to treat past trouble Y Read the diagnosis code No diagnosis code diagnosis code RE Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS Refer to applicable group Refer to the INSPECTION CHART FOR DIAGNOSIS CODES Refer to applicable group INTERMITTENT MALFUNCTIONS 1 For how to diagnose CAN bus lines refer to GROUP 54 P 54C 9 2 For the CAN bus diagnosis chart refer to GROUP 54C P 54C 15 3 When scan tool MB991958 detects a diagnos tic trouble 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 16 9 For how to cope with intermittent malfunc tions refer to P 00 15 6 For coding data refer to P 00 26 2 SYSTEM OPERATION AND SYMPTOM VERIF
11. 1 810 71 3 1 810 71 3 Tread front 1 545 60 8 1 545 60 8 1 545 60 8 Overall length 4 495 177 0 4 495 177 0 4 495 177 0 Overhang front 910 35 8 910 35 8 910 35 8 Wheelbase 2 650 104 3 2 650 104 3 2 650 104 3 Overhang rear 935 36 8 935 36 8 935 36 8 Ground clearance 140 5 5 140 5 5 140 5 5 Overall height unladen 1 480 58 3 1 480 58 3 1 480 58 3 Tread rear NI o C CON gt 1 545 60 8 1 545 60 8 1 545 60 8 Vehicle weight kg Ib Curb weight 1 595 3 517 1 620 3 572 1 630 3 594 Gross vehicle weight rating 2 060 4 542 2 060 4 542 2 060 4 542 Gross axle weight rating front 1 080 2 381 1 080 2 381 1 080 2 381 Gross axle weight rating rear 1 050 2 315 1 050 2 315 1 050 2 315 Seating capacity 5 5 5 Engine Fuel system Model No Piston displacement cm cu in Maximum output kW r min HP r min Maximum torque m r min ft Ib r min Fuel supply system 4811 1 998 121 9 217 6 500 291 6 500 407 4 000 300 4 000 MFI 4 11 1 998 121 9 217 6 500 291 6 500 407 4 000 300 4 000 MFI 4B11 1 998 121 9 217 6 500 291 6 500 407 4 000 300 4 000 MFI Transaxle Model No W5M6A W6DGA W6DGA Type 5
12. Present Chg Ok Rear S R Unlock Output Not present Trailer turn detection Present Shift Lever Not present lt 5M T gt Present lt TC SST gt AFS ACL Leveling Not present Satellite Radio 2 Not present or Present Display opening type MMC F A S T auto lock customize Not used DRL function Present Chg Ng FACU Not present S AWC Control display Available Diesel particulate filter Not present Language mode Not available or Available WSS Not present Door Unlock Mode Customize 2 Disabled RLS overwipe type Type 1 RLS WS type Type 2 Green Interior illumination customize Disabled NOTE 71 TPMS is an abbreviation of Tire Pressure Monitoring System DRL of Daytime Running Light and AFS of Adap tive Front lighting System 2 The setting can be changed by the option coding Refer to 3 Although the dual light discharge type is employed it is displayed as 4 beams TSB Revision 00 34 GENERAL PRECAUTIONS BEFORE SERVICE OPTION CODING A 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 Functions and systems do not work normally if the set ting does not correspond with the equipment With the ETACS functions being customized if any of the ETACS
13. EXPLANATION OF MANUAL CONTENTS Indicates the section title Denotes tightening torque For bolts and nuts which do not have a tightening torque listed refer to the Standard Parts tightening torque Table Indicates the group title BASIC BRAKE SYSTEM FRONT DISC BRAKE ASSEMBLY FRONT DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION 35A 20 1351006000366 Pre removal Operation Brake Draining Post installation Operation Brake Fluid Supplying and Air Bleeding Refer to 100 10 Nem Indicates the group number Indicates the page number Indicates procedures to be performed be fore 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 pro vided near the front of each section in order to give the reader a better understanding of the installed condition of component parts 00 5 6 2 Grease Brake caliper kit Pad set Shim kit Seal and boot repair kit Removal steps gt gt lt lt 1 Brake hose connection 2 Gasket gt gt lt lt 3 Brake caliper assembly 4 Brake disc Maintenance and servicing procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures
14. Mitsubishi Genuine Part No 1000A923 Between oil pan Three bond 1217G Mitsubishi Genuine Part No 1000A923 Three bond 1227D Mitsubishi Genuine Part No MZ100792 Three bond 1207F Mitsubishi Genuine Part No MD970389 Loctite 597 1 Loctite 5900 Loctite 5970 Between engine oil pressure switch Three bond 1215 Three bond 1212D Between engine coolant temperature switch Three bond 1324 Loctite 262 WEATHERSTRI PPING FOR GLASS Between tempered glass body flanges and weatherstrip 3M AAD Part No 8509 Auto Bedding and Glazing Compound or 3M AAD Part No 8633 Windo weld Resealant WEATHERSTRI PPING FOR GLASS INTERIORS Between laminated glass and weatherstrip Adhesive of vinyl chloride cloth 3M AAD Part No 8633 AAD No 8088 General Trim Adhesive or AAD Part No 8064 Vinyl Trim Adhesive Permatex Vinyl Repair Kit No 81786 Adhesion of door weatherstrip 3M AAD Part No 8001 yellow or 3M AAD Part No 8008 black Super Weatherstrip Adhesive or 3M AAD Part No 8011 Black Weatherstrip Adhesive Permatex Super Black Weatherstrip Adhesive No 82 81850 Sealing of various grommets and packing Adhesion of headliners and various interior decorative materials AAD Part No 8509 AAD Part No 8678 AAD Part No 8088 General Trim Adhesive or AAD Part No 8090 Super Trim Adhesive
15. and affect the warranty coverage validity This vehicle must use unleaded gasoline only This vehicle has a fuel filler tube which is especially designed to accept only the smaller diameter unleaded gasoline dispensing nozzle GASOLINE CONTAINING ALCOHOL Some gasoline sold at service stations contain alco hol although they may not be so identified Using fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory Gasohol A mixture of 10 ethanol grain alcohol and 9096 unleaded gasoline may be used in your vehicle If driveability problems are experienced as a result of using gasohol it is recommended that the vehicle be operated on gasoline Methanol Do not use gasoline containing metha nol wood alcohol Using this type of alcohol can result in vehicle performance deterioration and dam age critical parts in the fuel system components Fuel system damage and performance problems resulting from the use of gasoline containing methanol may not be covered by the new vehicle warranty GASOLINE CONTAINING METHYL TERTIARY BUTYL ETHER MTBE Unleaded gasoline containing 1596 or less MTBE may be used in your vehicle Fuel containing MTBE over 15 in volume may cause reduced engine per formance and produce vapor lock or hard starting MATERIALS ADDED TO FUEL Indiscriminate use of fuel system cleaning agents should be avoided Many of these materials intended
16. during hot weather above 32 C 90 F 3 Extensive idling 4 Driving in sandy areas 5 Driving in salty areas 6 Driving in dusty conditions 7 Driving off road ENGINE OIL N CAUTION Test results submitted to EPA have shown that laboratory animals develop skin cancer after pro longed contact with used engine oil Accordingly the potential exists for humans to develop a number of skin disorders including cancer from such exposure to used engine oil Therefore when changing engine oil be careful not to touch it as much as possible Protective clothing and gloves that cannot be penetrated by oil should be worn The skin should be thoroughly washed with soap and water or use waterless hand cleaner to remove any used engine oil Do not use gasoline thinners or solvents Either of the following engine oils should be used Engine oils displaying ILSAC certification symbol or conforming to the classification SM TSB Revision GENERAL 00 53 LUBRICATION AND MAINTENANCE For further details refer to LUBRICANTS SELEC TION LUBRICANTS AND GREASES Semi solid lubricants bear the NLGI designation and are further classified as grades O 1 2 3 etc Whenever Chassis Lubricant is specified Multipur pose Grease NLGI grade Number 2 should be used FUEL USAGE STATEMENT CAUTION Using leaded gasoline in this car will damage the catalytic converters and heated oxygen sensors
17. shields Replace Check and service X X X X X Engine oil Turbocharger Change Every 3 months or every 4 800 km 3 000 miles Engine oil filter Turbocharger Replace Every 6 months or every 9 600 km 6 000 miles Manual transaxle oil Change X X X X X X X X X X Twin clutch sportronic shift transmission oil Check oil leaks If necessary check the oil level X X X X X X X X X X Change TSB Revision 00 60 GENERAL SCHEDULED MAINTENANCE TABLE Maintenance Service Mileage in item intervals thousands Kilometers in thousands Months Twin clutch sportronic shift transmission oil filter Transfer oil Change Reserve tank for Check fluid level ACD and AYC Engine coolant Change Coolant hoses Inspect radiator hose heater hose Replace Disk brake pads Inspect for wear Every 3 months or every 4 800 km 3 000 miles rotors Brake hoses Check for deterioration or X X X X X X X X X X leaks Ball joint and Inspect for grease leaks and steering linkage damage seals Drive shaft boots Inspect for grease leaks and Every months or every 4 800 km 3 000 miles damage Suspension Inspect for looseness and Every 3 months or every 4 8
18. 8 000 km 5 000 miles Suspension system Inspect for looseness and damage Every 5 months or every 8 000 km 5 000 miles Rear axle oil for differential part Change X X X X X Rear axle oil for torque transfer part Change X X X Tires Rotate Every 5 months or e Air purifier filter Replace X X X X TSB Revision GENERAL SCHEDULED MAINTENANCE TABLE 00 59 NOTE 1 ACD Active Center Differential 2 AYC Active Yaw Center system SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS Maintenance should be carried out according to the following table Maintenance item Service intervals Mileage in thousands Kilometers in thousands Months Fuel system tank pipe line and connection and fuel tank filler tube cap Check for leaks Fuel hoses Air cleaner filter Check condition Replace Evaporative emission control system except evaporative emission canister Check for leaks and clogging Spark plugs Iridium tipped type Replace X X Intake and exhaust valve clearance Inspect and adjust X X If valve noise increases adjust valve clearance Drive belts for the generator and power steering oil pump Exhaust system connections portion of muffler muffler pipes and converter heat
19. A MT Information 9 Select Coding on the next screen 4 ABS ASC ASTC Model Year XXXX 5 SAS Model Code 6 Multi Select 4WD Loading Option Setup 7 SRS Airbag Y OPC Option Name With Option 8 IMMOBI amp Keyless amp TPMS 9 ETACS IMMOBI amp FAST TPMS 10 Meter T Select Model Year and System 1 py OK button AC609809AB TSB Revision 00 26 System Select EASTIMVOBIKayess PNS Coding VIN Writing Pisas select function eje 609799 FAS 1 6 7 Coding 7 VIN Writing VIN Writing VIN Engine ECU XX XXXXXXXXXXX XX VIN currently written in ECM is displayed Write the number displayed on the screen in Immobilizer KOS ECU OK button Press the OK bution to execute I 609798 EKSTIMMOBUKeyess TPMS Coding VIN Writing Result of VIN Writing VIN Writing XXMXMXX XXXXXXXXXX a a III 609285 GENERAL PRECAUTIONS BEFORE SERVICE 10 Select VIN Writing on Coding screen 11 Push the OK button after the VIN written in the engin
20. GENERAL VEHICLE IDENTIFICATION 00 17 INSPECTION SERVICE POINTS FOR A BLOWN FUSE M1001013800409 Remove the blown fuse and measure the resistance between the load side of the blown fuse and the ground Close the switches of all circuits which are connected to this fuse If the resistance is almost 0 Qat this time there is a short some where between these switches and the load If the resistance is not 0 Q 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 heat Water getting into the connector or circuitry e Human error mistakenly shorting a circuit etc Battery Short circuit Y occurrence section Load switch ACX00872 AD VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER PLATE M1001005501138 The vehicle identification number VIN plate is located on a plate attached to the left top side of the instrument panel AC205735 CODE CHART No Content 1 Country J JAPAN 2 Make A Mitsubishi Motors 3 Vehicle type 3 Passenger car 4 Others 2 Air bags driver passenger side 8 9 10 11 curtain driver knee AC707964AC 5 Line W LANCER EVOLUTION TSB Revision 00 18 MODELS GENERAL VEHICLE IDENT
21. Service intervals Mileage in thousands 30 60 105 120 135 150 Kilometers in thousands 48 96 168 192 216 240 Months 30 60 105 120 135 150 Engine oil Turbocharger Change Every 5 months or every 8 000 km 5 000 miles Engine oil filter Turbocharger Replace Every 10 months or every 16 000 km 10 000 miles Manual transaxle oil Check oil level X X X X X X X X X Change X X X X Twin clutch sportronic shift transmission oil Check oil leaks If necessary check the oil level X X X X X X X X Change Twin clutch sportronic shift transmission oil filter Change Transfer oil Check oil level Change Reserve tank for ACD and AYC Check fluid level Engine coolant Change Coolant hoses radiator hose heater hose Inspect Replace Disk brake pads rotors Inspect for wear Every 5 months or every 8 000 km 5 000 miles Brake hoses Check for deterioration or leaks X X X X X X X X X X Ball joint and steering linkage seals Inspect for grease leaks and damage X X X X X X X X X X Driveshaft boots Inspect for grease leaks and damage Every 5 months or every
