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P.00-15 - Evo X Service Manuals

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1. Drive shaft boots Inspect for grease leaks Every months or every 4 800 km 3 000 miles damage Suspension Inspect for looseness and Every 3 months or every 4 800 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 salt spread roads e Towing or police taxi or commercial operation e Extensive idling and or low speed operation e Repeated short trip operation at freezing temperatures engine not thoroughly warmed up e Extended use of brakes while driving e Driving in sandy areas e More than 50 operation in heavy city traffic during hot weather above 32 C 90 F TSB Revision GENERAL 00 63 MAINTENANCE SERVICE 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
2. TSB Revision 00 18 MODELS GENERAL VEHICLE IDENTIFICATION No Item Content Body style 6 4 door sedan Engine type V 2 0L DOHC MIVEC with charge air cooler turbocharger 4B11 9 Check digits 0 1 2 3 9 X 10 Model year 8 2008 year 11 Plant U 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 Model code VIN code Except sequence number Engine model Transaxle model M1001000302444 SNGFZL2M JA3AWB86V 80 SMGFZL2M SMPFZL2M JA3AW86V 80 JA3AWB86V 50 VEHICLES FOR CANADA Model code VIN code Except sequence number 4B11 DOHC MIVEC with Charge air cooler Turbocharger 1 998 cm 121 9 cu in petrol engine Engine model W5M6A AWD 5 W6DGA AWD Twin Clutch Sportronic Shift Transmission TC SST Transaxle model Fuel supply system SNGFZL3M JA3AW86V 80 SMPFZL3M JA3AW86V 50 4B11 DOHC MIVEC with Charge air cooler Turbocharger 1 998 cm 121 9 cu in petrol engine W5M6A AWD 5 W6DGA AWD Twin Clutch Sportronic Shift Transmission TC SST TSB Revision MFI GENERAL VEHICLE IDENTIFICATION 00 1 3 CHA
3. Intake and exhaust Inspect and adjust X X valve clearance If valve noise increases adjust valve clearance Drive belts for the Replace generator and power steering oil pump Exhaust system Check and service 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 60 GENERAL SCHEDULED MAINTENANCE TABLE GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE Service intervals General maintenance Mileage in thousands 30 60 105 120 135 150 Kilometers thousands 48 96 168 192 216 240 Months 15 30 60 90 105 120 135 150 Engine oil Turbo Change Every 5 months or every 8 000 km 5 000 miles Engine oil filter Turbo Replace Every 10 months or every 16 000 km 10 000 miles Manual transaxle oil level X X X X X X X Twin clutch sportronic shift Check oil leaks If necessary check the oil level X X X X X transmission oil Change Transfer oil Check oil level Change Reserve tank for Check fluid level ACD and AYC Engine coolant Change Coolant hoses Inspect radiator hose Replace heater hose Disk brake pads rotors Inspect for wear
4. N 9 gt 2 s No 1 tt Intake valve side AK502387AG GENERAL MAINTENANCE SERVICE 5 SPARK PLUGS REPLACE A CAUTION Iridium plugs are used 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 Maker Identifcation No NGK ILKR8E6 M1001002000476 2 The new plugs should be checked for the proper gap Spark plug gap 0 5 0 6 mm 0 020 0 023 inch 3 Install the spark plugs and tighten to 18 2 13 1 ft Ib 6 INTAKE AND EXHAUST VALVE CLEARANCE INSPECT AND ADJUST M1001012900180 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 A 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 v
5. 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 Vinyl Repair Kit No 81786 Permatex Super Black Weatherstrip Adhesive No 82 81850 Sealing of various grommets and packing 3M AAD Part No 8509 or 3M AAD Part No 8678 Adhesion of headliners and various interior decorative materials Sealing of sheet metal joints drip rail floor side panels trunk front panel tail gate hinge 3M AAD Part No 8088 General Trim Adhesive or 3M AAD Part No 8090 Super Trim Adhesive 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 Permatex Spray Adhesive No 82019 Miscellaneous body sealants original mounted w adhesive tape e Waterproof door film e Fender panel e Splash shield e Mud guard e Rear combination lamp Fuel Tank and Pad 3M AAD Part No 8633 Windo weld Resealant 3M AAD Part No 8088 General Trim Adhesive or 3M AAD Part No 8090 Super Trim Adhesive TSB Revision Permatex Spray Adhesive No 82019 00 82 Application GENERAL MAIN SEALANT AND ADHESIVE TABLE 3M three bond No Loctite permatex No CHASSIS SEALANT Sealant of various flange faces and threaded parts Packin
6. Check for deterioration or leaks Brake hoses Ball joint and steering linkage seals Inspect for grease leaks and damage Every 5 months or every 8 000 km 5 000 miles X IX X X X X X X X X Driveshaft boots Inspect for grease leaks and damage Every 5 months or every 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 X X Tires Rotate Every 5 months or every 8 000 km 5 000 miles Air purifier filter NOTE 1 ACD Active Center Differential AYC Active Yaw Center system Replace X IX X X X X TSB Revision X X X X GENERAL SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS Maintenance should be carried out according to the following table 00 61 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 Check condition Air cleaner filter Replace Evaporative emission control system except evaporative emission canister I
7. SRS ECU to the right and left with the IG ON and the harness installed A 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 A 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 check Does not reoccur Check trouble symptom CAN bus diagnosis chart Reoccurs Y NG CAN bus diagnosis Y diagnosis code Read the di
8. 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 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 0 16 4 5 0 16 4 TSB Revision 5 0 16 4 VEHICLES FOR CANADA GENERAL GENERAL DATA AND SPECIFICATIONS 00 53 Item 710509 NGFL3M MPFL3M Vehicle dimension mm in Overall width 1 810 71 3 1 810 71 3 Tread front 1 545 60 8 1 545 60 8 Overall length 4 495 177 0 4 495 177 0 Overhang front 910 35 8 910 35 8 Wheelbase 2 650 104 3 2 650 104 3 Overhang rear 935 36 8 935 36 8 Ground
9. 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 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 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 De M System Select screen Then select the applicable option stem Lis lodel Year p to 1 206 code item and push the OK button 2 FA S T IMMO Keyless TPMS 4 3 ATICVT A MT 9 Select Coding on the next screen 4 ABS ASC ASTC Model Year seek 5 SAS Model Code 6 Multi Sele
10. m 465 66 ft Ib 820 120 m 605 88 ft Ib Nominal bolt diameter mm Head mark 4 Head mark 7 Head mark 8 5 0 1 0 m 44 9 in Ib 10 2 m 89 17 in Ib 12 2 m 107 17 in Ib 13 2 m 111 22 in Ib 24 4 m 18 3 ft lb 28 5 m 20 4 ft lb 26 5 m 19 4 ft lb 25 4 18 3 ft lb 50 5 N m 37 4 ft lb 46 8 m 34 6 ft lb 58 7 m 43 5 ft lb 55 5 m 41 3 ft lb 47 9 m 35 6 ft lb 93 12 m 68 9 ft Ib TSB Revision 105 15 m 78 11 ft Ib 00 55 LUBRICATION AND MAINTENANCE Thread size Standard tightening torque Nominal bolt Head mark 4 diameter mm Head mark 7 Head mark 8 M12 43 8 m 32 6 ft lb 83 12 m 61 9 ft Ib 98 12 N m 72 9 ft Ib LUBRICATION AND MAINTENANCE Maintenance and lubrication service recommenda tions have been compiled 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 inte
11. If the VIN is Transmitter is described as the Keyless Opera 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 nate and the diagnostic trouble code is displayed Follow the procedure below to register the VIN of the 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 VIN Screen frow of scan tool M U T III When ECM is replaced When WCM or KOS ECU are replaced System Select System Select F A S T IMMO Keyless TPMS F A S T IMMO Keyless TPMS Coding VIN Registration VIN Registration Confirmation Special Function Key Code Registration Key Code Registration Completed VIN Registration completed Result of VIN Registration yee Engine VIN Registration OK Engine VIN Registration Confirmation Engine VIN Registration Completed 96 Result of Engine VIN Registration AC700593 AE TSB Revision 00 28 GENERAL PRECAUTIONS BEFORE SERVICE WRITING PROCEDURE Required Special Tools MB991958 Scan Tool M U T Il Sub Assembly MB991824 V C I MB991827 M U T III USB Cable e MB991910 M U T III Main Harness A CAUTION Check that dia
12. 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 mounting 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 0 9 Install the drain plug and refill engine oil Refer to P 12 5 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 16 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 16 M1001006100118 TSB Revision Filler plug hole Gasket Oil filler plug Transmission oil AC700330AE ae Filler plug hole Gasket ig te Oil filler plug Transmission oil AC7
13. 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 00 30 GENERAL PRECAUTIONS BEFORE SERVICE VIN WRITING STEPS FOR WCM AND KOS ECU A CAUTION Before the VIN registration to WCM and KOS ECU check that the VIN of ECM and vehicle are matched A 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 CAUTION Before connecting or disconnecting the MB991958 Scan Tool turn the ignition switch to the LOCK OFF position Connect scan tool 991958 to the 16 pin data link connector
14. appropriately monitor the amount of elongation of the timing chain Initializing learning value for MFl engine e Learned value Read amp Save e Write learned value Changed ECU When learning value for MFI engine is initialized initial learning value for timing chain elongation is also initialized Thus initial learning value for timing chain elongation must be stored before initializing learning value for MFI engine NOTE 2 The visual check of the elongation of the timing chain must be carried out using the scan tool MB991958 under the following conditions Refer to GROUP 11A Engine Mechanical On vehicle Service Timing Chain Elongation Visual Check 11 17 When the initial value cannot be written into the new ECM because of the ECM malfunction LEARNED VALUE READ amp SAVE AND WRITE LEARNED VALUE CHANGED ECU Required Special Tools MB991958 Scan Tool M U T Il Sub Assembly MB991824 V C I e MB991827 M U T III USB Cable MB991910 M U T III Main Harness TSB Revision 00 35 PRECAUTIONS BEFORE SERVICE 991827 608435 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 MB991958 to the diagno
15. 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 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 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 64 Iridium tp Platinum tip N AK704210 AB Timing mark AK604565AC Exhaust valve side Ee No 1 No 3 fel ta 2 Ep s q SEN
16. in the illustration to indicate removal removal steps steps Assembly steps e Disassembly steps Specified in case installation is impossible in The part designation number corresponds to reverse order of removal steps Omitted if the number in the illustration to indicate dis assembly is possible in reverse order of assembly steps disassembly steps AC610759AB TSB Revision GENERAL HOW TO USE THIS MANUAL 00 5 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 These are arranged together as major maintenance and service points and explained in detail A Indicates that there are essential points for removal or disassembly gt gt A lt lt Indicates that there are essential points for installation or assembly Operating procedures cautions etc on removal installation disassembly and assembly are described Installation service point A Disc brake assembly installation 1 To check the brake drag force after mounting the pad measure the hub torque in the advancing direction using a Spring balance with the pad is removed A CAUTION Do not allow any oil grease or other contamination to contact the friction surfaces o
17. information placard is located on the inside sill of the driver s door VEHICLE SAFETY CERTIFICATION LABEL M1001017300020 The vehicle safety certification label is attached to the face of the left door sill This label indicates the month and year of manufacture Gross Vehicle Weight Rating GVWR front and rear Gross Axle Weight Rating GAWR and Vehicle Identification Number VIN NATIONAL SAFETY MARK CANADA M1001017400016 The tire and loading information placard is located on the inside sill of the driver s door TSB Revision GENERAL 00 21 VEHICLE IDENTIFICATION THEFT PROTECTION LABEL A CAUTION When replacing a part that has the theft protection plate label or stamp on it be sure that the part has either A or B shown in the figure It is illegal if both A and B are attached or neither A nor B is attached In order to protect against theft a Vehicle Identification Number VIN is attached as a plate or label to the following major parts of the engine transaxle and main outer panels Engine cylinder For original parts block Transaxle housing Front fender Hood Trunk lid Bumpers Side outer panel Doors In addition a theft protec tion label is attached to replacement parts for main outer pan els The same data is stamped into replacement parts for the engine and the transaxle N CAUTION MITSUBISHI MOTORS Cautions regarding panel repairs e When repain
18. 00 1 HOW USE THIS MANUAL TROUBLESHOOTING GUIDELINES 2 xn Rn n a HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS TROUBLESHOOTING CONTENTS HOW TO USE THE INSPECTION CONNECTOR MEASUREMENT SERVICE POINTS zu oie he ted CONNECTOR INSPECTION SERVICE POINTS eie e n a HOW TO COPE WITH INTERMITTENT MALFUNCTIONS HOW TREAT PAST TROUBLE INSPECTION SERVICE POINTS FOR A BLOWN FUSE VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER CHASSIS ENGINE MODEL STAMPING VEHICLE IDENTIFICATION CODE TIRE AND LOADING INFORMATION GROUP 00 GENERAL CONTENTS 00 3 VEHICLE SAFETY CERTIFICATION LAB lis E 00 20 NATIONAL SAFETY MARK CANADA 00 20 00 6 THEFT PROTECTION LABEL 00 21 PRECAUTIONS BEFORE SERVICE 00 26 00 7 CAUTIONS FOR WORKING IN ENGINE 00 7 COMPARTMENT 00 26 SUPPLEMENTAL RESTRAINT SYSTEM 00 10 ERS DDR TET 00 26 HOW TO PERFORM VEHICLE IDENTIFICATION 00 12 NUMBER VIN 00 27 INITIALIZATION PROCEDURE FOR LEARNING 00 14 VALUE IN MFI ENGINE 00 31 ENGINE IDLING LEARNING 00 15 PROCEDURE 00 32 00 16 TIMING CHAIN MAINTENANCE 00 33 SERVICING ELECTRICAL SYST
19. 00330AE GENERAL 00 69 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 excessively 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 1 ft lb 6 Install the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 16 TRANSAXLE OIL CHANGE 1 Remove the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 16 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 2 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 Mitsubishi genuine Dia Queen New Multi Gear Oil SAE 75W 80 API GL 3 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 16 TSB Revision 00 70 CE ORE EN GENERAL MAINTENANCE SERVICE 12 TWIN CLUTCH SPORTRONIC SHIFT TRANSMISSION CHECK OIL LEAKS IF NECESSA
20. 2 ft lb 4 Fill the specified gear oil up to the bottom of the filler plug hole Specified gear oil DIAMOND ATF SP III Amount to use 0 55 0 60 dm 0 58 0 63 qt 5 Install the filler plug and tighten it to the specified torque Tightening torque 49 10 m 37 7 ft lb M1001007500164 24 TIRES ROTATE M1001008900529 Rotate tires regularly to equalize tire wear and help extend tire life Recommended tire rotation is every 12 000 km 7 500 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 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 TSB Revision GENERAL MAIN SEALANT AND ADHESIVE TABLE 25 AIR PURIFIER FILTER REPLACE TM 4 7 GEE LUPA Eb AC611715AB Application 3M three bond No M1001009000143 1 Remove the glove box Refer to GROUP 52A glove box 52 6 2 Loosen the two lugs as shown to replace the clean air filter 3 Install the glove box MAIN SEALANT AND A
21. 5 CHECK FORLEAKS 00 63 18 BRAKE HOSES CHECK FOR 2 FUEL HOSES CHECK CONDITION 00 63 DETERIORATION OR LEAKS 00 78 19 BALL JOINT AND STEERING LINKAGE AIR CLEANER ELEMENT REPLACE i das SEALS INSPECT FOR GREASE LEAKS AND 4 EVAPORATIVE EMISSION CONTROL SYSTEM DAMAGE dass EXCEPT EVAPORATIVE EMISSION CANISTER ws ttt CHECK FOR CLOGGING 20 DRIVE SHAFT BOOTS INSPECT FOR EIS E ey GREASE LEAKS AND DAMAGE 00 78 MORS 21 SUSPENSION SYSTEM INSPECT FOR VALVE E LOOSENESS AND DAMAGE 00 78 Pcie Bee aeh 22 REAR AXLE OIL FOR DIFFERENTIAL 4 rem AND PART 00 79 REPLACE ode 23 REAR AXLE OIL FOR TORQUE TRANSFER 2 CONNECTIONS MECHANISM PART CHANGE 00 79 MUFFLER MUFFLER PIPES 24 TIRES 00 79 AND CONVERTER HEAT SHIELDS 25 AIR PURIFIER FILTER REPLACE 00 80 CHECK AND 00 67 9 ENGINE OIL 00 67 MAIN SEALANT AND ADHESIVE 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 model Unless otherwise specified each service procedure covers all models Procedures covering specific mode
22. 58 NOTE For details on how to use the scan tool MB991958 refer to the M U T IIl 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 5 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 Start the M U T III system on the personal computer Turn the ignition switch to the ON position Select System select from the start up screen 0 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 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 the EC
23. AFS of Adap tive Front lighting System The setting can be changed by the option coding Refer toP 00 46 3 Although the dual light discharge type is employed it is displayed as 4 beams OPTION CODING A CAUTION e 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 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 Connect the scan tool MB991958 Refer to P 00 39 2 Turn the ignition switch to the ON position 3 Select System select from the start up screen 4 Select From 2006 MY under Model Year Check that Vehicle Information contents are correct 5 Select ETACS from System List and then press OK button NOTE If Loading Option Setup list is shown click appropriate box 6 Select Coding 7 Select Option Coding Information 8 Check the displayed option coding information How to change option coding data 1 Connect the scan tool MB991958 Refer to 2 Turn the ignition switch to the ON