22. Use special tool MB992006 extra fine probe IF INSPECTING WITH THE CONNECTOR DISCONNECTED When Inspecting a Female Pin From front side of the connector Required Special Tool MB991219 Inspection Harness Included in MB991223 Harness Set TSB Revision 00 13 HOW USE TROUBLESHOOTING INSPECTION SERVICE POINTS MB991219 SRS ECU harness connector 001607 00867 The inspection harness for connector contact pres sure should be used The test probe should never be forcibly inserted as it may cause a defective contact From back side of the connector SRS ECU harness side connector Since the SRS ECU harness connector is plated to improve conductivity observe the warning below when checking this connector Z WARNING Insert the backprobing tool into the connector from the harness side and connect the tester to the back probing tool If any tool other than the backprobing tool is used it may cause damage to the harness and other components Furthermore measurement should not be carried out by touching the backprob ing tool directly against the terminals from the front of the connector The terminals are plated to increase their conductivity so that if they are touched directly by the backprobing tool the plating may break which will decrease reliability lt When Inspecting a Male Pin gt N CAUTION At this
23. answer Disabled TSB Revision GENERAL 00 30 PRECAUTIONS BEFORE SERVICE Item name Initial value Theft alarm siren Not present CAMERA Not present Corner sensor control unit Not present Electric Slide door Left Not present Electric Slide door Right Not present ETG Not present ESS ECU Not present 2 Not present or Present Intelligent washer customize Enabled def E Headlight Leveling system type Type1 No present Rear wiper mode Without Lo 10MY SPEC Enable Rear wiper by reverse customize Disabled ABS Not present A S C Present Auto fold mirror SPD Not present SAS Present 4WD AWC Not present TCM Not present lt 5M T gt Present lt TC SST gt ACTV_STB Not used Door unlock by IG lock customize Enabled def D Rheostat cancel mode Available EPS Not present ACDAYC Present Coming home light customize Enabled def E Welcome light customize Enable d Small Indirect light Not present Power window Dr Present Power window As Not present Power window RR Not present Power window RL Not present ESS by stoplight Not present Sun roof Not present or Present RLS 2 Not present or Present TSB Revision GENERAL 00 31 PRECAUTIONS BEFORE
24. button After initializing the learning value the learning value of MFI engine idling is necessary Refer to Learning Procedure For Idling In Engine P 00 36 MB991827 AC608435 AB ENGINE IDLING LEARNING PROCEDURE M1001011800920 PURPOSE When the ECM is replaced or when the learned value is initial ized the idle may not be stabilized Carry out the learning method by following the procedures below LEARNING PROCEDURE 1 Start the engine and warm to reach 80 C 176 F or more NOTE When the engine coolant temperature is 80 176 F or more the warm up is not needed if the ignition switch is in ON position once 2 Turn the ignition switch to LOCK OFF position 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 idles normally Transaxle Neutral P range on vehicles with TC SST Operation in ignition related fan and attachments Not to be operated Engine coolant temperature 80 C 176 F or more NOTE If the engine stalls while idling check for a dirty on the throttle valve of the throttle body and clean if needed Then perform the service from Procedure 1 again Co TSB Revision GENERAL 00 37 PRECAUTIONS BEFORE SERVICE INITIALIZATION PROCEDURE FOR THROTTLE ACTUATOR CONTROL MOTOR When the battery cable is disconnected and reconnected throt
25. e Removal steps The part designation number corresponds to the number in the illustration to indicate remov al steps e Disassembly steps The part designation number corresponds to the number in the illustration to indicate disas sembly steps e Installation steps e Reassembly steps Mark denotes nonreusable part Repair kit or parts sets are shown Only very frequently used parts are shown Specified in case installation is impossible in reverse order of removal steps Omitted if installation is possible in reverse order of re moval 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 AC901523 TSB Revision 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 lt lt A gt gt Indicates that there are essential points for removal or disassembly gt gt A lt lt Indicates that there are essential points for installation or reassembly BASIC BRAKE SYSTEM FRONT
26. full closed position of the accelerator pedal The ECM stores the timing chain conditions as the initial learning value when the timing chain is installed The ECM stores the amount of elongation of the timing chain in the EEPROM as the current learning value compared with the initial learning value The ECM judges that the visual check of the elongation of the timing chain is necessary when the current learning value exceeds the specified value Thus use the scan tool 991958 to always carry out the maintenance of the initial learning value related to the timing chain that is stored by the ECM after the following service Sauce SOON TSB Revision 00 38 GENERAL PRECAUTIONS BEFORE SERVICE Maintenance items by scan tool MB991958 Maintenance purpose ECM replacement Visual check of elongation of timing chain Learned value Read amp Save 2 Write learned value Changed ECU Learned value reset The purpose is that the initial learning value regarding the amount of elongation of the timing chain stored by the current ECM is loaded in the scan tool MB991958 and then written into the new ECM This allows the ECM to appropriately monitor the amount of elongation of the timing chain after the ECM replacement The purpose is that the initial learning value stored by the current ECM is initialized after the visual check of the elongation of the timing chain by illuminating the warning lam
27. hose is exposed by cracks and abrasions in the fuel system the hoses should be replaced 3 AIR CLEANER ELEMENT REPLACE M1001001800424 The air cleaner element will become dirty during use reducing its effectiveness Replace it with a new one Replacement of air cleaner element 1 Unclamp the air cleaner housing 2 Remove the air cleaner element and install a new one 3 When clamping the air cleaner housing in place be sure that the cover is completed closed 4 EVAPORATIVE EMISSION CONTROL SYSTEM EXCEPT EVAPORATIVE EMISSION CANISTER CHECK FOR LEAKS AND CLOGGING M1001001900410 If the fuel vapor vent line is clogged or damaged fuel vapor will escape into the atmosphere causing excessive emissions Dis connect the line at both ends and blow it clean with com pressed air Remove the fuel tank filler tube cap from the filler tube and check to see if there is evidence that the seal makes improper contact to the filler tube TSB Revision 00 62 Iridium L X ib Platinum tip Timing mark AK704210AB AK604565AC Exhaust valve side No 1 No 3 E NU 3 27 fe A No 1 No 2 Intake valve side AK502387AG GENERAL MAINTENANCE SERVICE 5 SPARK PLUGS REPLACE A CAUTION Iridium plugs are u
28. light CNTL AUDIO CAN AND HFM hands free ECU Rain Light Sensor Front fog light Rear fog light Horn type Remote engine starter Wiper washer check bulb Compressor type Satellite Radio Keyless Door Unlock Mode Customize INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE M1001011700826 When the following service is performed initialize the learning value At replacing engine assembly At replacing throttle body and at cleaning At replacing knock sensor INITIALIZATION PROCEDURE Required Special Tools e MB991958 Scan Tool Sub Assembly e MB991824 V C I e MB991827 M U T IIl USB Cable e MB991910 M U T III Main Harness A TSB Revision 00 36 GENERAL PRECAUTIONS BEFORE SERVICE N CAUTION To prevent damage to scan tool MB991958 always turn the ignition switch to the LOCK OFF position before con necting or disconnecting scan tool MB991958 1 After the ignition switch is in LOCK OFF position connect scan tool MB991956 to the data link connector 2 Turn the ignition switch to the ON position 3 Select MFI from System select Screen of scan tool MB991958 4 Select Special Function from MFI Screen 5 Select Learned value reset from Special Function Screen 6 Select All learned value from Learned value reset Screen 7 8 Initialize the learning value by pressing the OK
29. mum fuel economy and cold starting e If engine oil other than 5W 30 is used the engine may be seized by poor lubrication AC710765AB TSB Revision 00 56 GENERAL RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE SELECTION OF COOLANT COOLANT Relationship between Coolant Concentration and Specific Gravity A CAUTION If the concentration of the coolant is below 30 the anti corrosion property will be adversely affected In addition if the concentration is above 6095 both the anti freeze and engine cooling properties will decrease affecting the engine adversely For these reasons be sure to maintain the concentration level within the specified range Do not use a mixture of different brands of anti freeze Coolant temperature C F and Freezing safe operating Coolant specific gravity temperature temperature concentration Specific volume 10 50 20 68 30 86 40 50 C F C F 104 122 1 054 1 050 1 046 1 042 1 036 1 063 1 058 1 054 1 049 1 044 1 071 1 067 1 062 1 057 1 052 30 35 1 079 1 074 1 069 1 064 1 058 36 32 8 31 23 8 Example The safe operating temperature is 15 C 5 F when the specific gravity is 1 058 at the coolant temperature of 20 C 68 F TSB Revision GENERAL 00 57 SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENAN
30. or 3M AAD Part No 8679 black or 3M AAD Part No 8678 black Press In Place Silicone gasket strips 3M AAD Part No 8661 or 3M AAD Part No 8663 Super Silicone sealant Permatex The Right Stuff No 25223 QUICK FIX ADHESIVE 3M AAD Part No 8155 Quick Fix Adhesive Loctite amp Quicktite Super Glue 21309 ANAEROBIC Fixing of various threads bolts screws Fixing of differential drive gear bolt Connecting of tilt steering bolt Fan pulley gear Sealing of small gaps and flange faces AAD Part No 8730 High Strength Threadlocker or 3M AAD Part No 8731 Medium Strength Threadlocker Loctite 271 High Strength Threadlocker 27100 or 27200 3M AAD Part No 8883 Rubberized Undercoating Aerosol or 3M AAD Part No 8864 Body Schutz Undercoating qt TSB Revision Permatex Heavy Duty Undercoating 81833 5
31. severe surface cracking pulling scuffing or worn spots If the fabric casing of the hoses is exposed by cracks or abrasion in the rubber hose cover the hoses should be replaced Eventual deterioration of the hose and possible bursting failure may occur Incorrect installation twisting or interference with wheel tire or chassis TSB Revision 00 78 Boots Dust cover AC100948 AC 000109 AC Filler plug SS Drain plug N 2 705198 GENERAL MAINTENANCE SERVICE 20 BALL JOINT AND STEERING LINKAGE SEALS INSPECT FOR GREASE LEAKS AND DAMAGE M1001003500548 1 These components which are permanently lubricated at the factory do not require periodic lubrication Damaged seals and boots should be replaced to prevent leakage or grease contamination 2 Inspect the dust cover and boots for proper sealing leakage and damage and replace them if defective 21 DRIVE SHAFT BOOTS INSPECT FOR GREASE LEAKS AND DAMAGE M1001003600545 1 These components which are permanently lubricated at the factory do not require periodic lubrication Damaged seals and boots should be replaced to prevent leakage or grease contamination 2 Inspect the dust cover and boots for proper sealing leakage and damage Replace them if defective 22 SUSPENSION SYSTEM INSPECT FOR LOOSENESS AND DAMAGE M1001009600264 Visu
32. the specified torque 100 N m 74 ft lb When all numbers of wheel nuts are not used the tightening torque is excessive or not equal the brake disk rotor or drum may be deformed resulting in judder If the disk thickness is less than the limits replace it with a new one If thickness variation exceeds the specification turn rotor with an on the car type brake lathe MAD DL 8700PF or equivalent If the calculated final thickness after turning the rotor is less than the standard value replace the disk FRONT BRAKE DISK RUN OUT CHECK AND CORRECTION 1 2 3 Remove the brake assembly and then hold it with wire Temporarily install the disk with the hub nut Place a dial gauge approximately 5 mm 0 2 inch from the outer circumference of the brake disk and measure the run out of the disk Limit 0 06 mm 0 0024 inch Front 0 08 mm 0 0032 inch Rear When the brake disk runout exceeds the limit value correct the brake disk runout according to the following procedure 1 Before removing the brake disk make marks using a chalk to the stud bolt on the side with the greater runout and to both sides of the stud bolt 2 Check the wheel bearing axial looseness Refer to GROUP 26 On vehicle Service Wheel Bearing End Play Check P 26 7 Front or GROUP 27 On vehicle Service Wheel Bearing End Play Check P 27 32 lt gt 3 When looseness is within the limit value install the brake
33. time be careful not to short the connector pins with the test probes Doing so may damage the circuits inside the ECU Touch the pin directly with the test probe TSB Revision 00 1 4 GENERAL HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS CONNECTOR INSPECTION SERVICE POINTS VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out Stretched an broken wires at terminal section Low contact pressure between male and female terminals Low connection pressure due to rusted terminals or foreign matter lodged in terminals Connector disconnected or improperly connected Low contact pressure ACX00868AE CONNECTOR PIN INSPECTION If the connector pin stopper is damaged the terminal connec tions male and female pins will not be perfect even when the connector body is connected because the pins may pull out of 3 gt the back side of the connector Therefore gently pull the wires gt 22 by one to make sure that no pins pull out of the connector 55 00869 5S TSB Revision GENERAL 00 15 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS MB991219 CONNECTOR ENGAGEMENT INSPECTION Required Special Tool MB991219 Inspection Harness contained in MB991223 Test Harness Use special tool MB991219 to inspect the engagement of the male pins and female pins Pin drawing for