24. CTION IS ELIMINATED Repair the malfunctioning part and try to duplicate the condi tion 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 e Shake the wiring harness up and down and right and left Especially check the splice points of wiring harnesses care fully Refer to GROUP 00 Harness Connector Inspection P 00E 2 e Shake the part or sensor 00871 AB HOW TO 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 C
25. DHESIVE 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 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 5971 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 Between laminated glass and weatherstrip 3M AAD Part No 8633 TSB Revision Application GENERAL MAIN SEALANT AND ADHESIVE TABLE 3M three bond No 00 81 Loctite permatex No INTERIORS BODY SEALANTS Adhesive of vinyl chloride cloth Adhesion of door weatherstrip 3M AAD Part No 8088 General Trim Adhesive or 3M AAD Part No 8064 Vinyl Trim Adhesive 3M
26. EM 00 37 00 17 VEHICLE 00 38 APPLICATION OF ANTI CORROSION 00 17 AGENTS AND UNDERCOATS 00 38 SCAN TOOL MULTI USE TESTER M U T III 00 17 SUB 00 39 00 18 CODING LIST de ds AS 00 39 00 19 BOLTS AND NUTS WITH STABILIZER FOR iota COEFFICIENT OF FRICTION 00 47 00 19 TOWING AND HOISTING 00 48 Continued on next page 00 20 00 2 GENERAL DATA AND 10 ENGINE OIL FILTER REPLACE 00 68 SPECIFICATIONS 00 52 11 MANUAL TRANSAXLE OIL CHECK OIL LEVEL AND CONDITION RCHANGE 00 68 TIGHTENING TORQUE 00 54 12 TWIN CLUTCH SPORTRONIC SHIFT TRANSMISSION CHECK OIL LEAKS IF NECESSARY CHECK THE OIL LEVEL LUBRICATION AND CHANGE 00 70 MAINTENANCE 00 55 13 TRANSFER OIL CHECK OIL LEVEL CHANGE 00 71 RECOMMENDED LUBRICANTS AND 14 RESERVE TANK FLUID FOR ACTIVE LUBRICANT CAPACITIES TABLE 00 56 CENTER DIFFERENTIAL AND ACTIVE YAW CONTROL SYSTEM SCHEDULED MAINTENANCE CHECK FLUID 00 72 TABLE 00 59 15 ENGINE COOLANT CHANGE 00 73 16 COOLANT HOSES RADIATOR HOSE MAINTENANCE SERVICE 00 63 HEATER HOSE INSPECT 00 74 1 FUEL SYSTEM TANK PIPE LINE AND 17 DISK BRAKE PADS AND ROTORS CONNECTION AND FUEL TANK FILLER TUBE CAP INSPECT FOR WEAR 00 7
27. FF 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 M1001016800022 M1001011600636 4 Always use the designated special tools and test equipment 5 Store components removed from the SRS in a 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 deployment 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 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 sy
28. On vehicle Service Timing Chain Elongation Visual Check P 11A 17 At that time if the timing chain elongates more than the specified value the timing chain can possibly interfere the other parts and damage the engine before the ECM detects the timing chain elonga tion NOTE When the engine ASSY is replaced the timing chain is simultaneously replaced Thus it is not necessary to perform Step 3 and 9 1 After the ignition switch is in LOCK OFF position connect scan tool MB991958 to the diagnosis connector 2 Turn the ignition switch to the ON position 3 The initial learning value for timing chain elongation must be stored in scan tool MB991958 Refer to Timing Chain Maintenance P 00 33 4 Select MFI from System select Screen of scan tool 991958 Select Special Function from MFI Screen Select Learned value reset from Special Function Screen Select All learned value from Learned value reset Screen Initialize the learning value by pressing the OK button The stored initial learning value for timing chain elongation during Step 3 must be written into the ECM Refer to Timing Chain Maintenance P 00 33 10 After initializing the learning value the learning value of MFI engine idling is necessary Refer to Learning Procedure For Idling In MFI Engine P 00 32 MB991827 AC608435 AB ON O Ci ENGINE IDLING LEARNING PROCEDURE M1001011800920 PURPOSE When th
29. RY CHECK THE OIL LEVEL CHANG E M10010166000 TC SST OIL LEVEL CHECK 1 After cleaning the outer surface of transaxle visually check that there is no oil oozing or oil leaking from the transaxle 2 If an oil oozing or leaking is present replace the transaxle assembly TC SST OIL CHANGE 1 Remove the engine compartment under cover front B assembly Refer to GROUP 51 Under Cover P 51 16 2 Remove the oil drain plug to drain the oil NOTE Because the oil in the oil cooler and oil filter cannot be drained the amount of drained oil will be approximately 5 5 3 Tighten the oil drain plug to the specified torque Tightening torque 25 m 4 Remove the air cleaner element air cleaner intake duct and air cleaner body Refer to GROUP 15 Air Cleaner P 15 10 5 Remove the oil filler plug then fill the oil Brand name Mitsubishi genuine Dia Queen SSTF I Filling amount Approximately 5 5 dm 6 Tighten the oil filler plug to the specified torque Tightening torque 25 m 7 Install the air cleaner element air cleaner intake duct and air cleaner body Refer to GROUP 15 Air Cleaner P 15 10 8 Start the engine then let it idle for 1 to 2 minutes 9 Move the shift lever to every position and then move it to the P or N range 10 Stop the engine then perform Steps 2 to 5 again 11 Check the oil level and oil fouling Refer to P 22A 116 If fouling is found repeat Steps 2 to 5 until the fouling is elimina
30. SMS PA shi Eo lv lt 708456 TSB Revision 00 24 GENERAL VEHICLE IDENTIFICATION Label area x for original equipment parts y for replacement parts View C Trunk lid AC612302AB AC710511AB AC710513 TSB Revision GENERAL 00 25 VEHICLE IDENTIFICATION Label area x for original equipment parts y for replacement parts View E Rear bumper AC608729AB AC608730AB View F Side outer panel The illustration indicates left outer side Right side is symmetrically opposite AC608733AB The illustration indicates left outer side Right side is symmetrically opposite AC611136AB Front door both side lt The illustration indicates left outer side Right side is symmetrically opposite View G Section c c y AC608731AC Rear door both side View H d The illustration indicates left outer side Right side is symmetrically opposite AC608734AC TSB Revision 00 26 GENERAL PRECAUTIONS BEFORE SERVICE PRECAUTIONS BEFORE SERVICE CAUTIONS FOR WORKING IN ENGINE COMPARTMENT A 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 O
31. SSIS NUMBER M1001005600369 The chassis number is stamped on the front floor pan Front a CODE CHART E Sus Chassis Content 25 number code CZ4A8U00001 Vehicle line CZ4A LANCER EVOLUTION 8U000001 Refer to 10th thru 17th digits of VIN plate m AC608772AD 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 4B11 2 0L The engine serial number is stamped near the engine model number Engine number 0201 to YY9999 700355 VEHICLE IDENTIFICATION CODE PLATE M1001005400116 The information code plate is riveted onto the cowl top outer panel in the engine compartment CODE CHART No Example Content 1 MODEL CZ4AS Vehicle model MGFZL2M Model series 2 ENGINE 4B11 Engine model 3 EXT W69C Exterior code 4 ITRANS W4A5A Transaxle model 5 W69 Body color code MITSUBISHI MOTORS CORPORATION 6 TRIM 06 Tum 1 Lacs i 7 OPT Q40 Equipment code 2 et 3_ we 4 1 ew 5 1L63 L73 AC608666 TSB Revision 00 20 GENERAL VEHICLE IDENTIFICATION TIRE AND LOADING INFORMATION PLACARD M1001015800137 The tire and loading
32. U with a correctly coded one For replacement of the engine control module refer to GROUP 13A engine control module P 13A 920 For replacement of the TC SST ECU refer to GROUP 22C transaxle assembly P 22C 341 For replacement of the ETACS ECU refer to GROUP 54 ETACS P 54A 676 NOTE TC SST ECU cannot be disassembled Thus replace the transaxle assembly MB991827 AC608435 AB O ON TSB Revision GENERAL 00 41 PRECAUTIONS BEFORE SERVICE ENGINE CONTROL MODULE CODING DATA LIST Item name Initial value Final gear ratio 5MT 6MT or 4 062 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 Destination U S Transaxle 5MT or TC SST Engine type D4 V V T 2 0L TC Engine power Normal Handle side LHD Chassis Type for A S C Type 1 Deadlock Button Operation 2 or Not present Final drive AWD FF Base Transfer ACD IG off delay control Disabled Vehicles without 55 gt or Enable Vehicles
33. V C I M U T III MAIN HARNESS DO NOT USE MB991826 GENERAL 00 39 PRECAUTIONS BEFORE SERVICE SCAN TOOL MULTI USE TESTER M U T III SUB ASSEMBLY N 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 ENTER key M1001012400226 M U T III USB CABLE M U T III MAIN HARNESS MB991910 MAIN HARNESS C MEASUREMENT ADAPTER DO NOT USE MB991825 AC21088AD CODING LIST M1001015000294 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 and ETACS ECU are normal If they are not the same as the initial settings various functions and systems will not work correctly VARIANT CODING Required Special Tools MB991958 Scan Tool M U T Il Sub Assembly MB991824 Vehicle Communication Interface V C 1 TSB Revision GENERAL 00 40 PRECAUTIONS BEFORE SERVICE e MB991827 USB Cable e MB991910 M U T III Main Harness A Vehicles with CAN communication system The coding data can be checked by operating scan tool 9919
34. a negative Approximately 5 volts are applied to the intake 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 Z 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 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 epolaiit temp ature was T6 45 F or Open or shorted engine coolant temperature sen more immediately before the engine was stopped sor circuit or loose connector at the last drive alll DIAGNOSIS Required special tool 991958 Scan Tool M e MB991824 V C I MB991827 USB Cabl
35. 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 M1001016500021 If the vehicle equipped with 4B 11 T C engine continues the rough driving like competitive running the amount of carbon mixed into the engine oil tends to increase This can possibly cause the timing chain to gradually elongate To prevent this the function or logic monitoring the amount of elongation 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 that the visual check of the elongation of the timing chain is necessary If this warning is continuously neglected the timing chain can possi bly 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 full closed position of the accelerator pedal TSB Revision GENERAL PRECAUTIONS BEFORE SERVICE 00 34 The ECM stores the timing chain conditions as the learning value when the timing chain is installed The ECM stores the amount of elongation of the timing chain
36. agnosis code displayed Current trouble 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 displayed Recheck trouble symptom How to treat past trouble Y Read the diagnosis code No diagnosis code diagnosis code r 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 54C P 54C 9 2 For the CAN bus diagnosis chart refer to GROUP 54C P 54C 14 3 When scan tool MB991958 detects 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 e 5 For how to cope with intermittent malfunc tions refer to P 00 15 6 For co
37. aintenance 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 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 Revision 00 38 GENERAL PRECAUTIONS BEFORE SERVICE A CAUTION e 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 e 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 an
38. alve 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 65 MAINTENANCE SERVICE 5 Turn the crankshaft clockwise 360 degrees and put the Timing mark timing mark on the exhaust camshaft sprocket in position eee oe pe sie esse s RS 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 No In the same procedure as 4 7 If the valve clearance is deviated from the standard value remove the camshaft and the valve tappet For the camshaft removal refer to Camshaft Removal and Installation o 0 NS 11 25 o No 3 No 4 Intake valve side AK502388AF 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 s
39. and As Horn type 2 Dual horn Gate trunk opener mode Present Cooling fan Relay control Security alarm mode C spec US 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 NotPresent ChgNg Panic Alarm Enable Front wiper Speed Sensitive or Rain Sensitive Comfort flasher type Present Chg Ok Dome light center switch Not present Wiper washer check bulb 2 Present AUDIO S RADIO type Other H L leveling type Not present AFS ACL type Not present ESS Not present Compressor type Scroll 90cc Temperature type Celsious 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 or MPG US Speed gauge tolerance U S Coolant temp gauge threshold Normal TSB Revision GENERAL 00 45 PRECAUTIONS BEFORE SERVICE Item name Initial value 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 availab
40. anti corrosion property will be adversely affected In addition if the concentration is above 60 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 e Do not use a mixture of different brands of anti freeze Coolant temperature F and specific Freezing safe operating Coolant gravity temperature temperature concentration Specific volume 10 50 20 68 30 86 40 104 50 122 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 59 SCHEDULED MAINTENANCE TABLE SCHEDULED MAINTENANCE 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 Emission control Service Mileage in system intervals thousands maintenance Kilometers in thousands Months Fuel system tank Check for leaks pipe line and connection and fuel tank filler tube cap Fuel hoses Check condition Air cleaner Replace element Evaporative Check for leaks and clogging emission control system except evaporative emission canister Spark plugs lridium tippe Replace X X d type
41. clearance 135 5 3 135 5 3 Overall height unladen 1 480 58 3 1 480 58 3 Tread rear o NI o al A O NI gt 1 545 60 8 1 545 60 8 Vehicle weight kg Ib Curb weight 1 600 3 528 1 635 3 606 Gross vehicle weight rating 2 060 4 542 2 060 4 542 Gross axle weight rating front 1 080 2 381 1 080 2 381 Gross axle weight rating rear 1 050 2 315 1 050 2 315 Seating capacity 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 4B11 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 Type 5 55 Turning radius m ft 5 0 16 4 TSB Revision 5 0 16 4 00 54 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 Standard tightening torque Thread size 1 2 3 ins
42. ct 4WD Loading Option Setup 7 SRS Airbag v Option Name With Option 8 A C IMMOBI 8 Keyless amp 9 ETACS Y IMMOBI amp FA S T amp TPMS 10 Meter Select Model Year and System UTE OK button AC609809AB TSB Revision System Select FAS LIMNOBIKeyessiTPNS Coding VIN Writing Please select function e e 8 609799 FAS TIMMOBIKeyiess TPMS 7 Coding VIN Writing VIN Writing VIN Engine ECU 00000000000000000 VIN currently written in ECM is displayed Write the number displayed on the screen in Immobilizer KOS ECU OK button Press the OK button to execute ale e m AC609798 AB EAS TIMMOBUKeyess TPMS Coding VIN Writing Result of VIN Writing VIN Writing 00000000000000000 AC609285 AB GENERAL 00 31 PRECAUTIONS BEFORE SERVICE 10 Select VIN Writing on Coding screen 11 Push the OK button after the VIN written in the engine 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 writi
43. d then check to be sure that the idle is satisfactory Engine coolant temperature 85 95 C 185 203 F e Lights and all accessories OFF e Transaxle P position e Steering wheel straight forward position 2 When servicing the electrical system disconnect the negative cable terminal from the battery 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 tain the spray nozzle at a distance of at least approximately Approximately pa cm 16 in or more 40cm 16 in from any plastic parts and all opening parts a y doors luggage compartment etc 5 f 5 0 2 If high pressure car washing equipment or steam car wash MR 20 ing equipment is used to wash the vehicle be sure to observe the following instructions to prevent damages to the plastic parts e Spray nozzle distance Approximately 40 cm 16 in or more e Spray pressure 3 900 kPa or less e Spray temperature 82 180 F or less e Time of intensive spraying to one point Within 30 sec onds 00881 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 TSB Revision VEHICLE COMMUNICATION INTERFACE
44. dditional key registration Key Registration Barcode No ENG key code amp VIN Reg Keyless ID Reg Tire Pressure Sensor ID Registration Tire Pressure Sensor ID Check Tire Pressure Sensor Check Please select function ale AC709283AB Item Key Code Registration OK button AES 01 AC709286AB FA S T MMOIKeylessTPMS Special Function Engine key code amp VIN Reg Current VIN New VIN 1 2 3 4 5 7 8 9 0 D E F G H J K E M N p Q R 5 T v w x Y 2 Space Clear Input new VIN then press OK button 44 e ly AC709287 Special Function Engine key code amp VIN Reg Result of VIN Writing Current Before Writing AC709285 10 Select ENG key code amp VIN Reg from the Special Function screen 11 Push the OK button after ENG key code amp VIN Reg is displayed 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
45. ding data refer to P 00 39 2 SYSTEM OPERATION AND SYMPTOM VERIFICATION 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 e 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 GENERAL 00 9 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS 7 SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptom listed in the Symptom Chart Refer to P 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 Conn
46. e MB991910 Main Harness 8 Start of the diagnosis procedure 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 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 ue 2 gt 1 Connect scan tool MB991958 to the data link connector a Y 2 Start the engine e 3 Set scan tool MB991958 to the data reading mode for item e JT 15 Transmission Fluid Temperature Sensor l e When the engine is cool Almost equal to the ambient 2 A temperature atmospheric temperature N 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 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 MB991827 AC206894AB Q Is the sensor operating properly YES It can be assumed that this malfunction is intermittent R