34. tle actuator control motor valve Fully closed position is elimi nated so that the throttle valve opening angle control would not be performed correctly When the battery cable is disconnected and reconnected initialize the throttle actuator control motor using the following procedure 1 Turn the ignition switch to the ON position then turn the ignition switch to LOCK OFF position 2 For 10 seconds or more keep the ignition switch in LOCK OFF position TIMING CHAIN MAINTENANCE 1001016500269 If the vehicle equipped with 2 0 turbocharged engine contin ues the rough driving like competitive running 1 the amount of carbon mixed into the engine oil tends to increase This can possibly cause the timing chain to gradually elongate To pre vent this the function or logic monitoring the amount of elonga tion of the timing chain is integrated into the ECM When the ECM detects the elongation of the timing chain the warning is shown on the multi information display of combination meter as shown in the illustration This gives the driver the information AK801166 that the visual check of the elongation of the timing chain is necessary If this warning is continuously neglected the timing chain can possibly interfere with the other engine components resulting in the engine damaged NOTE 1 The competitive running means the running that constantly repeats the cycle of the full opened position of the accelerator pedal and the
35. to provide maximum pro tection for the vehicle owner s investment against all reasonable types of driving conditions Since these conditions vary with the individual vehicle owner s driving habits the area in which the vehicle is oper ated and the type of driving to which the vehicle is subjected it is necessary to prescribe lubrication and maintenance service on a time frequency as well as mileage interval basis Oils lubricants and greases are classified and graded according to standards recommended by the Society of Automotive Engineers SAE the Ameri can Petroleum Institute API and the National Lubri cating Grease Institute NLGI MAINTENANCE SCHEDULES Information for service maintenance is provided in the SCHEDULED MAINTENANCE TABLE Three schedules are provided one for Required Mainte nance one for General Maintenance and one for Severe Usage Service The item numbers in SCHEDULED MAINTENANCE TABLE correspond to the section numbers in MAINTENANCE SERVICE SEVERE SERVICE Vehicles operating under severe service conditions will require more frequent service Component service information is included for vehi cles operating under one or more of the following conditions M1001001200529 1 Trailer towing or police taxi or commercial type operation 2 Operation of Vehicle 1 Short trip operation at freezing temperature engine not thoroughly warmed up 2 More than 50 operation in heavy city traffic
36. 00 1 HOW USE THIS MANUAL TROUBLESHOOTING GUIDELINES HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS TROUBLESHOOTING CONTENTS HOW TO USE THE INSPECTION CONNECTOR MEASUREMENT SERVICE POINTS ted a CONNECTOR INSPECTION SERVICE POINTS 2 Qo chai ae HOW TO COPE WITH INTERMITTENT MALFUNCTIONS HOW TO TREAT PAST TROUBLE INSPECTION SERVICE POINTS FOR A BLOWN VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER CHASSIS ENGINE MODEL STAMPING VEHICLE IDENTIFICATION CODE PLATE TIRE AND LOADING INFORMATION PRECAUTIONS BEFORE SERVICE CAUTIONS FOR WORKING IN ENGINE COMPARTMENT SUPPLEMENTAL RESTRAINT SYSTEM SRS RUE SCAN TOOL MULTI USE TESTER M U T Ill SUB ASSEMBLY GROUP 00 GENERAL CONTENTS 00 3 HOW TO PERFORM VEHICLE IDENTIFICATION NUMBER VIN 00 22 00 6 CODING smarts 00 26 INITIALIZATION PROCEDURE FOR LEARNING VALUE MFIENGINE 00 35 ENGINE IDLING LEARNING 00 7 PROCEDURE 425255745 09044725271 00 36 n TIMING CHAIN MAINTENANCE 00 37 SERVICING ELECTRICAL SYSTEM 00 41 00 10 HOW TO SHIFT LOCK FORCED 00 42 00 12 VEHICLE VV M LIIMC
37. 00 km 3 000 miles system damage Rear axle oil for Change X X X X X differential part Rear axle oil for Change X X X X X torque transfer part Tires Rotate Every 3 months or every 4 800 km 3 000 miles Air purifier filter Inspect for clogging Every 3 months or every 4 800 km 3 000 miles Replace Every 6 months or every 9 600 km 6 000 miles NOTE 1 ACD Active Center Differential 2 AYC Active Yaw Center system Severe usage conditions Driving on dusty rough muddy or salt spread roads Towing or police taxi or commercial operation Extensive idling and or low speed operation Repeated short trip operation at freezing temperatures engine not thoroughly warmed up Extended use of brakes while driving Driving in sandy areas More than 50 operation in heavy city traffic during hot weather above 32 C 90 F TSB Revision GENERAL MAINTENANCE SERVICE 00 61 MAINTENANCE SERVICE 1 FUEL SYSTEM TANK PIPE LINE AND CONNECTION AND FUEL TANK FILLER TUBE CAP CHECK FOR LEAKS M1001001600367 Check for damage or leakage in the fuel lines and connections 2 FUEL HOSES CHECK CONDITION M1001001700331 1 Inspect the surface of fuel hoses for heat and mechanical damage Hard and brittle rubber cracking tears cuts abrasions and excessive swelling indicate deterioration of the rubber 2 If the fabric casing of the rubber
38. 608435 AB System Select System List MPI GDI Diesel FA S T IMMO Keyless TPMS 2 ABS ASC ASTC SAS Model Year 7 Up to 2005 MY From to 2006 MY Vehicle Information Model Name Model Year Model Code FAKE IIE Multi Select 4WD Loading Option Setup SRS Airbag Option Name With Option 8 Keyless amp TPMS 44 IMMOBI amp FAST amp TPMS 8 ez Yar OK button AC609809AB CAUTION Check that diagnostic trouble code P0603 EEPROM fail is not set When diagnostic trouble code P0603 EEPROM fail is set the ECM cannot store the key code even if the key code is registered If this diagnostic trouble code is set troubleshoot the ECM and repair Then register the key code to the ECM A CAUTION Before connecting or disconnecting the MB991958 Scan Tool turn the ignition switch to the LOCK OFF position Connect scan tool MB991958 to the 16 pin data link connector as follows NOTE For details on how to use scan tool MB991958 refer to the Owner s Manual 1 Ensure that the ignition switch is at the LOCK OFF position 2 Start up the personal computer 3 Connect
39. AKE PAD CHECK A CAUTION If there is a significant difference in the thicknesses of the pads on the left and right sides check moving parts Refer to P 35A 21 1 Visually check the thickness of brake pad from the inspection hole of the caliper body Standard value 9 85 mm 0 39 inch lt Front gt 9 0 mm 0 35 inch lt Rear gt Limit 2 0 mm 0 08 inch lt Front gt 2 0 mm 0 08 inch lt Rear gt 2 When the thickness is lower than the limit value replace both brake pads right and left as a set Refer to P 35A 18 M1001003200569 TSB Revision GENERAL 00 75 MAINTENANCE SERVICE DISK BRAKE ROTOR CHECK N CAUTION Disk brakes must be kept within the allowable service val ues in order to maintain normal brake operation Before turning the brake disk the following conditions should be checked Inspection items Remarks Scratches rust saturated lining materials and wear If the vehicle is not driven for a long period of time sections of the disks that are not in contact with the pads will become rusty causing noise and shuddering f grooves and scratches resulting from excessive disk wear are not removed prior to installing a new pad assembly there will be inadequate contact between the disk and the lining pad until the pads conform to the disk Run out Excessive run out of the disks will increase the pedal depression resistance due to piston kick back
40. CE TABLE SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE Inspection and service should be performed any time a malfunction is observed or suspected No Emission control Service Mileage in 15 30 45 60 75 90 105 120 135 150 system intervals thousands maintenance Kilometers in 24 48 72 96 120 144 168 192 216 240 thousands Months 15 30 45 60 75 90 105 120 135 150 1 Fuel system tank Check for leaks X X X X X pipe line and connection and fuel tank filler tube cap 2 Fuel hoses Check condition X X X X X 3 Air cleaner Replace XX X X X X X X IX X element 4 Evaporative Check for leaks and clogging X X emission control system except evaporative emission canister 5 Spark plugs lridium tipped Replace X X type 6 Intake and exhaust Inspect and adjust X X valve clearance If valve noise increases adjust valve clearance 7 Drive belts for the Replace X X X X X generator and power steering oil pump 8 Exhaust system Check and service X X X X X connection portion of muffler muffler pipes and converter heat shields NOTE This maintenance is recommended but is not required to maintain the emissions warranty TSB Revision 00 58 GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE General maintenance GENERAL SCHEDULED MAINTENANCE TABLE
41. DISC BRAKE ASSEMBLY 35A 21 Operating procedures cautions etc on removal INSTALLATION SERVICE POINTS 1 In order to measure the brake drag torque gt gt lt lt BRAKE HOSE INSTALLATION measure the hub torque with the pads removed by 1 Install the brake hose end on the bracket and the following procedure another end on the front brake assembly 1 Use a spring balance to measure the hub torque in the forward direction View A BER 2 Record hub torque with pads removed racke EX Correct UN CAUTION Do not let any oil grease or other contamination get onto the friction surfaces of the pads and brake discs installation disassembly and reassembly are described 2 After re installing the caliper support to the knuckle install the pad clips and the pads to the caliper support Brake hose AC304119AC 2 Twist the brake hose towards the lesser torsion between the brake hose and bracket as shown and secure it to the bracket gt gt lt lt BRAKE CALIPER ASSEMBLY MB990520 4 INSTALLATION 7 K AC102474AB 3 Clean the piston and insert into cylinder with special tool disc brake piston expander MB990520 4 Install the pad clips and the pads to the caliper support and tighten the pin bolt to the specified torque AC302742 Tightening torque 38 4 N m The title of the page following th
42. ECU variant coding and option coding items are changed the customized contents are reset In such case the functions need to be recustomized The ETACS ECU option coding data can be checked or changed by operating scan tool MB991958 How to check option coding data 1 CON Ronmat N Connect the scan tool MB991958 Refer to P 00 26 2 Turn the ignition switch to the ON position 3 4 Select From 2006 MY under Model Year Check that Select System select from the start up screen Vehicle Information contents are correct Select ETACS from System List and then press OK button NOTE If Loading Option Setup list is shown click appropriate box Select Coding Select Option Coding Information Check the displayed option coding information ow to change option coding data Connect the scan tool MB991958 Refer to P 00 26 Turn the ignition switch to the ON position Select System select from the start up screen Select From 2006 MY under Model Year Check that Vehicle Information contents are correct Select ETACS from System List and then press OK button NOTE If Loading Option Setup list is shown click appropriate box Select Coding Select Option Coding Change to correct option coding data TSB Revision GENERAL 00 35 PRECAUTIONS BEFORE SERVICE LIST Item name Number of speaker Seat material Auto
43. GER is not followed the result is severe bodily harm or even death I WARNING is not followed the result could be bodily injury f a CAUTION is not followed the result could be damage to the vehicle vehicle components or service equipment TIGHTENING TORQUE INDICATION The tightening torque indicates a median and its tol erance by a unit of m in Ib or N m ft lb For fasteners with no assigned torque value refer to P 00 51 SPECIAL TOOL NOTE Only MMC special tool part numbers are called out in the repair sections of this manual Please refer to the special tool cross reference chart located at the beginning of each group for the special tool number that is available in your market ABBREVIATIONS The following abbreviations are used in this manual for classification of model types 2 0 L engine 1 998 liter lt 4 11 gt engine or a model equipped with such an engine Air conditioning AWD Indicates the all wheel drive vehicles Keyless Operation System KOS Free hand Advanced Security Transmitter F A S T key M T Indicates manual transaxle or models equipped with manual transaxle MFI Multiport fuel injection or engines equipped with multiport fuel injection ECM Indicates the engine control module Indicates the transaxle control module TC SST Indicates the twin clutch sportronic shift transmission TSB Revision 00 4 GENERAL HOW TO USE THIS MANUAL
44. ICATION TESTS If verification of the symptom s is difficult proce dures for checking operation and verifying symptoms are shown 704160 3 DIAGNOSTIC FUNCTION The following trouble code diagnosis are shown How to read diagnostic trouble codes How to erase diagnostic trouble codes Input inspection service points 4 DIAGNOSTIC TROUBLE CODE CHART If the scan tool displays a diagnostic trouble code find the applicable inspection procedure according to this chart 5 SYMPTOM CHART If there are symptoms even though the scan tools show that no DTCs are set inspection procedures for each symptom will be found by using this chart 6 DIAGNOSTIC TROUBLE CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnostic trouble code Refer to P 00 10 TSB Revision 00 9 HOW USE TROUBLESHOOTING INSPECTION SERVICE POINTS 7 SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptom listed in the Symptom Chart Refer to 00 10 8 SERVICE DATA REFERENCE TABLE Inspection items and normal judgment values have been provided in this chart as reference information 9 CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors inspec tion items and standard values have been provided in this chart as reference information TERMINAL VOLTAGE CHECKS 1 Connect a needle nosed wire probe to a voltmeter probe A CAUT