47. e 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 TSB Revision GENERAL 00 33 PRECAUTIONS BEFORE SERVICE TIMING CHAIN MAINTENANCE AK704218 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 3 After 10 seconds or more start the engine again 4 For 10 minutes carry out the idling under the condition shown below and then confirm the engine idles normally e Transaxle Neutral P range on vehicles with TC SST Operation in ignition related fan and attachments Not to be operated e 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 INITIALIZATION PROCEDURE FOR THROTTLE ACTUATOR CONTROL MOTOR When the battery cable is disconnected and reconnected throt 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
48. eam 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 16 4 Remove the air cleaner intake hose Refer to GROUP 15 Air Cleaner P 15 10 5 Remove the turbocharger compressor bracket Refer to GROUP 15 Exhaust Manifold and Turbocharger Assembly P 15 16 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 Ss 1 Turbo charger 7 air inlet P ez 7 TSB Revision 00 74 GENERAL MAINTENANCE SERVICE NS PA EN 7 C 705466 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 concentration for safe operating temperature within the range of 30 to 60 Use special tool 991871 to refi
49. ect a needle nosed wire probe to a voltmeter probe A CAUTION 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 an
50. efer to GROUP 00 How to Use Troubleshooting 10 Provides the inspection procedure Inspection Service Points How to Cope with for that DTC step by step Intermittent Malfunction Goto 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 a Blown Fuse P 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 WATERPROOF CONNECTORS 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 ORDINARY NON WATERPROOF CONNECTORS Required Special Tool MB992006 Extra Fine Probe Inspect by inserting a test probe from the harness side If t
51. el 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 709514 TSB Revision 00 52 GENERAL GENERAL DATA AND SPECIFICATIONS GENERAL DATA AND SPECIFICATIONS VEHICLES FOR USA Item NGFZL2M MGFZL2M a NN aaa Cim M1001000902565 Iipat pom 710509 MPFZL2M Vehicle Overall width 1 810 71 3 1 810 71 3 1 810 71 3 dimension mm Treag 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 135 5 3 135 5 3 135 5 3 Overall height unladen 1 480 58 3 1 480 58 3 1 480 58 3 N gt Tread rear 1 545 60 8 1 545 60 8 1 545 60 8 Vehicle weight Curb weight 1 595
52. elected through the procedure 9 and put the camshaft in position For the camshaft Q installation refer to Camshaft Removal and Installation P 11A 25 11 After installing the timing chain measure the valve 704211 clearance using the procedure 3 to 6 Confirm 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 66 Cylinder head 4 0 mm 0 16 in AK502760AF Auto tensioner GENERAL MAINTENANCE SERVICE A 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 exact 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 9 in Ib 2 Tighten to the specified torque in order shown in the illustration Specified torque 5 5 0 5 m 49 9 in Ib 15 Install the igniti
53. enuine Dia Queen LSD Gear Oil Quantity 0 9 dm 1 0 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 51 16 TSB Revision 00 72 Nut iecit MAX SET XT Oil reservoir AC705200AB GENERAL MAINTENANCE SERVICE 14 RESERVE TANK FLUID FOR ACTIVE CENTER DIFFERENTIAL AND ACTIVE YAW CONTROL SYSTEM CHECK FLUID LEVEL FLUID LEVEL CHECK lt WHEN THE SCAN TOOL IS NOT USED gt 1 2 5 M1001017500013 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 C 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 A CAUTION Turn the ignition switch to the LOCK OFF position before connecting or disconnec
54. erted nuts 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 used Nominal bolt diameter mm Head mark 4 Head mark 7 Head mark 8 2 5 40 5 N m 23 4 in Ib 5 0 1 0 m 44 9 in Ib 6 0 1 0 m 53 9 in Ib 5 0 1 0 m 44 9 in Ib 8 5 1 5 m 76 13 in Ib 10 2 m 89 17 in Ib 11 2 m 98 17 in Ib 20 4 m 15 3 ft lb 24 4 m 18 3 ft lb 23 4 m 17 3 ft lb 42 X8 N m 31 6 ft Ib 53 7 m 39 5 ft lb 42 8 m 31 6 ft Ib 80 10 m 59 7 ft lb 93 12 m 68 9 ft lb 70 10 m 52 7 ft Ib 130 20 N m 96 15 ft lb 150 20N m 111 14 ft lb 105 15 m 78 11 ft Ib 195 25 N ft Ib m 144 18 230 30 N m 170 22 ft Ib 150 20 ft lb m 111 14 290 40 N ft Ib m 214 29 335 45 N m 247 33 ft Ib 210 30 ft Ib m 155 22 400 60 N ft lb m 295 44 465 65 m 343 48 ft Ib 290 40 N ft Ib 375 55 N ft Ib m 214 29 m 277 40 FLANGE BOLT AND NUT TIGHTENING TORQUE Thread size 540 80 N ft lb 705 105 N m 520 77 ft lb m 398 59 Standard tightening torque 630 90 N
55. f the pads and brake discs 2 After re installing the caliper support to the knuckle install the pad clips and the pads to the caliper support The title of the page following the page on which the diagram of component parts is presented indicating the locations of lubrication and sealing procedures LUBRICATION AND SEALING POINTS Indicates by symbols where lubrication is necessary Symbols for lubrication sealants and adhesives Symbols are used to show the locations for lubrication Grease ee Multi purpose grease unless there is and for application of sealants and adhesives in brand or type specified These symbols are included in the diagram of component parts or on the page following the gt Sealant or adhesive mE component parts page symbols do not always Brake fluid or automatic transmission fluid have accompanying text to support that symbol Engine gear oil or air conditioning compressor oil Kemp Adhesive tape or butyl rubber tape AC610767AB TSB Revision 00 6 GENERAL TROUBLESHOOTING GUIDELINES TROUBLESHOOTING GUIDELINES VERIFY THE COMPLAINT e Make sure the customer s complaint and the ser vice writer s work order description are under stood before starting work e Make sure the correct operation of the system is understood Read the service manual descripti
56. faces in the direction shown in the illustration and then tighten the drain plug to the specified torque Tightening torque 39 5 N m 29 3 ft lb M1001002600661 A CAUTION Do not use conventional petroleum based motor oil Using conventional motor oil may cause engine or tur 40 30 20 10 0 10 20 30 40 50 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 as certification symbol Starburst symbol or 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 16 TSB Revision 00 68 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 16 4
57. g of fuel gauge unit 3M AAD Part No 8730 High Strength Red Threadlock or 3M 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 or 3M AAD Part No 8679 black or 3M AAD Part No 8678 black Press In Place Silicone gasket strips 3M AAD Part 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 STRONG SEALING 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 3M 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
58. gnition switch to the ON position 8 Select F A S T IMMO Keyless TPMS button from the I NEM port System Select screen Then select the applicable option stem Lis lodel Year p to 1 MPVGDVDiesel From to 2006 MY code item and push the OK button 2 5 55 5 4 3 ATICVT A MT ss suele Information 9 Select Special Function on the next screen 4 ABS ASC ASTC Model Year seek 5 SAS Model Code 6 Multi Select 4WD Loading Option Setup 7 SRS Airbag Option Name With Option 8 IMMOBI 8 Keyless amp 9 ETACS IMMOBI amp FA S T amp TPMS 10 Meter M Select Model Year and System ala Je amp OK button AC609809AB TSB Revision Option When IMMOBI amp F A S T amp TPMS is selected GENERAL 00 29 PRECAUTIONS BEFORE SERVICE System Select FAS T AMMO Keyless TPMS Special Function Key amp FA S T Key Reg ENG key code amp VIN Reg Steering lock unit Reg Comm Test Tire Pressure Sensor ID Registration Tire Pressure Sensor ID Check Tire Pressure Sensor Check Please select function 709284 Option When Keyless amp TPMS is selected ZSystem Select FAS TAMMOKeyless TPMS Special Function Key Registration A
59. gnostic 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 991958 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 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 991910 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 i
60. h to the LOCK OFF position before con necting or disconnecting scan tool MB991958 1 After the ignition switch is in LOCK OFF position connect S scan tool 991958 to the diagnosis connector Data link m 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 T Press OK to reset the learning value MB991827 AC608435 AB TSB Revision GENERAL 00 37 PRECAUTIONS BEFORE SERVICE 991827 608435 ACX00880AB TEST LIMIT VALUE READOUT Required Special Tools MB991958 Scan Tool M U T III Sub Assembly MB991824 V C I MB991827 M U T III USB Cable MB991910 M U T III Main Harness 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 MB9919568 to the diagnosis 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 m
61. he connector is too small to insert a test probe e g control unit connector do not insert it forcibly Use special tool MB992006 extra fine probe IF INSPECTING WITH THE CONNECTOR DISCONNECTED When Inspecting a Female Pin e From front side of the connector Required Special Tool MB991219 Inspection Harness Included in MB991223 Harness Set TSB Revision GENERAL 00 13 HOW TO USE TROUBLESHOOTING INSPECTION SERVICE POINTS MB991219 SRS ECU harness connector 001607 00867 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 e 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 wh
62. ich will decrease reliability When Inspecting a Male Pin N CAUTION At this 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 14 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 00868 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 ee SS connector body is connected because the pins may pull out of Ss 2 the back side of the connector Therefore gently pull the wires gt 2 by one to make sure that no pins pull out of the connector XQ 55 00869 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 too
63. in the EEPROM as the current learning value compared with the learning value The ECM judges that the visual check of the elongation of the timing chain is neces sary when the current learning value exceeds the specified value Thus use the scan tool MB991958 to always carry out the maintenance of the learning value related to the timing chain that is stored by the ECM after the following service Maintenance items by scan tool MB991958 Maintenance purpose ECM replacement Visual check of elongation of timing chain e Learned value Read amp Save 2 e Write learned value Changed ECU Learned value reset The purpose is that the initial 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 value stored by the current ECM is initialized after the visual check of the elongation of the timing chain by illuminating the warning lamp whether or not the timing chain is replaced Timing chain or engine ASSY 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 ASSY the timing chain is also replaced with a new one is replaced This allows the ECM to
64. ing 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 TSB Revision GENERAL 00 50 TOWING AND HOISTING LIFTING JACKING SUPPORT LOCATION FLOOR JACK AND RIGID RACK A CAUTION e 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 FLOOR JACK lt REAR gt Zw WVlJ Differential carrier j VI assembly LM Jc asl I lt ANG Zo 2 2 J N Mell olill RIGID RACK lt FRONT gt lt REAR gt a Rubber Th Rubber AC709513AB TSB Revision n aeu D GENERAL TOWING AND HOISTING 00 51 Special 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 N CAUTION When service procedures require removing rear suspen sion fu
65. ining alcohol is not recommended unless the nature of the blend can be determined as being satisfactory Gasohol A mixture of 1096 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 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 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS Lubricant Specification M1001001300719 Remark Engine oil Engine oils displaying ILSAC certification symbol or co
66. l MB991219 to inspect the engagement of the male pins and female pins Pin drawing force 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 MALFUN
67. le Trip autoreset IG OFF Available Variable Speed Alarm Not available Rest reminder Available Instant speed Not available Seat belt reminder type Type 1 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 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 Present Chg Ok Rear S R Unlock Output Not present Trailer turn detection Present Shift Lever Not present Vehicles without TC SST gt or Present Vehicles with 55 gt AFS ACL Not present Satellite Radio 2 Not present or Present Fuel tank type Not used F A S T auto lock customize Not used DRL function Present Chg Ng FACU Not present S AWC Control display Available TSB Revision 00 46 GENERAL PRECAUTIONS BEFORE SERVICE Item name Initial value Diesel particulate filter Not present Language mode Available WSS Not present DOOR UNLOCK MODE CUSTOMIZE Disabled RLS overwipe type Type 1 RLS WS type Type 2 Green NOTE 1 TPMS is an abbreviation of Tire Pressure Monitoring System DRL of Daytime Running Light and
68. ll the engine coolant up to the top of the radiator port A convenient mixture is 5096 water and 50 antifreeze solution freezing point 31 23 8 F Recommended antifreeze Long Life Antifreeze Coolant or an equivalent Quantity 7 5 dm 7 9 quarts NOTE For how to use special tool MB991871 refer to its manufacturer s instructions 12 Tighten the radiator 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 16 20 Install the air cleaner intake hose Refer to GROUP 15 Air Cleaner P 15 10 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 16 16 COOLANT HOSES RADIATOR HOSE HEATER HOSE INSPECT M1001009700175 Ins
69. ls 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 M1001000102097 DANGER WARNING AND CAUTION DANGER WARNING and CAUTION call special attention to a necessary action or to an action that must be avoided The differences among DANGER WARNING and CAUTION are as follows If a DANGER is not followed the result is severe bodily harm or even death Ifa WARNING is not followed the resu
70. lt could be bodily injury 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 N m in Ib or N m ft Ib For fasteners with no assigned torque value refer to P 00 54 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 4 wheel drive vehicles LIN Local interconnect network 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 PCM Powertrain control module TSB Revision E GENERAL 00 4 HOW TO USE THIS MANUAL EXPLANATION OF MANUAL CONTENTS Indicates the tion title Denotes tightening torque If there is no indication of tightening torque refer to Indicates the tightening torque Indica
71. nforming to the API classification SM For further details refer to LUBRICANTS SELECTION section Engine coolant Long life antifreeze coolant or an equivalent Transaxle oil Manual transaxle DiaQueen NEW MULTI GEAR OIL API classification GL 3 SAE 75W 80 Twin clutch sportronic shift transmission DIA QUEEN SSTF 1 Transfer oil MITSUBISHI limited slip differential oil LSD or equivalent AWC control fluid Vehicles with ACD Including hydraulic pipe section Vehicles with ACD AYC Including hydraulic pipe section DIAMOND ATF SP Control fluid for ACD AYC Apply for Reservoir tank AYC differential gear oil Differential mechanism part MITSUBISHI Limited Slip Differential Oil LSD or equivalent TSB Revision GENERAL 00 57 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE Lubricant Specification AYC differential gear oil Torque transfer DIAMOND ATF SP III part Power steering fluid Genuine Mitsubishi Power Steering Fluid Brakes and clutch Conforming to Brake fluid DOT 3 or DOT 4 Engine coolant Long Life Antifreeze Coolant or an equivalent Door hinges back door hinges Grease LUBRICANT CAPACITY TABLE Description Specification Engine oil dm at Oil pan excluding oil filter 4 8 5 07 Oil cooler 0 5 0 52 Oil filter 0 3 0 32 Engine coolan
72. ng is displayed 15 Resister the other ID code Refer to GROUP 42B Troubleshooting ID Code Registration Judgment Table P 42B 12 lt Vehicles with KOS gt or GROUP 42C Troubleshooting ID Code Registration Judgment Table P 42C 9 Vehicles with WCM gt INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE M1001011700826 When the following service is performed initialize the learning value At replacing engine assembly e At replacing throttle body and at cleaning e At replacing knock sensor INITIALIZATION PROCEDURE Required Special Tools MB991958 Scan Tool M U T III Sub Assembly MB991824 V C lI MB991827 M U T III USB Cable e MB991910 M U T III Main Harness TSB Revision 00 32 GENERAL PRECAUTIONS BEFORE SERVICE N CAUTION To prevent damage to scan tool MB991958 always turn the ignition switch to the LOCK OFF position before connecting or disconnecting scan tool MB991958 When the learning value for MFI engine is initialized the initial learning value for engine timing chain elonga tion is also initialized Thus the initial learning value for timing chain elongation must be stored in scan tool 991958 before working If the initial learning value for timing chain elongation is not stored and the learn ing value for MFI engine is initialized the visual check of the timing chain elongation must be carried out Refer to GROUP 11A Engine Mechanical
73. ntake and exhaust valve clearance Check for leaks and clogging Inspect and adjust X X If val ve noise increases adjust valve clearance Drive belts for the generator and power steering oil pump Replace X X X X X Exhaust system connections portion of muffler muffler pipes and converter heat shields Check and service Engine oil Engine oil filter Turbo Replace Every 3 months or every 4 800 km 3 000 miles 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 Transfer oil Check oil leaks If necessary check the oil level Change X X X X X Reserve tank for ACD and 2 Check fluid level Engine coolant Change TSB Revision 00 62 GENERAL SCHEDULED MAINTENANCE TABLE Maintenance Service Mileage in item intervals thousands Kilometers in thousands Months Coolant hoses Inspect radiator hose heater hose Replace Disk brake pads Inspect for wear Every 3 months or every 4 800 rotors Brake hoses Check for deterioration or X X JX IX X X leaks Ball joint and Inspect for grease leaks and X X X X X X steering linkage damage seals