45. IFICATION No Content 6 Trim level 5 PREMIUM Price class 8 SPORTS Body style 4 door sedan Engine type V 2 01 DOHC MIVEC with charge air cooler turbocharger 4B11 9 Check digits 0 1 2 3 9 X 10 year 2010 11 Mizushima 12 Serial number 000001 to 999999 NOTE Check digit means a single number or letter X used to verify the accuracy of transcription of vehicle identification number VEHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR USA VEHICLES FOR 50 STATES Model code VIN Except serial number Engine model M1001000304503 Transaxle model JA32W8FV AU JA32W8FV AU JA32W5FV AU CZ4AS NGFZL2M MGFZL2M MPFZL2M VEHICLES FOR PUERTO RICO Model code VIN Except serial number 4B11 1 998 cm 121 9 cu in DOHC MIVEC gasoline engine with charge air cooler turbocharger Engine model W5M6A AWD 5 W6DGA AWD Twin Clutch Sportronic Shift Transmission TC SST Transaxle model JA32W8FV AU JA32W8FV AU JA32W5FV AU CZ4AS NGFZL2M MGFZL2M MPFZL2M VEHICLES FOR CANADA VIN Except serial number Model code 4B11 1 998 cm 121 9 cu in DOHC MIVEC gasoline engine with charge air cooler turbocharger Engine model W5M6A AWD 5 W6DGA AWD Twin Clutch Sportronic Shift Tran
46. ION Short circuiting the positive probe between connector terminal and ground could damage the vehicle wiring the sensor the ECU or all three Use care to prevent this 2 Insert the needle nosed wire probe into each of the ECU connector terminals from the wire side and measure the voltage while referring to the check chart NOTE Measure voltage with the ECU connectors connected You may find it convenient to pull out the ECU to make it easier to reach the connector terminals Checks don t have to be carried out in the order given in the chart 3 If voltage readings differ from normal condition values check related sensors actuators and wiring Replace or repair as needed 4 After repair or replacement recheck with the voltmeter to confirm that the repair has corrected the problem TERMINAL RESISTANCE AND CONTINUITY CHECKS 1 Turn the ignition switch to the LOCK OFF position 2 Disconnect the ECU connector A CAUTION If resistance and continuity checks are per formed on the wrong terminals damage to the vehicle wiring sensors ECU and or ohmmeter may occur Use care to prevent this 3 Measure the resistance and check for continuity between the terminals of the ECU harness side connector while referring to the check chart NOTE Checks don t have to be carried out in the order given in the chart 4 If the ohmmeter shows any deviation from the Normal Condition value check the corres
47. LUID FOR ACTIVE CENTER DIFFERENTIAL AND ACTIVE YAW CONTROL SYSTEM CHECK FLUID LEVEL M1001017500057 FLUID LEVEL CHECK WHEN THE SCAN TOOL IS NOT USED 1 2 5 Remove the trunk room side trim lid on the right of the trunk room If the vehicle has been run leave it for 90 min or more in an ordinary temperature 10 30 50 86 F to allow the accumulator internal pressure to drop NOTE If the ambient temperature is 10 C 50 F or less allow more time to leave the vehicle to stand idle Check that the oil reservoir fluid level is in between MAX and MIN If the fluid level is not in between MAX and MIN fill the specified fluid Specified fluid DIAMOND ATF SP IlI Install the trunk room side trim lid WHEN THE SCAN TOOL IS USED 1 Remove the trunk room side trim lid on the right of the trunk room TSB Revision 00 72 cys MR V reservoir 705200 GENERAL MAINTENANCE SERVICE N CAUTION Turn the ignition switch to the LOCK OFF position before connecting or disconnecting the scan tool 2 Set the scan tool to the 16 pin data link connector Refer to 27 6 3 Turn ignition switch to the ON position 4 Using the scan tool forcibly activate the hydraulic unit item No 03 to reduce the pressure inside the accumulator Refer to GROUP 22A Actuator Test Table NOTE e With th
48. MMOBI amp Keyless amp TPMS is selected System Select FA STINNOKeyess TPMS 7 Special Function Tire Pressure Sensor ID Registration Tire Pressure Sensor ID Check Tire Pressure Sensor Check Key Registration Key Registration Barcode No Keyless ID Reg ENG key code Reg ENG key code amp VIN Reg Additional key registration Please select function lele 802949 FAS TIMNOXKeylessTPMS Special Funclion ENG key code amp VIN Reg Key Code Registration OK button Key Code is registered to Engine ECU Press OK bullon to execute II 709286 FAS T MMO Keyless TPMS Special Function Engine key code amp VIN Reg Current VIN acne New VIN 1 2 3 4 5 6 8 9 0 H J K L M N gp Q R 5 T w Y z Back Sace Clear Input new VIN then press OK button e ly 709287 AS TAMMO Keyless TPMS Special Function Engine key code amp VIN Reg Result of VIN Writing Current Before Writing AC709285 11 Push the OK button after ENG key code amp VIN Reg is dis
49. RIORATION OR ERIGI WT 20 BALL JOINT AND STEERING LINKAGE 7 DRIVE BELT FOR THE GENERATOR AND 8 SEALS INSPECT FOR GREASE LEAKS AND POWER STEERING OIL PUMP 00 64 8 EXHAUST SYSTEM CONNECTIONS 21 DRIVE SHAFT BOOTS INSPECT FOR PORTION OF MUFFLER MUFFLER PIPES AND GREASE LEAKS AND DAMAGE 00 78 CONVERTER HEAT SHIELDS CHECK AND 22 SUSPENSION SYSTEM INSPECT FOR 00 65 LOOSENESS AND DAMAGE 00 78 9 ENGINE OIL 00 65 23 REAR AXLE OIL FOR DIFFERENTIAL 10 ENGINE OIL FILTER REPLACE 00 66 PART 00 78 11 MANUAL TRANSAXLE OIL CHECK OIL ee AXLE OIL FOR TORQUE LEVEL AND CONDITION RCHANGE 00 66 s ANGE MECHANISM PART 12 TWIN CLUTCH SPORTRONIC SHIFT nes TRANSMISSION TC SST CHECK THE 25 TIRES 00 79 FLUID LEAKAGE IF NECESSARY CHECK 26 AIR PURIFIER FILTER REPLACE 00 79 THE FLUID LEVEL CHANGE 00 68 13 TWIN CLUTCH SPORT SHIFT MAIN SEALANT AND ADHESIVE TRANSMISSION OIL FILTER CHANGE 0070 00 80 GENERAL 00 3 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL MAINTENANCE REPAIR AND SERVICING EXPLANATIONS This manual provides explanations etc concerning procedures for the inspection maintenance repair and servicing of the subject m
50. Revision 00 42 GENERAL PRECAUTIONS BEFORE SERVICE A CAUTION Before connecting or disconnecting the negative bat tery cable be sure to turn the ignition switch to the LOCK OFF position and turn off the lights If this is not done there is the possibility of semiconductor parts being damaged After completion of the work and the negative battery terminals is connected warm up the engine and allow it to idle for approximately 10 minutes under the condi tions described below in order to stabilize engine con trol conditions and then check to be sure that the idle is satisfactory Engine coolant temperature 85 95 C 185 203 Lights and all accessories OFF Transaxle P position Steering wheel straight forward position 2 When servicing the electrical system disconnect the negative cable terminal from the battery HOW TO SHIFT LOCK FORCED RELEASE M1001018100193 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 lt 55 gt 1 Remove the floor console box cup holder and the floor console panel assembly Refer to GROUP 52 Console Assembly 52 10 2 Turn the ignition switch to the position other than the LOCK OFF position 3 Insert a screwdriver or a similar tool from the section A shown in the figure While pressing the shift lock forced
51. SERVICE Item name Initial value Washer function improvement Disabled IG key illumination W getting off Turn signal bulb 21W 21W 5W Rear wiper Disabled Fold mirror Disabled Headlight 4 beams 3 Comfort Hazard Disabled Headlight washer Disabled Front fog light mode A spec Front fog light Present Rear fog light 2 NotPresent ChgOk Room light delay timer door amp H L Long Room light by H L Full Gate Trunk light Mode 1 trunk Headlight auto cut mode C spec Headlight auto cut Enable Door lock system A spec NAS Auto door lock unlock Disabled key remainder unlock B spec Dr and As Horn type Dual horn Gate trunk opener mode Present Cooling fan Relay control Security alarm mode C spec Security alarm function Present Chg Ng Pre alarm Not present Multi mode RKE Disabled Gate Trunk Trunk type Manner Switch NotPresent ChgNg Remote engine starter 2 Present Chg Ok Panic Alarm Enable Roomlight improvement Enable Front wiper Speed Sensitive or Rain Sensitive Comfort flasher type Present Chg Ok Dome light center switch Not present Wiper washer check bulb Present TSB Revision GENERAL 00 32 PRECAUTIONS BEFORE SERVICE Item name Initial value AUDIO S RADIO type AM 1kHz step or Other H L leveling type Not present AFS ACL type Not present ESS by turn light Not present
52. ally inspect the front rear suspension components for dete rioration and damage Re tighten the front rear suspension components retaining bolts to specified torque 23 REAR AXLE OIL FOR DIFFERENTIAL PART CHANGE 1 Remove the filler plug 2 Remove the drain plug and drain oil 3 Install the drain plug and tighten it to the specified torque Tightening torque 32 2 m 23 2 ft lb 4 Fill the specified gear oil up to the bottom of the filler plug hole Specified gear oil MITSUBISHI Genuine DIA QUEEN Multi gear oil LS Amount to use 0 55 0 02 dm 0 58 0 02 qt 5 Install the filler plug and tighten it to the specified torque Tightening torque 49 10 m 37 7 ft lb M1001007200152 TSB Revision GENERAL 00 79 MAINTENANCE SERVICE 24 REAR AXLE OIL FOR TORQUE TRANSFER MECHANISM PART CHANGE CCS 1 Remove the filler plug oc 2 Remove the drain plug and drain oil 3 Install the drain plug and tighten it to the specified torque Tightening torque 32 2 m 23 2 ft lb M1001007500186 i Filler plug cee XC 4 Fill the specified gear up to the bottom of the filler plug hole Of Specified gear oil DIAMOND ATF SP III Drain plug Amount to use 0 55 0 60 dm 0 58 0 63 qt 7 gt AC705199AC 5 Install the filler plug and tighten it to the specified torque Tightening torque 49 10 m 37 7
53. arger Assembly P 15 18 TSB Revision GENERAL 00 73 MAINTENANCE SERVICE 6 Disconnect the turbocharger water return hose and drain the coolant in the water jacket 7 Remove the radiator condenser tank and drain the coolant 8 Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area 9 Securely tighten the drain plug of the radiator 10 Reinstall the radiator condenser tank A CAUTION Do not use alcohol or methanol anti freeze or any engine coolants mixed with alcohol or methanol anti freeze The use of an improper anti freeze can cause corrosion of the aluminum components 11 By referring to the section on coolant select an appropriate __ Turbo charger air inlet fitting 7 KE 2i concentration for safe operating temperature within the ir nua Sn range of 30 to 60 Use special tool MB991871 to refill the lt ae M 8991871 engine coolant up to top of the radiator port A TA A X convenient mixture is 50 water and 50 antifreeze V LZA m solution freezing point 31 C 23 8 2 ED E 3 j Recommended antifreeze Long Life Antifreeze i cJ Coolant or an equivalent N Quantity 7 5 dm 7 9 quarts AC705466 AC NOTE For how to use special tool 991871 refer to its manufacturer s instructions 12 Tighten the radiat
54. art other than the oil pan and the oil seal replace the TC SST assembly M1001016700014 TC SST FLUID LEVEL CHECK 1 Remove the engine room under cover front B assembly Refer to GROUP 51 Under Cover P 51 15 2 Start the engine and let it run at idle to warm it up for 15 minutes 3 Move the shift lever to every position P R N D manual mode Hold for 20 seconds in each position and then move it to the P range 4 Stop the engine 5 Remove the air cleaner element and air cleaner intake duct Refer to GROUP 15 Air Cleaner P 15 11 6 Remove the filler plug CAUTION The drained fluid can be reused if it is between the replacement intervals Replacement interval Normal condition 96 000 km 60 000 miles Severe condition 48 000 km 30 000 miles When reusing the drained fluid make sure that no for eign object gets into the fluid Transaxle control 7 Remove the drain plugs and leave it for 3 minutes to drain the fluid NOTE Because the fluid in the oil cooler oil filter and TC SST assembly cannot be drained the amount of drained fluid will be approximately 5 5 dm approximately 5 8 Uu Drain plu quarts 8 Tighten the drain plugs to the specified torque _ Tightening torque 35 5 m 26 4 ft lb SO Centermember 50255 670451766 N CAUTION Measure the drained fluid If the drained fluid is l
55. ce 1 N 0 2 pound or more HOW TO COPE WITH INTERMITTENT MALFUNCTIONS M1001013900451 Most intermittent malfunctions occur under certain conditions If those conditions can be identified the cause will be easier to find TO COPE WITH INTERMITTENT MALFUNCTION 1 ASK THE CUSTOMER ABOUT THE MALFUNCTION Ask what it feels like what it sounds like etc Then ask about driving conditions weather frequency of occurrence and so on 2 DETERMINE THE CONDITIONS FROM THE CUSTOMER S RESPONSES Typically almost all intermittent malfunctions occur from condi tions like vibration temperature and or moisture change poor connections From the customer s responses it should be rea soned which condition is most likely 3 USE SIMULATION TEST Use the simulation tests below to attempt to duplicate the cus tomer s complaint Determine the most likely circuit s and per form the simulation tests on the connectors and parts of that circuit s Be sure to use the inspection procedures provided for diagnostic trouble codes and trouble symptoms For temperature and or moisture condition related intermittent malfunctions try to change the conditions of the suspected cir cuit components then use the simulation tests below TSB Revision 00 1 6 GENERAL HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 4 VERIFY THE INTERMITTENT MALFUNCTION IS ELIMINATED Repair the malfunctioning part and try to duplicate the condi tio