74. o prevent leakage or grease contamination 2 Inspect the dust cover and boots for proper sealing leakage and damage Replace them if defective 21 SUSPENSION SYSTEM INSPECT FOR LOOSENESS AND DAMAGE M1001009600219 Visually inspect the front rear suspension components for dete rioration and damage Re tighten the front rear suspension components retaining bolts to specified torque TSB Revision Vallee UALS we Drain plug AC705198AC Se A e Filler plug E SAk TOt Drain plug J 705199 SB Crs Ss C amp S AC000120 GENERAL 00 79 22 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 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 MAINTENANCE SERVICE M1001007200118 23 REAR AXLE OIL FOR TORQUE TRANSFER MECHANISM 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
75. o 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 33 LN Chalk marks e lt gt 3 When the looseness is within the limit value install the 201323 AD brake disk after changing the phase between the hub and the brake disk then check the runout of the brake disk again A CAUTION e 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 e 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 m 74 ft lb 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 5 f the run out cannot be corrected by changing the phase of the brake disk replace the brake disk o
76. on to verify normal system operation e Operate the system to see 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 e 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 ste
77. on coils 7 DRIVE BELT FOR THE GENERATOR AND POWER STEERING OIL PUMP 1 Remove the radiator condenser tank Refer to GROUP 14 Radiator P 14 31 A CAUTION Check the drive belt tension after turning the crankshaft clockwise one turn or 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 31 TSB Revision GENERAL MAINTENANCE SERVICE 00 67 8 EXHAUST SYSTEM CONNECTIONS PORTION OF MUFFLER MUFFLER PIPES AND CONVERTER HEAT SHIELDS CHECK AND SERVICE M1001005800459 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 F A 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 16 4 Remove the drain plug to drain oil 5 Install a new drain plug gasket so that it
78. 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 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 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 Remove the brake assembly and then hold it with wire Temporarily install the disk with the hub nut TSB Revision GENERAL 00 77 MAINTENANCE SERVICE 3 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 4 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 t
79. ope with Intermittent Malfunction P 00 15 TSB Revision 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 O at this time there is a short some where between these switches and the load If the resistance is not 0 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 e Harness being clamped by the vehicle body e Damage to the outer casing of the harness due to wear or heat e 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 M1001005500243 The vehicle identification number VIN plate is located on a plate attached to the left top side of the instrument panel CODE CHART No Content 1 Country J JAPAN 2 Make A Mitsubishi Motors 3 Vehicle type 3 Passenger car 4 Others A Driver and passenger air bags 5 Line W LANCER EVOLUTION AC707964 6 Trim level 5 PREMIUM Price class 8 SPORTS
80. p by step pro cedures to help diagnose the problem make a series 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 e general to specific e most likely to least likely e 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 Rese the right and left with the IG ON or tilt the
81. pect 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 TSB Revision GENERAL 00 75 MAINTENANCE SERVICE 17 DISK BRAKE PADS AND ROTORS INSPECT FOR WEAR DISK BRAKE PAD CHECK N 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 Front 9 0 mm 0 35 inch Rear Limit 2 0 mm 0 08 inch Front 2 0 mm 0 08 inch Rear 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 M1001003200440 Rear DISK BRAKE ROTOR CHECK A 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 e 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 e f grooves and scratches resulting from excessive disk wear a
82. position 3 Select System select from the start up screen TSB Revision GENERAL PRECAUTIONS BEFORE SERVICE 00 47 4 Select From 2006 MY under Model Year Check that Vehicle Information contents are correct 5 Select ETACS from System List and then press OK button NOTE If Loading Option Setup list is shown click appropriate box 6 Select Coding 7 Select Option Coding 8 Change to correct option coding data LIST Item name Number of speaker Seat material Auto light control AUDIO CAN AND HFM hands free ECU Rain Light Sensor Front fog light Rear fog light Horn type Manner switch Remote engine starter Wiper washer check bulb Compressor type Satellite Radio DRL function Keyless 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 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 wi
83. r grind it with the lat washier on the car type brake lathe MAD DL 8700PF or equivalent AC006226 AE TSB Revision 00 78 Dust cover AC100948AC Boots 000109 GENERAL MAINTENANCE SERVICE 18 BRAKE HOSES CHECK FOR DETERIORATION OR LEAKS M1001003400488 Inspection of brake hoses should be included in all brake ser vice operations The hoses should be checked for 1 Incorrect length 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 2 Incorrect installation twisting or interference with wheel tire or chassis 19 BALL JOINT AND STEERING LINKAGE SEALS INSPECT FOR GREASE LEAKS AND DAMAGE M1001003500496 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 20 DRIVE SHAFT BOOTS INSPECT FOR GREASE LEAKS AND DAMAGE M1001003600493 1 These components which are permanently lubricated at the factory do not require periodic lubrication Damaged seals and boots should be replaced t
84. re 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 Change in thickness parallelism If the thickness of the disk changes this will cause pedal pulsation shuddering and surging TSB Revision GENERAL 00 76 MAINTENANCE SERVICE Inspection items Remarks Inset or warping flatness Overheating and improper handling while servicing will cause warping or distortion 00668 lat washer AC006226 AE 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 lt Front gt 22 0 mm 0 87 inch lt Rear gt Limit 30 0 mm 1 18 inch lt Front gt 20 0 mm 0 79 inch lt Rear gt NOTE Thickness variation at least 8 positions should not be more than 0 015 mm 0 0006 inch N 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
85. rval 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 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 during hot weather above 32 C 90 F 3 Extensive idling 4 Driving in sandy areas 5 Driving in salty areas M1001001200529 6 Driving in dusty conditions 7 Driving off road ENGINE OIL A 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 disorder
86. s 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 For further details refer to LUBRICANTS SELEC TION LUBRICANTS AND GREASES Semi solid lubricants bear the NLGI designation and are further classified as grades 0 1 2 3 etc Whenever Chassis Lubricant is specified Multipur pose Grease NLGI grade Number 2 should be used FUEL USAGE STATEMENT N CAUTION Using leaded gasoline in this car will damage the catalytic converters and heated oxygen sensors 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 TSB Revision 00 56 GENERAL RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE GASOLINE CONTAINING ALCOHOL Some gasoline sold at service stations contain alco hol although they may not be so identified Using fuels conta
87. sis 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 OK to store the learning value file NOTE When the 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 Learned value reset from Timing chain maintenance Screen 10 Select the learning value file stored during Step 3 to write the learning value NOTE Use only the learning value file stored during Step 3 without using any other files NOTE When the learning value is appropriately written Learned value writing Completed is shown on the screen of the scan tool 991958 TSB Revision 00 36 GENERAL PRECAUTIONS BEFORE SERVICE LEARNED VALUE RESET Required Special Tools MB991958 Scan Tool M U T Il Sub Assembly MB991824 V C I MB991827 M U T III USB Cable MB991910 M U T III Main Harness A CAUTION To prevent damage to scan tool MB991958 always turn the ignition switc