56. disk after changing the phase between the hub and the brake disk then check the runout of the brake disk again TSB Revision lat washer AC006226 AE 610304 GENERAL 00 77 MAINTENANCE SERVICE A CAUTION After a new brake disk is installed always grind the brake disk with on the car type brake lathe If this step is not carried out the brake disk run out exceeds the specified value resulting in judder When the on the car type lathe is used first install M12 flat washer on the stud bolt in the brake disk side according to the figure and then install the adapter If the adapter is installed with M12 flat washer not seated the brake disk rotor may be deformed resulting in inac curate grinding Grind the brake disk with all wheel nuts diagonally and equally tightened to the specified torque 100 N m 74 ft Ib When all numbers of wheel nuts are not used or the tightening torque is excessive or not equal the brake disk rotor or drum may be deformed resulting in judder If the run out cannot be corrected by changing the phase of the brake disk replace the brake disk or grind it with the on the car type brake lathe MAD DL 8700PF or equivalent 19 BRAKE HOSES CHECK FOR DETERIORATION OR LEAKS M1001003400552 Inspection of brake hoses should be included in all brake ser vice operations The hoses should be checked for 1 Incorrect length
57. e Door hinges Trunk lid hinges LUBRICANT CAPACITY TABLE Description Specification 4 8 5 07 0 5 0 52 0 3 0 32 7 5 7 93 Engine oil dm qt Oil pan excluding oil filter Oil cooler Oil filter Engine coolant dm qt TSB Revision GENERAL 00 55 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE Description Specification Transaxle oil dm qt Manual transaxle M T 2 5 2 6 Twin clutch sport shift transmission 7 6 8 0 TC SST Transfer oil dm qt 0 8 0 85 ACD and AYC differential fluid dm qt 1 0 1 06 AYC differential gear oil Differential mechanism part dm qt 0 55 0 58 Power steering fluid dm qt 1 0 1 06 Fuel tank dm gal 55 0 14 5 LUBRICANT SELECTION ENGINE OIL N CAUTION ILSAC certification symbol Never use nondetergent or straight mineral oil Starburst symbol Use only engine oils displaying the ILSAC certification mark Starburst symbol on the container 2 2 e GASOLINE E AC609011AB If these oils are not available an API classification SM or API service symbol higher can be used AC709997AB OIL VISCOSITY The SAE grade number indicates the viscosity of the oil A proper SAE grade number should be selected according to 40 30 20 10 0 10 20 30 40 50 C ambient temperature NOTE SAE 5W 30 engine oil is strongly recommended for opti
58. e control module is displayed 12 Push the OK button after VIN Writing will start Are you sure is displayed 13 Push the OK button after Completed is displayed 14 Result of VIN writing is displayed 15 Resister the other ID code Refer to GROUP 42B Troubleshooting ID Code Registration Judgment Table P 42B 11 Vehicles with KOS or GROUP 42C Troubleshooting ID Code Registration Judgment Table P 42C 9 Vehicles with WCM gt CODING LIST N CAUTION With the ETACS functions being customized if any of the ETACS ECU variant coding and option coding items are changed the customized contents are reset In such case the functions need to be recustomized Before troubleshooting check that the coding data written into the engine control module TC SST ECU and ETACS ECU are normal If they are not the same as the initial settings various M1001015000937 functions and systems will not work correctly VARIANT CODING Required Special Tools e MB991958 Scan Tool Sub Assembly e MB991824 Vehicle Communication Interface e MB991827 USB Cable e MB991910 M U T III Main Harness A Vehicles with CAN communication system TSB Revision GENERAL 00 27 PRECAUTIONS BEFORE SERVICE 7 991827 608435 coding data be checked by operating scan tool MB991958 NOTE For detai
59. e forced activation oil level check mode the hydraulic unit direction valve is operated 20 times to right and left and then the operation is canceled automati cally Also using the clear key on the scan tool the acti vation can be forcibly canceled e When the functions are suspended by the fail safe func tion the hydraulic unit cannot be forcibly activated 5 Check that the oil reservoir fluid level is in between MAX and MIN 6 If the fluid level is not in between MAX and MIN fill the specified fluid Specified fluid DIAMOND ATF SP IlI T Install the trunk room side trim lid 16 ENGINE COOLANT CHANGE M1001003100669 1 Remove the engine room under cover front A RH Refer to GROUP 51 Under Cover P 51 15 Z WARNING When removing the radiator cap use care to avoid contact with hot coolant or steam Place a shop towel over the cap and turn the cap counterclockwise a lit tle to let the pressure escape through the vinyl tube After relieving the steam pressure remove the cap by slowly turning it counterclockwise 2 Drain the water from the radiator heater core and engine after unplugging the radiator drain plug and removing the radiator cap 3 Remove the engine room under cover front B Refer to GROUP 51 Under Cover P 51 15 4 Remove the air cleaner intake hose Refer to GROUP 15 Air Cleaner P 15 11 5 Remove the turbocharger compressor bracket Refer to GROUP 15 Exhaust Manifold and Turboch
60. e page on which the diagram of component parts is presented indicating the locations of lubrication and sealing procedures LUBRICATION POINTS lt Indicates by symbols where lubrication is necessary CAUTION The piston seal inside the caliper seal kit is coated with a special grease d Do not wipe this grease off Brake fluid DOT 3 or DOT 4 Symbols for lubrication sealants and adhesives Symbols are used to show the locations for lubrication and for application of sealants and adhesives Multi purpose grease unless there is a brand These symbols are included in the diagram of compo or type specified nent parts or on the page following the component Sealant or adhesive parts page The symbols do not always have accomp Automatic transmission fluid brake fluid power anying text to support that symbol steering fluid or air conditioning compressor oil Engine oil or gear oil Adhesive tape or butyl rubber tape 00 5 AC509265AO TSB Revision 00 6 GENERAL TROUBLESHOOTING GUIDELINES TROUBLESHOOTING GUIDELINES VERIFY THE COMPLAINT Make sure the customer s complaint and the ser vice writer s work order description are under stood before starting work Make sure the correct operation of the system is understood Read the service manual description to verify normal system operation Operate the system to se
61. e the symptoms Look for other symptoms that were not reported by the customer or on the work order that may be related to the problem DETERMINE POSSIBLE CAUSES Compare the confirmed symptoms to the diagnostic symptom indexes to find the right diagnosis proce dure If the confirmed symptoms cannot be found on any symptom index determine other possible causes Analyze the system diagrams and list all possible causes for the problem symptoms Rank all these possible causes in order of proba bility based on how much of the system they cover how likely they are to be the cause and how easy they will be to check Be sure to take experience into account Consider the causes of similar problems seen in the past The list of causes should be ranked in order from general to specific from most likely to least likely and from easy to check to hard to check M1001008800287 FIND THE PROBLEM After the symptoms have been confirmed and prob able causes have been identified the next step is to make step by step checks of the suspected system components junctions and links in logical order Use the diagnostic procedures in the service manual whenever possible Follow these procedures care fully to avoid missing an important step in the diagno sis sequence It might be the skipped step that leads to the solution of the problem If the service manual doesn t have step by step pro cedures to help diagnose the problem make a serie
62. ess than approximately 5 5 dm approximately 5 8 quarts add new fluid to make it approximately 5 5 dm approximately 5 8 quarts TSB Revision 00 69 9 Fill the fluid into the filler plug Brand name Dia Queen SSTF I Filling amount Approximately 5 5 dm approximately 5 8 quarts 10 Tighten the filler plug to the specified torque Tightening torque 35 5 m 26 4 ft lb 11 Install the air cleaner element and air cleaner intake duct Refer to GROUP 15 Air Cleaner P 15 11 12 Install the engine room under cover front B assembly Refer to GROUP 51 Under Cover P 51 15 TRANSMISSION FLUID CHANGE 1 Remove the engine room under cover front B assembly Refer to GROUP 51 Under Cover P 51 15 2 Start the engine and let it run at idle to warm it up for 15 minutes 3 Move the shift lever to every position P R N D manual mode Hold for 20 seconds in each position and then move it to the P range 4 Stop the engine 5 Remove the air cleaner element and air cleaner intake duct Refer to GROUP 15 Air Cleaner P 15 11 6 Remove the filler plug Transaxle control AC704813AE 7 Remove the drain plug and leave it for 3 minutes to drain bo the fluid Los NOTE Because the fluid in the cooler oil filter TC SST assembly cannot be drained the amount of drained Pro N 3 gt 2 fluid will be approxima
63. for gum and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts TSB Revision 00 54 Lubricant GENERAL RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS Specification M1001001300719 Remark Engine oil Engine coolant Transaxle oil Manual transaxle Twin clutch sportronic shift transmission Engine oils displaying ILSAC certification symbol or conforming to the API classification SM Long life antifreeze coolant or an equivalent DiaQueen NEW MULTI GEAR OIL API classification GL 3 SAE 75W 80 DiaQueen SSTF I For further details refer to LUBRICANTS SELECTION section Transfer oil AWC control fluid Vehicles with ACD Including hydraulic pipe DiaQueen LSD gear oil DIAMOND ATF SP Ill Control fluid for ACD AYC Apply for Reservoir tank section Vehicles with ACD AYC Including hydraulic pipe section AYC differential gear oil Differential mechanism part DiaQueen LSD gear oil AYC differential gear oil Torque transfer DIAMOND ATF SP III part Power steering fluid Genuine Mitsubishi Power Steering Fluid Conforming to Brake fluid DOT 3 or DOT 4 Long Life Antifreeze Coolant or an equivalent Brakes and clutch Engine coolant Greas
64. ft lb 25 TIRES ROTATE M1001008900574 Rotate tires regularly to equalize tire wear and help extend tire life Recommended tire rotation is every 12 000 km 7 500 aecz miles Timing for the rotation may vary according to vehicle condition road surface conditions and individual driver s habits When rotating tires check for uneven wear damage and Cc SS wheel alignment Abnormal wear is usually caused by incorrect tire pressure improper wheel alignment out of balance wheels or severe braking The first rotation is the most important to achieve more uniform wear for all tires on the vehicle AC000120 26 AIR PURIFIER FILTER REPLACE 1 Remove the glove box Refer to GROUP 52 glove box P 52A T 2 Loosen the two lugs as shown to replace the clean air filter 3 Install the glove box AC611715AB TSB Revision 00 80 Application GENERAL MAIN SEALANT AND ADHESIVE TABLE 3M three bond No MAIN SEALANT AND ADHESIVE TABLE M1001003800516 Loctite permatex No ENGINE AND DRIVETRAIN Between rocker cover cylinder head and timing chain case Three bond 1217G Mitsubishi Genuine Part No 1000A923 Three bond 1227D Mitsubishi Genuine Part 2100792 Between cylinder head gasket Between timing chain case Three bond 1217G
65. in order to stabilize the axial force and to ensure the high axial force at bolt nut connections resulting in improved reliability NOTE The bolts and nuts with stabilizer for coefficient of fric tion mean that the bolts and nuts with surface treatment to sta bilize and reduce the coefficient of friction allowing to achieve the stable axial force and to secure the high axial force with low tightening torque FORM 4N PLACE GASKET M1001014200176 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 proce dure 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 There fore to eliminate the leak from the joint it is indispensable that the FIPG be applied with a correct amount and without any gap TSB Revision 00 44 GENERAL PRECAUTIONS BEFORE SERVICE Because the FIPG used for the engine parts becomes hard ened by the reaction with the atmospheric moisture it is nor mally 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 deg
66. ing surface and ensure AC103249AL the old O ring has been removed 7 Apply a small amount of engine oil to the O ring of the new oil filter 8 Screw on the oil filter by hand until it touches the surface of the flange and then tighten it with an oil filter wrench Number Special tool Tightening torque MD356000 991610 or Approximately 7 O ring equivalent 3 4 turn 14 2 AC103250AG m 124 17 in4b 9 Install the drain plug and refill engine oil Refer to P 12 4 10 Rev the engine a few times and check to be sure that no engine oil leaks at the oil filter 11 Install the engine room under cover extension Refer to GROUP 51 Under Cover P 51 15 11 MANUAL TRANSAXLE OIL CHECK OIL LEVEL AND CONDITION RCHANGE TRANSAXLE OIL LEVEL CHECK 1 Remove the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 15 M1001006100118 TSB Revision i filler M gt el drain plug Md EN VCI gt Filler plug hole Gasket a Oil filler plug Transmission oil AC700330AE Filler plug hole Gasket E v Oil filler plug Transmission oil AC700330AE GENERAL 00 67 MAINTENANCE SERVICE 2 Remove the oil filler plug and gasket 3 Check that the oil level is just below the lower edge of the oil filler plug hole 4 Check that the oil is not excess
67. installed CAUTION During diagnosis a diagnostic trouble code associated with other system may be set when the ignition switch is turned ON with connec tor s disconnected On completion confirm all systems for diagnostic trouble code s If diag nostic trouble 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 control module and activates the radiator fan to prevent over heating as fail safe 1 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Troubleshooting sections are based on the diagnos tic 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 TSB Revision 00 8 GENERAL HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS Diagnostic method Gathering information from the customer Coding data 5 Does not reoccur Check trouble symptom CAN bus diagnosis chart Reoccurs Y NG CAN bus diagnosis gt Y diagnosis code Read the diagnosis code displayed Current trouble
68. ively foul and has moderate viscosity 5 Install the oil filler plug and new gasket then tighten them to the specified torque Tightening torque 32 2 m 24 ft lb 6 Install the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 15 TRANSAXLE OIL CHANGE 1 Remove the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 15 2 Remove the oil drain plug and gasket to drain the oil 3 Install the oil drain plug and new gasket then tighten them to the specified torque Tightening torque 32 2 m 24 1 ft lb 4 Remove the oil filler plug and gasket then fill the oil up to the lower edge of the oil filler plug Brand name DiaQueen NEW MULTI GEAR OIL API classification GL 3 SAE 75W 80 Quantity 2 5 dm 2 6 quarts 5 Install the oil filler plug and new gasket then tighten them to the specified torque Tightening torque 32 2 m 24 1 ft lb 6 Install the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 15 TSB Revision GENERAL 00 68 MAINTENANCE SERVICE 12 TWIN CLUTCH SPORTRONIC SHIFT TRANSMISSION TC SST CHECK THE FLUID LEAKAGE IF NECESSARY CHECK THE FLUID LEVEL CHANGE TC SST FLUID LEAKAGE CHECK 1 Clean the TC SST exterior and visually check the TC SST for fluid leaks 2 If the fluid is leaking from the pan or the oil seal replace the part If the fluid is leaking from the p
69. k operation customize Disabled After wipe customize Enabled def D Tire circumference 2026mm TSB Revision GENERAL gt PRECAUTIONS BEFORE SERVICE 00 29 Item name Initial value Fuel tank Not used DRL type Dimming DRL w P halogen type IndependentDRL P discharge type Smart entry system Not present or Type A or Type C TPMS Present Keyless 2 Air bag Auto Hazard Not Present Immobilizer Type B lt Vehicles for USA gt Type A lt Vehicles for CANADA gt Cruise control Present Corner sensor Not present Headlight auto leveling device Not present Oil level warning Not present Water separate warning Not present Speed meter scale Not used Idle neutral control Not used Theft alarm sensor Not present T M oil cooler Not present Theft sensor gain setting Type 1 Side air bag Present ACC power auto cut Default enabled Number of speaker 2 Speaker less or Premium or 6 speakers Seat material 2 Fabric or Leather Auto light control 2 No Cng Ng or Hi RLS chg Ng Front differential Helical Rear differential AYC Power window type Type P4 Sun roof type Not present or Type S4 WCM Present OCM Present ORC Present A C Present AUDIO Not present or Present AND Not present or Present Siren
70. ls on how to use the scan tool MB991958 refer to the Owner s manual A CAUTION To prevent damage to scan tool MB991958 always turn the ignition switch to the LOCK OFF position before con necting or disconnecting scan tool MB991958 1 Ensure that the ignition switch is at the LOCK OFF position 2 Start up the personal computer 3 Connect special tool MB991827 to special tool MB991824 and the personal computer 4 Connect special tool MB991910 to special tool MB991824 Connect special tool MB991910 to the data link connector 6 Turn the power switch of special tool MB991824 to the ON position NOTE When special tool MB991824 is energized special tool MB991824 indicator light will be illuminated in a green color 7 Start the M U T IIl system on the personal computer 8 Turn the ignition switch to the ON position 9 Select System select from the start up screen 10 Select From 2006 MY under Model Year Check that Vehicle Information contents are correct 11 On the system list screen select MPI GDI DIESEL to check the engine control module data AT CVT A MT TC SST to check the TC SST ECU data and ETACS to check the ETACS ECU data NOTE If Loading Option Setup list is shown click appro priate box 12 Select Coding 13 Select Coding information amp copy 14 If the displayed coding information is different from the corresponding initial setting in the list replace
71. more 2 Make sure that the indicator mark on the auto tensioner is within the area marked with A in the illustration 3 If the mark is out of the area A replace the drive belt Refer to P 11A 21 NOTE The drive belt tension check is not necessary as the auto tensioner is adopted 4 Install the radiator condenser tank Refer to GROUP 14 Radiator P 14 32 TSB Revision GENERAL MAINTENANCE SERVICE 00 65 8 EXHAUST SYSTEM CONNECTIONS PORTION OF MUFFLER MUFFLER PIPES AND CONVERTER HEAT SHIELDS CHECK AND SERVICE 1001005800459 Check for holes and exhaust gas leaks due to damage corrosion etc 1 Check the joints and connections for looseness and exhaust gas leaks 2 Check the rubber hangers and brackets for damage 9 ENGINE OIL CHANGE 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 90 C 176 194 WARNING Use care as oil could be hot 2 Remove the engine oil filler cap 3 Remove the engine room under cover extension Refer to GROUP 51 Under Cover P 51 15 4 Remove the drain plug to drain oil 5 Install a new drain plug gasket so that it faces in the direction shown in the illustration and then tighten the drain plug to the specified torque Tightening torque 39 5 m 29 3 ft lb M1001002600661 N CAUTION Do not use conventional petroleum based motor oil Usi
72. n s again to verify the intermittent malfunction has been eliminated SIMULATION TESTS NOTE In case of difficulty in finding the cause of the intermit tent malfunction the data recorder function in the scan tool is effective For these simulation tests shake then gently bend pull and twist the wiring of each of these examples to duplicate the inter mittent malfunction e Shake the connector up and down and right and left Shake the wiring harness up and down and right and left Especially check the splice points of wiring harnesses care fully Refer to GROUP OOE Harness Connector Inspection 00 2 Shake or sensor 00871 HOW TREAT PAST TROUBLE M1001014100384 Since the trouble may still be present even the status 2 If yes erase the diagnostic trouble code and then is Stored set the vehicle to the diagnostic trouble check that no diagnostic code is reset If no code detection condition and check that the status diagnostic trouble code is reset the diagnosis is changes to Active If the status does not change complete from Stored carry out the following procedure 3 If no follow the applicable Diagnostic Trouble 1 Establish from the customer whether a fuse or Code Chart Then check the wiring harness and connector has been replaced or disconnected connector and refer to How to Cope with Intermittent Malfunction 00 15 TSB Revision
73. ng conventional motor oil may cause engine or tur 40 30 20 10 0 10 20 30 40 50 C bocharger damage Do not used blends of conventional oil and synthetic oil If engine oil other than 5W 30 is used the engine may be seized by poor lubrication 6 Refill the specified quantity of oil Specified Engine Oil Engine oils displaying ILSAC certification symbol Starburst symbol con forming to the API classification SM or higher Total quantity 5 6 dm 5 9 quarts 7 Install the engine oil filler cap 8 Let the engine run for a few minutes 9 Stop the engine and then check the oil level using the oil dipstick after a few minutes 10 Install the engine room under cover extension Refer to GROUP 51 Under Cover P 51 15 TSB Revision 00 66 GENERAL MAINTENANCE SERVICE 10 ENGINE OIL FILTER REPLACE M1001002700594 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 90 C 176 194 F WARNING Use care as oil could be hot 2 Remove the engine oil filler cap 3 Remove the engine room under cover extension Refer to GROUP 51 Under Cover P 51 15 4 Remove the drain plug to drain oil 5 Use the respective tool in the following table to remove the engine oil filter Number Special tool MB991610 or equivalent MD356000 Oil filter wrench MB991610 or equivalent 6 Clean the filter bracket side mount
74. ntake air temperature coefficient type of resistor When the temperature sensor output terminal terminal 6 intake air temperature rises the resistance from the PCM terminal 64 via the resistor in the decreases PCM The ground terminal terminal 5 is The intake air temperature sensor output voltage grounded with or PCM terminal 57 increases when the resistance increases and decreases when the resistance decreases AC610770AB TSB Revision GENERAL 00 11 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 5 Explains about technical details TECHNICAL DESCRIPTION e The engine coolant temperature se the engine coolant temperature to a voltage and output it DTC SET CONDITIONS Check Conditions 6 Describes the conditions for that DTC being set stored 7 Describes possible cause s for that DTC s6r converts The PCM checks whether this voltage is within a specified range TROUBLESHOOTING HINTS The most likely causes for this code to be set are Engine coolant temperature sensor failed Engine temp ature was T 45 F or Open or shorted engine coolant temperature sen more immediately before the engine was stopped sor circuit or loose connettori at the last drive DIAGNOSIS Required special tool 991958 Scan Tool e MB991824 e MB991827 USB Cable e MB991910 Main Harness 8 Start of the diagnosis p
75. odel Unless otherwise specified each service procedure covers all models Procedures covering specific models are identified by the model codes or similar designation engine type transaxle type etc A description of these des ignations is covered in this manual under VEHICLE IDENTIFICATION ON VEHICLE SERVICE The ON VEHICLE SERVICE section has proce dures for performing inspections and adjustments of particularly important components These proce dures are done with regard to maintenance and ser vicing but other inspections looseness play cracking damage etc must also be performed SERVICE PROCEDURES The service steps are arranged in numerical order Attention to be paid in performing vehicle service are described in detail in SERVICE POINTS DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging whether or not a part or adjustment is correct LIMIT Shows the maximum or minimum value for judging whether or not a part or adjustment is acceptable 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 M1001000102547 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 Ifa DAN
76. odule Disposal 2 If heat damage may occur during paint work Procedures remove the SRS ECU the air bag module 2 Observe the following when carrying out clock spring the front impact sensor the side operations on places where SRS components are impact sensor and the seat belt pre tensioner installed including operations not directly related SRS ECU air bag module clock spring front to the SRS air bag impact sensor the side impact sensor 93 C 200 F or more Seat belt pre tensioner 90 C 194 F or more SCAN TOOL MULTI USE TESTER M U T III SUB ASSEMBLY A CAUTION Turn the ignition switch to the LOCK OFF position before disconnecting or connecting the scan tool NOTE M U T III trigger harness is not necessary when push ing V C I ENTER key M1001012400226 VEHICLE COMMUNICATION M U T III USB CABLE M V I III MAIN HARNESS INTERFACE V C l MB991910 M U T III MAIN HARNESS MAIN HARNESS C MEASUREMENT ADAPTER DO NOT USE DO NOT USE MB991825 MB991826 AC21088AD TSB Revision 00 22 GENERAL PRECAUTIONS BEFORE SERVICE HOW TO PERFORM VEHICLE IDENTIFICATION NUMBER VIN WRITING N CAUTION M1001011400609 The VIN is stored in the engine control module The F A S T Key Free hand Advanced Security WCM and the KOS ECU If the VIN is Transmitter is described as the Keyless Opera impr
77. operly erased the engine warning light or the tion System KOS in this manual KOS is indi keyless operation system warning indicator illumi cated as F A S T in the scan tool display Follow the procedure below to register the VIN of the nate and the diagnostic trouble code is displayed When the ECM WCM and the KOS ECU are Wireless Control Module WCM and the Keyless replaced follow the procedure below to write the Operation System KOS Screen flow of scan tool M U T When ECM is replaced System Select F A S T IMMO Keyless TPMS Special Function Key Code Registration Key Code Registration Completed 19 Engine VIN Registration OK Engine VIN Registration Confirmation Engine VIN Registration Completed Result of Engine VIN Registration VIN lt When WCM or KOS ECU are replaced gt System Select F A S T IMMO Keyless TPMS Coding VIN Registration VIN Registration Confirmation 05 VIN Registration completed Result of VIN Registration 700593 WRITING PROCEDURE Required Special Tools e MB991958 Scan Tool Sub Assembly e MB991824 V C I e MB991827 USB Cable e MB991910 Main Harness TSB Revision 00 23 PRECAUTIONS BEFORE SERVICE MB991827 AC