88. stem functions properly 8 Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag Refer to GROUP 52B P 52B 417 Air Bag Module Disposal Procedures Air bag module Driver s or front 2 Observe the following when carrying out passenger s operations on places where SRS components are Clock spring installed including operations not directly related e SRS ECU to the SRS air bag e Knee air bag module 1 When removing or installing parts do not allow e Sun visor any impact or shock to occur to the SRS components 2 If heat damage may occur during paint work remove the SRS ECU the air bag module clock spring the front impact sensor the side impact sensor and the seat belt pre tensioner e SRS ECU air bag module clock spring front impact sensor the side impact sensor 93 200 F or more e Seat belt pre tensioner 90 C 194 F or more e Seat belt pre tensioner e Side airbag module Driver s side and front passenger s side e Curtain air bag module Driver s side and front passenger s side e Center pillar Driver s side and front passenger s side e Glove box TSB Revision GENERAL 00 27 PRECAUTIONS BEFORE SERVICE HOW TO PERFORM VEHICLE IDENTIFICATION NUMBER VIN WRITING CAUTION The VIN is stored in the engine control module The F A S T Key Free hand Advanced Security WCM and the KOS ECU
89. t dm qt 7 5 7 93 Transaxle oil dm qt Manual transaxle M T 2 5 2 64 Twin clutch sport shift transaxle 7 8 8 24 TC SST Transfer oil dm qt 0 9 0 95 ACD and AYC differential fluid dm qt 7 1 7 50 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 A CAUTION ILSAC certification symbol Never use nondetergent or straight mineral oil Starburst symbol Use only engine oils displaying the ILSAC certification mark 2 7 e GASOLINE E AC609011AB Starburst symbol on the container TSB Revision 00 58 GENERAL RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE If these oils are not available classification SM or API service symbol higher 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 e SAE 5W 30 engine oil is strongly recommended for opti 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 SELECTION OF COOLANT COOLANT Relationship between Coolant Concentration and Specific Gravity A CAUTION e If the concentration of the coolant is below 30 the
90. ted 12 Install the engine compartment under cover front B assembly Refer to GROUP 51 Under Cover P 51 16 TSB Revision Filler plug hole Gasket mama Oil filler plug Transmission oil AC700330AE AC704516AE Filler plug hole Gasket Oil filler plug Transmission oil AC700330AE GENERAL 00 71 MAINTENANCE SERVICE 13 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 16 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 excessively 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 1 ft lb 6 Install the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 16 TRANSFER OIL CHANGE 1 Remove the engine room under cover front B assembly Refer to GROUP 51 Under cover P 51 16 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 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 hole Brand name Mitsubishi g
91. tes the group number group title BASIC BRAKE SYSTEM 35A 81 FRONT DISC BRAKE ASSEMBLY Indicates the page number Indicates procedures to be performed be Post installation operation fore the work in that section is started and Brake fluid supplying and air bleeding Refer to procedures to be performed after the work in that section is finished FRONT DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION Pre removal operition Brake fluid Y 11329 Nm 93 7flb 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 Repair kit or parts sets are shown Only very frequently used parts are shown Brake caliper kit Seal and boot kit Removal steps Removal steps Cont 1 Brake hose connection gt gt lt lt 3 Disc brake assembly 2 Gasket 4 Brake disc Required special tool MB990520 Disc brake piston expander Maintenance and servicing procedures The numbers provided within the diagram indicate the e Installation steps sequence for maintenance and servicing procedures Specified in case installation is impossible in e Removal steps reverse order of removal steps Omitted if The part designation number corresponds to installation is possible in reverse order of the number
92. th low tightening torque TSB Revision 00 48 GENERAL TOWING AND HOISTING TOWING AND HOISTING WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP A CAUTION SLING TYPE e The vehicle must not be towed by placing only its front NO 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 e If this vehicle is towed use flat bed equipment REAR TOWING PICKUP A CAUTION SLING TYPE e The vehicle must not be towed by placing only the rear 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 e If this vehicle is towed use flat bed equipment AC611522AC TSB Revision GENERAL 00 49 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 towing the vehicle 1 Do not lift or tow the vehicle by attaching to or wrapping around the bumper 2 Any loose protruding or damaged parts such as hoods doors fenders trim etc should be secured or removed prior to mov
93. ting original parts do so after first masking the theft protection label After painting be sure to peel off the masking tape For replacement parts e The theft protection label for replacement parts is cov ered by masking tape so such parts can be painted as R is The masking tape should be removed after painting is finished The theft protection label should not be removed from original parts or replacement parts M1001015700260 Theft protection plate and label WTSUBEH MITSUB MITSUBISHI MITSUB CH WTSUBISR MITSUBISHI BISHI MITSUBISHI MITSUBISHI BUBISI MITSUBISHI MITSUBISHI MITSUBISHI TSUBISHI B 704152 TSB Revision 00 22 GENERAL VEHICLE IDENTIFICATION LOCATIONS 710510 TSB Revision GENERAL 00 23 VEHICLE IDENTIFICATION Label area x for original equipment parts y for replacement parts Engine AC609841AB AC612304AB 708134 Twin clutch sportronic shift transmission TC SST AC707965AB View A Front fender S ctiona a Section b b AC608723AB The illustration indicates left outer side Right side is symmetrically opposite View B Hood NEL I p A Bs Y i B p 0 Tej JE 0909 0 Sal W
94. ting the scan tool 2 Set the scan tool to the 16 pin data link connector Refer to P 27 6 Turn the ignition switch to the ON position Using the scan tool forcibly activate the hydraulic unit item No 03 to reduce the pressure inside the accumulator Refer to GROUP 22 Actuator Test Table NOTE e With the 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 TSB Revision GENERAL 00 73 MAINTENANCE SERVICE 5 Check that the oil reservoir fluid level is in between MAX and OE MIN N 6 If the fluid level is not in between MAX and MIN fill the specified fluid Oil reservoir XT i Specified fluid DIAMOND ATF SP IlI Nur uh AC705200AB T Install the trunk room side trim lid 15 ENGINE COOLANT CHANGE M1001003100573 1 Remove the engine room under cover front A RH Refer to GROUP 51 Under Cover P 51 16 A 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 st
95. vision 00 43 PRECAUTIONS BEFORE SERVICE Item name Initial value Electric Slide door Left Not present Electric Slide door Right Not present ETG Not present MSMD Not used HFM Not present or Present ABS Not present A S C Present SAS Present AWD Not present TCM Not present Vehicles without TC SST gt or Present Vehicles with 55 gt ACTV STB Not used Pre Crush Not used EPS Not present ACDAYC Present Power window Dr Present Power window As Not present Power window RR Not present Power window RL Not present Power window BK Not used Sun roof Not present or Present RLS Not present or Present 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 2 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 TSB Revision 00 44 SRECAUTIONS BEEORE SERVICE Item name Initial value 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
96. with TC SST Tire size Tire circumference 2026mm Fuel tank Not used DRL type Dimming DRL w P lt halogen type gt or IndependentDRL P lt discharge type gt Smart entry system Not present or Type A or Type C TSB Revision GENERAL 00 42 PRECAUTIONS BEFORE SERVICE Item name Initial value TPMS Present Keyless entry Present Air bag Auto Hazard Not Present Immobilizer Type A lt Vehicles for CANADA gt or Type B lt Vehicles for USA 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 ENG CVT unit control Not used INVECS control Not used Look up slip control Not used Side air bag Present ACC Default disabled Number of speaker Premium or 6 speakers Seat material 2 Fabric or Leather Auto light control 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 Present AUDIO Not present or Present AND Not present or Present VES Not used DISP Not used NAVI Not used CAMERA Not present TUNER Not used TSB Re
97. y deviation from the Normal Condition value check the corresponding 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 80 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 ACKO AAN component or its relevant parts in that circuit CIRCUIT OPERATION o The intake air temperature sensor is

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