78. or two hours elapses do not contact the oil or water to the appli cation 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 TSB Revision TOWING AND HOISTING 00 45 TOWING AND HOISTING WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP A CAUTION SLING TYPE The vehicle must not be towed by placing only its front wheels on a rolling dolly because to do so will result in deterioration of the viscous coupling and in the vis cous coupling causing the vehicle to jump forward sud denly If this vehicle is towed use flat bed equipment REAR TOWING PICKUP A CAUTION SLING TYPE The vehicle must not be towed by placing only the rear N O wheels on a rolling dolly because to do so will result in deterioration of the viscous coupling causing the vehi cle to jump forward suddenly If this vehicle is towed use flat bed equipment AC611522AC TSB Revision 00 46 GENERAL TOWING AND HOISTING TOWING WHEN KEYS ARE NOT AVAILABLE When a locked vehicle must be towed and keys are not avail able the vehicle may be lifted and towed from the front pro vided 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 to
79. or cap securely 13 Remove the radiator condenser tank cap and add the engine coolant up to the FULL line 14 Turn the A C switch to OFF position to start the engine and warm up until the cooling fan operates NOTE This step opens the thermostat fully 15 Rev the engine several times and then stop it Check that there are no coolant leaks 16 Remove the radiator cap with the engine cool and then refill the engine coolant up to the top of the radiator port 17 Tighten the radiator cap securely N CAUTION Do not overfill the radiator condenser tank 18 Remove the radiator condenser tank cap and add the engine coolant up to the FULL line 19 Install the turbocharger compressor bracket Refer to GROUP 15 Exhaust Manifold and Turbocharger Assembly P 15 18 20 Install the air cleaner intake hose Refer to GROUP 15 Air Cleaner P 15 11 21 Remove the engine room under cover front A and engine room under cover front A RH Refer to GROUP 51 Under Cover P 51 15 TSB Revision 00 74 lt gt GENERAL MAINTENANCE SERVICE 17 COOLANT HOSES RADIATOR HOSE HEATER HOSE INSPECT M1001009700216 Inspect the surface of radiator hoses and heater hoses for heat and mechanical damage Hard and brittle rubber cracking tears cuts abrasions and excessive swelling indicate deterio ration of the rubber 18 DISK BRAKE PADS AND ROTORS INSPECT FOR WEAR DISK BR
80. ottom of the oil filler plug hole Brand name DiaQueen LSD gear oil Oil filler plug 14 mm 0 6 inch 6 Install the filler and new gasket then tighten them to the specified torque Tightening torque 32 2 m 24 1 ft lb 7 Install the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 15 AC700330 AY TSB Revision GENERAL MAINTENANCE SERVICE TRANSFER OIL CHANGE 00 71 425 2 24 j drain plug Z 7 704516 1 Remove the engine room under cover front assembly Refer to GROUP 51 Under cover P 51 15 Remove the drain plug and gasket to drain the oil Install the drain plug and new gasket then tighten them to the specified torque Tightening torque 32 2 m 24 ft lb e Jil drain plug 4 Remove the filler plug and gasket then fill the oil up to the SLI lower edge of the filler plug hole du oe SKC Brand name DiaQueen LSD gear oil Quantity 0 8 0 85 quarts Install the filler plug and new gasket then tighten them to the specified torque Filler plug hole Tightening torque 32 2 N m 24 1 ft lb Gasket 6 Install the engine room under cover front B assembly Refer 1 to GROUP 51 Under cover P 51 15 Filler plug Transfer oil AC700330AG Oil reservoir 705200 MEI 15 RESERVE TANK F
81. p whether or not the timing chain is replaced This allows the ECM to appropriately monitor the amount of elongation of the timing chain Timing chain or engine assembly replaced Learned value reset The purpose of this procedure is that the initial learning value stored by the current ECM is initialized when the timing chain or the engine assembly the timing chain is also replaced with a new one is replaced This allows the ECM to appropriately monitor the amount of elongation of the timing chain NOTE 2 The visual check of the elongation of the timing chain must be carried out under the following con ditions when the initial learning value cannot be written into scan tool MB991958 from the current ECM because of the ECM malfunction and when the initial learning value cannot be written into the new ECM Refer to GROUP On vehicle Service Timing Chain Elongation Visual Check P 11A 17 If elongated more than the specified length at this time the timing chain can possibly interferes with the other engine com ponents before the new ECM detects the elongation of the timing chain The timing chain must be replaced with a new one to prevent engine damage LEARNED VALUE READ amp SAVE AND WRITE LEARNED VALUE CHANGED ECU Required Special Tools e MB991958 Scan Tool Sub Assembly e MB991824 V C I e MB991827 M U T IIl USB Cable e MB991910 Main Harness A TSB Revision
82. played 12 Push the OK button after Completed Press the OK button and move to VIN writing function is displayed 13 Enter the VIN of registering vehicle and push the OK button 14 Push the OK button after 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 17 VIN writing result is displayed 18 Complete the scan tool MB991958 19 Disconnecting the scan tool 991958 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 scan tool MB991958 22 Turn the ignition switch to the LOCK OFF position and then disconnect scan tool MB991958 TSB Revision GENERAL 00 25 PRECAUTIONS BEFORE SERVICE VIN WRITING STEPS FOR WCM AND KOS ECU CAUTION Before the VIN registration to WCM and KOS ECU check that the VIN of ECM and vehicle are matched CAUTION Check that diagnostic trouble code B2416 ECU internal error is not set When diagnostic trouble code B2416 ECU internal error is set the WCM and the KOS ECU cannot store the VIN even if the VIN is written If this diag nostic trouble code is set troubleshoot the WCM or the KOS ECU and repair Then write the VIN to the WCM or the KOS ECU A CAUTION Before connecting or disconnec
83. ponding sensor actuator and related electrical wiring then repair or replace 5 After repair or replacement recheck with the ohmmeter to confirm that the repair has corrected the problem 10 INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope these are listed TSB Revision 00 1 0 GENERAL HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS HOW TO USE THE INSPECTION PROCEDURES M1001013500550 The causes of many of the problems occurring in electric circuitry are generally the connectors components the ECU and the 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 DTC P0110 Intake Air Temperature Circuit Malfunction Intake air temperature sensor Incorporated in volume air flow sensor 1 Relevant circuit s of the component which the DTC indicates are described RED BLUE D 108 MU803781 Powertrain control module PCM 2 For connector color refer to GROUP 80A How to read configuration diagrams 3 Shows the location of the connector s from the circuit s above B 48 B 4 Explains about the operation principle of the component or its relevant parts that circuit CIRCUIT OPERATION o The intake air temperature sensor is a negative Approximately 5 volts are applied to the i
84. put the Timing mark timing mark on the exhaust camshaft sprocket in position CII shown in Figure Therefore No 4 cylinder goes to the compression top dead center Exhaust valve side 6 Check the valve clearance with the arrow shown in Figure No 2 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 aa Ep ok LC removal refer to Camshaft Removal and Installation AO AO P 11A 25 Z 5 No 3 No 4 Intake valve side AK502388 AF Wall thickness 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 0 008 inch Exhaust valve A B C 0 30 mm 0 012 inch NOTE The valve tappet ranges 3 000 3 690 mm 0 1181 0 1453 inch and has 47 types per 0 015 mm 0 0006 inch 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 O installation refer to Camshaft Removal and Installation P 11A 25 11 After installing the timing chain measure the valve AK704211 AB clearance using the procedure 3 to 6 Confirm
85. rease the FIPG application surface care fully 3 According to the FIPG application procedures 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 smooth thin gasket scraper into the mating surface but in this case a sufficient caution is required not to damage the mating surface The oil pan FIPG cutter Special tool MD998727 is provided Thus use this special tool GASKET SURFACE CLEANING Use a gasket scraper or wire brush to completely remove all the foreign materials adhering to the gasket surface Check that the FIPG application surface is smooth There must be no grease or foreign material 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 When the FIPG is still moistened within three minutes perform the installation to the specified position 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 approximately f
86. release switch move the shift lever Shift lock release switch IN II ON RE AC808410AD TSB Revision GENERAL 00 43 PRECAUTIONS BEFORE SERVICE VEHICLE WASHING M1001012000660 1 If high pressure car washing equipment or steam car wash ing equipment is used to wash the vehicle be sure to main Approximately tain the spray nozzle at a distance of at least approximately 22 16 or more 40cm 16 in from any plastic parts and all opening parts X 7N doors luggage compartment etc 5 2 If high pressure car washing equipment steam car wash ing equipment is used to wash the vehicle be sure to observe the following instructions to prevent damages to the plastic parts Spray nozzle distance Approximately 40 cm 16 in or more e Spray pressure 3 900 kPa or less e Spray temperature 82 C 180 F or less Time of intensive spraying to one point Within 30 sec onds APPLICATION ANTI CORROSION AGENTS AND UNDERCOATS M1001011000117 Be careful not to apply oil or grease to the heated oxygen sen sor If applied the sensor may malfunction Protect the heated oxygen sensor with a cover before applying anti corrosion agent etc BOLTS AND NUTS WITH STABILIZER FOR COEFFICIENT OF FRICTION M1001014800082 The bolts and nuts with stabilizer for coefficient of friction have been used for the connections such as the suspension arm and crossmember
87. rocedure for that DTC ub Assembly 9 Identifies the special tool s necessary for diagnosing that DTC STEP 1 Using scan tool MB991958 check data list item 15 Transmission Fluid Temperature Sensor CAUTION To prevent damage to scan tool MB991958 always turn the ignition switch to the LOCK OFF position before con necting or disconnecting scan tool MB991958 1 Connect scan tool 991958 to the data link connector 2 Start the engine 3 Set scan tool MB991958 to the data reading mode for item 15 Transmission Fluid Temperature Sensor When the engine is cool Almost equal to the ambient temperature atmospheric temperature NOTE Set scan tool MB991958 to data reading mode for item number 13 Intake Air Temperature IAT Sensor and note the temperature measurement When the engine is cool the temperature should be almost equal to the ambient temperature atmospheric temperature and the IAT sensor measurement should be approxi mately the same as the Transmission Fluid Temperature Sensor When the engine is warm 70 to 80 C 158 to 176 F 4 Turn the ignition switch to the LOCK OFF position 991827 AC206894AB Q Is the sensor operating properly YES It can be assumed that this malfunction is intermittent Refer to GROUP 00 How to Use Troubleshooting 10 Provides the inspection procedure Inspection Service Points Ho
88. s of checks based on the ranked list of probable causes Troubleshooting checks should be made in the order that the list of causes was ranked general to specific most likely to least likely easy to check to hard to check REPAIR THE PROBLEM When the step by step troubleshooting checks find a fault perform the proper repairs Make sure to fix the root cause of the problem not just the symptom Just fixing the symptom without fixing the root cause will cause the symptom to eventually return VERIFY THE REPAIR After repairs are made recheck the operation of the system to confirm that the problem is eliminated Be sure to check the system thoroughly Sometimes new problems are revealed after repairs have been made TSB Revision GENERAL 00 7 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS TROUBLESHOOTING CONTENTS M1001013300653 N DANGER Troubleshooting of electronic control systems for The SRS ECU adopts the rollover specifica Which scan tool MB991958 can be used follows the tion that the curtain air bag and seat belt basic outline described below Even in systems for pre tensioner operate at the occurrence of Which scan tool MB991958 cannot be used some of rollover Therefore do not tilt the vehicle to ese SUA the right and left with the IG ON or tilt the SRS ECU to the right and left with the IG ON and the harness
89. sed Use care not to damage the iridium tips of the plugs Do not adjust the spark plug gap 1 Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission level Therefore they should be replaced periodically with new ones Spark plug type M1001002000476 Maker Identifcation No NGK ILKR8E6 2 The new plugs should be checked for the proper gap Spark plug 0 5 0 6 mm 0 020 0 023 inch 3 Install the spark plugs and tighten to 18 2 m 13 1 ft Ib 6 INTAKE AND EXHAUST VALVE CLEARANCE INSPECT AND ADJUST M1001012900265 NOTE Perform the valve clearance check and adjustment at the engine cold state 1 Remove all of the ignition coils 2 Remove the cylinder head cover CAUTION Turn the crankshaft always clockwise 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 center 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 0 008 0 0012 inch Exhaust valve 0 30 0 03 mm 0 012 0 0012 inch TSB Revision GENERAL 00 63 MAINTENANCE SERVICE 5 Turn the crankshaft clockwise 360 degrees and
90. smission TC SST Transaxle model JA32W8FV AU JA32W8FV AU JA32W5FV AU CZ4AS NGFZL3M MGFZL3M MPFZL3M 4811 1 998 cm 121 9 cu in DOHC MIVEC gasoline engine with charge air cooler turbocharger W5M6A AWD 5 W6DGA AWD Twin Clutch Sportronic Shift Transmission TC SST TSB Revision GENERAL VEHICLE IDENTIFICATION 00 1 9 CHASSIS NUMBER M1001005601447 The chassis number is stamped on the front floor pan passengers seat CODE CHART 40 CZ4AAU00001 Vehicle line CZ4A LANCER EVOLUTION AU000001 Refer to 10th thru 17th digits of VIN plate ee _ 608772 ENGINE MODEL STAMPING M1001005700322 The engine model is stamped on the cylinder block The engine model number is as shown as follow Engine model Engine displacement 4 11 2 0L The engine serial number is stamped near the engine model number Engine number 0201 to YY9999 AC700355 VEHICLE IDENTIFICATION CODE PLATE M1001005400116 The information code plate is riveted onto the cowl top outer panel in the engine compartment CODE CHART No Item Example Content 1 MODEL CZ4AS Vehicle model MGFZL2M Model series 2 ENGINE 4B11 Engine model 3 EXT W69C E
91. special tool MB991827 to special tool MB991824 and the personal computer 4 Connect special tool MB991910 to the special tool 991824 5 Connect special tool MB991910 to the data link connector of the vehicle 6 Turn the special tool MB991824 power switch to the ON position NOTE When the special tool MB991824 is energized the special tool MB991824 indicator light will be illuminated in green color 7 Start the M U T IIl system on the personal computer and turn the ignition switch to the ON position 8 Select F A S T IMMO Keyless TPMS button from the System Select screen Then select the applicable option code item and push the OK button 9 Select Special Function on the next screen TSB Revision 00 24 GENERAL PRECAUTIONS BEFORE SERVICE Option When IMMOBI amp F A S T amp TPMS is selected H a SHEETS SPOS FOTN Function screen Tire Pressure Sensor ID Registration Tire Pressure Sensor ID Check Tire Pressure Sensor Check Key amp F A S T Key Reg Steering lock unit Reg Comm Test ENG key code Reg ENG key code amp VIN Reg Please select function 802950 10 Select key code amp VIN Reg from the Special Option When I
92. tely 5 5 approximately 5 8 quarts 8 Tighten the drain plug to the specified torque UNT Tightening torque 35 5 m 26 4 ft lb 1 ES e Centermember X CES AC704517AE 9 Fill the fluid into the filler plug Brand name Dia Queen SSTF I Filling amount Approximately 5 5 dm approximately 5 8 quarts 10 Tighten the filler plug to the specified torque Tightening torque 35 5 m 26 4 ft lb 11 Install the air cleaner element and air cleaner intake duct Refer to GROUP 15 Air Cleaner P 15 11 TSB Revision 00 70 GENERAL MAINTENANCE SERVICE 12 Install the engine room under cover front assembly Refer to GROUP 51 Under Cover P 51 15 13 TWIN CLUTCH SPORT SHIFT TRANSMISSION OIL FILTER CHANGE M1001018700021 For information concerning the replacement procedures refer to GROUP 22 TC SST filter P 22C 431 assembly AC91670AB 14 TRANSFER OIL CHECK OIL LEVEL CHANGE TRANSFER OIL CHECK 1 Remove the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 15 2 Remove the filler plug and gasket Oil filler plug 2 Engine oil pan B 3 Check that the oil level is not 14 mm 0 6 inch below the bottom of the oil filler plug hole 4 Check that the oil is not excessively foul and has moderate viscosity 5 If the oil level is not in between the upper limit and the lower limit refill the specified oil to the b
93. the ECU with a correctly coded one For replacement of the engine control module refer to GROUP 13A Engine Control Module P 13A 888 For replacement of the TC SST ECU refer to GROUP 22C Transaxle Assembly P 22C 412 For replacement of the ETACS ECU refer to GROUP 54 ETACS P 54A 742 NOTE TC SST ECU cannot be disassembled Thus replace the transaxle assembly TSB Revision 00 28 Sec GAUTONE BEEORE SERVICE ENGINE CONTROL MODULE CODING DATA LIST Item name Initial value Final gear ratio 5MT 6MT lt 5 gt 4 062 lt TC SST gt Tire circumference 2026mm IMMOBILIZER Present ABS Not present A S C Present S W variation No 1 TC SST ECU CODING DATA LIST Item name Initial value Vehicle line LANCER EVO Destination U S Tire size 245 40R18 Cruise control Present A S C Present Turbo charger T C INCONEL AL ETACS ECU CODING DATA LIST Item name Initial value Vehicle line LANCER EVO Model year Displays the model year SST oil cooling fan Not present Destination U S Transaxle 5MT lt 5M T gt TC SST lt TC SST gt Engine type 2 0L D4 VVT T C Engine power Normal Handle side LHD Chassis Type for A S C Type 1 OSS Not present Final drive AWD FF Base Transfer ACD IG off delay control Disabled lt 5M T gt Enable lt TC SST gt Dead loc
94. the clearance is within the standard value N CAUTION Completely remove all the old FIPG which might be remaining among the components 12 After completely removing the liquid gasket adhering on the timing chain case cylinder block and cylinder head degrease them with white gasoline AK304938 AE Under view Thickness stamp TSB Revision 00 64 4 0 mm 0 16 in P Cylinder head AK502760AF Auto tensioner GENERAL MAINTENANCE SERVICE CAUTION The cylinder head cover should be installed within 3 min utes of applying liquid gasket 13 Apply a 4 mm bead of liquid gasket as illustrated Specified sealant THREE BOND 1217G or equivalent 14 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 27 8 in Ib 2 Tighten to the specified torque in order shown in the illustration Specified torque 5 5 0 5 N m 49 4 in Ib 15 Install the ignition coils T DRIVE BELT FOR THE GENERATOR AND POWER STEERING OIL PUMP REPLACE 1 Remove the radiator condenser tank Refer to GROUP 14 Radiator P 14 32 CAUTION Check the drive belt tension after turning the crankshaft clockwise one turn or
95. the initial learning value is appropriately written Learned value writing Completed is shown on the screen of the scan tool 991958 LEARNED VALUE RESET Required Special Tools e MB991958 Scan Tool Sub Assembly e MB991824 V C I e MB991827 USB Cable e MB991910 M U T III Main Harness TSB Revision 00 40 GENERAL PRECAUTIONS BEFORE SERVICE A CAUTION To prevent damage to scan tool MB991958 always turn the ignition switch to the LOCK OFF position before con necting or disconnecting scan tool MB991958 1 After the ignition switch is in LOCK OFF position connect scan tool MB991958 to the data link connector 2 Turn the ignition switch to the ON position 3 Select MFI from System select Screen of scan tool 991958 4 Select Special Function from MFI Screen 5 Select Timing chain maintenance from Special Function Screen 6 Select Learned value reset from Timing chain maintenance Screen 7 Press to reset the initial learning value MB991827 AC608435 AB TEST LIMIT VALUE READOUT Required Special Tools e MB991958 Scan Tool Sub Assembly e MB991824 V C I e MB991827 0 USB Cable e MB991910 Main Harness TSB Revision 00 41 PRECAUTIONS BEFORE SERVICE
96. ting the MB991958 Scan Tool turn the ignition switch to the LOCK OFF position Connect scan tool MB991958 to the 16 pin data link connector as follows NOTE For details on how to use scan 100 MB991958 refer to the Owner s Manual 1 Ensure that the ignition switch is at the LOCK OFF position 2 Start up the personal computer 3 Connect special tool MB991827 to special tool MB991824 and the personal computer 4 Connect special tool MB991910 to the special tool 991824 5 Connect special tool MB991910 to the data link connector of the vehicle 6 Turn the special tool MB991824 power switch to the ON position NOTE When the special tool MB991824 is energized the special tool MB991824 indicator light will be illuminated in a green color MB991827 AC608435 AB Start the M U T IIl system on the personal computer and turn the ignition switch to the ON position 8 Select F A S T IMMO Keyless TPMS button from the DLL _ Un VECES System Select screen Then select the applicable option stem Lis lodel Year p to 1 206 MY code item and push the OK button 2 FAS T MMO Keyless TPMS 4 i _ ATICVT
97. vice procedures require removing rear suspen sion fuel tank and spare tire place additional weight on the rear end of vehicle or anchor vehicle to hoist to pre vent tipping when the location of the center of gravity changes TTT LI D El b 22 s gt Z YS I 1 SEIEN 709514 TSB Revision GENERAL GENERAL DATA AND SPECIFICATIONS GENERAL DATA AND SPECIFICATIONS VEHICLES FOR USA INCLUDES PUERTO RICO Item NGFZL2M MGFZL2M 00 49 M1001000904680 rN _ _ Iipat pom 710509 MPFZL2M Vehicle Overall width 1 810 71 3 1 810 71 3 1 810 71 3 dimension mm Fread front 1 545 60 8 1 545 60 8 1 545 60 8 in Overall length 4 495 177 0 4 495 177 0 4 495 177 0 Overhang front 910 35 8 910 35 8 910 35 8 Wheelbase Overhang rear 2 650 104 3 935 36 8 2 650 104 3 935 36 8 2 650 104 3 935 36 8 Ground clearance 140 5 5
98. w to Cope with for that DTC step by step Intermittent Malfunction Go to Step 2 AC210616AD HARNESS INSPECTION MEASURES TO TAKE AFTER Check for an open or short circuit in the harness REPLACING THE ECU the connector measurements Carry out this inspec after replacing the ECU repeat the inspection proce nector Inspection 00 2 Here Check harness between power supply and terminal xx also includes checking for blown fuse For inspection service points when there is a blown fuse refer to Inspec tion Service Points for Blown Fuse 00 17 TSB Revision 00 1 2 GENERAL HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS CONNECTOR MEASUREMENT SERVICE POINTS M1001013600610 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 IF INSPECTING WITH THE CONNECTOR CONNECTED lt WATERPROOF CONNECTORS gt Be sure to use special tool Never insert a test probe from the harness side as this will reduce the waterproof performance and result in corrosion IF INSPECTING WITH THE CONNECTOR CONNECTED lt ORDINARY NON WATERPROOF CONNECTORS gt Required Special Tool MB992006 Extra Fine Probe 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
99. wing 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 sup ported by safety stands 4 Never allow passengers to ride in a towed vehicle 5 State and local rules and regulations must be followed when towing a vehicle LIFTING JACKING SUPPORT LOCATION FLOOR JACK AND RIGID RACK A CAUTION Never place a support at any point other than the speci fied one or that point will be deformed For lifting put rubber or similar material between the side sill and rigid rack otherwise the side sill area will be damaged TSB Revision GENERAL TOWING AND HOISTING 00 a FLOOR JACK lt REAR gt V Differential carrier 7 assembly olll RIGID RACK lt FRONT gt lt REAR gt 4 Rubber m AC709513AB TSB Revision 00 48 GENERAL TOWING AND HOISTING POST TYPE Special care should be taken when raising the vehicle on a frame contact type hoist The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations CAUTION When ser
100. xterior code 4 ITRANS W4A5A Transaxle model 5 COLOR W69 Body color code MITSUBISHI MOTORS CORPORATION 6 TRIM 06 Tum 4 4 7 040 Equipment code 6 2 et L 3 6 5 1061 71 608666 TSB Revision GENERAL PRECAUTIONS BEFORE SERVICE TIRE AND LOADING INFORMATION PLACARD M1001015800137 The tire and loading information placard is located on the inside sill of the driver s door PRECAUTIONS BEFORE SERVICE CAUTIONS FOR WORKING IN ENGINE COMPARTMENT M1001016800022 WARNING Just after the ignition switch is turned to LOCK OFF position the adjustments must always be made with the cooling fan stopped After the ignition switch is turned to LOCK OFF position the cooling fan might be driven for a few minutes by the after run fan control If the adjustments are made with the cooling fan driven injury or damage may occur SUPPLEMENTAL RESTRAINT SYSTEM SRS 1 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 Serious injury may result from unintended air bag deplo
101. yment if work is done on the SRS system immediately after the battery cable is disconnected 3 Warning labels must be heeded when servicing or handling SRS components Warning labels can be found in the following locations Air bag module Driver s or front passenger s Clock spring SRS ECU Knee air bag module M1001011601509 Sunvisor Seat belt pre tensioner Side airbag module Driver s side and front passenger s side Curtain air bag module Driver s side and front passenger s side Center pillar Driver s side and front passenger s side Glove box 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 6 Never attempt to disassemble or repair the SRS components SRS ECU air bag module and clock spring If there is a defect replace the defective part 7 Whenever you finish servicing the SRS check the SRS warning light operation to make sure that the system functions properly TSB Revision GENERAL PRECAUTIONS BEFORE SERVICE 00 21 8 Be sure to deploy the air bag before disposing 1 When removing or installing parts do not allow of the air bag module or disposing of a vehicle any impact or shock to occur to the SRS equipped with an air bag Refer to GROUP components 52B P 52B 443 Air Bag M

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